1. MAHAKAL INSTITUTE OF TECHNOLOGY &
MANAGEMENT, UJJAIN
A Seminar Presentation On Vocational Training
At
DIESEL SHED RATLAM
(Western Railway)
Submitted by :-
Ashwani Dixit
M.E.- 1 (VII th Sem.)
0714CS111017
Submitted to :-
MECHANICAL DEPARTMENT
From 21/06/2014 to 05/07/2014
session 2014-15
2. Contents
• Introduction (Diesel Shed & Diesel Locomotives)
• Day 1 to 2 (Maintenance)
• Day 3 to 5 (Starting System, Generator, Motors & Batteries)
• Day 6 to 7 (Fuel-Oil System)
• Day 8 to 9 (Air Compressor)
• Day 10 to 11 (Braking System )
• Day 12 to 13 (Safety Devices)
• Day 14 to 15 (Lubrication)
• Manufacturing
• Engine Block, Turbo-Supercharger, Water Cooling System
• Pictures & Certificate
3. INTRODUCTION
(Diesel Shed & Diesel Locomotives)
Brief History:-
Ratlam Diesel Shed, Located on the main line
between Delhi-Mumbai, started with a meager holding of 15
locomotives on 1st May 1967. As on today the shed has
holding of 126 locos comprising of WDM2A, WDM3A,
Inferior Service (WDM2A)-14, WDS6-04 and WDS4B-07
class locomotives.
4. Brief Details of Diesel Shed Ratlam
Year Of Establishment 1st May, 1967
ISO Certification Year
ISO : 9001-2008
ISO : 14001-2004
ISO : 18001-2007
Integrated Management System Certification achieved on 04.09.2009
( OSAS )
(Occupational Health & Safety Assurance Series)
Total LOCO Homing Capacity 100 Locos
Employees Strength 1120
No. of Officers 08
No. of Supervisors 132
Total Area 119000 m2 (Approx.)
Covered Area 6902 m2 (Approx.)
Percentage of Staff housed in Railway
Quarters
24.75%
Power Consumption 2400 Unit per day (Avg.)
Water Consumption 1.5 Lacks liters/day
Shed Consumption of Fuel 488.6liters/Loco/Month (Avg.)
5. Purpose of Diesel Shed
Maintenance
Service
Fix Time Fix Distance
Repair
When Problem
Occur in
Locomotive
6. Starting System of Locomotive
(Generator, Motor, Battery)
Engine Generator
Exciter
Generator No. of Batteries- 8 (9 VOLT
each)
Motor 1
(735V)+ (400
HP)
Motor 2
(735V)+ (400
HP)
Motor 3
(735V)+ (400
HP)
Motor 4
(735V)+ (400
HP)
Motor 5
(735V)+ (400
HP)
Motor 6
(735V)+ (400
HP)
Motor Control Device –
Armature current control
reactor (ACCR)
(A.C. supply)
7. Power Transmission System - Electrical & Mechanical,
The 400 HP is transmitted by each motor to each Wheel axle
9. Air Compressor
Supply of Air From Compressor
From MR Tank No.1 – Sand Gear
Viper Motor
Air Compressor
Horn
MR Safety valve
From MR Tank No.2 – All Braking Systems
MR Pressure Gauge
Air Pressure at MR Tanks – 10 kg/cm²
10. Braking System In Diesel Locomotive
Brake Pipe Pressure – 5 kg/cm²
Types of Braking System
• Air Brake – 1) Independent(without load)
2) Automatic (Whole train is
connected).
3) Emergency.
• Dynamic Brake – Electrical.
11. Lubrication System
Lube Oil Pressure - (Max.) 9.5kg/cm²
(Min.) 1.6kg/cm²
LUBE OIL SYSTEM IN V-SHAPED DIESEL ENGINE
CRANK SHAFT OF V-SHAPED DIESEL ENGINE
12. Safety Devices
Locomotive Idle Locomotive Shutdown
VCD System
( Vigilance Control Device)
OSTA System
( Over Speed Trip Assembly)
Automatically operated when RPM will increase more
than 1000.
GR (Ground Relay) LWS (Low Water Switch)
DMR (Dead mains relay) OPS (oil pressure switch)
Operate when oil pressure reduced to 1.3 kg/cm²
PCS (Power cut off switch) Safety auxiliary Relay (SAR)
ETS (Engine Temperature Switch)
[Operate when temp. of water is increased above 93˚c ]
Circuit Breaker
13. Manufacturers
• Manufacturers Alco (American Locomotive Company), DLW (Diesel Locomotive Works, Varanasi)
• Engine Alco 251-B, 16 cylinder, 2,600 hp (2,430 hp site rating) with Alco 710/720/?? turbo
supercharged engine. 1,000 rpm max, 400 rpm idle; 228 mm x 266 mm bore/stroke; compression ratio
12.5:1. Direct fuel injection, centrifugal pump cooling system (2,457 l/min at 1,000 rpm), fan driven by eddy
current clutch (86 hp at 1,000 rpm)
• Governor GE 17MG8 / Woodward's 8574-650 / Medha MEG 601
• Transmission Electric, with BHEL TG 10931 AZ generator (1,000 rpm, 770 V, 4,520 amperes)
• Traction motors GE752 (original Alco models) (405 hp), BHEL 4906 BZ (AZ?) (435 hp) and (newer) 4907
AZ (with roller bearings)
• Axle load 18.8 tones, total weight 112.8 t
• Bogies Alco design cast frame trimount (Co-Co) bogies
The class WDM-2 is Indian Railways' workhorse diesel locomotive. The first units were imported fully built from
the American Locomotive Company (Alco) in 1962. Since 1964, it has been manufactured in India by the Diesel
Locomotive Works (DLW), Varanasi. The model name stands for broad gauge (W), diesel (D), mixed traffic (M) engine.
The WDM-2 is the most common diesel locomotive of Indian Railways. the gear ratio is 65:18.
