Summer training report

on

diesel locomotive works Varanasi

SUMMER TRAINING REPORT

ON

“DIESEL LOCOMOTIVE WORK”

SUBMITTED TO:- SUBMITTED BY:-RAMJANM CHAUBEY Gaurav Singh

EE

214505

CONTENTS

• Introduction

• Shop 1: Main Receiving Substation

• Shop 2: Traction assembly Shop

• Shop 3: Loco Testing Shop

• Shop 4: Colony

• Conclusion

• References

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.

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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.

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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.

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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

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.

8Fig 1: Block Diagram of LOCO

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

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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)

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Fig 2: Control Panel of WG3A loco

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

1. Block Divisions2. Engine Divisions3. Loco Divisions

Production Shops

Block Division

1. Heavy Weld Shop

2. Heavy Machine Shop

Engine Division

1. Engine Erection Shop2. Engine Testing Shop3. Light Machine Shop4. Sub Assembly Shop5. Rotor Shop6. Heat Treatment Shop7. Turbo Section

Loco Division

1. Loco Frame Shop2. Pipe Shop3. Truck Machine Shop4. Traction Assembly Shop5. Sheet Metal Shop6. Loco Assembly Shop7. Loco Paint Shop8. Loco Test Shop

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.

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

TRACTION ASSEMBLY SHOP(T.A.S.)

This shop consists of following sections-

• Harnessing section

• Battery section

• Assembly section

• Sub-Assembly section

• Cab section

Harness section

In this section all the multiple unit cables are

harnessed for making connection between

two locos under overloading condition of single

Loco.

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)

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.

LOCO TEST SHOP(LTS)

Fig 3: FINAL LOCO TEST

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

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.

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.

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.

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

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

Fig:Substation transformer. Fig: Block diagram

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

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.

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Fig: diesel engine of ALCO loco

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/.