DLW vocational training report

VOCATIONAL TRAINING
TECHNICAL TRAINING CENTRE
DIESEL LOCOMOTIVE WORKS
SUBMITTED BY:
PRASHANT SHARMA
BTECH - 2nd
(MECHANICAL ENGG.)
Reg.No.- TTC/DLW/18/1346
Session - 2016-2020
College - GURUKULA KANGRI VISHWAVIDYALAYA
(HARIDWAR, UTTRAKHAND)
VOCATIONAL TRAINING
REPORT
SEL LOCOMOTIVE WORKS
(VARANASI )
SUBMITTED AT:
PRASHANT SHARMA Technical Training Centre
(MECHANICAL ENGG.) Diesel Locomotive Works
TTC/DLW/18/1346 Varanasi (U.P.)
KANGRI VISHWAVIDYALAYA
UTTRAKHAND)
VOCATIONAL TRAINING
SUBMITTED AT:
Technical Training Centre
sel Locomotive Works
Varanasi (U.P.)

PREFACE
The objectives of the practical training are to learn something about
industries practically and to be familiar with the working style of a
technical person to adjust simply according to the industrial
environment.
It is rightly said practical life is far away from theoretical one. We
learn in class room can give the practical exposer real life experience
no doubt they help in improving the personality of the student, but
the practical exposure in the field will help the student in long run of
life and will be able to implement the theoretical knowledge.
As a part of academic syllabus of four year degree course in
Mechanical Engineering, every student is required to undergo a
practical training.
I am student of second year mechanical and this report is written on
the basis of practical knowledge acquired by meduring the period of
practical training taken at Diesel Locomotive

CONTENTS
[1]. Introduction to DLW……………………………………………
[2].Introduction To Machine Shop…………………………….
[3]. Light Machine Shop ……………………………………….....
[4]. Heavy Machine Shop ………………………………………...
[5]. Loco Test Shop…………………………………………..........
[6]. Engine Test Shop..................................................
[7]. Conclusion…………………………………………………………
[8]. Bibliography………………………………………………………

INTRODUCTION TO DLW
Diesel Locomotive Works (DLW) is a production unit under the ministry of
railways. This was setup in collaboration with American Locomotive
Company (ALCO), USA in 1961 and the first locomotive was rolled out in
1964. This unit produces diesel electronic locomotives and DG sets for Indian
railways and other customers in India and Abroad.
Subsequently a contract for transfer of technology of 4000 HP
Microprocessor Controlled AC/AC Freight (GT 46 MAC) / passenger (GT 46
PAC) locomotives and family of 710 engines has been signed with electro
motive division of GENERAL MOTORS of USA for manufacture in DLW. The
production of these locomotives has now started and thus DLW is the only
manufacturers of Diesel Electric Locomotives with both ALCO and General
Motors technologies in the world.

Brief History:
• Set up in 1961 as a green-field project in technical collaboration with
ALCO/USA to Manufacture Diesel Electric Locomotives.
• First locomotive rolled out and dedicated to nation in January, 1964.
• Transfer-of-Technology agreement signed with General Motors/ USA in
October, 95 to manufacture state-of-the-art high traction AC-AC diesel
locomotives.
• A flagship company of Indian Railways offering complete range of
flanking products in its area of operation.
• State-of-the art Design and Manufacturing facility to manufacture more
than 150 locomotives per annum with wide range of related products
viz. components and sub-assemblies.
• Unbeatable trail-blazing track record in providing cost-effective, eco-
friendly and reliable solutions to ever-increasing transportation needs
for over three decades.
• Fully geared to meet specific transportation needs by putting Price-
Value-Technology equation perfectly right.
• A large base of delighted customers among many countries viz. Sri
Lanka, Malaysia, Vietnam, Bangladesh, Tanzania to name a few, bearing
testimony to product leadership in its category.

SALIENT FEATURES:
• Annual production capacity 330Locomotives
• Annual turn-over (Rs) 8000 million(approx.)
• Total number of staff 7223
• Workshop land 89 Hectares
• Township area 211 Hectares
• Covered area in shops 86300 m2
• Covered area of other service buildings 73700 m2
• Electrical power requirement 3468 KV
• (Average maximum demand)
• Electrical energy consumption (units/year) 19.8 million
• Standby power generation capacity 3000 KW

PRODUCT OF DLW:
DLW is an integrated plant and its manufacturing facilities are flexible in
nature. These can be utilized for manufacture of different design of
locomotives of various gauges suiting customer requirements and other
products. The product range available is as under:
• WDG4 4000 HP AC/AC Freight Traffic Locomotive
• WDP4 4000 HPAC/AC Broad Gauge High Speed Locomotive
• WDG3D 3400 HP AC/AC Broad Gauge Mixed Traffic Micro-Processor
Controlled Locomotive.
• WDM3C 3300 HP AC/DC Broad Gauge Mixed Traffic Locomotive.
• WDM3A 3100 HP AC/DC Broad Gauge Mixed Traffic Locomotive.
• WDP3A 3100 HP AC/DC Broad Gauge High Speed Passenger
Locomotive.
• WDG3A 3100 HP AC/DC Broad Gauge Freight Locomotive.
• WDM2 2600 HP AC/DC Broad Gauge Mixed Traffic Locomotive.
• WDP1 2300 HP AC/DC Broad Gauge Intercity Express Locomotive.
• WDM7 2150 HP DC/DC Broad Gauge Mixed Traffic Locomotive.
• WDM6 1350 HP DC/DC Broad Gauge Mixed Traffic Locomotive.
• YDM4 1350 HP AC/DC & DC/DC Broad Gauge Mixed traffic Locomotive.
• EXPORT LOCO 2300 HP AC/DC Meter Gauge/Cape gauge Mixed Traffic
Locomotive.
• Diesel Generating Sets 800 KW to 2500 KW
• Spare Parts for engines, locomotives and generating sets.

DESIGN OFFICE:
Prepare diag. of each part and sent to Material Control & inform timely in
any change in any parts to relative department.
3D MODEL OF DIESEL LOCO MOTIVE
PLANNING OFFICE:
Prepare JPO, Monthly Production Program, Scheduling, Processing, Rate
Fixing, Issue Work Orders, Schedule Orders, Issue Job card & other
production Documents. Preparing DLW Budget & Sent to Rly Board.
PROGRESS OFFICE:
After opening of work orders collect the prod. Documents from PCO and
hand over to user shop draw the material from depot & given to shop &
hand over the ready material of shop to user shop/store. After completion of
work, close the work order.

PRODUCTION SHOPS:
Production shops are divided in three divisions-
1. Block Divisions
2. Engine Divisions
3. Loco Divisions
BLOCK DIVISION:
1. Heavy Weld Shop
2. Heavy Machine Shop
ENGINE DIVISION:
1. Engine Erection Shop
2. Engine Testing Shop
3. Light Machine Shop
4. Sub Assembly Shop
5.Rotor Shop
6. Heat Treatment Shop
LOCO DIVISION:
1. Loco Frame Shop
2. Pipe Shop
3. Truck Machine Shop
4. Traction Assembly Shop
5.Sheet Metal Shop
6. Loco Assembly Shop
7. Loco Paint Shop
8. Loco Test Shop

13.
No. of Cells 32 50
14.
Cell Voltage 2.1 1.5
15.
Total Voltage 68 75
16.
Engine Starting
Switch
Located in Engine starting
room
Located in Engine control
panel
17.
For quick engine
firing
Governor Lay Shaft Manually
operation
Governor booster pump starts
automatically
18.
Radar System Located between front bogie
&Fuel tank
Located between fuel tank
&rear bogie
19.
Cab Light Switch Near Cab Light In control stand side switch
panel
20.
Lube oil Filter Drum Only Bye-pass Valve Bye-pass valve with gauge
(Like fuel oil Primary filter
21.
Blended Brake Not provided Provided
22.
Location of Blended
Brake
Not provided On engine control panel
23.
Low water Level
Switch
Not provided Provided in the engine Cooling
Water system
24.
Temperature Gauge Not provided Located on the inlet line to the
Water pump
25.
Colour Code
(Temperature gauge)
Not provided Blue (cold), Green (Normal) &
Red (Hot)

Fig. WDP4D LOCOMOTIVE
Fig. WDG4D LOCOMOTIVE

INTRODUCTION TO MACHINE SHOP
Machine shop work is generally understood to include all cold-metal work by which an
operator, using either power driven equipment or hand tools, removes a portion of the
metal and shapes it to some specified form or size. It does not include sheet metal work
and copper. The function of all machine tools is to produce metal parts by changing the
shape, size, or finish of a piece of material. The shape of a part made with a machine
tool is limited by the types of motion the tool can apply.
Standard machine tools are grouped in six basic classes:
1. LATHES
2. DRILLING MACHINES
3. SHAPERS
4. PLANERS
5. MILLING MACHINES
6. GRINDING MACHINES
LATHE:
The lathe is used for turning various metals against a cutting tool that shapes it to the
desired product. The engine lathe is a machine tool that produces a cutting action by
rotating the work piece against the cutting edge of the tool.
Fig. Lathe Machine

DRILLING MACHINES:
The drilling machine is a machine tool that produces the necessary cutting action by the
rotation of a multiple edge cutting tool.
Fig. Drilling Machine

SHAPING AND PLANING MACHINES:
Both of these machines can machine flat surfaces with a single point reciprocating,
motion is applied to both the work piece and tool in these machines.
Fig. Shaper Machine

SAFETY RULES FOR MACHINE TOOLS:
The following are general safety rules for any machine tool:
1. Gears, pulleys, belts, couplings, ends of shafts having keyways, and other revolving or
reciprocating parts should be guarded to a height of 6 feet above the floor. The guards
should be removed only for repairing or adjusting the machine and must be replaced
before operating it.
2. Safety setscrews should be used in collars and on all revolving or reciprocating
members of the machine tool or its equipment.
3. Do not operate any machine tool without proper lighting.
4. Never attempt to operate any machine tool until you fully understand how it works
and know how to stop it quickly.
5. Never wear loose or torn clothing and secure long hair, since these items can become
caught in revolving machine parts. Ties should be removed and shirt sleeves should be
rolled up above the elbow.
6. Gloves should never be worn when operating machinery except when absolutely
necessary.
7. Always stop the machine before cleaning it or taking measurements of the work
piece.
8. Do not lubricate a machine while it is in motion. Injury to the operator and damage to
the machine may result from this practice.
9. Always wear safety glasses or goggles while operating machine tools. Also, wear
respiratory protection if operation creates hazardous dust. All persons in the area where
power tools are being operated should also wear safety eye protection and respirators
as needed.
10. Know where tire extinguishers are located in the shop area and how to use them.
11. Never wear jewellery while working around machine tools. Rings, watches, or
bracelets maybe caught in a revolving part which could result in the hand being pulled
into the machine.
12. Avoid horseplay. Tools are very sharp and machines are made of hard steel. An
accidental slip or fall may cause a serious injury.
13. Never use compressed air without a safety nozzle to clean machines or clothing. It
will blow sharp, dangerous metal chips a long distance.
14. Never place tools or other materials on the machine table. Cluttering up a machine
with tools or materials creates unsafe working conditions. Use a bench or table near the
machine for this purpose.

LIGHT MACHINE SHOP
This shop deals with the machining of various small components required for the power
pack unit such as, cam shaft, connecting rod, liners, gears, leavers, F.P. support, piston
pin, nuts and bolts bushes, various shaft etc.
The light machine shop is divided into following section:
• Econometric section
• Gear section
• Grinding section
• Cam shaft section
• A.T.L. section
• Benching section
• Connecting rod section
• Lathe section
• Liners section
• Drilling section
• Milling section
Fig. Light Machine Shop

ECONOMIC SECTION:
This section deals with the economics of manufacturing of various parts.
Machine provided: Econometric machine, do all machine, belt grinding machine(for
control shaft feed).
GEAR SECTION:
This section deals to making various gears impeller such as cam shaft gear, crank shaft
gear, extension shaft gear, impeller gear(follower and drive) and broaching machine
provided.
• Gear hobbing machine
• Gear shaving machine
• VTL machine
• Radial drilling machine
• Broaching machine
• Centre milling machine
Fig. Gear Hobbing Machine

GRINDING MACHINE:
In this section the various small components are grinding as per required finishing after
machining operation and each components having grinding allowance main piston pin,
impeller and fuller and follower gear, pin value guide, various studs, cam roller, seat
spider various bushes, etc.
MACHINE PROVIDED:
• Cylindrical grinding machine
• Internal grinding machine
• Centre less grinding machine
• Thread rolling machine
• Universal grinding machine
• External grinding machine
CAM SHAFT SECTION:
This section making cam shaft (both B.G. and M.G.) with completed machining
operation by various special type of machine. In B.G. 08 no’s per loco and in M.G. 03 per
loco.
MACHINE PROVIDED:
• Centre milling machine
• Auto lathe machine
• Gun drill machine
• External grinding machine
• Lathe machine
• Cam grinding machine
• Radial drilling machine
• Cam angle checking machine
• Magna flux machine

Fig. Cam Shaft
BENCHING SECTION:
In this section the benching operation of the entire component which are manufacturing
in the shop are done here. In the benching section, there having hand cutter machining
and belt grinding machine, with the half of these machine bar removing from all the
components.
CYLINDER LINER SECTION:
In this section cycle liner machine operation have done here by the various types of
machine. The material of the cylinder liner is special cast iron and the set per loco is in
B.G. 16 and in M.G. 6cylinder.
MACHINE PROVIDED:
• Shot blast machine
• Vertical boring machine
• Auto lathe machine
• Honning machine
• Cylindrical grinding machine

AUTOMATIC TURRET LATHE (A.T.L.)SECTION:
This section manufacturing various types of small components for power pack engine
such as:
Lock spring seat ,spewing seat. Ball end, cup end .
Screw cop screw L.A.S. retainer, spring lever, F.P. Inlet, piston pin liner sleeve, body
outer spacier etc.
MACHINE PROVIDED:
• M.T.L.(Bar type, chuck type)
• U.T.L.
The A.T.L. section is the vital section of this shop. Maximum small components are
manufacturing in this section.
Fig. Automatic Turret Lathe

CONNECTING ROD SECTION:
In this section the connecting rod is made. All the machining operations of the
connecting completed here with the help of various types of machine. The connecting
rod has two parts, one is cap and other is rod. The material of the connecting rod is
steep forging. In B.G. 16 per loco and image. 6 per loco.
MAIN DIMENSION:
• Crank bore (big bore) = 6.411” to 6.421”.
• Piston pin bore (small bore) = 3.998” to 3.999”.
• Distance between two = 20.995” to 21.000” base centre.
• Rod thickness = 3.020” to 3.022”.
• Weight = 32 kg 950 gram to 32 kg gram.
• Pressure torque = 150 P.S.I.
DRILLLING MACHINE:
This section deals with the various types of drilling, reaming, counter bore, spot facing
and counter sinking operation done of various small components.
The components are F.P. support, P.R. lighter, X head, valve lever, spring lever, brag,
bracket, pin, ECC lever, upper housing etc.
MACHINE PROVIDED:
• Radial drilling machine.
• Gang drilling machine of multi spindle drilling machine.
• Drilling machine.
• Electronic drilling machine.

HEAVY MACHINE SHOP
This shop carries out the machining of Cyl. BLOCK (M.G. & B.G.) main base, saddler Main
bearing caps, S.P. lines, Turbo Super Charger, Lube Oil, Fuel Oil & Water header) com
bearing housing.
OPERATION:-
• Planning,
• Milling,
• Drilling,
• Tapping,
• Boring Honing,
• Angular Boring,
• Serration milling etc.
Types of Machine provided in the shop are:-
• Double Housing planned machine (32”, 24’, & 16’).
• Radial drilling machine.
• Radial drilling machine Traveling type.
• Boring Machine
• Angular Boring Machine (Ex-cello)
• Tracer
• Planner machine.
• Hill Acme doing structural milling machine
TOOLS USE:-
• O.K. Tool (Rough & Finish)
• C.C. Milling cutter (4”, 9”, & 10”)
• Boring Tipped Tool (Rough & Finish)
• Honing Stone (For hand honing)
• Drill, Reamer, Top (Various Seizer)

MEASURING INSTRUMENT:
• Dial Bar gauge
• Micron meter (outside and depth)
• Vernier Height gauge.
• Vernier callipers
• Mandrill or optical shad rill machine
BLOCKS
Fig.Heavy Machine Shop

EX-CELLO ANGULAR BORING MACHINE:
Motor R.P.M. in constant, Spindle, speed is control by clutch system.
H.M.T. ANGULAR BORING MACHINE:
• Spindle speed is directly controlled through motor. (Coated carbide is used in
H.M.T. angular Boring machine)
• Cyl. Block made of fabricated class II material except main bearing cop as it made
class IV material.
• The machining of Cyl. Block is complicated and challenging job. It required great
skill and knowledge. After duly fabricated, stress relieved and shot blasted the
block is subjected to layout to ensure availability of adequate machining
allowance, where necessary and to provide guide liner for subsequent machining
the weight of the block is 6.02 Tons approx. (Fabricated Material)
• After completion of all operations as per drawings the black subjected to
inspection in addition to stage inspection dimension live radial distance between
centre of Crank bore and com bore, distance between centre of com bore and
liner seat etc. are checked at this stage the weight of the black is 05.02 tons
approx. 01 ton of material removed by the machining and then blank is block send
for assembly.
Angular Boring Machine:
• Angular boring "V" boring is done of special purpose machine which is a special
purpose machine, which has two high precision angular boring bars on which
different boring inserts are mounted.
• The cutting inserts on boring bars to achieve evenly distributed cutting load
during boring operation. This contributes to accuracy while machining.
• Boring bars are mounted on high precision bearings which provide control on size
during angular boring. The machine is capable of boring and drilling to different
size.

Fig. Angular Boring of G.M. Block
Method: - Load the block on fixture:
For checking whether there is any gap or not put the filler of the size 0.001” to 0.0015”
in side location pad. If there is no gap then start work otherwise tight the fixture and
recheck till no gap situated.
Tool:
There are 18 tools are used. I tool in each side. Each are adjusted automatically for
rough cut and finish cut. During rough cut, finish tool remains idle and during finish cut,
rough tool remains idle. 7 tools are fixed in each side in boring bar and two are replaced
according to demand of boring.
Different tools which are used are as follows:
• M.I.D. Counter Insert No – TPUN – 160308
• Rough – snmm – 190612 (weight) 190616 (yellow)
• Liner seat rough TNMG 220412
• T/D Chamfer P.G. 002 (only for 1263 m/c)
• Liner seat finish – TPUN – 110308
• Micro boring tool OOC No. 10A2LB
• Counter insert wide no. – PNUN – 160402
• T.I.D. Counter No. (Rough) – 1263 (N.C.)TN – 28
• (TNUN 220 412)
• 2187 M/c. – MIS Counter No. TNMM – 160408

Horizontal Boring Machine:
MW :
(no): 2155 & mw No. : - 2154
Cam and Crank.
Boring of cylinder block crank and cam.
Method:
• Load the block on fixture.
• For checking whether there is any gap
• Or not put the filler of size 0.001” to
• If there is 0.0015” inside location pad The fixture and recheck till no gap situation
• No gap then tart work otherwise tight
.
Boring of Cam Bore: (LS & RS):-
This is done in three steps:
(a) Rough Bore: - Do this in one pass
R.P.M.: 35 Feed: 6 mm/min.
(b) Semi Finish Boring: - Do this in one pass
R.P.M.: 35 Feed: 6 mm/min.
(c) Finish Boring: - Do this in one pass
Pass No. Bore No. R.P.M. Feed
1. 1, 4, 7, 10
2. 2, 5, 8, 224 25mm/min
3. 3.6.9.

Boring of Crank Bore: This is also in three steep.
(a) Rough Boring: Do this in three pass.
Pass No. Bore No. R.P.M. Feed
1. 1, 4, 7, 14 5 mm/min
2. 2, 5, 8,
3. 3, 6, 9
(b) Semi Finish Boring: Do in one pass
R. P. M.: 14 Feed: 5 mm/min
(c) Finish Boring: Do in one pass
R. P. M.: 140 Feed: 25 mm/min
Tool:
Two tools are used for boring both tools are fixed in slot of boring bar. Due to spindle
rotation boring is done. Tool movement and machine action is governed by G Code and
M Code respectively. Absolute mode and incremental modes are used for tool
movement. Single point cutting tool (two) is first fitted in devise block then in boring
bar.
Cutting Oil:
Boring finishing operation cutting oil is used for smooth operation
Fixture: J/F No. : FB (E) 15/2
Different: Different tools are used in different step of Boring!
Crank:-
Rough Boring : 8.880”
Semi Finish Boring : 8-997”
Finish Boring : 9.035”
Cam:-
Rough Boring : 4.700”
Semi Finish Boring : 4.720”
Finish Boring : 4.750”

Maximum removal of metal takes place in rough boring.
For making thrust (Cutting) :
Tool Size : 10”
R.P.M. : 14
Feed : 22.86 mm/min
(.09”/min)
Tool material used in rough and semi finish boring is high speed steel and in finish
boring amended carbide.
Main parts of the Cyl. Block (B.G.)
• Foundation Rail (R.S. AND L.S.)
• Saddle ( 9Nos)
• S.P. line
• Inner well (R.S. and L.S.)
• Other well (R.S. and L.S.)
• Top deck (Middle)
• Top deck (R.S. and L.S.)
• Side sheet (R.S. and L.S.)
• Com bearing (16 Nos.)
• Cop (9 Nos.)
• Rib (16 Nos.)
• Bottom Deck. Or Middle deck
• Fuel self-comport

Main dimension of Cyl. Block:-
• Did of com bore = 4.750” to 4.7515”
• (B.G. & M.G.)
• Did of blank bore = 9.0355” to 9.0370”
• (M.G. & B.G.)
• Did of liner bore = 10.750” to 10.752” (Upper) (B.G. of M.G.) = 10.621” to 10.623
(Lower)
• Die of thirst Collar = 10ψ ”
• Thickness of thrust bearing = 4.247” to 4.249”
• Thickness of the plate = free end = ”= gen. End = 1ω”
• Radial distance between the centre of crank of Cam bore = 10.499” to 9.501”
• Distance of liner seat from centre of crank Bore = 32.480” to 32.485”
• Total length of the M.G. black = 106.370” = 106.380”
• Total length of main Bush B.G. = 172.380” ,B.G. = 172.370”
• Total length of main Bush M.G. = 117.130” ,= 117.120”
• Total length of B.G. Black = 161.625” ,= 161.630”

LOCO TESTING SHOP
Fully assembled locomotive is sent to Loco Test Shop for
dispatched to the customer. Testing
equipment load test, air brake test, electrical tra
Test), etc. Finally the locomotive goes to pre dispatch
for service.
Some of the Loco Test are as :
• Air brake test
• Track test
• Load test
• Insulation resistance and high pot test
LOCO TESTING SHOP
motive is sent to Loco Test Shop for complete testing befo
atched to the customer. Testing of locomotive involves mechanical & electrical
test, air brake test, electrical track test, Shower Test, RRT (Rode
ally the locomotive goes to pre dispatch inspection before fin
Fig. Loco Test Shop
Insulation resistance and high pot test
complete testing before it is
cal & electrical
ck test, Shower Test, RRT (Rode Run
fore final dispatch

AIR BRAKE TEST:
An air brake or, more formally, a compressed air brake system, is a type of friction brake
for vehicles in which compressed air pressing on a piston is used to apply the pressure
to the brake pad needed to stop the vehicle. Conduct a standing locomotive air brake
test when performing any of the following tasks.
Air brake test parameter:
• M.R. Pressure
• B.P. Pressure
• F.P. Pressure
• B.C. Pressure (auto A9)
• B.C. Pressure (SA9)
Follow these steps to test the air brakes:
• Apply Hand Brake: Secure the locomotive with hand brakes.
• REGULATING VALVE: Adjust the regulating valve to the required brake pipe
pressure. 90-FRT 110-PASS.
• Regulating Valve: The valve that reduces air pressure from the locomotive main
reservoir to the desired pressure in the brake pipe. The regulating valve will
automatically maintain that pressure when the automatic brake valve is in the
RELEASE position.
• Preparation Before Starting Test: Move the independent and automatic brake
valve handles to RELEASE.
• Independent brake valve.
• Checking Independent Brake Application.
• Checking Independent Brake Release.
• Automatic Brake Valve.
• Checking Locomotive Brake Pipe Leakage.

INSULATION RESISTANCE:
The Insulation Resistance Test consists in measuring the Insulation resistance of a device
under test, while phase and neutral are short circuited together. The measured
resistance has to be higher than the indicated limit from the international standards.
A megohmmeter (also called insulation resistance tester, teraohmmeter) is then used to
measure the ohmic value of an insulator under a direct voltage of great stability.
Insulation Resistance Test Parameter:
Test operation for Insulation Resistance are as:
• Control Circuit
• Direct Current Link
• T.M. Phase
• Companion Alternator
• Starting Motor
• Power Circuit
HIGH POTENTIAL TEST:
Hipot is an abbreviation for high potential. A hipot test (also called Dielectric
Withstanding Voltage (DWV) test) verifies that the insulation of a product or component
is sufficient to protect the operator from electrical shock. In a typical hipot test, high
voltage is applied between a product's current-carrying conductors and its metallic
shielding. The resulting current that flows through the insulation, known as leakage
current, is monitored by the hipot tester.
Three types of hipot tests are commonly used. These three tests differ in the amount of
voltage applied and the amount (or nature) of acceptable current flow:
Dielectric Breakdown Test:The test voltage is increased until the dielectric fails, or
breaks down, allowing too much current to flow. The dielectric is often destroyed by this

test so this test is used on a random sample basis. This test allows designers to estimate
the breakdown voltage of a product's design and to see where the breakdown occurred.
Dielectric Withstand Test: A standard test voltage is applied (below the established
Breakdown Voltage) and the resulting leakage current is monitored. The leakage current
must be below a preset limit or the test is considered to have failed. This test is non-
destructive providing that it does not fail and is usually required by safety agencies to be
performed as a 100% production line test on all products before they leave the factory.
High Potential Test Parameter:
Test operation for High Potential Test are as:
• Control Circuit
• Direct Current Link
• T.M. Phase
• Companion Alternator
• Starting Motor
• Power Circuit

ENGINE TEST SHOP
In this shop testing of engine is performed
• Initial filling of lubricating oil and fuel.
• Observation of vibration
• Sensing of and controlling the temperature
• Controlling pressure
• Soak valve pump
• Circulation of water and sensing of temperature
• Initial supply of 72 V for starting
Fig. Engine Test Shop

Fig. Set up for engine testing

WATER TESTING:
Water acts as a coolant for moving part of the engine because constant movement or
rotation causes various arts to heat up and water working as coolant cooled down the
concerned part.
Fig. Water circulation pump
LOAD TESTING:
For load testing electrical load is provided to the engine. If there is any abnormal sound
then the engine is again tested for lubrication so that any flaw which is there can be
removed.

PERFORMANCE TEST:
The thermal energy produced by the combustion of fuel in an engine is not completely
utilized for the production of the mechanical power. The thermal efficiency of I.C.
Engines is about 33 %. Of the available heat energy in the fuel, about1/3 is lost through
the exhaust system, and 1/3 is absorbed and dissipated by the cooling system. It is the
purpose of heat balance sheet to know the heat energy distribution, that is, how and
where the input energy from the fuel is is distributed. The heat balance sheet of an I. C.
Engine includes the following heat distributions:
• Heat energy available from the fuel brunt.
• Heat energy equivalent to output brake power.
• Heat energy lost to engine cooling water.
• Heat energy carried away by the exhaust gases.
• Unaccounted heat energy loss
PROCEDURE:
• Before starting the engine check the fuel supply, lubrication oil, and availability of
cooling water.
• Set the dynamometer to zero load and run the engine till it attain the working
temperature and steady state condition.
• Note down the fuel consumption rate, Engine cooling water flow rate, inlet and
outlet temperature of the engine cooling water, Exhaust gases cooling water flow
rate, Air flow rate, and Air inlet temperature.
• Set the dynamometer to 20 % of the full load, till it attains the steady state
condition. Note down the fuel consumption rate, Engine cooling water flow rate,
inlet and outlet 12 temperature of the engine cooling water, Exhaust gases
cooling water flow rate, Air flow rate, and Air inlet temperature.
• Repeat the experiment at 40 %, 60 %, and 80 % of the full load at
constantspeed.6. Disengage the dynamometer and stop the engine. 7. Do the
necessary calculation and prepare the heat balance sheet

ENGINE TEST OPERATION SEQUENCE
• Base inspection under screen and fitting over screen.
• Water circulation.
• Lubricating oil filling and check deflection crank shaft.
• Lubricating oil circulation.
• Pre run on no load 3 to 5 times of duration 10 to 30 minutes each 400 rpm.
• Intermediate runs 12 runs of 30 min duration each from 400 to 1000 rpm.
• Check over speed trip and recheck 3 times.
• Check bake in nozzles and set tapped clearance.
• Inspection before of first hour performance.
• Base inspection.
• Second hour performance on full load.
• Attend defects of first hour performance.
• Final base inspection.
• Check engine deficiencies.
• Engine clearance.

CONCLUSION:
RECENT MILESTONES:
321 locomotives (including 25 electric locos) manufactured in FY 2017 18, amounting
to 2% higher over Railway Board’s target.
• In addition to above, First time in the world, DLW successfully converted two old
diesel locos (WDG3A) into Electric loco (WAGC3). Converted loco will work as a twin
loco consist (2 X 5000 HP) and comprises of one cab per loco.
• DLW has won the ‘Best Production Unit Shield 2017-18’ for 3rd consecutive year
• This year DLW has obtained certification of NABL for laboratory and 5 S Workplace
Management. Now DLW have following certifications:
- ISO 9001
- ISO 14001
- OHSAS 18001
- ISO 50001
- ISO 3834
- Green Co Silver Rating
- NABL Accreditation
- 5S
• DLW has delivered 36 locos to NRCs worth ₹ 333 Cr during 2017-18. This includes
including 18 YDM4 locos exported to Myanmar and 01 WDG4D to
OPGC/Bhubneshwar
FUTURE PLANS:
295 locos (107 HHP Diesel, 173 electric and 15 locos for NRC) have been planned to
manufacture in FY 2018-19 as per Railway Board mandate.

BIBLIOGRAPHY
1. www.indianrailways.gov.in
2. Cris-dlw.cirs.org.in
3. www.irfca.org

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