This document provides information about a 4-week industrial training at Bharat Heavy Electricals Limited (BHEL) in Jhansi, India. It discusses BHEL's diesel locomotive department and includes sections on diesel locomotive parts like the diesel engine, traction motors, pneumatic control systems, and bogie assembly. Diagrams show aspects like the layout of a diesel locomotive engine and its various components.

1. BHARAT HEAVY ELECTRICALS LIMITED, JHANSI
Submitted To:- Submitted By :-
Under The Guidance Of; RAVINDRA DEV RAWAT
Dr.Dhruv Bhargav B.Tech 3rd
Year
Er.Y.R.Tripathi (Instrumentation Engg)
(Sr.DGM,HRD) I.E.T. B.U Jhansi(U.P)
(prod.Engineer, LMM) M.No-8858039861
BHEL, Jhansi (U.P) ravindrarawatjhansi@gmail.com
FOUR WEEKS INDUSTRAIL TRAINING AT

2. Emai- ajay.ranawat10@gmail.com
1.Introduction
2.Diesel Locomotive Department
3.Locomotive definition
4.Diesel locomotive
5.Parts of Diesel-Electric locomotive
6.Another View
7.Diesel Engine
8.Engine View
9.Traction Motor
10.Other Parts Of Engine
11.Turbo Charging
12.Breaking System Locomotive
13.Air Breaking System
14.PneumaticControl System
15.Twine Power -Pack 700HPDiesel Engine
16.Single Power –Pack 2400HPDiesel Engine
17.Locomotive Data
18.Maximum Overall Dimension
19.AxiliaryHorse Power Requirement
20.BoogeShop Assembly
CONTENT

3. 21.Part Of Bogi
22.AsquithCNC Machine
23.ResultAnd Conclusion
24.References

4.  BharatHeavy Electricals Limited, Jhansi was founded on 9
January 1974 and is one of the 14 manufacturing units of the Bharat
Heavy Electricals Limited (BHEL) Corporation. It is located on NH-26,
15 km away from Jhansi city. The Jhansi unit is spread in 1064 acres,
which includes 519 acres of township having large green cover and
excellent amenities. BHEL Jhansi started productionof Transformers
in the year 1976.BHEL Jhansi is in the business of two product
groups namely, Transformerand Locomotive.Marketing of products
and services is done at the corporate level by Power sector,Industry
sector,International operation division and Regional Office Divisions
spread all over India.
Products
 Power Transformers up to 400 kV class/Tractiontrfr/ESP trfr./Special
trfr/Dry TypeTrfr./Inst trfr up to 400 kV class and voltage transformer and
current transformers are also produced.
 Locomotive WAG 7 AC locomotive forIndian railway/diesel locos.all
application 3300 hp/wagons up to 300 MT 27 axle/railway track
equipment/metro for Kolkata/emu coaches.
Certifications & recognitions
 BHEL Jhansi has been certified for ISO 9001:2001 forQuality
Assurance.
INTRODUCTION

5. DIESEL LOCOMOTIVE
DEPARTMENT

6. 
A locomotive or engine is a railway vehicle that
provides the motive power for a train. The word
originates from the Latin loco – "from a place",
ablative of locus, "place" + Medieval Latin
motivus, "causing motion", and is a shortened
form of the term locomotive engine.

The first successful locomotives were built
by Cornish inventor Richard Trevithick in 1804.
LOCOMOTIVE

7.  A diesel locomotive is a type of railway
locomotive in which the prime mover is a diesel
engine.

Several types of diesel locomotive have been
developed, differing mainly in the means by
which mechanical power is conveyed to the
driving wheels (drivers). 

The hybrid diesel locomotive is an incredible
display of power and ingenuity. It combines
some great mechanical technology, including a
huge, 12-cylinder,two-stroke diesel engine, with
some heavy duty electric and generators,
throwing in a little bit of computer technology
for good measure.
DIESEL LOCOMOTIVE

8. BLOCK DIAGRAM OF DIESEL ENGINE
PARTS OF DIESEL-ELEC TRIC LOCOMOTIVE

9. LAYOUT OF DIESEL LOCOMOTIVE ENGINE
ANOTHER VIEW

10. 

This is the main power source for the
locomotive. 


A diesel engine (also known as a
compression-ignition engine) is an internal
combustion engine that uses the heat of
compression to initiate ignition to burn the
fuel that has been injected into the combustion
chamber. 


It comprises a large cylinder block, with the
cylinders arranged in a straight line or in a V. 


The diesel engine has the highest thermal
efficiency of any standard internal or external
combustion engine due to its very high
compression and inherent lean burn which
enables heat dissipation by the excess air

Diesel engines are manufactured in two-
stroke and four-stroke versions
DIESEL ENGINE
DIESEL ENGINE

11. 


ENGINE VIEW
DIESEL ENGINE

12. 
The diesel engine drives the main
alternator which provides the power to
move the train. 


The alternator generates AC electricity
which is used to provide power for the
traction motors mounted on the trucks
(bogies). 


In older locomotive, the alternator was
a DC machine, called a generator.




MAIN ALTERNATER
DIESEL ENGINE

13. 
Locomotives used to operate passenger trains
are equipped with an auxiliary alternator. 



This provides AC power for lighting, heating,
air conditioning, dining facilities etc. on the
train. 



The output is transmitted along the train through
an auxiliary power line. 
MOTOR BLOWER

The diesel engine also drives a motor blower. 



As its name suggests, the motor blower provides
air which is blown over the traction motors to
keep them cool during periods of heavy work. 



The blower is mounted inside the locomotive
body but the motors are on the trucks, so the
blower output is connected to each of the motors
through flexible ducting. 


The blower output also cools the alternators. 
AUXILIARY ALTERNATER
DIESEL ENGINE

14. 
Since the diesel-electric locomotive uses electric
transmission, traction motors are provided on the
axles to give the final drive. 


These motors were traditionally DC but the
development of modern power and control
electronics has led to the introduction of 3-phase
AC motors.


There are between four and six motors on most
diesel-electric locomotives. A modern AC motor
with air blowing can provide up to 1,000 hp.

Pinion/Gear
• The traction motor drives the axle through a
reduction gear of a range between 3 to 1 (freight)
and 4 to 1 (passenger).
Air Compressor
• The air compressor is required to provide a
constant supply of compressed air for the
locomotive and train brakes.
TRACTION MOTOR
DIESEL ENGINE

15. FUEL TANK

A diesel locomotive has to carry its own fuel
around with it. 


The fuel tank is normally under the loco frame
and This huge tank in the underbelly of the
locomotive holds 2,200 gallons (8,328 L) of
diesel fuel. 
Sand Box
• Locomotives always carry sand to assist adhesion
in bad rail conditions.
• Sand is not often provided on multiple unit trains
because the adhesion requirements are lower and
there are normally more driven axles.
AIR RESERVOIRS

Air reservoirs containing compressed air at high
pressure are required for the train braking and
some other systems on the locomotive. 


These are often mounted next to the fuel tank
under the floor of the locomotive. 
OTHER PARTS OF ENGINE
DIESEL ENGINE

16. 
The amount of power obtained from a cylinder in
a diesel engine depends on how much fuel can be
burnt in it. 


The amount of fuel which can be burnt depends
on the amount of air available in the cylinder. So,
if you can get more air into the cylinder, more fuel
will be burnt and you will get more power out of
your ignition. 


Turbo charging is used to increase the amount of
air pushed into each cylinder. 


Turbocharging gives a 50% increase in engine
power. 
RADIATOR AND RADIATOR FAN

The radiator works the same way as in an
automobile. 


Water is distributed around the engine block to
keep the temperature within the most efficient
range for the engine. 


The water is cooled by passing it through radiator
blown by a fan driven by the diesel engine.
TURBO CHARGING

17. DYNAMIC BRAKING SYSTEM
Dynamic braking is the use of the
electric traction motors of a railroad vehicle as
generators when slowing the locomotive. It is
termed rheostat if the generated electrical power
is dissipated as heat in brake grid resistors,
and regenerative if the power is returned to the
supply line. Dynamic braking lowers the wear
of friction-based braking components, and
additionally regeneration can also lower energy
consumption. Dynamic braking can also be used
on railcars multiple vehicles, units lights rails
vehicles, trams and PCC streetcars
Principle of operation
During braking, the motor fields are connected
across either the main traction generator (diesel-
electric loco) or the supply (electric locomotive) and
the motor armatures are connected across either the
brake grids or supply line. The rolling locomotive
wheels turn the motor armatures, and if the motor
BRAKING SYSTEM IN LOCOMOTIVE

18. fields are now excited, the motors will act as
generators.
During dynamic braking, the traction motors, which
are now acting as generators, are connected to the
braking grids (large resistors), which put a large load
on the electrical circuit. When a generator circuit is
loaded down with resistance, it causes the generators
to slow their rotation. By varying the amount of
excitation in the traction motor fields and the amount
of resistance imposed on the circuit by the resistor
grids, the traction motors can be slowed down to a
virtual stop (approximately 3-5 MPH).
For permanent magnet motors, dynamic braking is
easily achieved by shorting the motor terminals, thus
bringing the motor to a fast abrupt stop. This
method, however, dissipates all the energy as heat in
the motor itself, and so cannot be used in anything
other than low-power intermittent applications due
to cooling limitations. It is not suitable for traction
applications.

19. A railway air brake is a railway brake power
braking system with compressed air as the operating
medium. Modern trains rely upon a fail-safe air
brake system that is based upon a design patented by
George Westinghouse on March 5, 1868.
OVERVIEW
In the air brake's simplest form, called the straight
air system, compressed air pushes on a piston in a
cylinder. The piston is connected through
mechanical linkage to brake shoes that can rub on
the train wheels, using the resulting friction to slow
the train. The mechanical linkage can become quite
elaborate, as it evenly distributes force from one
pressurized air cylinder to 8 or 12 wheels.
The pressurized air comes from an air compressor in
the locomotive and is sent from car to car by a train
line made up of pipes beneath each car and hoses
between cars. The principal problem with the
AIR BRAKING SYSTEM

20. straight air braking system is that any separation
between hoses and pipes causes loss of air pressure
and hence the loss of the force applying the brakes.
This could easily cause a runaway train. Straight air
brakes are still used on locomotives, although as a
dual circuit system, usually with each bogie (truck)
having its own circuit.

21. Pneumatics is a Greek which means "breath",
"breath") is a branch of physics applied
to technology that makes use of gas or pressurized
air.
Pneumatic systems used extensively in industry are
commonly powered by compressed air or
compressed inert gases. A centrally located and
electrically
powered compressor powers cylinders, air motors,
and other pneumatic devices. A pneumatic system
controlled through manual or automatic solenoid
valves is selected when it provides a lower cost,
more flexible, or safer alternative to electric
motors and actuators.
Pneumatics also has applications
in dentistry, construction, mining, and other areas.
Advantages of pneumatics
 Simplicity of design and control—Machines are
easily designed using standard cylinders and other
components, and operate via simple on-off
control.
PNEUMATIC CONTROL SYSTEM

22.  Reliability—Pneumatic systems generally have
long operating lives and require little maintenance.
Because gas is compressible, equipment is less
subject to shock damage. Gas absorbs excessive
force, whereas fluid in hydraulics directly
transfers force. Compressed gas can be stored, so
machines still run for a while if electrical power is
lost.
 Safety—There is a very low chance of fire
compared to hydraulic oil. Newer machines are
usually overload safe.

23. Twin Power-Pack 700HP Diesel Engine

24. Single Power-Pack 2400HP Diesel Engine

25. General Data Of Locomotive:-

Model No. : WDM2

Specification : 16 cylinder V-type 4
stroke
Diesel Engine

Type : Co-Co

Power : 700hp, 1400hp,
2400hp

Maximum Speed : 120 kph

Gear Ratio : 68/18

Compression Ratio : 16:1

Cylinder Bore : 230mm
Wheel Base:-

Wheel Dia : 1092mm

Wheel Base : 12834mm

Traction Motor : Bhel 165

Track Gauge : 1676mm

Brake Equipment : Vaccun/Air
Locomotive Data

26. Height : 4185mm
Width : 3010mm
Length : 17120mm
Capacity:-
Fuel : 5000 lt
Cooling Water : 1210 lt
Lube Oil : 910 lt
Water Expansion : 155 lt
Sand : 0.4 m3
Maximum Overall Dimension

27. Auxiliary Generator Maximum : 17HP
Exciter Maximum : 12HP
Traction Motor : 400HP
Blower at full speed : 62HP
Radiator Fan : 80HP
Expresser Unloaded at 1000 rpm :13 HP
Auxiliary Horse Power Requirement

28. BOOGY SHOP ASSEMBLY

29. PARTS OF BOGI

30. 
Bogie Shop
The locomotive bogies are rebuilt with new wheel sets,
suspension bearings
and remanufactured traction motors. Separateshop has
been set up for
machining of wheel sets and assembly of locomotive
bogies.

32. 
Computer Numeric Control machines is a closed
loop machine.



As the name depicts these machines use
computer for their operation.




Computer Numeric Control machines are
controlled by a set of different ISO codes that
helps in proper controlling of the


machine.




In modern CNC systems, end-to-end component
design is highly automated using CAD/CAM
programs.

ASQUITH CNC MACHINE

33. 
View Of ASQUITH CNC Machine

34. 
In this machine all the operation which is
essential for bogi is performances. Mainly
these operation are following-


Cutting



Milling



Finishing



Drilling



Fillit



Grinding


35. Radial Arm Drilling Machine

In radial arm drilling machine there is a one
column on which radial arm is fixed. 


Radial arm are horizontal arm this is movable
around the column. This is main advantage of
this machine. 


In drilling machine different type drill can be
fixed. But twist drills are very common in use.
Holes of different diameter can be done by using
drills of different diameter. 

36. 
View Of Radial Arm Drilling
Machine

37. 
Axle turning machine is also called lathe
machine. 

• In this machine material is removed by the
single point cutting tool. Turning of axle,
grinding of axle operation are performed on this
machine.
•
Axle Turning Machine

38. 
The BHARAT HEAVY ELECTRICALS is the most
widely used transport system in India. The production
of the parts and units of rails forms an important

and integral part of the proper functioning of the
railway system in India.


Its World's largest manufacturer of ALCO diesel loco
spares such as Gears, Cams, Con rods, Pins, Carbon
Brushes etc.




DCW manufactures large componentssuch as traction
motors and locomotive power packs, rebuilds engine
blocks, traction generators, etc.




RESULT AND CONCLUSION

39. 
http://www.google.co.in/


www.bhel.com



http://en.wikipedia.org



http://www.railway-technical.com



http://www.howstuffworks.com/



Manual Report of BHEL

REFERENCES

40. thanks

41. tt