o TYPE o o o o INDUSTRY FOUNDED HEADQUARTERS KEY PEOPLE

o o o o o o o

SERVICE REVENUE NET INCOME EMPLOYEES PARENT DIVISION WEBSITE

Departmental undertaking of the ministry of Railways ,Government of India Railway & Locomotive 16 April 1853 New Delhi , Delhi , India Mamata banerjee (ministry of railway) vivek sahai( chairman, railway board) Rail transport Rs 88,355 crore(US$ 202.56 million)(2009-10) Rs. 951 crore(US$ 202.56 million) (2009-10) 1,600,000(2009) Ministry of Railway, Government of India 16 Railway Zones(excluding konkan Railway) indianrailway.gov.in

History of DLW
DLW is production unit under ministry of railway. This is set in collaboration with AMERICAN LOCOMOTIVE COMPANY (ALCO) U.S.A in 1961, in ancient temple city Varanasi. First locomotive in rolled out in 1964. D.L.W is only manufacture of Diesel Electric locomotive with both ALCO and General Motors Technologies in the world. DLW got its first ISO certification in 1997.Recently DLW has obtained Integrated Quality and Environment Management System certification based on ISO-9001 and ISO-14001 in dec,02. DLW exports Locos to SRILANKA ,MALAYSIA, BANGLADESH, TANZANIA, VIETNAM.

 Basic InformationAddressRailway StationAirportTelecommunication-

Diesel locomotive works Varanasi- 221004 (India) Varanasi Babatpur, Varanasi Telephone +91-0542-270551 t0 270555 Fax +91-0542-270603 Website www.diesellocomotive.com

Silent featureAnnual productionTotal no. Of StaffWorkshop LandCovered Area ShopElectrical Power Requirement(Average Maximum Demand) Electrical Energy Consumption125 Locomotive 7223 89 hectares 86300 Sq.m. 3468KVA 19.8 Million

Diesel fuel
The word "diesel" is derived from the German inventor Rudolf Christian Karl Diesel who in 1892 invented the diesel engine. Diesel, or diesel fuel, is any fuel that is used to operate a diesel engine. Most commonly, it refers to a specific liquid fuel obtained by the fractional distillation of petroleum, often called petro diesel. Alternative diesel fuels not derived from petroleum are biodiesel and biomass to liquid (BTL) or gas to liquid (GTL) diesel. Diesel and petrol both are petroleum product. Yet diesel is more used.

Locomotive
A locomotive is a railway vehicle that provides the motive power for a train. The word originates from the latin loco "from a place" + Medieval Latin motivus, "causing motion", and is a shortened form of the term locomotive engine. The first successful locomotives were built by Cornish inventor Richard Trevithick. Locomotive in India consist of electric and diesel locomotives .Steam locomotives are no longer used, except in heritage area. Locomotives are also called locos or engines.

Training is being followed in following areas

SHOP FLOOR
HWS HMS LMS ROTOR CRP HTS SAS EES ET LFS SMS TM TMS PS LAS LTS TR PMS INSP MRS

OUTSIDE SHOP FLOOR

MCO SPC DES MKTG AC Plant PCO TOT MOD TTC ELECT Lab (TTC) WELD Lab T.Ex. Colony TOT MOD PLG EDP

MRS

LTS

My four week training was confined to three different sections

EMS

Main Receiving Substation(MRS)

MRS receives main supply from UPPCL at 33kv. Earlier it was UPSEB. This is step down with 7.5MVA transformer. The 33kv feeder is transformed is two 11kv feeder with a bus coupler in between. The MRS follows the ring type distribution system for supplying power to DLW. The advantage of ring type system is that each substation is fed from two sides. If in case one line is faulted then the substation is fed by other line. But major disadvantage of ring type system is that it is too costly.

 Main component of MRS

Transformer Control Panel Bus Coupler Relays Circuit Breakers Capacitor Bank Switch board Attendant

Different type of transformer used in MRS

Potential transformer Current transformer Distribution transformer

Single line diagram

11KV feeder supply from UPPCL

33 kv of feeder from UPPCL P.T. L.A. G.O. SWITCH C.T. OCB B.C.

MRS SUBSTATION

CIRCUIT BREAKER
It is an automatic- operated electrical switch Designed to protect an electrical circuit from damage Caused by overload or short- circuit. Circuit breaker, electrical device that cut off the electric current through electric circuit under abnormal condition.

They are classified as: Low voltage CB Medium voltage CB High voltage CB

Oil circuit breaker

There are 3 DG sets in DLW

IT CONSIST OF: Cylinder Alternator VCB Prime mover Compressor Transformer Cooling tank Breather Panel Natural grounding relay
Load 1780 850 2250 Cylinder 16 12 16 Horse power 2600 HP 1200 HP 3500 HP

COOLING SYSTEM
There is a RADIATOR COOLING system:in this system Mobile ( gets cooled by) Chromate water (gets cooled by) Raw water

Control Panel
Control panel is a flat , often vertical area where control or monitoring instruments are displayed.

PROTECTION METERING & INDICATION BREAKER

RELAYS : Relays are used for protection of the power system from different faults which are occurring in the power system. A relay is a simple electrochemical switch made up of an electromagnets and a set of contacts. Relays are found hidden in all sorts of devices.

TWO TYPE OF RELAY USED IN MRS :(QUANTITY AND AMPLITUDE)

Definite relay Inverse relay

CAPACITOR BANK:In the electrical system the power factor play a important role because by improving the power factor one can reduce losses . Generally power factor should not be brought below 0.8 for industrial loads. To improve power factor, capacitor bank are placed in parallel with the power supply. In DLW, 600KVAR capacitor bank is used for the improvement of power factor. Reason for Improvement of Power Factor: Reduced losses Reactive power decreased active power increases Efficiency of machine increases Advantages of Using Capacitor Bank: Easy to increase the capacity Reliability of the system is high Controlling of bank is easy Maintenance is easy

ELECTRICAL MAINTENANCE SHOP

DLW is divided into two divisions (as per production) Engine division Locomotive division As per EMS is divided into following area:B & C (Engine div) D ,G, F (Loco div) Electronic lab Overhead crane shop

Area-B
1-Heavy machine shop (HMS) 2-Heavy weld shop (HWS) 3-Rotor shop (RS) 4-Service shop (PMS, CTS, ERS) 5-TTC TYPES OF MACHINE: Conventional Numerical Control (NC) Computerized Numerical Control (CNC)

CONVENTIONAL Occupies more space Cycle time is more Run by operator and complex is not possible Prone to human error, design modification is difficult

N.C. Depend on design Cycle time is less Run by paper tape and complex machine is partially possible Flexibility to some extent

C.N.C Occupies less space Cycle time is less Run by paper tape or memory and complex machine is possible High degree of flexibility design, modification and editing

Repeatability depends on operator No facility of storing diagnostic of designed algorithm

Limitation in selecting specific cutting parameters

Depends only a little on operator Though not available in all machines, some NCS have back up memory for limited input
Selection of optimum speed and feed is possible to some extent

Very high repeatability, independent of operator Program storage, editing and fault diagnostics is possible
Selection of specific parameters is possible

C.N.C. MACHINE
Control system further energized with a mini-computer or postprocessor. C.N.C machines have the ability to edit or alter the existing program in no time .

AREA C :
1-LMS (Light Machine shop) 2-SAS (Sub-Assembly shop) 3-ES (Engine Erection Shop) 4-engine testing shop (ET) 5-Main gauge room TYPE OF MAINTENANCE: Breakdown maintenance Preventive maintenance

Continued
This area consists of large number machines which are used for many purposes like:-

Boring Drilling Tapping Reaming Cutting Milling

Portal milling machine:There are several machines in this area, which are used for milling purpose.

WALDRICH COBURG (made in Germany)

COST Rs/-259000000
Used for both horizontal and vertical purpose. There are four axis in this machine X, Y, Z, W.

BREAKDOWN MAINTENANCE In this case of maintenance, repair can be done after the break down occur. Breakdown of machine can occur due to unpredicted failure of components which cannot be prevented or due to gradual wear and tear of the part. PREVENTIVE MAINTENANCE In this case maintenance is done on the basis of predication checking. This is sometimes called maintenance maintenance or systematic point maintenance. It is an extremely important function for the reduction of maintenance cost, less expenditure of repairs etc. Reduction in production downtime. Lesser over-time pay for maintenance personnel. Lesser number of standby equipments in needed. Less expenditure of repairs. Due to planned spare parts replacement, lesser spare parts are needed to remain in store all time. Greater safety to employees because of reduced breakdown

AREA D 1-Crom plating shop (CRP) 2-Heat treatment shop (HTS) 3-Tool room (TR) 4-Chemical & metallurgical testing Lab (PS) 5-Technical training centre (TTC) AREA F 1-loco test shop (LTS) 2-Loco frame shop (LFS) 3-Loco assembly shop (LAS) 4-Pipe shop (PS) 5-Traction assembly shop (TAS) AREA G Truck machine shop (TMS) Sheet metal shop (SMS)

Plasma cutting & welding machine(made in china)

Nitrogen & oxygen (plasma gas) at 6000 degree are used as cutting media

Stako machine (dry cutting)

(made in neither land)

Oxygen & acetylene are used as cutting media at 3100deg 3500deg

Electronic Lab
Different type of transformer, diode, transistor, IC, pins. PCB repair tool for third-party repair shops Small to medium volume production testing Card edge testing with the QT200. IC testing is performed by QT-200. VISUAL WORKSTATION is specially used checking ICs.
QT200 - Flex Circuit Production Tester

LOCO TESTING SHOP

This mainly consists of the operations which are required in the mechanical testing . All the component of loco are tested In this area.

Number of testing are being performed in in this area

ALCO-LOCO Power transmission AC-DC HP-3100 and four stroke engine Semi microprocessor control (panel up only) Frequency distortion and fuel efficient

GM-LOCO Power transmission AC-AC HP-4000 and two stroke engine Fully microprocessor controlled No distribution in frequency and highly efficient No use of CCE Turbo using CCE Separate alt. use for AC drive(companion alt) No distortion in break control Frequency control in dynamic brake control It will stop with dynamic brake AC traction motor having less cost, portability and maintenance free

Using crank case exhaust(CCE) motor

Turbo using suction and exhaust No use of separate alternator Distortion in break control Current distortion in dynamic brake LOCO will not stop with dynamic brake DC series motor covering high cost, bulky and hard maintenance

MAIN COMPONENT OF DIESEL-ELECTRIC LOCOMOTIVE

Continue.
DIESEL ENGINE MAIN ALTERNATOR AUXILIARY ALTERNATOR CONTROL STAND BATTERIES PINION/GEAR CAB TRACTION MOTOR DRIVE SHAFT AIR COMPRESSOR FUEL TANK MOTOR BLOWER AIR INTAKES RECTIFIER/INVERTER ELECTRONIC CONTROL