The document provides an overview of Diesel Locomotive Works (DLW) in Varanasi, India, which produces diesel-electric locomotives. DLW was established in 1961 through collaboration with American Locomotive Company and has since produced locomotives using both ALCO and Electro-Motive Division technologies. The document details the various types of locomotives produced at DLW, including their specifications and components.
Industrial training report on dlw varanasi for Main Receiving Substation, Tra...Devendra Kumar
Industrial training report on dlw Varanasi for Main Receiving Substation, Traction assembly shop, Maintenance area 2 and Loco Testing Shop(LTS).The industrial training report of DLW (DIESEL LOCOMOTIVE WORKS) is a different trade. i.e. Electronics and Communication, Electrical, Mechanical, Electrical & Electronics and many engineering holders have participated. The content of my industrial topic Main Receiving Substation, TRACTION ASSEMBLY SHOP, Maintenance area 2 and Loco Testing Shop
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.
Industrial training report on dlw varanasi for Main Receiving Substation, Tra...Devendra Kumar
Industrial training report on dlw Varanasi for Main Receiving Substation, Traction assembly shop, Maintenance area 2 and Loco Testing Shop(LTS).The industrial training report of DLW (DIESEL LOCOMOTIVE WORKS) is a different trade. i.e. Electronics and Communication, Electrical, Mechanical, Electrical & Electronics and many engineering holders have participated. The content of my industrial topic Main Receiving Substation, TRACTION ASSEMBLY SHOP, Maintenance area 2 and Loco Testing Shop
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.
It is a Vocational Training Report (Summer Training Report) of 4 weaks in DLW, Varanasi, which consists introduction of DLW, Varanasi and 4 shops SMS (Sheet Metal Shop), SAS (Sub Assembly Shop), TMS (Truck Machine Shop) and LFS (Loco Frame Shop).
this is ppt based on my 4 weeks training at D.L.W varanasi I have included brief introduction along with introduction and working of various shops hope you will find helpful
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.
Summer Training Report,DIESEL LOCOMOTIVE WORKS,VARANASI(DLW)Vivek Yadav
Summer Training Report,
Locomotive Manufacturing Workshops(EES,LTS,LFS,HMS)
DIESEL LOCOMOTIVE WORKS, VARANASI(DLW),
MECHANICAL ENGINEERING,
Diesel locomotive works (DLW) is production unit under the ministry of railways. This was set up 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.
diesel locomotive works training report by somesh dwivedisomesh dwivedi
4week summer training report on D.L.W. Varanasi by Somesh Dwivedi.
on the topics 1.-Heavy Weld Shop(HWS)
2.- Heavy Machine Shop(HMS)
3. Light Machine Shop(LMS)
4. Truck Machine Shop(TMS)
4 weeks at internship - DLW VARANASI (U.P.) By Parvind GuptaParvind Gupta
About the industry:
Diesel Locomotive Works [DLW] is production unit under the ministry of railways. DLW is only manufacture of diesel electric locomotive with ALCO & General Motors [GM] based technologies in the words.
HELLO FRINDS THIS REPORT IS OF INDUSTRIAL TRAINING ON DIESEL LOCOMOTIVE TECHNOLOGY.
IT IS VERY HELP FULL FOR YOU .
SO GO THROUGH IT .
**********************Best Of Luck ************************
INTRODUCTION OF INDIAN RAILWAY
DIESEL LOCOMOTIVE WORKSHOP .CHARBAGH
DIESEL ELECTRIC LOCOMOTIVE
WORKING MECHANISIM
IMPORTANT COMPONENTS OF LOCOMOTIVES
a) POWER PACK
b) FUEL SECTION
c) LUBE OIL CONTROL SECTION
i. FUEL INJECTION PUMP (FIP)
ii. INJECTORS
d) TURBO SUPER CHARGING (TSC)
e) BRAKES
f) COMPRESSOR / EXPRESSOR
g) GOVERNORS
h) TRACTION MOTER
i) BOGIE
j) GENERATOR
k) RADIATOR
l) ENGINE SECTION
m) CROSS HEAD
i. INLET AND EXHAUST VALVE
FAILURE ANALYSIS
a) MAGNAFLUX LAB
b) ULTRASONIC TEST
c) ZYGLO TEST
d) RDP TEST
It is a Vocational Training Report (Summer Training Report) of 4 weaks in DLW, Varanasi, which consists introduction of DLW, Varanasi and 4 shops SMS (Sheet Metal Shop), SAS (Sub Assembly Shop), TMS (Truck Machine Shop) and LFS (Loco Frame Shop).
this is ppt based on my 4 weeks training at D.L.W varanasi I have included brief introduction along with introduction and working of various shops hope you will find helpful
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.
Summer Training Report,DIESEL LOCOMOTIVE WORKS,VARANASI(DLW)Vivek Yadav
Summer Training Report,
Locomotive Manufacturing Workshops(EES,LTS,LFS,HMS)
DIESEL LOCOMOTIVE WORKS, VARANASI(DLW),
MECHANICAL ENGINEERING,
Diesel locomotive works (DLW) is production unit under the ministry of railways. This was set up 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.
diesel locomotive works training report by somesh dwivedisomesh dwivedi
4week summer training report on D.L.W. Varanasi by Somesh Dwivedi.
on the topics 1.-Heavy Weld Shop(HWS)
2.- Heavy Machine Shop(HMS)
3. Light Machine Shop(LMS)
4. Truck Machine Shop(TMS)
4 weeks at internship - DLW VARANASI (U.P.) By Parvind GuptaParvind Gupta
About the industry:
Diesel Locomotive Works [DLW] is production unit under the ministry of railways. DLW is only manufacture of diesel electric locomotive with ALCO & General Motors [GM] based technologies in the words.
HELLO FRINDS THIS REPORT IS OF INDUSTRIAL TRAINING ON DIESEL LOCOMOTIVE TECHNOLOGY.
IT IS VERY HELP FULL FOR YOU .
SO GO THROUGH IT .
**********************Best Of Luck ************************
INTRODUCTION OF INDIAN RAILWAY
DIESEL LOCOMOTIVE WORKSHOP .CHARBAGH
DIESEL ELECTRIC LOCOMOTIVE
WORKING MECHANISIM
IMPORTANT COMPONENTS OF LOCOMOTIVES
a) POWER PACK
b) FUEL SECTION
c) LUBE OIL CONTROL SECTION
i. FUEL INJECTION PUMP (FIP)
ii. INJECTORS
d) TURBO SUPER CHARGING (TSC)
e) BRAKES
f) COMPRESSOR / EXPRESSOR
g) GOVERNORS
h) TRACTION MOTER
i) BOGIE
j) GENERATOR
k) RADIATOR
l) ENGINE SECTION
m) CROSS HEAD
i. INLET AND EXHAUST VALVE
FAILURE ANALYSIS
a) MAGNAFLUX LAB
b) ULTRASONIC TEST
c) ZYGLO TEST
d) RDP TEST
The Diesel Locomotive Works (DLW) in Varanasi, India, is a production unit owned by Indian Railways, that manufactures diesel-electric locomotives and its spare parts. It is the largest diesel-electric locomotive manufacturer in India.
Locally it is called as D L W.
DLW SUMMER TRAINING REPORT FOR ECE BRANCH SUBHAM SINGH
this report is very usful for student who are doing in a DLW summer training and also learns a lot of thing from this report .I have learnt a lot of things from DLW training and i feel lucky to this part of summer training in a DLW ,varanasi .And last things,I suggest to all of u ,please dont do training for attendance purpose ,honestly u should learn a lot of things which is better for ur future.DLW is an integrated plant and its manufacturing facilities are flexible in nature.
Summer Training Report Front page (DLW).Vivek Yadav
Summer Training Report,Only front page,
Locomotive Manufacturing Workshops,
DIESEL LOCOMOTIVE WORKS, VARANASI(DLW),
Full report on next upload,
Diesel locomotive works (DLW) is production unit under the ministry of railways. This was set up 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.
DLW Summer Training in Various Shop Like Telephone Exchange, ETS, MSS, SCADA. With Front Page Conclusion and Reference. In other Complete Summer Training Report for ECE Branch Student. if you want to download this report then click on the given link-
https://uploadocean.com/0rrwnlcvg2o8
Design and fabrication of multiway hacksaw machine pptEshver chandra
In this project work and effort has been made to develop a modernized multi way hacksaw machine and less stress full operation for cutting wood, metal and plastic materials. The aim of this work is to develop a hacksaw machine that will use a less effort to produce uniform cutting of PVC pipes, metals, wood. It is also done to show the performance difference between hand driven, pedal drive and multi way hacksaw machine.
Design and fabrication of multi way hacksaw machine REPORT Eshver chandra
In this project work and effort has been made to develop a modernized multi way hacksaw machine and less stress full operation for cutting wood, metal and plastic materials. The aim of this work is to develop a hacksaw machine that will use a less effort to produce uniform cutting of PVC pipes, metals, wood. It is also done to show the performance difference between hand driven, pedal drive and multi way hacksaw machine. This model implies a conversion of rotary motion of swashplate to reciprocating motion of hacksaw blades, which is done by using Wobble Plate Mechanism. This motion is used for hacksaw machine; in this model we can operate multi hacksaws simultaneously. This model will overcome the traditional hacksaw machine which done material cutting of single piece at particular times interval and also fulfils the need of more material cutting accounts to mass production. This machine works significantly with minimum vibrations and jerks. Hence the purposed model of hacksaw machines will be welcomed by many industries due to compactness and efficiency. To achieve this goal the multi way hacksaw machine is developed.
DESIGN & FABRICATION OF SHREDDING CUM BRIQUETTING MACHINE REPORT Eshver chandra
The demand for energy is becoming a critical challenge for the world as the population continues to grow. This call for Sustainable energy production and supply such as renewable energy technologies. Renewable energy technologies are safe sources of energy that have a much lower environmental impact than conventional energy technologies. So shredding machine is a key to make briquettes which will be used in industries as well as domestic purpose.
Fabrication of hydraulic wood splitter machine ReportEshver chandra
The cutter-splitter includes a wedge and a primary splitting blade for splitting a log along its length .Splitted wood can be used for the domestic as well as industries.
Complete Description of BHEL TRAINING REPORT for final year student of mechanical . Total Vocational training Report is listed with the content and proper description of turbine blade as well as major component of the training place .
Saudi Arabia stands as a titan in the global energy landscape, renowned for its abundant oil and gas resources. It's the largest exporter of petroleum and holds some of the world's most significant reserves. Let's delve into the top 10 oil and gas projects shaping Saudi Arabia's energy future in 2024.
Final project report on grocery store management system..pdfKamal Acharya
In today’s fast-changing business environment, it’s extremely important to be able to respond to client needs in the most effective and timely manner. If your customers wish to see your business online and have instant access to your products or services.
Online Grocery Store is an e-commerce website, which retails various grocery products. This project allows viewing various products available enables registered users to purchase desired products instantly using Paytm, UPI payment processor (Instant Pay) and also can place order by using Cash on Delivery (Pay Later) option. This project provides an easy access to Administrators and Managers to view orders placed using Pay Later and Instant Pay options.
In order to develop an e-commerce website, a number of Technologies must be studied and understood. These include multi-tiered architecture, server and client-side scripting techniques, implementation technologies, programming language (such as PHP, HTML, CSS, JavaScript) and MySQL relational databases. This is a project with the objective to develop a basic website where a consumer is provided with a shopping cart website and also to know about the technologies used to develop such a website.
This document will discuss each of the underlying technologies to create and implement an e- commerce website.
Industrial Training at Shahjalal Fertilizer Company Limited (SFCL)MdTanvirMahtab2
This presentation is about the working procedure of Shahjalal Fertilizer Company Limited (SFCL). A Govt. owned Company of Bangladesh Chemical Industries Corporation under Ministry of Industries.
Event Management System Vb Net Project Report.pdfKamal Acharya
In present era, the scopes of information technology growing with a very fast .We do not see any are untouched from this industry. The scope of information technology has become wider includes: Business and industry. Household Business, Communication, Education, Entertainment, Science, Medicine, Engineering, Distance Learning, Weather Forecasting. Carrier Searching and so on.
My project named “Event Management System” is software that store and maintained all events coordinated in college. It also helpful to print related reports. My project will help to record the events coordinated by faculties with their Name, Event subject, date & details in an efficient & effective ways.
In my system we have to make a system by which a user can record all events coordinated by a particular faculty. In our proposed system some more featured are added which differs it from the existing system such as security.
Vaccine management system project report documentation..pdfKamal Acharya
The Division of Vaccine and Immunization is facing increasing difficulty monitoring vaccines and other commodities distribution once they have been distributed from the national stores. With the introduction of new vaccines, more challenges have been anticipated with this additions posing serious threat to the already over strained vaccine supply chain system in Kenya.
Water scarcity is the lack of fresh water resources to meet the standard water demand. There are two type of water scarcity. One is physical. The other is economic water scarcity.
Forklift Classes Overview by Intella PartsIntella Parts
Discover the different forklift classes and their specific applications. Learn how to choose the right forklift for your needs to ensure safety, efficiency, and compliance in your operations.
For more technical information, visit our website https://intellaparts.com
Welcome to WIPAC Monthly the magazine brought to you by the LinkedIn Group Water Industry Process Automation & Control.
In this month's edition, along with this month's industry news to celebrate the 13 years since the group was created we have articles including
A case study of the used of Advanced Process Control at the Wastewater Treatment works at Lleida in Spain
A look back on an article on smart wastewater networks in order to see how the industry has measured up in the interim around the adoption of Digital Transformation in the Water Industry.
Courier management system project report.pdfKamal Acharya
It is now-a-days very important for the people to send or receive articles like imported furniture, electronic items, gifts, business goods and the like. People depend vastly on different transport systems which mostly use the manual way of receiving and delivering the articles. There is no way to track the articles till they are received and there is no way to let the customer know what happened in transit, once he booked some articles. In such a situation, we need a system which completely computerizes the cargo activities including time to time tracking of the articles sent. This need is fulfilled by Courier Management System software which is online software for the cargo management people that enables them to receive the goods from a source and send them to a required destination and track their status from time to time.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdffxintegritypublishin
Advancements in technology unveil a myriad of electrical and electronic breakthroughs geared towards efficiently harnessing limited resources to meet human energy demands. The optimization of hybrid solar PV panels and pumped hydro energy supply systems plays a pivotal role in utilizing natural resources effectively. This initiative not only benefits humanity but also fosters environmental sustainability. The study investigated the design optimization of these hybrid systems, focusing on understanding solar radiation patterns, identifying geographical influences on solar radiation, formulating a mathematical model for system optimization, and determining the optimal configuration of PV panels and pumped hydro storage. Through a comparative analysis approach and eight weeks of data collection, the study addressed key research questions related to solar radiation patterns and optimal system design. The findings highlighted regions with heightened solar radiation levels, showcasing substantial potential for power generation and emphasizing the system's efficiency. Optimizing system design significantly boosted power generation, promoted renewable energy utilization, and enhanced energy storage capacity. The study underscored the benefits of optimizing hybrid solar PV panels and pumped hydro energy supply systems for sustainable energy usage. Optimizing the design of solar PV panels and pumped hydro energy supply systems as examined across diverse climatic conditions in a developing country, not only enhances power generation but also improves the integration of renewable energy sources and boosts energy storage capacities, particularly beneficial for less economically prosperous regions. Additionally, the study provides valuable insights for advancing energy research in economically viable areas. Recommendations included conducting site-specific assessments, utilizing advanced modeling tools, implementing regular maintenance protocols, and enhancing communication among system components.
Hybrid optimization of pumped hydro system and solar- Engr. Abdul-Azeez.pdf
DLW Summer training report
1. 1
A VOCATIONAL TRAINING REPORT
ON
IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR
THE DEGREE OF BACHELOR OF TECHNLOGY
TO
DEPARTMENT OF MECHANICAL ENGINEERING
MAULANA AZAD NATIONAL INSTITUTE OF TECHNOLOGY
BHOPAL , MADHYA PRADESH
SUBMITTED TO; SUBMITTED BY;
Eshver Chandra
Mr. B.tech , 4th
YEAR
Mechanical engineering
Sch. no. 131116244
2. 2
ACKNOWLEDGEMENT
This Project Report is combined effort of many people who have
contributed in their own ways in making this report effective and
purposeful. In my report, I would like to take the opportunity of thanking
all those who have been instrumental in preparing this report.
I would sincerely like to thank the employees and the officers of DLW,
Varanasi for their help and support during the vocational training. Despite
their busy schedule, they took out time for us & explained to us the various
aspects of the working of the plant, from the production shops.
I would sincerely like to thank Mr. Ashutosh Singh (JE/E.E.S.) ,Mr. P.K.
Shukla (SSE/E.T.S.) and Mr. Jitendra yadav (JE/L.T.S.), Mr. Shyam Prajapati
(JE/L.A.S. ) who was instrumental in arranging the vocational training at
DLW Varanasi, and without whose help and guidance the training could not
have materialized.
I express my deep sense of gratitude to Mr. Gyanesh tripathi (Principal,
TTC) for given me such a great opportunity.
I expressed my thanks to the lecture Mr. J.L. Bhagoria & HOD of
department, I would also thank my institution & my faculty members
without whom this report would have been a distant reality.
I also extend my heartfelt thanks to my family & well wishers.
3. 3
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 exposure or real life experience no doubt
they help in improving the personality of 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 the Final Year Mechanical Engineering & this report is
written on the basis of practical knowledge of acquired by me during the
period of practical training taken at Diesel Locomotive Works, Varanasi.
This report is presented in very simple & understanding language on the basis
of Primary and Secondary data.
Eshver chandra
M.E. (4th
Year)
131116244
4. 4
DECLARATION
I Eshver Chandra, Sch. No-131116244, student of B.Tech
(Mechanical Engineering) 4th
year of Maulana azad National Institute of
Technology hereby declare that my project report on “ DIESEL
LOCOMOTIVE WORKS ” is an original and authenticated word done by me.
I further declare that it has not been submitted elsewhere by any person in
any of the institutes for the degree of bachelor’s of technology.
Eshver chandra
Mechanical Engineering
Final year
131116244
5. 5
TABLES OF CONTENTS
Acknowledgement
Preface
Declaration
Introduction of D. L W.
Identification of locomotives
Product
EMD Specification
ALCO Specification
Vision & Mission
Line Diagram of Diesel Locomotive
Engine erection Shop
Engine testing Shop
Loco assembly Shop
Loco testing Shop
Finding & Conclusion
Learning Experience
6. 6
INTRODUCTION
Background
Diesel Locomotive Works (DLW) is 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 LCO/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 locomotive. Indian Railways is the state-owned railway
company of India.
7. 7
It comes under the Ministry of Railways. Indian Railways has one of the largest
and busiest rail networks in the world, transporting over 18 million passengers
and more than 2 million tonnes of freight daily. Its revenue is Rs.107.66 billion.
It is the world's largest commercial employer, with more than 1.4 million
employees. It operates rail transport on 6,909 stations over a total route length
of more than 63,327 kilometres (39,350 miles).The fleet of Indian railway
includes over 200,000 (freight) wagons, 50,000 coaches and 8,000 locomotives.
It also owns locomotive and coach production facilities. It was founded in 1853
under the East India Company. Indian Railways is administered by the Railway
Board. Indian Railways is divided into 16 zones. Each zone railway is made up of
a certain number of divisions. There are a total of sixty-seven divisions. It also
operates the Kolkata metro. There are six manufacturing plants of the Indian
Railways. The total length of track used by Indian Railways is about 108,805 km
(67,608 mi) while the total route length of the network is 63,465 km
(39,435 mi). About 40% of the total track kilometer is electrified & almost all
electrified sections use 25,000 V AC. Indian railways uses four rail track gauges.
The broad gauge (1670 mm)
The meter gauge (1000 mm)
Narrow gauge (762 mm)
Narrow gauge (610 mm).Indian Railways operates about 9,000 passenger
trains and transports 18 million passengers daily .Indian Railways makes 70%
of its revenues and most of its profits from the freight sector, and uses these
profits to cross-subsidies the loss-making passenger sector. The Rajdhani
Express and Shatabdi Express are the fastest trains of India.
CLASSIFICATION
Standard “Gauge” designations and dimensions:-
W = Broad gauge (1.67 m)
Y = Medium gauge ( 1 m)
Z = Narrow gauge ( 0.762 m)
N = Narrow gauge ( 0.610 m)
8. 8
“ Type of Traction” designations:-
D = Diesel-electric traction
C = DC traction
A = AC traction
CA=Dual power AC/DC traction
The “ type of load” or “Service” designations:-
M= Mixed service
P = Passenger
G= Goods
S = Shunting
“ Horse power ” designations from June 2002 (except WDP-1 & WDM-2
LOCOS)
‘ 3 ’ For 3000 horsepower
‘ 4 ’ For 4000 horsepower
‘ 5 ’ For 5000 horsepower
‘ A ’ For extra 100 horsepower
‘B’ For extra 200 horsepower and so on.
Hence ‘WDM-3A’ indicates a broad gauge loco with diesel-electric traction.
It is for mixed services and has 3100 horsepower
10. 10
SALIENT FEATURES:
Annual production capacity125 Locomotives
Annual turn-over (Rs) 5000 million
Total number of staff 7223
Workshop land 89 Hectares
Township area 211 Hectares
Covered area in shops86300 Sq.m
Covered area of other service buildings 73700 Sq.m
Electrical power requirement 3468 KVA
(Average maximum demand)
Electrical energy consumption (units/year) 19.8 million
Standby power generation capacity 3000 KW
11. 11
IDENTIFICATION OF LOCOMOTIVES AT DLW
Following types of diesel loco are being produced in the DLW:-
WDM- Wide Diesel Mixed
WDP- Wide Diesel Passenger
WDG- Wide Diesel Goods
WDS- Wide Diesel Shutter
The First Letter (Gauge)
W- Indian broad gauge(The “W” stand for wide Gauge-5ft)
Y- Meter gauge(The “Y” stands for Yard gauge-3ft )
Z- Narrow gauge(2ft 6 inch)
N- Narrow gauge (2ft)
The Second Letter (Motive Power)
D- Diesel
C -DC Electric(can run under DC traction only)
A- AC Electric(can run under AC traction only)
12. 12
CA- Both DC & AC(can run under both AC & DC tractions)
B- Battery Electric locomotive (rare)
The Third Letter (Job Type)
G- Goods
P- Passenger
M- Mixed, both goods & passenger
S- Shunting(also known as switching engines)
U- Electric multiple units (used as commuters in city suburb
14. 14
Products
EMD(Electro Motive Division)
WDG-4000 HP GOODS LOCOMOTIVE
Broad Gauge free ght traffic Co-Co diesel electric locomotive with 16
Cylinder 4000 HP, AC-A C transmission, microprocessor controlled
propulsion and braking with high traction high speed cast steel trucks.
First turned out i n 1999 with transfer of technology from General Motor
(USA), this locomotive has exceptional fuel efficiency and very lo w
maintenance requirements. It is specific ally designed for heavy haul freight
traffic requirements of Indian Railways for the 21st Century.
The heart of loco Traction Control Converter uses the GT O devices (obsolete
technology). Now the IGBT devices, has been introduced from Oct 2006. It is
the latest technology and will be cost effective and gives higher reliability
.The locomotive power has been upgraded to 4500 BCV an d the first Loco
(Loco No 12114) was manufactured in May 07.
15. 15
General Characteristic
Installed Power Axle Load
Gauge
Wheel arrangement Wheel diameter
Height Width
Overall Length (Over Buffer Beam)
Weight
Max tractive effort Maximum speed
Fuel tank capacity Locomotive Control
4000 HP 21 T
1676 mm Co-Co
1092 mm 4201 mm 3127 mm 19964 mm 126 T
54 T
100 Kmph 6000 lts
EM 2000 with SIBAS-16 Traction Control
WDG4-4000 HP GOODS TRACTIVE EFFORT & POWER CHART
LOCOMOTIVE
16. 16
2. WDP4-4000 HP PASSENGER LOCMOTIVE
State-of-Art, Microprocessor controlled AC-AC, Passenger Locomotive Powered with 16-
710G3B4000HPTurbo charged Two stroke Engine.
Fabricated rigid design Under frame, two stage suspension, High Traction High Speed 3
axle (HTSC) light weight cast truck frame attribute to high adhesion performance.
First turned out in 2003, this locomotive has exceptional fuel efficiency and
very low maintenance requirements. It is specifically designed for heavy haul passenger
traffic requirements for Indian Railways.
The WDP4 fleet is being upgraded by provision of hotel load feature along with power
up gradation to 4500 HP. Theprototype will be manufactured in the year 2007.
Diesel Engine Transmission
16 Cylinder 710 G3B, 2 stroke, Electrical AC-AC
turbocharged after cooled
4 Traction motor ( 3 in parallel per
Fuel Efficient Engine bogie)
Injection System Direct Unit Suspension Axle hung / taper
Injector roller bearing
Governor Woodward Gear Ratio 77:17
Compression Ratio- 16:1
Lube Oil Sump Capacity 1073 Lts
17. 17
Truck Brakes
High adhesion HTSC ( High Electronic Air Brake System (
Tensile Steel Cast) truck or bogie KNORR-NYAB-Computer Controlled
Adhesion 0.42
Braking)
Air , hand , dynamic brake with fully
blended with automatic brakes
Pure air brake
General Characteristic
Installed Power 4000 HP
Axle Load 19.5 T
Gauge 1676 mm
Wheel arrangement A-A-I I-A-A
Wheel diameter 1092 mm
Height 4201mm
Width 3127 mm
Overall Length (Over 19964 mm
Buffer Beam)
117 T
Weight
27 T
Max tractive effort
160 Kmph
Maximum speed
4000 lts
Fuel tank capacity
EM 2000 with SIBAS-16 Traction Control
Locomotive Control
18. 18
ALCO(AMERICAN LOCOMOTIVE COMPANY)
1350 HP CAPE GAUGELOCOMOTIVE VDM 4
TECHNICAL INFORMATION
1350 HP Locomotivehaving fabricated cape gauge Co-Co bogie. These locomotives
have been supplied to Angola and Sudan.
Track Gauge
1067 mm Cape gauge
Weight
72 t
Overall Length
15600 mm
Wheel Diameter
921 mm
Gear Ratio
19. 19
18: 93
Maximum Speed
90 Kmph
Diesel Engine Type : ALCO 251 D 6 Cyl.
1350
Transmission
Electrical AC/DC
Brake
28LAV-1 system
Loco
Air, dynamic,
parking
Train Air & Vacuum
Fuel Tank Capacity 3000 ltr
20. 20
2. 2300 HP CAPE GAUGE LOCOMOTIVE
TECHNICAL INFORMATION
2300 HP Main Line Locomotive, having fabricated cape gauge Co-Co bogies. These are provided
with two driver’s cabs, one at each end. These locomotives have been supplied to Angola and
Sudan.
Wheel Arrangement Co-Co
Track Gauge 1067 mm Cape Gauge
Weight 102 t
Overall Length 17620 mm
Wheel Diameter 921 mm
Gear Ratio 18 : 93
Maximum Speed 100 Kmph
Diesel Engine Type: ALCO 251-B 12 Cyl. V- Engine
HP 2300
Transmission Electrical AC/DC
Brake IRAB-1
Loco Air, Dynamic, parking
Train Air
21. 21
3. 2300HP METER GAUGE LOCOMOTIVE
TECHNICAL INFORMATIO
2300 HP Main Line Locomotive, having fabricated meter gauge Co-Co bogies. These are provided
with two drivers cabs, one at each end. These locos have been supplied to Malaysia, Senegal and
Mali.
Wheel Arrangement Co-Co
Track Gauge 1000 mm Meter Gauge
Weight 102 t
Overall Length 17620 mm
Wheel Diameter 921 mm
Gear Ratio 18 : 93
Maximum Speed 100 Kmph
Diesel Engine Type: ALCO 251-B 12 Cyl. V- Engine
HP 2300
Transmission Electrical AC/DC
Brake IRAB-1
Loco Air, Dynamic, parking
Train Air
22. 22
4. BROAD GAUGE MAIN LINE FREIGHT LOCOMOTIVE
WDG 3A
TECHNICAL INFORMATION
Diesel Electric main line, heavy duty goods service locomotive, with 16 cylinder ALCO engine and
AC/DC traction with micro processor controls.
Wheel Arrangement Co-Co
Track Gauge 1676 mm
Weight 123 t
Length over Buffers 19132 mm
Wheel Diameter 1092 mm
Gear Ratio 18 : 74
Min radius of Curvature 117 m
Maximum Speed 105 Kmph
Diesel Engine Type : 251 B,16 Cyl.- V
HP 3100
Brake IRAB-1
Loco Air, Dynamic
Train Air
Fuel Tank Capacity 6000 liters
23. 23
VISION & MISSION
Our Vision -”To be a world class manufacturer of Diesel - electric
locomotives."
Our Mission- "We shall achieve our vision through Continuous
Improvement in the areas of Product Quality, Research and
Development, Supplier Partnership, Human Resource
Development and Team Work with emphasis on Core Competence
leading to Customer Satisfaction and Business Excellence."
24. 24
LINE DIAGRA M OF DIESEL LOCMO TIVE
Main Alternator:-
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. In older locomotives, the
alternator was a DC machine, called a generator. It produced direct current
which was used to provide power for DC traction motors. Many of them
machines are still in regular use. The next development was the replacement of
the generator by the alternator but still using DC traction motors. The AC
output is rectified is give the DC required for the motors.
Auxiliary Alternator:-Locomotive used to operate passenger trains are
equipped with an auxiliary alternator. This provides AC power for lightening,
heating, air conditioning, dining facilities etc on the train .The output is
transmitted along the train through an auxiliary power line.
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MOTOR BLOWER
The diesel engine also drives a motor blower. As its name suggests , The motor blower
provides the air which is blown over the traction motors to keep them coolduring
periods of heavy work. The blower is mounted inside the locomotive bodybut 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. Some design s have separate blowers for
the group of motors on each truck and others for the alternators. Whatever the
arrangement , a modern locomotive has a complex air management system which
monitors the temperature of the various rotating machines in the locomotive and adjust
the flow of air accordingly.
AIR INTAKE.
The air for cooling the locomotives motors is drawn in from outside the locomotive . It
has to be filtered to remove dustand other impurities and its flow regulated by
temperature , both sides and of the locomotive. The air temperature system has to take
account of the wide range of temperatures from the possible +40°C of summer and to
the possible -40°C of winter.
ELECTRONIC CONTROLE
Almost every part of the modern locomotive equipment has some of electronic control.
These are usually collect d in a control cubicle near the cab for easy access.
26. 26
Cab :
The standard configuration of US- designed locomotive is to have a cab at one end of
the locomotive only.
Batteries
Just like automobile , the diesel engine needs a battery to start it and to provide
electrical power for the lights and controls when the engine is switched off and the
alternator is not running.
Tractionmotor
Since the diesel- 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 the modern power and control electronics has led to the introduction of 3Φ AC motors.
27. 27
PINION/GEAR ;-
The traction motor drives the axles through a reduction gear of a range between 3 to1
and 4 to 1 (passenger)
Fuel tank;-
A diesel locomotive has to carry its own fuel around with it and there has to be enough
for a reasonable length of trip. The fuel tank is normally under the loco frame and will
have a capacity of say 1000 imperial gallons .the new AC 6000s have 5500 gallon tanks
.In addition to fuel , the locomotive will carry around , typically about 300US gallon of
cooling water and 250 gallon of lubrication oil for the diesel engine.
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Air compressor :-
The air compressoris required to provide a constant supply of compressed air for the
locomotive and train brakes.
Drive shaft;-
The main output from the diesel engine is transmitted by the drive shaft to
the alternators at one end and the radiator fans and compressorat the other end.
Gearbox :-
The radiator and its cooling fan are often located in the roof of the
locomotive . Drive to the fan is therefore through a gearbox to change the direction of
the drive upwards.
Turbo charger;-
The amount of the power attained from a cylinder in a diesel engine depends on how
much fuel can be burn it in. the amount of fuel which can be burnt depends on the
amount of air available in the cylinder .So turbocharger is used to increase the amount
of air pushed into each cylinder . The turbocharger is driven by exhaust gas from the
engine . This gas drives a fan which in turn , drives a small compressor which pushes
the additional air into the cylinder. The turbo charging gives a 50% increase in engine
power.
29. 29
Sand box:_
Locomotives always carry sand to assist adhesion in bad rail conditions.
Truck frame :-
This is part (called the bogie in the UK) carrying the wheels and traction motors of the
locomotive.
MECHANICAL TRANSMISSION:-
As the name suggests, a mechanical transmission on a diesel locomotive consists a
direct link between the diesel engine and the wheels. In the example given below , the
diesel engine is in the 350-500HP range and the transmission is similar to that of an
automobile with a four speed gearbox
30. 30
STARTING :-
A diesel engine is started(like an automobile) by turning over the crankshaft until the crankshaft until
the cylinders fire or begin combustion .The starting can be done electrically or pneumatically
.Pneumatic starting was used for some engines. Compressed air was pumped into the cylinders of the
engine , until it gain sufficient speed to allow the ignition , than fuel was applied to fire the engine. The
compressed air was supplied from a small auxiliary engine or by high pressure air cylinders carried by
the locomotive. Electric starting is now standard . It works same way as for an automobile, with
batteries providing the power to turn a start motor which turns over the main engine. In older
locomotives fitted with DC generators instead of AC alternators, the generator was used as a starter
motor by applying battery power to it.
Governor:-
Once a diesel engine is running , engine speed is monitored and controlled through a
governor . Governors ensures that the engine speed stays high enough to idle at right speed and that the
engine speed will not raised to high when full power is demanded. The governors is simple mechanical
device which first appeared on steam engines . It operate on the diesel engine as shown in the diagram
below .
31. 31
Cooling:-
Like an automobile engine , the diesel engine need to works at an optimum
temperature for best efficiency .when it starts , it is too cold , and when
working ,it must not to be allowed to get too hot. To keep the temperature
stable , a cooling system is provided
.this consist of a water based coolant circulating around the engine block,
the coolant being kept cool by passing it through a radiator. Another
reason for keeping diesel engines running is that the constant heating and
cooling caused by produce leaks.
Lubrication:-
Like an automobile engine , a diesel engine needs
lubrication. In an arrangement similar to the engine cooling system,
lubrication oil is distributed around the engine to the cylinder ,crankshaft
and other moving parts .The radiator is sometimes design as a heat
exchanger ,where the oil passes through pipes encased in a water tank
which is connected to the engine cooling system .The oil has to be filtered
to remove impurities and it has to monitored for low pressure if oil
pressure falls to a level which could cause the engine to size up ,a “low oil
pressure switch” will shut down the engine .There is also a high pressure
relief valve ,to drain off excess oil back to the sump
.
Transmissions:-
Like an automobile, a diesel locomotive cannot start
itself directly from a stand. It will not develop maximum power at idling
speed, so it needs some form of transmission system to multiply torque
when starting. It will also be necessary to vary the power applied according
to the train weight or the line gradient. There are three methods of doing
this: mechanical, hydraulic or electric . Most diesel locomotive use electric
transmission and are called “diesel-electric” locomotive . Mechanical and
hydraulic transmission are still used but are more common on multiple unit
trains or lighter locomotives.
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engine erection shop
This shop mainly deals with the fabrication of the engine
block and base (B.G. & M.G.) Turbo support. There are
many components which are assembled . some of them are
listed below-
Assembly of the major component of the locomotive engine
1. Lube oil container ( base )
2. Crankshaft and crankcase
3. Governor and double fuel filter
4. Strainer
5. Double water circulator
6. Flywheel
7. OST shaft
8. Rocker arm
9. Alternator
10. Turbo super charger
33. 33
11. Air intake and exhaust system
1. Inspection standard
2. Proper materials
3. Proper electrodes and flux
4. proper welding technique
5. welfare of staff
34. 34
ENGINETESTING SHOP
The testing of the engine is done for 3 hours in this shop
In this shop testing of the engine performed
1. Initial filling of the lube oil and fuel
2. Observation of the vibration
3. Sensing and controlling the temperature
4. Controlling the pressure
5. soak valve pump
6 . Circulation of water and sensing of temperature
7. Initial supply of the 72 V for starting
35. 35
LOCOASSEMBLYSHOP
Assembly of the major component of the locomotive on the locomotive
frame
1. Driver cabin
2. Fins , cooler and fan
3. Rack positioning
4. Water circulation tube and tank
5 . Major lube oil filter
6. Governor system
7. Engine assembly
8 . Alternator and auxiliary generator
9. Air filter and blower
39. 39
LOCOTESTING SHOP
When all the perform are done then finallyengine come in ETS,
for the first inspectionreport and after this it will be agreed for the
performance
Testing of the final locomotive on the basis of several performance
1. Initial filling of lube oil ( approx 4200 ltr)
2. Filling of all fuel ( approx 3000 ltr)
3. Load testing
4. Testing of MR1 and MR2
5. Air brake testing
6. Water circuit check
7. Testing of dynamic brake
8. Lightning inspection
9. testing of speed
10. testing of alignment
42. 42
FINDING ANDCONCLUSION:-
After completing my project I familiarize with DLW, and I get that diesel
locomotive works is a famous technological temple, which came in
existence, in 1964 by Late Shri Lal Bahadur Shastri. DLW export to the
following countries like Sri Lanka,
Bangladesh, Angola, Tanzania, Vietnam ,Sengal Mozambique, Malaysia,
Sudan, Myanmar etc.
There are many facilities for the employees as hospital, health club, sports
club, school and college, sewing center, technical training center etc. In short
we can say that all the facility which the ordinary employee needed is
provided by welfare department and the entire employee are very well
aware with welfare programmers. They take advantage with programme in
any form. Very few improvement but important improvement, which
mentioned above, is needed in welfare programmes, which make the
employees more satisfied.
43. 43
Learning Experience
Working on this project was a pleasure for me as I learned lot of things
which was unknown to me before doing this project. I worked In, engine
erection shop (EES), Engine testing Shop (ETS),Loco assembly shop
Shop(LAS) ,Loco testing shop (LTS) and my job description includes regular
updating status to know about all related to Production Unit, Diesel
Generating sets and their spares for Indian Railways and Non-Railways
customer.
I tried to give my best effort on this project but it could be more better if I
would have theoretical knowledge about workshops before taking this
project. As this topic was new to me and due to time constraint I was not
able to through each and every Procedure.