Diesel Locomotive Works: Moving ahead withtechnology

It was on 3rd January, 1964 that the firstlocomotive (No. 18233, WDM2) rolled out ofDiesel Locomotive Works. Since its inception,DLW has manufactured 7,164 locomotives (upto31.03.2015) of various makes. During this journey,DLW has acquired domain knowledge and

expertise in developing new diesel-electric locomotive designs withvariety of technical configurations to suit traffic needs of IndianRailways and other non-railway customers in India and abroad. It hasachieved the distinction of being the top diesel electric locomotivemanufacturer in Asia and no. 3 in the World (in terms of no. oflocomotives turned out). In fact DLW now manufactures “More thanone Locomotive a day” which by any comparison is no mean feat.During 2015-16, it is likely to produce ever highest number oflocomotives (about 325 nos.), by beating its earlier highest production

of 304 locomotives during 2013-14.

Ten Years’ Production Performance

1st High Horse Power (HHP) locomotive (4500 HP) wasmanufactured at DLW in March’02. Since then, the production of HHPlocomotives has been steadily increasing. Five years ago, in 2010-11,DLW produced 150 HHP locomotives. This will become more thandouble in 2015-16. The 1500th HHP loco “Gaurav” (WDP4D) was

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flagged off from DLW by Hon’ble Minister for Railways, Shri.Suresh Prabhu on 8th June, 2015.

At present WDG4, WDG4D, WDP4D locomotives are beingmanufactured. Gradually production is shifting from Single Cab loco toDouble Cab loco. Hence, in future WDG4D and WDP4D loco will bemanufactured.

Table-1

Type 2010-11 2011-12 2012-13 2013-14 2014-15 TOTAL

HHP

WDG4 101 158 208 187 144 798

WDG4D - - 01 05 49 55

WDP4B 47 31 01 07 - 86

WDP4D 02 - 21 67 55 145

WDG5 - 01 - - 01 02

TOTAL 150 190 231 266 249 1086

ALCO 117 69 63 38 17 244

Product mix of the last 5 years

DLW has not only succeeded in increasing the share of HHPlocomotives in its product mix but has also taken up the challenge ofreducing the product cost. Due to a concerted effort in indigenizationand multi-sourcing of loco sub-assemblies and components, there hadbeen a reduction of around Rs. 21 lakhs in 2015-16. In the coming yearthis reduction will become more pronounced and the locomotive costwill be reduced by more than Rs. 2 Crores (i.e. around 14.5% ofpresent day cost).

DLW has been supplying its locomotives to Non-Railway Customers(NRC) in India and abroad as well. With its proven track record andquality of its product and through increased productivity and bettermanufacturing practices DLW has become a meaningful player in thedomestic and international markets. DLW has till date supplied 678locomotives to various customers including 137 locomotives exportedto various countries. During the last five years DLW has earnedRs.1,268 Crores by way of revenue from its NRC business.

Technical Training:

DLW has a full-fledged Technical Training Centre (TTC) which hasbeen engaged in skill development of DLW’s human resource since1959. It imparts training to the newly recruited staff and ActApprentices, organizes refresher courses for staff and supervisors andgives vocational training to undergraduate engineering andmanagement students. In addition it organizes quality and industrialsafety related courses also. Indian Railway Welding Research Institute(IRWRI) which is also the nodal and coordinating organization for all

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other Regional Welding Training institutes has been functioning underits auspices. TTC provides training to more than 8,000 personnelannually.

Safety of Staff:

Safety of staff at DLW has been accorded the highest priority. Thesafety organization apart from doing routine inspections also undertaketraining in firefighting and first aid. Mock drills are organized foremergency preparedness. Safety seminars and safety awarenesscamps highlight the importance of safety at workplace. These safetymeasures are also audited by external agency as DLW is accreditedwith OHSAS 18001-2007 certification for occupational health andsafety.

Recent steps taken for safe working are: Provision of wider footsteps on ladders of EOT cranes Provision of steel chequered plates on walkways of EOT cranes Provision of hand-rails along the walkways in open gantry and

provision of steel platform adjoining the walkways Provision of safety belt (body harness) to staff.

Environment Improvement:

As a harbinger for environmental protection, way back in late 1980s,DLW took the lead in the “Clean Ganga” campaign and installed twotreatment plants viz. Sewage Treatment Plant (STP) for treatment ofdischarged human waste and Industrial Effluent Treatment Plant(IETP) for treating contaminated & mixed Petroleum oil and Lubricants(POL). The plants, besides ensuring that Ganga remains clean, alsocontribute to significant recycling of resources. At IETP alone, around

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3,000 litres of oil and grease is separated and sold off, whereas inSTP 3 million litres of water is being recycled every day. Thetreated water is released for agricultural and gardening purposes. DLWtakes pride in the fact that none of sewage, whether treated oruntreated, is discharged into Holy River Ganga. The digested bio-manure as sludge dried is used as fertilizer for horticultural purposes.

In order to meet environmental obligation, DLW accredited itself withISO 14001 certification for its Environmental Management Systems, asearly as in 2002. In line with this certification targets have been framed,which are at par with global norms for water, air, exhaust-emission,work place environs, hazardous waste, etc.

Stepping towards energy conservation and to tap the benefits of non-conventional energy resources, 103 solar lights are fitted in theworkshop and colony as well as 30 solar water heaters have beeninstalled in hospital and officers’ guest house. In addition to give fillip toenergy conservation, 227 energy efficient LED lights have been fittedat DLW. Roof mounted Solar power plants of 250 KWp, 100 KWp and45 KWp with a total capacity of 395 KWp are also planned at DLW.

Solar equipments at DLW premises

It is no exaggeration that Varanasi breathes through campuseslike DLW.

Presently, DLW township area has more than one lakh small & bigtrees. Every year thousands of tree plantations are religiously done. Inthe year 2014-15, more than 4000 tree planted at DLW. DLW boast ofa green area of 40% of its total area. The moment one enters DLW, adrop in temperature of 3-4 degree Celsius from the outside area ispalpable.

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Clean and green DLW premises

We, at DLW, understand and appreciated that environment is apriceless gift of nature. To protect our environment and to maintain theecological balance, we must bestow our immediate attention to it. Thestrategy adopted by DLW is not only to maintain emission norms withinits premises but also equip its locomotives with fuel efficienttechnology. Introduction of Auxiliary Power Units (APUs), AutomaticEngine Start and Stop (AESS) in the locomotives reduce the emissionsby reducing the engine running when not required. Electronic FuelInjection system will further improve fuel efficiency of the locomotivethereby reducing fuel consumption and exhaust emissions.

Technology Improvement:

Since its inception, DLW has gradually shifted its focus from“Systems Integration” to “Systems Engineering” and has been makingconstant efforts for acquiring domain knowledge about “Know why”rather than “Know how”. The knowledge, expertise and skill setacquired by DLW engineers over a period of time has enabled DLW toupgrade HHP locomotive technology on a continuous basis.Locomotive technology upgrades implemented by DLW with theobjective of improving energy efficiency, operational safety and crewcomfort include dual cab architecture, ‘hotel load’ (Head end power)feature, ACES (Auto Control of Engine Stop) with APU (AuxiliaryPower Unit), DPCS (Distributed Power Control System) feature, AirConditioned locomotive driving Cabs, Integrated Driver Display systemand water-closet onboard with motor driven oil free air compressors.These have been possible with the joint engineering efforts put in byDLW and RDSO.

Current Projects:

DLW is working on induction of new traction technologies which wouldimprove energy efficiency and would be environment friendly. Theseinclude development of hydrogen based Fuel Cell Hybrid locomotives,Dual Mode locomotives, UIC-1 / Tier-2 compliant 6000 HP AC-ACdiesel electric locomotives, 3000 HP AC-AC (Meter Gauge) diesel

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electric locomotives for export and induction of electronic fuel injectionsystem and 3-phase inverter based Motor Driven Oil Free AirCompressors in HHP locomotives.

Crew comfort and ergonomics is another focus area where DLW hasput in efforts to improve the working environment. Provision ofintermediate vacuum type toilet module with on-board bio-digester(sewage treatment system) for crew and improved acoustic insulationtreatment of crew cabins to reduce noise levels are steps taken in thisdirection.

The new technologies under development at DLW in the highhorsepower (HHP) and new generation locomotive designs aresummarized below:

i) Dual Mode Locomotive

Dual mode locomotives, as the name suggests, have the capabilityto work in electrified as well as non-electrified territories. Suchlocomotives are already in use on European and Americanrailroads. In addition to operational advantage i.e. reduction in trainrunning time due to elimination of traction change at interchangepoints of electrified and non-electrified territories etc., there is alsoreduced net requirement of locomotives as well as of crew of eachtype (i.e. diesel & electric locomotives separately) for haulage oftrains. Railway Board has sanctioned manufacture of five DualMode locomotives at DLW.

The functional requirements of the intended design targetspassenger train operation with power capability of 4500 HP in Dieselmode and 4500 to 5000 HP in electric mode. The locomotive wouldbe manufactured using the existing dual cab version of 4500 HPhigh horse power WDP4D locomotive and therefore the Dual Modelocomotive would also be equipped with twin cabs. The targetedspeed potential for this locomotive would be between 110 to 135kmph. The existing high horse power (4500 HP) dual cab passengerlocomotive architecture and also broad architectural modificationsneeded to create dual mode loco architecture are illustrated in thesketch:

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16-710G3B Engine

Radiators

Compressor

Traction Alternator

DB Grid & Fans

ECC-1

TCC

Existing WDP4D locomotive layout

Underslung TransformerOn board Heat Exchanger

Roof mounted Pantograph, VCB, Surge arrestor

Underslung Motor driven Compressor

Dual Mode Locomotive layout

The major challenges involved in design and manufacture of dualmode locomotive include, amongst others, the weight and strengthoptimization of car body and structural members so as to meet thefunctional requirements within the existing axle load constraints.This will be the first locomotive of its kind having universal capabilityfor seamless operation on Indian Railways.

DLW is targeting to roll-out first Dual Mode Locomotive in 2016-17.

ii) Reduction in level of noise emission:

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DLW has initiated action for achieving substantial reduction in thenoise levels in driver cabins as also the external noise being emittedby the locomotive. Implementation plan included:

Assessment of existing noise levels in HHP locomotives Benchmarking with International Standards Identifying critical areas / major contributors to the sound energy Generating SPL data and understanding noise spectrum Exploring solutions specific to frequency bands Trials on a limited number of HHP locomotives to assess the

efficacy of selected solution

DLW engaged CMTI / Bangalore (Central ManufacturingTechnology Institute, A Govt. of India organization) to measure andmap the existing noise levels of a WDP4D locomotive. The existingnoise map details provided by CMTI / Bangalore was used tobenchmark the WDP4D noise levels with International Standards(49 CFR Part 229) and ranking of noise sources with regard to theircontribution to the overall noise spectrum has been defined. Typicalranking of noise sources of HHP locomotive is given in Table-2:

Table – 2

EquipmentIntensity

level(dBA)

Ranking

Radiator hood with fan 111.9 1

DB Grid with fan 109.4 2

Chimney with turbocharger 107.6 3

Radiator core 107.5 4

ECC and TCC 104.9 5

Suction air primary filter 104.9 6

TM Blower 102.8 7

Equipment rack & compressor 102.7 8

Traction Alternator 100.2 9

Engine 99.7 10

The existing overall sound pressure levels (SPL) in the rear cab of4500 HP dual cab high horse power locomotives (WDP4D/WDG4D)has been recorded as 96 dB(A) while that in the front cab is 88dB(A). The existing international standard for in-cab noise definesnoise exposure limit as 85 dB(A).

Standard methodologies of noise control are (a) Source Control (b)Path Control and (c) Receiver Control. Rear cab being the noisiestworking zone for the loco pilot, DLW has attempted to bring down

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the sound pressure levels in the rear cab of 4500 HP dual cablocomotives by adopting “Path Control” and “Receiver Control”methods but with limited success. New acoustic materials includingabsorber, dampener, barrier and sealing materials were used toisolate rear cabs from the noise sources onboard and the resultsachieved are summarized in Table – 3.

Table – 3

Loco No. / Month Results

WDP4D-20704

(Dec-2014)

Noise level in Rear cab reduced from

96 dB(A) to 91 dB(A)

WDG4D-70355

(April-2015)

Noise level in Rear cab reduced from

96 dB(A) to 88 dB(A)

As a part of continuing efforts to meet the 85 dB(A) benchmark,DLW has now engaged NVH (Noise, Vibration & Harshness)experts (M/s. Megasorber/Australia, M/s. Henkel/India and M/s.Pyrotech/India) for designing a suitable acoustic insulation schemefor application in dual cab HHP locomotives to bring down the noiselevels in both the cabs to within 85 dB(A) in locos beingmanufactured by DLW.

iii) Toilet onboard 4500 HP WDG4D Diesel Electric Locomotive

Keeping in view the inherent need for improving crew comfort, DLWis working on providing a vacuum based micro-processor controlledtoilet module onboard. This will be equipped with environmentfriendly and self-sustaining bio-digester module for onboard sewagetreatment. First WDG4D HHP locomotive No. 70486 fitted withvacuum based toilet system is under manufacture at DLW and islikely to be rolled-out in March-2016.

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WDG4D-70486 under manufacture at DLW

Further, WDG4D-70486 will also be the first diesel locomotive fittedwith underslung mounted motor driven oil free compressor.

Motor driven oil free compressor

The switch-over to motor driven air compressor was essential togenerate space for accommodating toilet module onboard theplatform of WDG4D loco. The added advantage of using oil freecompressor is improved air quality entering the computer controlledbrake system leading to improved reliability of brake system valvesand other critical components in the circuit.

iv) Hydrogen Fuel Cell Hybrid locomotive

DLW has been manufacturing locomotives for mainline and shuntingoperation with conventional power-train onboard. ConventionalPower train design for locomotive application utilizes medium speedmulti-cylinder compression ignition engine with associated electrics

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Toilet Module

and propulsion control system integrated together for desiredfunctionality. The existing design variants of diesel electriclocomotives being manufactured by DLW and other locomotivemanufacturers across the world, however, have a definite carbonfootprint linked to the exhaust emissions levels. Considering theenvironmental concerns specifically related to the environmentalimpact of various technologies and the rising societal awareness forbringing-in more and more environment friendly technologies,design review and adoption of new innovative traction technologieshaving minimal impact on environment has become inevitable. Oneof the new unconventional power-trains being tried out worldwide fortraction application is hydrogen based fuel cell in hybrid architecturewith a battery bank, hydrogen storage and propulsion control systemonboard. The hydrogen powered fuel cells have inherenttechnological advantages like zero carbon emission and reduceddependence on fossil fuel and thereby imports. This makes thehydrogen fuel cell technology attractive for addressing climatechange.

Considering the advantages discussed above, Railway Board hassanctioned manufacture of 2 hybrid locomotives having capability tofeed the traction power requirement directly from either thehydrogen fuel cell stack or battery bank onboard or both as per theinstantaneous power requirement.

A typical hydrogen based fuel cell locomotive layout

DLW is working on manufacture of these locomotives. India will be the third country in the world to introduce fuel cell technology in the field of traction. The locomotive will be a technology demonstrator for creating awareness in establishing use of environmentally sustainable green technology in the field of traction. It will be equipped with 300 KW rating

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PEM (Proton Exchange Membrane) type fuel cell stack modules and battery bank and have peak transient power capability of 700 KW

v) 6000 HP Diesel Electric Locomotive

Considering the need for heavy haul and higher balancing speedsfor realizing maximum through put over IR sections, Railway Boardhas sanctioned manufacture of sixteen 6000 HP diesel electriclocomotives at DLW. DLW has already manufactured freightlocomotives with 5500 HP power rating. 6000 HP locomotive wouldtherefore be the next upgrade delivering an increase in the haulagecapacity. The maximum achievable speed of a standard freight trainhaving 59 BOXN (5385T) load hauled by the existing HHPlocomotives on a level track is around 90 kmph with 5500 HP WDG5freight loco and 80 kmph with 4500 HP WDG4 freight loco. A 6000HP Diesel Electric locomotive hauling this load will achieve amaximum speed of 100 Kmph on level track. The maximum startingtractive effort of 6000 HP locomotive will be 58T as compared to54T of a 4500 HP WDG4D locomotive.

The design features of 6000 HP diesel electric locomotive includeimportant technological upgrades like compliance to UIC-1/Tier-2emission standards.

The methodology planned for design and manufacture of theselocomotives will give opportunity to DLW and RDSO engineers foracquiring domain knowledge in technically advanced system designand system integration. First two prototype 6000 HP locomotives aretargeted to be rolled out in 2017-18.

Leveraging IT for indigenization and multisourcing

With a view to have more indigenized vendors, DLW has leveragedinformation technology (IT) for developing more vendors andexpediting prototype development. The developed systems are notonly transparent but also linked to specific timelines. Two such ITapplications being used at DLW and their impact are mentioned below:

Web based portal for vendor registration

In an effort to create transparency in dealing with the vendors andimprove procedural efficiency in processing of their applications,DLW has launched a web-based portal for vendors on its officialwebsite www.dlw.indianrailways.gov.in. This portal has manyenabling features including facility for the vendors to register their

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application online. It provides them with login authority which can beused by the vendor to access DLW’s vendor portal for anyinformation related to the status of processing of their application.Each activity related with the processing of vendor application(including scrutiny of documents, physical verification ofmanufacturing infrastructure etc.) is tied to a specific timeline andthe system automatically generates alerts as and when thesedefined timelines are violated at any stage. The systemautomatically ensures monitoring of process time and the slacks areeliminated. The advantages of web based portal are summarized asunder:

• Facility to vendors for online submission of VA form• System generated acknowledgement to Vendor and alerts to

DLW officials at every stage • Paperless transaction• Smart tracking of document / Timeline Monitoring of complete

process / Status of application visible to vendor

As a result, the application processing / approval time has reducedfrom 240 days to 60 days. The module implemented for onlinevendor application is a scaleable module and can be interfaced withother lateral modules in future.

Web based product development monitoring system:

In an effort to increase the available vendor base for sourcinglocomotive components/assemblies, DLW places developmentalpurchase orders on vendors against regular and developmentaltenders and the typical process time taken from the issue ofpurchase order to the final acceptance of prototypes was around 34months. In order to improve the process efficiency and reduce theproduct development cycle time, DLW has launched a web-enabled“product development monitoring system”. The system waslaunched on 18th August 2015 and is hosted on DLW’s officialwebsite www.dlw.indianrailways.gov.in.

The algorithm responsible for running the web enabled productdevelopment system has been programmed to ensure that eachactivity of the complete process work flow, right from the issue ofdevelopmental purchase order to the final validation and acceptanceof prototype(s), is tied to a specific timeline and the systemautomatically generates alerts as and when these defined timelinesare violated at any stage. The system automatically ensuresmonitoring of process time and the slacks are eliminated. With this

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system, the product development process time is likely to comedown from around 34 months (existing) to 9 months.

The advantages of web based portal are summarized as under:

• Reduction in process time / Timeline Monitoring of completeprocess

• Paperless transaction , File movements eliminated• System generated alerts /SMS/Emails to all concerned• Real time monitoring of activities, Activity logs / Responsibility for

delay• Access to vendors for tracking of stages during development • System generated customized reports• Use of data base for managerial decision makingThe module is scaleable and can be interfaced with other lateralmodules in future.

Diesel Mitra - Service Engineering and customer satisfaction

Zonal railways/ Diesel sheds homing diesel electric locomotivesmanufactured by DLW are treated as valued customers by DLW.Their feedback on quality and design inputs are therefore given dueconsideration and prompt efforts are made to resolve them.

There are currently 29 diesel loco sheds which are homing morethan 1750 HHP locomotives. To improve DLW'S co-ordination withthe diesel loco sheds across Indian Railways, and to get first handfeedback from the sheds regarding not only the performance ofthese locos but also issues linked with reliability, maintenancespares, technical and maintenance issues, confidence building inthe sheds concept of diesel mitras was introduced. One officer fromDLW has been nominated as DLW's co-ordinator for each zone andthe sheds therein. This officer also known as ‘Diesel Mitra’ for thezone personally visits the sheds and the HQs of his nominated zoneat least thrice a year, personally interacts with the officers and staffand on return to DLW gives his report to the management. Currentlythere are 16 Diesel Mitras who, in the last year alone have carriedout 44 visits across 16 Zones and 29 diesel sheds. DLW has put inefforts to study the feedbacks received and has taken correctiveaction for resolution of the issues. The analysis and action advisoryis being regularly documented in the form of “Design Bulletins”which are being uploaded on DLW official website to enable widepublicity and provide unrestricted access to all concerned. Till dateDLW has already issued 76 design bulletins on various serviceengineering related issues highlighted by various railways.

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Diesel Locomotive Works is committed to adopt new technologies,manufacture new design locomotives, improve quality of HHPlocomotives and innovate to achieve new standards of crew comfortand safety in the coming future

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डडीजल रसेल इइंजन करारखरानरा

हर ददिन......

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DLW AT A GLANCE

23rd April, 1956 - Foundation stone by the 1st President of India Late Dr. Rajendra Prasad. 3rd January, 1964 - 1st BG locomotive WDM2 commissioned by Late Lal Bahadur Shastri. February, 1975 - 1st BG shunting locomotive (WDS6) turned out. March, 1976 - 1st Export Loco turned out for Tanzania. March, 2002 - 1st High Horse Power (4500 HP) locomotive WDG4 turned out. Installed capacity : 200 loco/year Ever highest production : 304 (in 2014-15) Locomotives produced since inception: 7164 (Up to 31.03.2015). Locomotives supplied to other than Zonal Railways: India: 543, Abroad: 137. Annual Turnover : Rs.4193 Crores (FY 2014-15) Total Manpower: 6270. No. of Staff Quarters: 3675. Total Area: 299.7 hectares. (Workshop: 89.0 hectares Township: 210.7 hectares.) Road network: 102 km. Boundary perimeter: 10.35 km. Green Area : 119.88 hectares (40% of total area of DLW) No. of Trees: More than 1 lakh. Sewage Treatment Plant (STP) : 12 Million Litres per day (MLD) Industrial Effluent Treatment Plant (IETP) : 3 Million Litres per day (MLD) Recycling of water : 3 Million Litres per day (MLD)

DLW IS NOT DISCHARGING ANY SEWAGE (TREATED OR UNTREATED) INTO GANGES.

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