This document is a summer training report about diesel locomotive works in Varanasi, India. It provides an introduction to the DLW facility, which manufactures diesel-electric locomotives. It then summarizes the main shops in DLW, including the main receiving substation, traction assembly shop, and loco testing shop. Key components of the locomotives like the diesel engine and traction motors are also described. The document concludes with references used in compiling the report.

1. Summer training report
on
diesel locomotive works Varanasi

2. SUMMER TRAINING REPORT
ON
“DIESEL LOCOMOTIVE WORK”
SUBMITTED TO:- SUBMITTED BY:-
RAMJANM CHAUBEY Gaurav Singh
EE
214505

3. CONTENTS
• Introduction
• Shop 1: Main Receiving Substation
• Shop 2: Traction assembly Shop
• Shop 3: Loco Testing Shop
• Shop 4: Colony
• Conclusion
• References

4. INTRODUCTION
 DLW, was founded by Late Railway Minister Mr. Lal Bahadur
Shastri on 23 April 1956. It is spread in 300 acres area at
Varanasi.
 It is a production unit owned by Indian railways , for which it
manufactures diesel–electric locomotives and its spares parts.
 DLW rolled out its first locomotive 8 years later, on January 3,
1964. It manufactures locomotives.
4

5. CONTINUE…..
• Got its first ISO certification in 1997 and ISO-9001 and ISO-
14001 in December 2002.
• At present the latest locomotive produced by DLW; i.e. WDG 5
has capacity upto 5000 HP & trying to make it 5500 HP.
• It has supplied locomotives to other countries such as Sri Lanka,
Bangladesh, Malaysia, Tanzania and Vietnam etc.
• DLW is supplying locos to PSU’s & Industries Like NTPC,
COAL, INDOGULF etc.
5

6. Some Facts About Diesel Electric Locomotive
DLW’s annual production - 250 Locomotives
Cost of one loco - 12 to 14 crore (EMD)
8 crore (Alco)
Weight of one Loco - 121 Ton
Fuel Consumption; At Full Load - 540 lt/hr.
Idle Load - 40 lt/hr.
6

7. Fuel Consumption; At Full Load - 540 lt/hr.
Idle Load - 40 lt/hr.
Max. Speed - 160 Km/hr.
Dia of Wheel - 1092 mm
Wheel to Wheel Distance - 1596.5 mm
Length of Under Frame - 19962 mm

8. DIESEL ELECTRIC LOCOMOTIVE
• In a diesel-electric locomotive, the diesel engine drives an electrical generator or
alternator whose output provides power to the traction motors. There is no
mechanical connection between the engine and the wheels.
8
Fig 1: Block Diagram of LOCO

9. LOCOMOTIVE PARTS
• Main Alternator
• Auxiliary Alternator
• Motor Blower
• Rectifiers/Inverters
• Electronic controls
• Cab
• Truck Frame
• Traction Motor
• Fuel Tank
• Air Reservoirs
• Air Compressor
• Gear Box
• Radiator and Radiator Fan
• Turbo Charging
• Sand Box
9

10. CLASSIFICATION OF LOCOMOTIVES
Locos, except the older steam ones, have classification codes that identify them. This code is of
the form:
WDG5A which means “ [ gauge ][ power ][load ][ series ][ sub type ]”
• THE FIRST LETTER (GAUGE)
W- Indian broad gauge
Y- meter gauge
Z- narrow gauge(2.5 ft)
N- narrow gauge (2 ft)
 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)
CA- Both DC and AC (can run under both AC and DC tractions)
B- Battery electric locomotive (rare)
10

11. Fig 2: Control Panel of WG3A loco

12. Continue……
 THE THIRD LETTER (LOAD TYPE)
G- Goods
P- Passenger
M- Mixed traffic ; both goods and passenger
S- Used for shunting
U- Electric multiple units (E.M.U.)
R- Railcars
• THE FOURTH LETTER (SERIES)
The series digit identifies the horsepower range of the locomotive.
e.g. Series letter ‘3’ means that the locomotive has power over 3000 hp but less than
4000 hp.
• THE FIFTH LETTER (SUBTYPE)
an optional letter or number that indicates some smaller variations in the basic model.
e.g.: ‘A’ for 100 hp; ‘B’ for 200 hp and so on……..
12

13. 1. Block Divisions
2. Engine Divisions
3. Loco Divisions
Production Shops
 Block Division
1. Heavy Weld Shop
2. Heavy Machine Shop

14. 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
7. Turbo Section

15. 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

16. MAIN RECEIVING SUBSTATION
• It receives the supply of 11 kv .which is supplied through 132KV
kanchanpur
• Substation . it distribute the supply to all the workshops by Ring main
distri
• -bution system. The advantage of ring main system is that each end is
fed
• From two sides .if in case one line is faulted then the substation is fed
by
• Other line .but its cost is its major disadvantage.

17. Cont…
• Main components of MRS
• Transformer
• Control panel
• Bus coupler
• Relays
• Circuit breakers
• Capacitor bank
• Different type of transformer used in MRS
• Potential transformer
• Current transformer
• Distribution transformer
• There are total 3DG sets are available in DLW,in which two DG sets are having
capacity of 2.4MW and one DG has capacity of 3 MW

18. TRACTION ASSEMBLY SHOP(T.A.S.)
This shop consists of following sections-
• Harnessing section
• Battery section
• Assembly section
• Sub-Assembly section
• Cab section

19. Harness section
In this section all the multiple unit cables are
harnessed for making connection between
two locos under overloading condition of single
Loco.

20. Battery Section
Battery is an electrochemical cell which convert
Chemical energy into electricity
There are two types of battery used
• Lead acid(8volt,500ah)
• Ni cd (1.2 volt,150ah)

21. Assembly section
In a diesel-electric locomotive ,the diesel engine
drives an electric generator or alternator whose
output provides power to the traction motors
There is no mechanical connection between the
Engine and the wheels.

22. LOCO TEST SHOP(LTS)
Fig 3: FINAL LOCO TEST

23. LUBRICATING OIL TESTING
• Lubrication is done for better performance of the engine
parts.
• testing is done by checking the circulation of lubricant oil.
• For rotating parts checking is done by seeing the returning
path of the oil i.e. checking not only the forward path but also
the returning path.
• RR40 is used as lubricating oil.
TYPES OF TESTING

24. WATER TESTING
• Water acts as a coolant for moving part of the engine because constant
movement or rotation causes various parts to heat up and water working as
coolant cooled down the concerned part.
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.

25. ENGINE TEST OPERATION SEQUENCE
 Base inspection under screen and fitting over screen.
 Water circulation.
 Lube oil filling and check deflection crank shaft.
 Lube oil circulation.
 Pre run on no load 3 to 5 times of duration 10 to 30 min
each 400 rpm.
 Intermediate runs 12 runs of 30 min duration each from
400 to 1000 rpm.

26.  Check over speed trip of recheck 3 times.
 Check bake in nozzles and set tapped clearance.
 Inspection before fist hour performance.
 First hour performance on full load.
 Base inspection.
 Second hour performance on full load.
 Attend defects of first hour performance.
 Final base inspection.
 Check engine deficiencies.
 Engine clearance.

27. COLONY
• A 132/33 KV substation is present in kanchanpur which
receives power from UPPTCL.
• This substation supplies power to colony as well as Main
receiving station
• Here one 40 MVA transformer is installed for for UPPCL
from which supply is received and two 20MVA
transformer are installed to supply MRS & colony
• Measuring and protection equipment are installed to help
in proper controlling power supply and SCADA system
helps in controlling the switchyard easily

28. TRACTION MOTOR
• Electric motor providing the primary rotational
torque of a machine, usually for conversion into
linear motion.
•DC series-wound motors, running on
approximately 600 volts.
•The availability of high-powered semiconductors
such as thyristors has now made practical the use
of much simpler, higher-reliability AC induction
motors.
28
Fig 3: Traction Motor

29. Fig:Substation transformer. Fig: Block diagram

30. ELECTRIC TRANSMISSION
• The diesel-electric locomotive uses electric transmission, where 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.
• Generally there are six motors on most diesel-electric locomotives. A modern AC
motor with air blowing can provide up to 1,000 hp.
30

31. DIESEL ENGINE
• This is the main power source for the locomotive.
• The engines mostly used are V Type.
• As the transmission is electric, the engine is used as the power source for the
electricity generator or alternator, as it is called nowadays.
31

32. Fig: diesel engine of ALCO loco

33. REFERENCES
• 1.Materials provided at DLW, Varanasi, India.
• 2. www.dlw.indianrailways.gov.in/.
• 3. onlinedlwinternship.in/.
• 4.https://www.slideshare.net/summer-training-report/.