The Diesel Locomotive Works (DLW) in Varanasi, India, is a production unit owned by Indian Railways, that manufactures diesel-electric locomotives and its spare parts. It is the largest diesel-electric locomotive manufacturer in India.
Locally it is called as D L W.
o TYPE Departmental undertaking of the ministry of Railways ,Government of Indiao INDUSTRY Railway & Locomotiveo FOUNDED 16 April 1853o HEADQUARTERS New Delhi , Delhi , Indiao KEY PEOPLE Mamata banerjee (ministry of railway) vivek sahai( chairman, railway board)o SERVICE Rail transporto REVENUE Rs 88,355 crore(US$ 202.56 million)(2009-10)o NET INCOME Rs. 951 crore(US$ 202.56 million) (2009-10)o EMPLOYEES 1,600,000(2009)o PARENT Ministry of Railway, Government of Indiao DIVISION 16 Railway Zones(excluding konkan Railway)o 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.
• Basic Information- Address- Diesel locomotive works Varanasi- 221004 (India) 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 Land- 89 hectares Covered Area Shop- 86300 Sq.m. Electrical Power Requirement- 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.
LocomotiveA locomotive is a railway vehicle that provides the motivepower for a train.The word originates from the latin loco – "from a place" +Medieval Latin motivus, "causing motion", and is a shortenedform of the term locomotive engine.The first successful locomotives were built by Cornishinventor Richard Trevithick.Locomotive in India consist of electric anddiesel locomotives .Steam locomotives are nolonger used, except in heritage area.Locomotives are also called locos or engines.
Training is being followed in following areas SHOP FLOORHWS 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 TTCELECT 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
33 kv of feeder from UPPCL11KV feedersupply from P.T.UPPCL L.A. G.O. SWITCH C.T. OCB B.C.MRS SUB-STATION
CIRCUIT BREAKERIt is an automatic- operated electricalswitch Designed to protect an electricalcircuit from damage Caused byoverload or short- circuit.Circuit breaker, electrical device that cut offthe electric current through electric circuitunder 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 PanelControl panel is a flat , oftenvertical area where control ormonitoring instruments aredisplayed.PROTECTIONMETERING & INDICATIONBREAKER
RELAYS : Relays are used for protection of the power system fromdifferent faults which are occurring in the power system. Arelay is a simple electrochemical switch made up of anelectromagnets and a set of contacts. Relays are foundhidden 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 byimproving the power factor one can reduce losses . Generally power factorshould not be brought below 0.8 for industrial loads. To improve powerfactor, capacitor bank are placed in parallel with the power supply. InDLW, 600KVAR capacitor bank is used for the improvement of power factor. Reason for Improvement of Power Factor:Reduced lossesReactive power decreased active power increasesEfficiency of machine increasesAdvantages of Using Capacitor Bank:Easy to increase the capacityReliability of the system is highControlling of bank is easyMaintenance is easy
ELECTRICAL MAINTENANCE SHOPDLW is divided into two divisions (asper production)•Engine division•Locomotive divisionAs per EMS is divided into followingarea:-•B & C (Engine div)•D ,G, F (Loco div)•Electronic lab•Overhead crane shop
Area-B1-Heavy machine shop (HMS)2-Heavy weld shop (HWS)3-Rotor shop (RS)4-Service shop (PMS, CTS, ERS)5-TTCTYPES OF MACHINE:• Conventional• Numerical Control (NC)• Computerized Numerical Control (CNC)
CONVENTIONAL N.C. C.N.COccupies more space Depend on design Occupies less spaceCycle time is more Cycle time is less Cycle time is lessRun by operator and Run by paper tape and Run by paper tape orcomplex is not possible complex machine is memory and complex partially possible machine is possibleProne to human error, Flexibility to some extent High degree of flexibilitydesign modification is design, modification anddifficult editingRepeatability depends on Depends only a little on Very high repeatability,operator operator independent of operatorNo facility of storing Though not available in all Program storage, editingdiagnostic of designed machines, some NCS have and fault diagnostics isalgorithm back up memory for limited possible inputLimitation in selecting specific Selection of optimum speed Selection of specific parameterscutting parameters and feed is possible to some is possible extent
C.N.C. MACHINEControl system further energized with a mini-computer or post-processor.C.N.C machines have the ability to edit or alter the existingprogram 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 roomTYPE 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 millingmachine:-There are several machines inthis area, which are used formilling purpose.WALDRICH COBURG(made in Germany)COST Rs/-259000000Used for both horizontal andvertical purpose. There arefour axis in this machineX, 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 D1-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 F1-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 SHOPThis mainly consists of theoperations which are required inthe mechanical testing .All the component of loco aretested In this area.Number of testing are beingperformed in in this area
ALCO-LOCO GM-LOCOPower transmission AC-DC Power transmission AC-ACHP-3100 and four stroke engine HP-4000 and two stroke engineSemi microprocessor control (panel up Fully microprocessor controlledonly)Frequency distortion and fuel efficient No distribution in frequency and highly efficientUsing crank case exhaust(CCE) motor No use of CCETurbo using suction and exhaust Turbo using CCENo use of separate alternator Separate alt. use for AC drive(companion alt)Distortion in break control No distortion in break controlCurrent distortion in dynamic brake Frequency control in dynamic brake controlLOCO will not stop with dynamic brake It will stop with dynamic brakeDC series motor covering high cost, bulky AC traction motor having less cost, portabilityand hard maintenance and maintenance free
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