rt on Summer training rep diesel locomotive works Varanasi

Introduction
It is a production unit owned by Indian railways , for which it manufactures diesel-electric locomotive and its spares parts. To meet the increased transportation needs of the Indian railways it was established in collaboration with M\s ALCO( American Locomotive Company), USA. Founded in 1961, the D.L.W. rolled out its first locomotive three year later, on January 3, 1964. It manufactures locomotives which are variants based on the original ALCO design dating to 1960s and the GM EMD design of the 1990s. It has evolved into an integrated dieselelectric locomotive manufacturing plant, capable of building all components of the locomotive in-house, including the engines, super structures, and

fabricated bogies and under frames.

 Diesel-electric locomotive were introduced to exploit their versatility, maintenance requirements and cost effectiveness as compared to steam engine. got its first ISO certification in 1997 and ISO-9001 and ISO-14001 in December 2002. with technology transfer agreement from manufacturers such as GM-EMD, DLW today produces advance locomotives having output range from 2600 to 4000 hp. It has supplied locomotives to other countries such as Sri Lanka, Bangladesh, Malaysia, Tanzania and Vietnam etc. Diesel-electric locomotive were introduced

to exploit their versatility, maintenance requirements and cost effectiveness as compared to steam engine.

steam

Diesels advantages over

They can safely be operated by one person, making them ideal for switching/shunting duties in yards. the operating environment is much more attractive, being much quieter, fully weatherproof and without the dirt and heat that is an inevitable part of operating a steam locomotive.

Steam locomotives require intensive maintenance, lubrication and cleaning before, during and after use.

The thermal efficiency of steam was considerably less than that of Diesel engines.

PRINCIPLE OF DIESEL ENGINE

When the piston is at the top of its travel, the cylinder contains a charge of highly compressed air.

Diesel fuel is sprayed into the cylinder by the injector and immediately ignites because of the heat and pressure inside the cylinder.

The air in the cylinder is raised to about 500600 psi which raises the temperature inside to about 1000 0 F.

The pressure created by the combustion of the fuel drives the piston downward. This is the

power stroke.

As the piston nears the bottom of its stroke, all of the exhaust valves open. Exhaust gases rush out of the cylinder, relieving the pressure

As the piston bottoms out, it uncovers the air intake ports. Pressurized air fills the cylinder, forcing out the remainder of the exhaust gases.

The exhaust valves close and the piston starts travelling back upward, re-covering the intake ports and compressing the fresh charge of air. This is the compression stroke.

engine

Components in diesel

1. Valves: For a two-stroke engine, there may

simply be an exhaust outlet and fuel inlet instead of a valve system.

2. Exhaust systems: The exhaust system frequently contains devices to control pollution, both chemical and noise pollution.

3. cooling systems: Combustion generates a great dea of heat, and some of this transfers to the walls of the engine. Cooling systems usually employ air or liquid (usually water) cooling. 4. Piston: It is located in a cylinder and is made gas-tight by piston rings. Its purpose is to transfer force from expanding gas in the cylinder to the

crankshaft via a piston rod and/or connecting rod. In two-stroke engines the piston also acts as a valve by covering and uncovering ports in the cylinder wall. 5. Crank shaft: Most reciprocating internal combustion engines end up turning a shaft. This means that the linear motion of a piston must be converted into rotation. This is typically achieved by a crankshaft.

6. Starter systems: All internal combustion engines require some form of system to get them into operation. Most piston engines use a starter motor powered by the same battery as runs the rest of the electric systems.

7. Lubrication Systems: Internal combustions engine Require lubrication in operation that moving parts slide smoothly over each other. Insufficient lubrication subjects the parts of the engine to metal-tometal contact, friction, heat build-up etc.

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. The important components of dieselelectric propulsion are : Diesel engine ( 16 cylinder , two stroke ) The main generator or alternator Traction motor Control system consisting of the engine governor Electrical or electronic component to control or modify the electrical supply to the traction motions Inverters

Alternating voltage may be generated by rotating a coil in the magnetic field or by rotating a magnetic field within a stationary coil. The value of the voltage generated depends on The number of turns in the coil. Strength of the field. The speed at which the coil or magnetic field rotates.

Synchronous Speed
The output frequency of an alternator depends on the number of poles and the rotational speed. The speed corresponding to a particular frequency is called the synchronous speed for that frequency.
Rpm at 50 Hz Rpm at 60 Hz

2 4

3000 1500

3600 1800

6 8 10

1000 750 600

1200 900 720

The relation between speed and frequency is given by N = 120f / P Where f is the frequency in Hz (cycles per second) P is the number of poles (2, 4, 6...) and N is the rotational speed in revolutions per minute (RPM)

Traction
Traction refers to the maximum frictional force that can be produced between surfaces without slipping. Coefficient of traction: The coefficient of traction is defined as the usable force for traction divided by the weight on the running gear (wheels,

tracks etc) i.e. Usable Traction = coefficient of Traction x Weigh As the coefficient of traction refers to two surfaces which are not slipping relative to one another it is the same as Coefficient of static friction.

Factors affecting tractive coefficient

Traction between two surfaces depends on several factors including: Material composition of each surface. Macroscopic and microscopic shape . Normal force pressing contact surfaces together. Contaminants at the material boundary including lubricants andadhesives. Relative motion of tractive surfaces In the design of wheeled or tracked vehicles, high traction between wheel and ground is more desirable than low traction, as it allows for more energetic acceleration (including cornering and braking) without wheel Slippage.

Traction control system

Attraction control system (TCS), also known as Anti-Slip Regulation (ASR), is designed to prevent loss of traction of the driven road wheels, and therefore the control of the vehicle, when excessive throttle is applied by the driver.

The intervention can consist of one or more of the following: Retard or suppress the spark to one or more cylinders Reduce fuel supply to one or more cylinders Brake one or more wheels Close the throttle, if the vehicle is fitted with drive by wire throttle.

Bogie
A bogie is a wheeled wagon or trolley. In mechanics terms, a bogie is chassis or framework carrying wheels, attached to avehicle. Usually the train floor is at a level above the bogies, but the floor of car may be lowerbetween bogies .

the

Rectifiers
A rectifiers an electrical device that converts AC to DC, a process known as rectification. Rectifiers have many uses including as components of power supplies and as detectors of radio signals. A device which performs the opposite function (converting DC to AC) is known as an inverter. Rectifiers are of two types: a) Half wave rectifier b) Full wave rectifier

Classification of locomotives
The classification syntaxes: Locos, except the older steam ones, have classification codes that identify them. This code is of the form

[ gauge ][ power ][load ][ series ][ sub type ][ suffix ] 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)

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), 'CA' is considered a single letter B- Battery electric locomotive (rare)

The Third letter (load Type)

G-goods P-passenger M-mixed traffic; both goods and passengerS-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. Example for the series letter 3 means that the locomotive has power over 3000 hp but less than 4000 hp. an optional letter or number that indicates some smaller variations inthe basic model. For ex: A for 100 hp,

The fifth letter (subtype)

B for 200 hp and so on..

Main distribution frame

It is a signal distribution frame for connecting equipment to cables and subscriber carrier equipment.

Termination point within the local exchange .

Exchange equipment and terminations of local loops are connected by jumper wires at the MDF.

The fuse is attached on the back side of the tag block for the safety. As when w thundering or vibrations occurs the fuse gets blow off making the circuit break and thus e can prevent further damage .

Electric maintenance shop

Types of machines
1. Conventional machines 2. NC machine 3. CNC machines

1. Conventional machine:
old technique.

It is a simple machine which is now an

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.

Elements of numeric control

1. Control unit 2. Machine 3. Axis drive unit 4. Operators control unit 5. Tape reader unit The manufacturing information on the drawing is converted into punchedholes on a paper tape. The preparation of the tape can be on manual flux writer or by a post processor. The tape thus prepared is fed through thecontrol unit tape reader. For the control units with memory, the tape information is preserved in the memory. The tape serves like a guide for the machine movement and other machines related functions.

Classification of numeric Control

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

In CNC the control system further energized with a mini computer or a post processor. the control unit stores the programmed information of the work piece, the 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. CNC machines have the ability to edit or alter the existing program in no

time.

CONCLUSION
DLW manufactures that thing which pulls more than half portion of the transport. DLW is not only a manufacturing company, it also provide good environment to learn more than aspect. It provides more trainers (expert engineers) to guide us. Any student can easily take their summer training from DLW Varanasi. DLW also provide other facilities like low cost canteen, ambulance, theater etc. I suggest you to take part in summer training in DLW Varanasi.

Breakdown maintenance
Break down of machine can occur due to the following two reasons: Due to unpredictable failure of component which cannot be prevented. Due to 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 extremely important function for the reduction of the maintenance cost and to keep the good operational condition of equipment.

Objective of preventive maintenance

To obtain maximum availability of the plant by avoiding break down and by reducing shut down period to a maximum.

To keep the machine in proper condition so as to maintain the quality of the product.

To ensure the safety of the workers. To keep the plant at the maximum production efficiency. To achieve the above objectives with most economical combination.

Electric repair shop

Meter section

Calibration of meter is done and the fault in the meter

is detected.

Calibration is a comparison between measurements-on of known magnitude or correctness made or set with one device and another measurement made in as similar a way as possible with a second device. The device with the known or assigned correctness is called the standard. The second device is the unit under test (UUT), test instrument (TI).

Calibration

Overhauling section
Induction motor
The most common motors used in industrial motion control systems, as well as in main powered home appliances. Advantage of AC induction motor: 1. Simple and rugged design, 2. low-cost, 3. low maintenance and 4. direct connection to an AC power source .

BASIC CONSTRUCTION AND OPERATING PRINCIPLE

An AC induction motor has a fixed outer portion, called the stator and a rotor that spins inside with a carefully engineered air gap between the Two. the rotating magnetic field is created naturally in the stator because of the nature of the supply. Formula: the relation between supply frequency f, the no of poles p, and the synchronous speed is Ns = 120f /p. Rotor speed: Nr = Ns (1 - s) , where s is the slip.

A synchronous motor always runs at synchronous spee

with 0% slip.

TORQUE-SPEED CURVES OF DIFFERENT TYPES OF SINGLEPHASE INDUCTION MOTORS

THREE-PHASE AC INDUCTION MOTOR

Widely used in industrial and commercial applications.

Classified either as squirrel cage or wound-

rotor motors. These motors are self-starting.

They produce medium to high degrees of starting torque.

Applications include grinders, lathes, drill presses, pumps, compressors, conveyors, also printing equipment, farm equipment etc.

Transport section
In transport section there are basically two types of machine are used for transportation purpose of the different jobs from one shop to other. Different machines used are 1. Fork lift truck 2. Cranes

Fork lift truck

Fork lift is a powered Industrial truck used to lift and transport materials .

A crane is a lifting machine, generally equipped with a winder (also called a wire rope drum), wire ropes or chains and sheave as, that can be used both to lift and lower materials and to move them Horizontally .

Cranes

General characteristics
Used

to move loads over variable (horizontal and vertical) paths within a

restricted area Used when there is insufficient (or intermittent) flow volume such that the use of a conveyor cannot be justified Provide more flexibility in movement than conveyors

Engine testing
Types of testing 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.

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.

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.

Load testing

characteristics

General

Installed 3100 hp Power input to traction under site condition2750 hp Gauge 1676 mm Locomotive weight Nominal axel load

Principle dimension
123000 kg 20500 kg

Wheel diameter 1092 mm Maximum starting tractive effort37884 kg Fuel tank capacity 6000 liters Max speed 100 km/hr

Basic features
Diesel engine
Model 16 cylinder ALCO251C, DLW built Medium speed, 4 strokes Fuel efficient

Transmission system
AC-DC Electronic excitation control Traction alternator - BHEL TA10102DW Traction motor - BHEL TM4907 AZ - roller suspension bearings
Electrical