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TYPE
Departmental undertaking of the ministry of Railways ,Government of India
INDUSTRY
Railway & Locomotive
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FOUNDED
16 April 1853
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HEADQUARTERS HEADQU ARTERS
New Delhi , Delhi , India
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KEY PEOPLE
Mamata banerjee (ministry of railw railway) ay)
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vivek sahai( chairman, railway board) o
SERVICE
Rail transport
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REVENUE
Rs 88,355 cror crore(US$ e(US$ 202.56 million)(2009-1 million)(2009-10) 0)
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NET INCOME
Rs. 951 cror crore(US$ e(US$ 202.56 million) (2009-10)
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EMPLOYEES
1,600,000(2009)
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PARENT
Ministry of Railway Railway,, Government of India
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DIVISION
16 Railway Zones(excluding konk konkan an Railway)
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WEBSITE
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.
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Basic Information Address-
Diesel locomotive works Varanasi- 221004 (India)
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Railway Station-
Varanasi
Airport-
Babatpur, Varanasi
Telecommunication-
Telephone +91-0542-270551 t0 270555 Fax
+91-0542-270603
Website
www.diesellocomotive.com
Silent feature Annual production-
125 Locomotive
Total no. Of Staff-
7223
Workshop LandCovered Area ShopElectrical Power Requirement-
89 hectares 86300 Sq.m. 3468KVA
(Average Maximum Demand) Electrical Energy Consumption-
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
LTS
MRS
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.
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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
33 kv of feeder from UPPCL
11KV feeder supply 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
Cylinder
Horse power
1780
16
2600 HP
850
12
1200 HP
2250
16
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
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Numerical Control (NC)
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Computerized Numerical Control (CNC)
CONVENTIONAL
N.C.
C.N.C
Occupies more space
Depend on design
Occupies less space
Cycle time is more
Cycle time is less
Cycle time is less
Run by operator and complex is not possible
Run by paper tape and complex machine is partially possible
Run by paper tape or memory and complex machine is possible
Prone to human error, design modification is difficult
Flexibility to some extent
High degree of flexibility design, modification and editing
Repeatability depends on operator No facility of storing diagnostic of designed algorithm
Depends only a little on operator Though not available in all machines, some NCS have back up memory for limited input
Very high repeatability, independent of operator Program storage, editing and fault diagnostics is possible
Limitation in selecting specific cutting parameters
Selection of optimum speed and feed is possible to some extent
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
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Preventive maintenance
Continued…… This area consists of large number machines which are used for many purposes like:•
Boring
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Drilling
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Tapping
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Reaming
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Cutting
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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.
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Lesser over-time pay for maintenance personnel.
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Lesser number of standby equipments in needed.
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Less expenditure of repairs.
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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
GM-LOCO
Power transmission AC-DC
Power transmission AC-AC
HP-3100 and four stroke engine
HP-4000 and two stroke engine
Semi microprocessor control (panel up only)
Fully microprocessor controlled
Frequency distortion and fuel efficient
No distribution in frequency and highly efficient
Using crank case exhaust(CCE) motor
No use of CCE
Turbo using suction and exhaust
Turbo using CCE
No use of separate alternator
Separate alt. use for AC drive(companion alt)
Distortion in break control
No distortion in break control
Current distortion in dynamic brake
Frequency control in dynamic brake control
LOCO will not stop with dynamic brake
It will stop with dynamic brake
DC series motor covering high cost, bulky and hard maintenance
AC traction motor having less cost, portability and maintenance free
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
