The document is a report submitted by Manoj Kumar Verma summarizing his summer vocational training at Diesel Locomotive Works (DLW) in Varanasi, India. It provides an overview of DLW, including its manufacturing process, products, and the departments and areas Manoj received training in, such as the telephone exchange, maintenance service shop, and SCADA. It also includes line diagrams of diesel locomotive components like the alternator, motor blower, electronic control, cab, batteries, and traction motor.

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SUMMER VOCATIONAL TRAINING
REPORT -2018
AT
TTC DLW, VARANASI
SUBMITTED TO: SUBMITTED BY :
TECHNICAL TRAINING CENTER (TTC ) MANOJ KUMAR VERMA
DLW , VARANASI BRANCH – ELECRONICS &
COMMUNICATION ENGG.
B.TECH 3RD
YEAR
NAME OF COLLAGE -SCRIET ,MEERUT
REG. NO.-TTC/DLW/18/1952
Disel Locomotive Works, Varanasi
An ISO 9001,ISO 14001 & OHS 18001 Certified Organisation
Varanasi 221004 , Utter Pradesh (India)

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TABLE OF CONTENTS
ACKNOWLEDGEMENT
PREFACE
CHAPTER 1
Introduction to DLW ------------------------------------------------------------------------
CHAPTER 2
Manufacturing Process-----------------------------------------------------------------------
CHAPTER 3
Classification of locomotives ----------------------------------------------------------------
CHAPTER 4
Line Diagram of diesel locomotives-----------------------------------------------------------
4.1 Alternator------------------------------------------------------------------------------
4.2 Motor Blower---------------------------------------------------------------------------
4.3 Electronic Control----------------------------------------------------------------------
4.4 Cab----------------------------------------------------------------------------------------
4.5 Batteries-------------------------------------------------------------------------------------
4.6 Traction Motor--------------------------------------------------------------------------------
4.7 Turbo Charger-----------------------------------------------------------------------------------
4.8 Air Compressor-----------------------------------------------------------------------------------
4.9 Truck Frame -----------------------------------------------------------------------------------------
TRAINING AREAS( ASSIGNED SHOP)
1. TELEPHONE EXCHANGE
2. MAINTENANCE SERVICE SHOP
3. SCADA
4. MAINTANANCE AREA (II)
CONCLUSION------------------------------------------------------------------------------------------

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ACKNOWLEDGEMENT
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 schedules, they took time out for us
and explained to us the various aspects of the working of the plant from the production shops.
I would sincerely like to thank ER. GUPTA SIR.(Assistant ELECTRONIC Engineer), Mr. Pawan
Kumar Srivastava (Chief Workshop Instructor/Weld), who was instrumental in arranging the
vocational training at DLW Varanasi, and without whose help and guidance the training could not
have materialize.
I express my deep sense of gratitude to Mr. Ram Janm Chaubey (Principal, TTC) for given me such
a great opportunity.

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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 Electronic & Communication
Engineering, every student is required to undergo a practical training.
I am student of third year mechanical and this report is written on the basis of practical knowledge
acquired by me
during the period of practical training taken at Diesel Locomotive Works, Varanasi.

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Chapter 1
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 GENERL 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.
Fig1.1 Diesel Locomotive Works, Varanasi
ABOUT DLW:-
a) Set up in 1961 as green field project in technical collaboration with ALCO /USA to manufacture
Diesel electric locomotives.
b) First locomotive rolled out and dedicated to nation in January, 1964.
c) Transfer of Technology agreement signed with General motors /USA in October, 1995 to
manufacture state of the art high traction AC-AC diesel locomotives.
d) A flagship company of Indian Railways offering complete range of flanking products in its area
of operation.

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e) 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.
f) Unbeatable trail blazing track record in providing cost effective, eco-friendly and reliable
solutions to ever increasing transportation needs for over three decades.
g) Fully geared to meet specific transportation needs by putting Price-Value Technology equation
perfectly right.
h) 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 categories.
SALIENT FEATURES:-
Annual production capacity 125 Locomotives
Annual turn over (Rs) 5000 millions
Total number of staff 7223
Workshop land 89 hector
Township area 211 hectares
Covered area in shops 86300 m^2
Covered area of other service buildings 73700 m^2
Electrical power requirement 3468 KVA
(Average maximum demand)
o
Electrical energy consumption (units/year) 19.8 million
Standby power generation capacity 3000 KW
//

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Chapter-02.
2.1.MANUFACRTING PROCESS
Production unit are divided in three Divisions:-
1. Block division
2. Engine division
3. Loco division
a) Block division
1. Heavy Weld shop
2. Heavy Machine Shop
b) 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
c) 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
d) Service shop
1. Maintenance Area @ 1, 2, 3

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2. Tool Room
3. Central Transport Shop
e) Personal department
Prepare payment of Staff, Leave Record, Personal Record of every Employee, Housing
allotment, Welfare of Staff Etc.
f) Health department
Having facility of Indoor & Outdoor patients.
g) Civil department
Maintenance of colony quarters, up gradation of facilities in quarters, sanitation.
h) Electrical department Maintenance of Lighting in quarters and in workshop, electrical work in
locomotive Etc.
i) Technical training centre
Provide training to all employees at time to time to refresh update their
knowledge. j) Research & development
1. A Customer centric Activity Committed to innovation and Continuous Improvement.
2. Highly skilled manpower capable of handling complete R&D activities.
3. A sophisticated design centre with modern CAD/CAE workstations equipped with unigraphics
and Ansys.
4. Back-up support from RDSO, a centralized R&D organization at corporate
level.
5. Several milestones in the past – an enviable pedigree viz.
a) Original ALCO design made 7% more fuel efficient.
b) Many design improvements leading to better performance, incorporated in the original
ALCO design.
c) Many new design for locomotives such as WdP1, WDG2, WDP2, WDP4, WDP5 to name a
few.
k) Recent milestones
a) Agreement with General Motor of USA for technology transfer to manufacture high horse-power
GT46MAC 4000HP & WDG-5 5000HP AC/AC locomotive in India. b) Only country outside North-
America to have this bleeding edge technology many export/repeat orders complied successfully in
recent past and many more in the pipeline, Supplied more than 400 locomotives to

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various non railway customers. Emerging as a leading manufacturer of ALCO/GM locomotives for
developing countries.
l) Future plans
a) Assimilation of GM technology to manufacturing their latest 710 series of diesel electric
locomotives.
b) To emerge as a globally competitive locomotive manufacturer.
c) To develop as an export hub for ALCO/GM locos for Asian market.
d) To follow an export led growth strategy through continuous improvement.
e) Cost effective and technology/product up-gradation as a key to retain global competitiveness by
pitting price-value-technology equation right.
2.2. Wheel Arrangement
Co-Co is a code for a locomotive wheel arrangement with two six wheeled bogies with all axles
powered, with a separate motor per axle. Co-Co is the code for a similar wheel arrangement but
with an articulated connection between the bogies. The equivalent UIC classification for this
arrangement is Co-Co. These arrangements are most suited to freight work as the extra wheels give
them good traction. They are also popular because the greater number of axles results in a lower
axle load to the track. Used where it is necessary to reduce axle load. Each "Co" bogie has an
additional non-powered axle in an integral pony truck to spread the load.
Bo-Bo is British classifications of wheel arrangement for railway locomotives with four axles in
two individual bogies. The arrangement of two, two-axled, bogies is a common wheel arrangement
for modern electric and diesel locomotives. Bo-Bo is the UIC indication of a wheel arrangement for
railway vehicles with four axles in two individual bogies, all driven by their own traction motors. It
is a common wheel arrangement for modern electric and diesel-electric locomotives, as well as
power cars in electric multiple units. The Bo-Bo configuration allowed for higher cornering speeds
due to the smaller rigid wheelbase. Furthermore, it allowed better adhesion because all the wheels
were now powered. Due to the absence of frame mounted wheels no leading or trailing axles were
necessary to aid cornering, reducing weight and maintenance requirements.

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CHAPTER 3
3.1. Classification Of Locomotive
What do the designations such as ‘WDM-2’ mean?
Locos, except for older steam ones, have classification codes that identify them. This code is of the
form
Types of WDM26 & WDP2 engine respectively
[Gauge][Power][Load][Series][Subtype][Suffix]’
In this the first term, ‘[gauge]’, is a single letter identifying the gauge the locos run on:
a) W = Broad gauge
b) Y = Meter gauge
c) Z = Narrow gauge (2’ 6”)
d) N = Narrow gauge (2’)
The second item, ‘[power]’, is one or two letters identifying the power source:
D = Diesel
C = DC traction
A = AC traction
a) CA = Dual-power AC/DC traction
b) B = Battery electric (rare)
The third item, ‘[load]’, is a single letter identifying the kind of load the loco is normally used for:
a) M = Mixed Traffic
b) P = Passenger

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c) G = Goods
o
d) S = Shunting
e) L = Light duty (light passenger) (no longer in use)
f) U = Multiple Unit (EMU/DEMU)
g) R = Railcar 7
The fourth term, ‘[series]’, is a digit identifying the model of the loco. Until recently, this series
number was assigned chronologically as new models of locos were introduced.
However, starting in 2002, for diesel passenger, goods, and mixed locos, i.e., WDP, WDG, and
WDM sequences, (and only for them, apparently, not for electrics, nor for diesel shunters), the
series digit identifies the horsepower range of the loco, with ‘3’ for locos with over 3000 hp but less
than 4000 hp, ‘5’ for locos over 5000hp but less than 6000hp, etc. This new scheme will be applied
to all passenger/goods/mixed-haul diesel locos starting in June 2002, except for the WDM-2 and
WDP-1 classes of locos.
The fifth item, ‘[subtype]’, is an optional letter or number (or two of them) that indicates some
smaller variation in the basic model o series, perhaps different manufacturer. With the new scheme
for classifying diesel locos (see above), the fifth item is a letter that further refines the horsepower
indication in 100hp incremental: A for 100hp, B for 200hp, C for 300hp, etc. So in this scheme, a
WDM-3A refers to a 3100hp loco, while a WDM-3F would be a 3600hp loco.
The last item, ‘[suffix]’, is an optional indication that indicates something special about the loco,
such as a different gearing ratio or brake system than usual.
So, a WCM-2 is a broad-gauge (W) DC electric (C) mixed traffic (M) engine, model2. Likewise, a
WDS/5 is a broad-gauge diesel shunting, model 5, and a ZDM-5 is a narrow gauge diesel mixed
traffic model 5 loco. YAU-1 is the old series of MG EMUs run on the Madras-Tambaram line.
The subtype indication of minor variations is not very systematic. Often successive variants of a
model are given subtypes ‘A’, ‘B’, etc. in alphabetic order, e.g. ZDM5A, WAM-4A, WAM-4B,
etc., but not always. For many loco classes (WDM-2A, WDP-2A, notably), the ‘A’ also indicates
dual braking systems (capable of hauling air-braked stock). But in some, such as the WDM-2CA,
the ‘A’ indicates a loco with only air-brakes. A WAM-4R is a faster version (‘R’ for rapid) of the
WAM-4, and WAM-4P is a version of the WAM-4 designed specifically for passenger use (‘P’).
But a WAM4 6P is a version regarded and allowing all parallel operation of the traction motors.
A WDM-2P is a prototype version of a WDM-2 class.
3.3. PRODUCTS 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:
a) WDG4 4000 HP AC/AC Freight traffic Locomotive

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b) WDP4 4000 HP AC/AC Broad gauge high speed Locomotive
c) WDG3D 3400HP AC/AC Broad Gauge Mixed Traffic MicroProcessor Controlled Locomotive.
d) WDM3C 3300 HP AC/DC Broad Gauge Mixed Traffic Locomotive.
e) WDM3A 3100 HP AC/DC Broad Gauge Mixed Traffic Locomotive
f) WDP3A 3100 HP AC/DC Broad Gauge High Speed Passenger
g) WDG3A 3100 HP AC/DC Broad Gauge Freight Locomotive
h) WDM2 2600 HP AC/DC Broad Gauge Mixed Traffic Locomotive
i) WDP1 2300 HP AC/DC Broad Gauge Intercity Express Locomotive 9
j) WDM7 2150 HP DC/DC Broad Gauge Mixed Traffic Locomotive
k) WDM6 1350 HP DC/DC Broad Gauge Mixed Traffic Locomotive
l) WDS6 1350 HP AC/DC & DC/DC Broad Gauge Shunting Locomotive
m) YDM4 1350 HP AC/DC &DC/DC Broad Gauge Mixed Traffic Locomotive
n) EXPORT LOCO 2300 HP AC/DC Meter Gauge/Cape Gauge Mixed Traffic Locomotive.
o) DIESEL GENERATING SETS 800 KW to 2500 KW
p) Spare parts for engines, locomotive & generating sets.
WDP4-4000 HP PASSENGER LOCMOTIVE
State-of-Art, Microprocessor controlled AC-AC, Passenger Locomotive Powered with 16-710G3B
4000HP Turbo charged two stroke Engine.
Fabricated rigid design under frame, two stage suspension, and 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. The prototype will be manufactured in the year 2007.
Diesel Engine Transmission

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´ 16 Cylinder 710 G3B, 2 stroke,
turbocharged after cooled
´ Fuel Efficient Engine
´ Injection System Direct Unit Injector
´ Governor Woodward
´ Compression Ratio- 16:1
´ Lube Oil Sump Capacity 1073 Lts
´ Electrical AC-AC
´ 4 Traction motor ( 3 in parallel per bogie)
´ Suspension Axle hung / taper roller
bearing
´ Gear Ratio 77:17

This is the type of WDP4D engine

14

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CHAPTER 4
LINE DIAGRAM OF DIESEL LOCMOTIVE
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 truck (bogie). 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. AC output is rectified is give the DC required for the
motors.
Auxiliary Alternator:
Locomotive used to operate passenger trains with an auxiliary alternator. This provides AC power
for lightening, heating, air conditioning, dining facilities etc. on train .The output is transmitted
along the train through an auxiliary power line.
Motor Blower :-

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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 cool during period 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 blower also cools the alternators. Some designs 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 stem 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 dust and 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 possible +40°C of summer and to the possible -40°C of winter.
Electronic Controle: -
Almost every part of the m art of the modern locomotive equipment has some of electronic control.
These are usually collected elected in a control cubicle near the cab for easy elected in a control
cubicle near the cab for easy access.
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.

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Pinion/Gear:-
The traction motor drives the axles through a reduction gear of a range between 3 to1 (freight) and
4 to 1 (passenger).
Gear box:-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.
Traction motor:-
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 3FAC motors.
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 compressor is 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 compressor at the other end.
Turbo charger:-
The amount of the power obtained 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

18. 18 | P A G E
compressor which pushes the additional air into the cylinder. The turbocharging gives a 50%
increase in engine power.
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.

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TELEPHONE EXCHANGE
Equipment which effects interconnection of
telephones is known as switching
equipment.
The switching centre, which houses the
terminating and switching equipment is
called telephone exchange.
A telephone exchange is tele communication
system used in public switched telephone
network or in large enterprises.
An exchange consists of electronic components that interconnect (switch) telephone subscribers
lines or virtual circuits of digital systems to establish telephones calls between subscribers.-
𝐹𝑖𝑔. 𝑇𝑒𝑙𝑒 ℎ 𝑒 𝑒𝑥𝑐ℎ𝑎 𝑔𝑒 𝑒

20. 20 | P A G E
Principles of Telephony
Telephony provides a means of sending information through human speeches when required
between two persons situated at a distance apart. In line telephony the information is sent
through the medium of line conductors between them.
 All Telephone Exchanges shall be
* Automatic
* Electronic
* Digital
* Stored Program Controlled (SPC)
* Pulse Code Modulation (PCM, Time Division Multiplexing (TDM) technology.
a) Telephones: The apparatus that are used for transmitting and receiving speech signals are
cal ed ”Telephones” and the persons who use them for sending information between them are
cal ed “Subscribers”.
The telephone transmitter and telephone receiver must be such that the conversion from
speech sounds into electrical currents and vice-versa must be perfect ie. free from frequency
distortion, amplitude distortion
b) Telephone exchange: It is a place where switching between two subscribers is done through
either manually or electronically. In addition to switching, signaling and controlling are
also done at “Exchange”.
c) Human speech and its transmission: Human speech consists of a large number of
frequency components of different values between 0.3 to 3.4 K Hz having different
amplitudes and different phase relations between them.
Steps in Telephone transmission:
i) Conversion of speech sounds into the electrical voice frequency currents
at transmitting end.
ii) Transmission of speech currents through lines to the distant end.
iii) Conversion of voice frequency currents into speech sounds at the receiving end
d) Types of currents:
There are two types of currents to be generated in an exchange.
i) Speech currents- carry information between subscribers
ii) Signaling currents – carry the signaling information.

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There are two types of currents to be generated in an exchange.
iii)Speech currents- carry information between subscribers
iv) Signaling currents – carry the signaling information.
6.1.1 Cables used in Telephony:
In line telephony speech currents are carried by lines first into the exchange and there to the
receiver of the called subscriber through separate pair of lines. The type of transmission lines
used are generally insulated copper conductors, which are formed into a bunch of 10, 20,50 or
100 pairs ca ed as “Telephone cables”.
The copper is used for Telephony transmission due to, less attenuation and less distortion
provided that the insulation resistance of conductor is within the given values.
a) Characteristics of Telecom cables:
Sl. No L b/Mile Kg/Km Copper conductor
Di in mm
Loop resistance
per Km in Ω
DB loss per
KM
1 6.5 1.85 O.51 182 1.379
2 10 2.84 0.63 114 O.91
3 20 5.68 0.90 56 0.75
4 40 11.36 1.24 27.4 0.43
6.2 Basics of Telephone Exchange
It is a place where switching between two subscribers is done through either manually or
electronically. In addition to switching, signaling and controlling are also done at exchange.
It consists of the following functional blocks:
a) Main Distribution Frame.
b) Card Frame.
c) Mother board.
d) Power supply panel with protective devices .
a)Main Distribution Frame (MDF):
In a Telephone exchange different subscribers from different places are terminated on a
frame called “ Main Distribution Frame” (MDF) in the exchange and from there they are
extended to subscribers line cards/Trunk cards kept in the exchange rack. Protective
devices are located in the MDF.

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Purpose of MDF:l
There are three purposes of MDF,
1) It is the place where both external and internal cables are terminated
The cross connection between the two cables conductors is done on the
MDF and this is done by means of jumper wires (Red & White).
2) It carries all the protective devices used in the exchange. They are
Fuses, Heat coils & Lightning protectors.
3) The MDF is the most suitable place for testing purposes.
b) Card Frame:
It contains different slots in which the nominated cards are to be inserted. It is
different in different types of exchanges.
c) Mother board:
It connectivity between different cards. It is a PCB with 1,2,3 layers.
d) Power supply panel:
It provides power supply to different cards in the exchange at different low D.C.
voltages. It also includes protective devices like fuses etc.
Main functional areas in Telephone Exchange:
a) Switching Function: The switching functions are carried out through the
switching network, which provides a temporary path for simultaneous, bi-
directional speech between,
!)TwosubscribersĐoŶŶeĐtedtothesaŵeexĐhaŶge.ThisisĐalledas͞LoĐal switĐhiŶg͟
ii) Two suďsĐriďersĐoŶŶeĐtedtodiffereŶtexĐhaŶges.Thisis kŶowŶas͞TruŶkswitĐhiŶg͟.
iii) Pairs of truŶks towards differeŶt exĐhaŶges. This is kŶowŶ as ͞TraŶsit switĐhiŶg͟

23. 23 | P A G E
b) Signaling function: The signaling function enables the various equipment in a
network to communicate with each other in order to establish and supervise the
calls. It is of two types,
subscriber line signaling: It enables the exchange to identify calling subscribers line, extend
dial tone, receive the dialed digits, extend the ringing voltage to the called subscriber,
extend the ring back tone to the calling subscriber to indicate the called subscriber is
being is being connected. In the event the called subscriber is busy, engage tone is sent to
the calling subscriber.
i) Inter exchange signaling: It enables a call to be set up, supervised and
cleared between exchanges.
c) Controlling function: The controlling function performs the task of processing
the signaling information and controlling the operation of the switching network.
The control functions may be,
i) Wired logic control: In this pre wiring is done between different speech
path devices and common control. Any changes are required in facilities
of subscribers or introduction of new services require wiring changes.
ii) Stored Program Control (SPC): After introduction of microprocessor,
stored program control system and is came into use. In this system the
establishment and supervision of the connections in the exchange is under
the control of “Microprocessor”, which is suitably programmed.

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About the exchange
All telephonesubscribers are served byautomatic
exchanges.
i) Today’s automatic exchanges use a pair of
computers.
ii) One running the program that provides
services. Second, monitoring the
operation of the first, ready to
iii) take over in a few seconds in the event of
equipment
iv) failure.
v) Various exchanges present in BSNLare:
vi) C-DOT
vii) OCB(ORGANE DECOMMANDE B2
VERSION)
viii) EWSD

25. 25 | P A G E
C-DOT
It work on telecom technology, products and services. Provide solutions for
current and future requirements of telecommunicationand converged
networksincluding those
required for rural application.
Provide market orientation to R & D activities and sustain C-DOT as center of excellence.
OCB(ORGANE DE COMMANDE B2 VERSION)
It is a digital switching system.
The system supports all the existing signaling system.
The system has 3 auto recovery feature. When a serious fault occur in control unit, it gives a
message to SMM (operation & maintenanceunit).
Fig. OCB(ORGANE DE COMMANDE B2VERSION)

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EWSD
The EWSD Digital Switching Systems offer a wide range of telephony features and
supplementary services. Further capabilities can be developed to meet specific
customer needs.
MAIN DISTRIBUTIUON FRAM(MDF)
M.D.F.isa media between switching network and subscribers line. Itis a termination point within the
local telephone exchange where exchange equipment and terminations of local loops are connected
by
jumper wires.
FUNCTIONS OF MDF:
All cable copper wires supplying services through user telephone lines are terminated and
distributedthroughMDF.
The most common kind of large MDF is a long steel rack accessible from both sides. Each
jumper is a twisted wire.

27. 27 | P A G E
It consists of local connection and broadband connection frames for the main Exchange area.
The MDF usually holds central office protective devices including heat coils and functions
as a test point between a line and the office.
It provides testing of calls.
It checks whether fault is indoor
or external. All l ines terminate
individually
Fig . Structure of MDF

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ORGANISATION OF MDF
i) VERTICAL SIDE
ii) HORIZONTAL SIDE
VERTICAL SIDE
RACK- On the rack tags are situated. One rack is having
Eight tags . The counting is from up(0) to down (7)
Tags:- Each rack consists of eight tags 1
tag = 4 core
1 core = 4 bunch
1 bunch = 2 line
N.E:-ThewordNEstandsforthe‘NUMBEROFEQUIPMENT’.Itisused for testing number.
Wedge:- Wedge is used as a device for checking the ring. Wedge is placed in jack strips,
which is connected to telephone for checking.
Horizontal side
The horizontal side is connected to under ground cabal. These cabal is having 100 pairs . These pair
are distributed when company allot the telephone number to the subscriber.
Horizontal side is again subdivided in two parts:
One part is connected with the vertical side. Anotherwiththe subscriberlineby
using 100 pair underground cable .
Power plant
As we know that, the power is main source of any organization. It is the case of E-10B exchange.
That is the requirement of any organization is the input.
The main source of this exchange is AC supply.

29. 29 | P A G E
The main parts of power room are:-
1) Batteries of providing 48 v supply.
2) UPS (Uninterruptable Power Supply)
3) Charging – Discharging Unit
4) Inverter and Converter Unit
SWITCH ROOM
Switch room consist of BM(Benjamin Moore) and CM cabinets mounted in standard switch.
These cabinets are fastened to a switch room and interconnected by cables

30. 30 | P A G E
VARIOUS INTERNET SERVICES
LEASED LINES
The information send through the leased line travels along dedicated secure channels, eliminating
the congestion that occurred in shared networks. Between two points setup by a telecommunication
carriers . They can be used for tele phone data , or Internet services . A leased line (dedicated line)
is a Permanent.
Optical Fiber Cables (OFC) or telephone connection. It commonly used in ATMs.
WI-FI (WIRELESS FIDELITY)
A Wi-Fi networks provide the features and benefits of traditional LAN technology such as E –
internet And Token Ring without the limitations of wires or cables . Wi- Fi wireless LAN
technologies to deliver Wireless broad band speed up to 128Mbps to Laptops , PCs Wi- Fi enabled
phones etc.

31. 31 | P A G E
MAINTENANCE SERVICE SHOP(MSS)
Introduction
Maintenance, repair, and overhaul involve fixing any short of mechanical , pluming or
electrical device should it become out of order or broken . It also include performing
routine action which keep the device in working order or prevent trouble from arising.
MRO may be defined as “ALL ACTION WHICH HAVE THE OBJECTIVE OF
RETAINING OR RESTORING AN ITEM IN OR TO A STATE IN WHICH IT CAN
PERFORM ITS REQUIRED FUNCTION “ . The action include the combination of all
technical and administrative , managerial and supervision actions .
Fig . MSS
MAINTANENCE SERVICE SHOP IS DEVIDED INTO FOLLOWING SECTIONS :
 ELECTRONIC LAB
 METER
 AIR CONDITIONER
 WINDING SECTION

32. 32 | P A G E
 ELECTRONIC LAB
IN DLW MSS electronic lab section mainly here repairing of PCBs is done . Which is
coming from the all the section where their electronic devices are used . The printed
circuit board (PCB) is made of cupper and the circuit is design by the computer program
i.e. PCBs wizard . The process of normal PCBs designing is first design the layout by
computer program , print the track through laser printer and print the track in the cupper
plate by proving some heat through the iron and washing through normal water ,the track
is ready.
There is a full-fledged Electronic lab to cater to maintenance need of highly
sophisticated CNC machine and components sub-assembly level trouble shooting of
PCBs , Servo Drives , and microprocessor based controllers and electronics units.
This Lab also supports other Zone Railways in repair of PCBs
What is a Printed Circuit Board?
Printed circuit boards (PCBs) are the boards that are used as the base in most electronics
– both as a physical support piece and as the wiring area for the surface-mounted and
socketed components. PCBs are most commonly made out of fiberglass, composite
epoxy, or another composite material.
Most PCBs for simple electronics are simple and composed of only a single layer. More
sophisticated hardware such as computer graphics cards or motherboards can have
multiple layers, sometimes up to twelve.
Although PCBs are most often associated with computers, they can be found in many
other electronic devices, such as TVs, Radios, Digital cameras and Cell phones. In
addition to their use in consumer electronics and computers, different types of PCBs are
used in a variety of other fields, including:

33. 33 | P A G E
Medical devices. Electronics products are now denser and consume less power than previous
generations, making it possible to test new and exciting medical technology. Most medical devices
use a high-density PCB, which is used to create the smallest and densest design possible. This
helps to alleviate some of the unique constraints involved with developing devices for the medical
field due to the necessity of small size and light weight. PCBs have found their way into
everything from small devices, such as pacemakers, to much larger devices like X-ray equipment
or CAT scan machines.
Industrial machinery. PCBs are commonly used in high-powered industrial machinery. In places
where current one-ounce copper PCBs do not fit the requirements, thick copper PCBs can be
utilized instead. Examples situations where thicker copper PCBs would be beneficial include
motor controllers, high-current battery chargers and industrial load testers.
Lighting. As LED-based lighting solutions catch on in popularity because of their low power
consumption and high levels of efficiency, so too do aluminum-backed PCBs which are used to
make them. These PCBs serve as heat sinks and allow for higher levels of heat transfer than a
standard PCB. These same aluminum-backed PCBs form the basis for both high-lumen LED
applications and basic lighting solutions.
Automotive and aerospace industries. Both the automotive and aerospace industries make use
of flexible PCBs, which are designed to withstand the high-vibration environments that are
common in both fields. Depending on specifications and design, they can also be very
lightweight, which is a necessity when manufacturing parts for transportation industries. They are
also able to conform to the tight spaces that might be present in these applications, such as inside
instrument panels or behind the instrument gauge on a dashboard. There are several overall types
of PCB boards each with their own particular manufacturing specifications, material types and
usages: Single-layer PCBs, Double-layer PCBs, Multi-layer PCBs, Rigid PCBs, Flexible PCBs,
Rigid-Flex PCBs, High-frequency PCBs, Aluminum-backed PCBs.
Single-layer PCBs
A single-layer or single-sided PCB is one that is made out of a single layer of base material or
substrate. One side of the base material is coated with a thin layer of metal. Copper is the most
common coating due to how well it functions as an electrical conductor. Once the copper base
plating is applied, a protective solder mask is usually applied, followed by the last silk-screen to
mark out all of the elements on the board.

34. 34 | P A G E
Since single-layer/single-sided PCBs only have their various circuits and components soldered
onto one side, they are easy to design and manufacture. This popularity means that they can be
purchased at a low-cost, especially for high-volume orders. The low-cost, high volume model
means they are commonly used for a variety of applications, including calculators, cameras,
radio and stereo equipment, solid state drives, printers and power supplies.
Double-layer PCBs
Double-layer or double-sided PCBs have a base material with a thin layer of conductive metal,
like copper, applied to both sides of the board. Holes drilled through the board allow circuits
on one side of the board to connect to circuits on the other.

35. 35 | P A G E
Benefits of Double Sided PCBs:
More flexibility for designers
Increased circuit density
Relatively lower costs
Intermediate level of circuit complexity
Reduced board size (which can reduce costs)
Applications of Double Sided PCBs
There are near limitless applications for old and new designs. Fine line surface mount, ultra
high
copper build, high and low temperature, Solder coated, Silver, and Gold finishes are just a few
examples of DSPT applications.
The following are applications in which Double Sided PCBs can be used:
Industrial controls
Power supplies
Converters
Control relays
Instrumentation
Regulators UPS systems
Power conversion
What is SMT (Surface Mount Technology )and why?

36. 36 | P A G E
Surface-mount technology (SMT) is a method for producing electronic circuits in which the
components are mounted or placed directly onto the surface of printed circuit boards (PCBs).
An electronic device so made is called a surface-mount device (SMD). In the industry it has
largely replaced the through-hole technology construction method of fitting components with
wire leads into holes in the circuit board. Both technologies can be used on the same board for
components not suited to surface mounting such as large transformers and heat-sinked power
semiconductors. An SMT component is usually smaller than its through-hole counterpart
because it has either smaller leads or no leads at all. It may have short pins or leads of various
styles, flat contacts, a matrix of solder balls (BGAs), or terminations on the body of the
component.
What are SMT components?
Surface mount devices, SMDs by their nature are very different to the traditional
leaded components. They can be split into a number of categories:
Passive SMDs: There is quite a variety of different packages used for passive SMDs.
However the majority of passive SMDs are either resistors or capacitors for which the package
sizes are reasonably well standardised. Other components including coils, crystals and others
tend to have more individual requirements and hence their own packages.
Resistors and capacitors have a variety of package sizes. These have designations that include:
1812, 1206, 0805, 0603, 0402, and 0201. The figures refer to the dimensions in hundreds of
an inch. In other words the 1206 measures 12 hundreds by 6 hundreds of an inch. The larger
sizes such as 1812 and 1206 were some of the first that were used. They are not in
widespread use now as much smaller components are generally required. However they may
find use in applications where larger power levels are needed or where other
considerations require the larger size. The connections to the printed circuit board are
made through metallized areas at either end of the package.
Transistors and diodes: These components are often contained in a small plastic package.
The connections are made via leads which emanate from the package and are bent so that they
touch the board. Three leads are always used for these packages. In this way it is easy to
identify which way round the device must go.

37. 37 | P A G E
Integrated circuits: There is a variety of packages which are used for integrated circuits. The
package used depends upon the level of interconnectivity required. Many chips like the simple
logic chips may only require 14 or 16 pins, whereas other like the VLSI processors and
associated chips can require up to 200 or more. In view of the wide veriatio8non of
requirements there is a number of different packages available. For the
smaller chips, packages such as the SOIC (Small Outline Integrated Circuit) may be used.
These are effectively the SMT version of the familiar DIL (Dual In Line) packages used for the
familiar 74 series logic chips. Additionally there are smaller versions including TSOP (Thin
Small Outline Package) and SSOP (Shrink Small Outline Package). Other packages are
also available. One known as a BGA (Ball Grid Array) is used in many applications. Instead of
having the connections on the side of the package, they are underneath. The connection pads
have balls of solder that melt during the soldering process, thereby making a good connection
with the board and mechanically attaching it. As the whole of the underside of the package
can be used, the pitch of the connections is wider and it is found to be
much more reliable. A smaller version of the BGA, known as the micro BGA is also
being used for some ICs. As the name suggests it is a smaller version of the BGA.
SMT in use
SMT is used almost exclusively for the manufacture of electronic circuit boards these days.
They are smaller, often offer a better level of performance and they can be used with automated
pick and place machine that in many cases all bit eliminate the need for manual intervention in
the assembly process.
Wired components were always difficult to place automatically because the wires needed to
be pre-formed to fit the relevant hole spacing, and even then they were prone to problems
with placement.
Although many connectors and some other components still require assisted placement, printed
circuit boards are normally developed to reduce this to an absolute minimum, even to the extent
of altering the design to use components that can be placed automatically.

38. 38 | P A G E
METER
In order to reduce the energy consumption in your company or organization it is
necessary to identify where the energy consumption is too high and essentially
where investments need to be made. Sub-metering provides a detailed picture of
the energy consumption and the specific areas where energy is wasted.
EQ meters is the new range of meters for sub-metering and energy efficiency from
ABB.
Main benefits:
 Consumption transparency allows enables precise planning for the future
 Economical in the long run thanks to low power consumption; less than 2.2
VA
 All EQ meters from ABB have the following instrumentation values as a
minimum:
o Active power
o Voltage
o Current
o Power factor
Main features:
 Scalable solutions to meet customers’ requirements
 Easy configuration thanks to push buttons on the front
 Compliance with relevant international standards (IEC, MID annex B, MID
annex D)
fig. electric meter

39. 39 | P A G E
Units
The most common unit of measurement on the electricity meter is the kilowatt hour [kWh],
which is equal to the amount of energy used by a load of one kilowatt over a period of one hour,
or 3,600,000 joules. Some electricity companies use the SI megajoule instead.
Demand is normally measured in watts, but averaged over a period, most often a quarter- or
half-hour.
Reactive power is measured in "thousands of volt-ampere reactive-hours", (kvarh). By
convention, a "lagging" or inductive load, such as a motor, will have positive reactive power. A
"leading", or capacitive load, will have negative reactive power.[13]
Volt-amperes measures all power passed through a distribution network, including reactive and
actual. This is equal to the product of root-mean-square volts and amperes
OPERATION
Electricity meters operate by continuously measuring the instantaneous voltage (volts) and
current (amperes) to give energy used (in joules, kilowatt-hours etc.). Meters for smaller services
(such as small residential customers) can be connected directly in-line between source and
customer. For larger loads, more than about 200 ampere of load, current transformers are used,
so that the meter can be located other than in line with the service conductors. The meters fall
into two basic categories, electromechanical and electronic.

40. 40 | P A G E
About AC and Work
An air conditioner (AC) in a room or a car works by collecting hot air from a
given space, processing it within itself with the help of a refrigerant and a bunch of coils
and then releasing cool air into the same space where the hot air had originally been
collected. This is essentially how air conditioners work.
 Parts of an air conditioner
Air conditioner installations mainly come in two types: window systems and split
systems (these are further classified into mini-split and central systems). In everyday
language, these are commonly referred to as window ACs and split ACs, respectively.
Regardless of the type of installation, all air conditioners consist of four major
components that are listed below:
 Evaporator
An evaporator is basica y a heat exchanger coil that’s responsible for
collecting heat from inside a room through a refrigerant gas. This
component is known as the evaporator, and is where the liquid
refrigerant absorbs heat and evaporates to become gas.
Some of the most common refrigerant gases used in air conditioning
systems include hydrofluorocarbons or HFCs (like, R-410A)
hydrochlorofluorocarbons or HCFCs (like, R-22) and hydrocarbons (like
R-290 and R-600A). It is this gas that actually absorbs the heat from the
room and travels to the the next component for further processing, which
is…
 Compressor
As the name clearly signifies, this is where compression of the gaseous
refrigerant
occurs. It’s located in the outside unit, i.e., the part that’s installed outside the
house.
 Condenser
The condenser receives the vaporized refrigerant from the compressor,
converts it back to liquid and expels the heat outside. Needless to say, it’s
also located on the outside unit of the split AC.

41. 41 | P A G E
 Expansion valve
Also referred to as the throttling device, the expansion valve is located
between the two sets of coils (the chilled coils of the evaporator and
the hot coils of the condenser). It keeps tabs on the amount of
refrigerant moving towards the evaporator.
Note that in the case of window ACs, the three aforementioned
components are all located inside a small metal box that is installed in
a window opening.
These are the main components of an air conditioner. Now let’s look at how
they work
together to make an AC do what it does.
 Air conditioner (AC) working principle
An air conditioner collects hot air from a given space, processes it within itself
with the help of a refrigerant and a bunch of coils and then releases cool air into
the same space where the hot air had originally been collected. This is
essentially how all air conditioners work.
Many folks believe that an air conditioner produces chilled air with the help
of machine s installed inside it, allowing it to cool a room so quickly. That
might also explain why it consumes so much electricity. In reality, however,
that’s a misconception. An air conditioner is not a magical device; it just uses
some physical and chemical phenomena very effectively to cool a given space.
When you switch an AC on and set your desired temperature (say, 20
degrees Celsius), the thermostat installed in it senses that there is a difference
in the temperature of the room’s air and the temperature that you’ve chosen.
This warm air is drawn in through a grille at the base of the indoor unit,
which then flows over some pipes through which the refrigerant (i.e., a
coolant fluid) is flowing. The refrigerant liquid absorbs the heat and becomes a
hot gas itself. This is how heat is removed from the air that falls on the
evaporator coils. Note that the evaporator coil not only absorbs heat, but
also wrings out moisture from the incoming air, which helps to dehumidify
the room.
This hot refrigerant gas is then passed on to the compressor (located on the
outside unit). Being true to its name, the compressor compresses the gas so
that it becomes hot, since compressing a gas increases its temperature. This hot,
high- pressure gas then travels to the third component – the condenser. Again,
the condenser remains true to its name, and condenses the hot gas so that it
becomes a liquid. The refrigerant reaches the condenser as a hot gas, but
quickly becomes a cooler liquid because the heat of the ‘hot gas’ is dissipated
to the surroundings through metal fins.

42. 42 | P A G E
WINDING SHOP
"Winding" redirects here. For other uses, see Winding (disambiguation).
The magnetic field lines (green) of a current-carrying loop of wire pass through the center of the loop,
concentrating the field there
An electromagnetic coil is an electrical conductor such as a wire in the shape of
a coil, spiral or helix.[1][2]
Electromagnetic coils are used in electrical engineering, in applications
where electric currents interact with magnetic fields, in devices such as electric
motors, generators, inductors, electromagnets, transformers, and sensor coils. Either an electric
current is passed through the wire of the coil to generate a magnetic field, or conversely an
external time-varying magnetic field through the interior of the coil generates an EMF (voltage) in
the conductor.
A current through any conductor creates a circular magnetic field around the conductor due
to Ampere's law.[3]
The advantage of using the coil shape is that it increases the strength of
magnetic field produced by a given current. The magnetic fields generated by the separate turns
of wire all pass through the center of the coil and add (superpose) to produce a strong field
there.[3]
The more turns of wire, the stronger the field produced. Conversely, a changing external
magnetic flux induces a voltage in a conductor such as a wire, due to Faraday's law of
induction.[3][4]
The induced voltage can be increased by winding the wire into a coil, because the
field lines intersect the circuit multiple times.[3]
The direction of the magnetic field produced by a coil can be determined by the right hand grip
rule. If the fingers of the right hand are wrapped around the magnetic core of a coil in the
direction of conventional current through the wire, the thumb will point in the direction
the magnetic field lines pass through the coil. The end of a magnetic core from which the field
lines emerge is defined to be the North pole.
Windings and taps

43. 43 | P A G E
Diagram of typical transformer configurations
The wire or conductor which constitutes the coil is called the winding.[5]
The hole in the
center of the coil is called the core area or magnetic axis.[6]
Each loop of wire is called
a turn.[2]
In windings in which the turns touch, the wire must be insulated with a coating of
nonconductive insulation such as plastic or enamel to prevent the current from passing
between the wire turns. The winding is often wrapped around a coil form made of plastic or
other material to hold it in place.[2]
The ends of the wire are brought out and attached to an
external circuit. Windings may have additional electrical connections along their length; these
are called taps.[7]
A winding which has a single tap in the center of its length is called center-
tapped.[8]
Coils can have more than one winding, insulated electrically from each other. When there are
two or more windings around a common magnetic axis, the windings are said to
be inductively coupled or magnetically coupled.[9]
A time-varying current through one
winding will create a time-varying magnetic field which passes through the other winding,
which will induce a time-varying voltage in the other windings. This is called
a transformer.[10]
The winding to which current is applied, which creates the magnetic field, is
calle
Types of coils
Coils can be classified by the frequency of the current they are designed to operate with:
Direct current or DC coils or electromagnets operate with a steady direct current in their
windings
Audio-frequency or AF coils, inductors or transformers operate with alternating currents in
the audio frequency range, less than 20 kHz
Radio-frequency or RF coils, inductors or transformers operate with alternating currents in
the radio frequency range, above 20 kHz
Coils can be classified by their function:d the primary winding. The other windings are
called secondary windings.

44. 40 | P A G E
SCADA
5.1 What is SCADA?
Supervisory Control and Data Acquisition or simply SCADA is one of the solutions
available for data acquisition, monitor and control systems covering large geographical areas. It
refers to the combination of data acquisition and telemetry.
SCADA systems are mainly used for the implementation of monitoring and control system of an
equipment or a plant in several industries like power plants, oil and gas refining, water and waste
control telecommunications etc.

45. 41 | P A G E
In this system, measurements are made under field or process level in a plant by number of remote terminal
units and then data are transferred to the SCADA central host computer so that more complete process or
manufacturing information can be provided remotely.This system displays the received data on number
of operator screens and conveys back the necessary control actions to the remote terminal units in process
plant.
Components of Typical SCADA System
The major components in SCADA system are
 Remote Terminal Units (RTUs)
RTU is the main component in SCADA system that has a direct connection with various sensors,
meters and actuators associated with a control environment. These RTUs are nothing but real-
time programmable logic controllers (PLCs) which are responsible for properly converting
remote station information to digital form for modem to transmit the data and also converts the
received signals from master unit in order to control the process equipment through actuators and
switchboxes.
 Master Terminal Units (MTUs)
A central host servers or server is called Master Terminal Unit, sometimes it is also called as SCADA
center. It communicates with several RTUs by performing reading and writing operations during
scheduled scanning. In addition, it performs control, alarming, networking with other nodes, etc.
 Communications System
The communication network transfers data among central host computer servers and the field data
interface devices & control units. The medium of transfer can be cable, radio, telephone, satellite, et

46. 42 | P A G E
Operator Workstations
These are the computer terminals consisting of standard HMI (Human Machine Interface) software
and are networked with a central host computer. These workstations are operator terminals that request
and send the information to host client computer in order to monitor and control the remote field
parameters.
Automation of Electrical Distribution System
Modern SCADA systems replace the manual labor to perform electrical distribution tasks and
manual processes in distribution systems with automated equipments. SCADA maximizes the
efficiency of power distribution system by providing the features like real-time view into the
operations, data trending and logging, maintaining desired voltages, currents and power factors,
generating alarms etc.
SCADA performs automatic monitoring, protecting and controlling of various equipments in
distribution systems with the use of Intelligent Electronic Devices (or RTUs). It restores the power
service during fault condition and also maintains the desired operating conditions.
SCADA improves the reliability of supply by reducing duration of outages and also gives the cost-
effective operation of distribution system. Therefore, distribution SCADA supervises the entire
electrical distribution system. The major functions of SCADA can be categorized into follow ing
types.
 Substation Control
 Feeder Control
 End User Load Control

47. 43 | P A G E
5.3 SCADA Features in DLW

48. 44 | P A G E
5.4 SCADA System Architecture in DLW
Fig: Functional Units of SCADA

49. 45 | P A G E
5.5 DLW Infrastructure under monitoring and conrol

50. 46 | P A G E
5.5 DLW Ring
5.6 Advantages of Implementing SCADA systems for Electrical Distribution
 Due to timely recognition of faults, equipment damage can be avoided
 Continuous monitoring and control of distribution network is performed from remote locations
 Saves labor cost by eliminating manual operation of distribution equipment
 Reduce the outage time by a system-wide monitoring and generating alarms so as to address
problems quickly
 Improves the continuity of service by restoring service after the occurrence of faults (temporary)
 Automatically improves the voltage profile by power factor correction and VAR control
 Facilitates the view of historian data in various ways

51. 47 | P A G E
5.7 DLW POWER SUPPLY DIAGRAM

52. 48 | P A G E
MAINTENANCE AREA 2(MA-II)
Break down of machine can occur due to the following two reasons: Due unpredictable failure of
component which cannot be prevented. Due lo gradual wear and tear of the parts of the machine which
can be prevented by regular inspection known as preventive maintenance.
PREVENTIVE MAINTENANCE Also termed as "planned maintenance" or "systematic maintenance an
extreme important function for the reduction of the maintenance cost and to keep the good operational
condition of equipment.
OBJECTIVE OF PREVENTIVE MAINTENANCE
h) To obtain maximum availability of the plant by avoiding break down and by reducing
shut
i) down period to a maximum.
j) To keep the machine in proper condition so as to maintain the quality of the product.
k) To ensure the safety of the workers.
l) To keep the plant at the maximum production efficiency
m) To achieve the above objectives with most economical combinat

53. 49 | P A G E
ELECTRICAL MAINTENANCE SHOP DLW is divided into two divisions (as per production)
1. Engine division
2. Locomotive division
As per EMS divided into following area
B & C (Engine div) D
,G, F (Loco div )
Electronic lab
Overhead crane shop
AREA C
LMS (Light Machine shop) SAs
(Sub-Assembly shop) ES
(Engine Erection Shop) engine
testing shop (ET)
Main gauge room
TYPE OF MAINTENANCE:
Breakdown maintenance
Preventive maintenance

54. 50 | P A G E
Break down maintenance
Break down of machine can occur due to the following two reasons:
regular inspection known as preventive maintenance.
preventive maintenance
o termed as “planned maintenance” or “systematic maintenance” .
keep the good operational condition of equipment.
Objective of prenventive maintenance
lability of the plant by avoiding break down and
by reducing shut down period to a maximum.
product.
production efficiency.
Machine area in maintenance
1.Heavy machine shop
2. Heavy welding shop

55. 51 | P A G E
Types of machine
1. Conventional machine
2. NC machine
3. CNC machine
1. conventional machine:
It is a simple machine which is now an old technique.
2. numerical control machine:
Numerical control is defined as a system in which the actions of the machines
are controlled by the insertion of the numerical data. In other words number
controls the action.
Classification of numeric machine
1. point to point system:
This feature is only useful for drilling and boring
operations. The machine operations are possible at specified positions.
2. straight line system:
In this system the control can command a path operation
in a single axis at a time.
3. continuous path system:
In this system the control instructs the machine to
make movements like 2 or 3 axis at a time. The machine may be directed
to make helical or circular path.
computerized numerically controlled machine
processor.
travel limits, collisions zones and the diagnostic information etc. it also
gives a feedback to the operator about the current position and distance to
be travelled etc.

56. 52 | P A G E
time.
Anugular boaring machine
purpose machine has
two high precision angular boring bars.
precision bearings which provide
control on size during angular
boring.
Fabrication of block
Components after flame cutting and
various machining operations are fit
and tack welded before taking on
rollovers. Heavy Argon-CO2 welding
is done on these rollovers

57. PAGE 0
CONCLUSION
As DLW focuses not on quantity , but on quality & satisfaction of its customers . It has
always been in top of public sector companies . Last year DLW won second consecutive time
BEST PRODUCTION UNIT SHIELD OF 2017-18 of Indians Railways .
As vision of DLW is :-
To be a world class manufacturer of reliable , cost-effective state of art Diesel / Electric
locomotives .
Mission of DLW is :-
We shall achieved our vision through
 Focus on quality for sustained and continuous improvement in reliability & performance
on the product leading to customer satisfaction .
 Developing core competence with due emphasis on innovation , human resource
development team work.
 Achieving environmental excellence by prevention of pollution , reduction of emission
energy conservation and prevention of natural resources.