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SEMINAR ON INDUSTRIAL TRAINING ATNORTHERN RAILWAY LOCOMOTIVE WORKSHOP LUCKNOWBY: TUSHAR SETH 1215340191

Introduction to Indian RailwaysRailways serve the people of India since 1853. Indian Railways are the biggest organization in our country, which is engaged in transportation.

Indian Railways has more than 64,215 kilometres (39,901 miles) of track and 7,083 stations. It has the world's fourth largest Railway network after those of the United States, Russia and China.

Introduction to Indian RailwaysIndian Railways is divided into zones, which are further sub-divided into divisions. The number of zones in Indian Railways increased from six to eight in 1951, nine in 1952, and finally 17 in 2010.

It is one of the world's largest commercial or utility employers, with more than 1.6million employees. As to rolling stock, IR owns over 230,000 (freight) wagons, 60,000 coaches and 9,000 locomotives.

Introduction to Locomotive Workshop Lucknow Front View of Workshop

Introduction to Locomotive Workshop LucknowThis Locomotive Workshop was established by the princely state of Oudh & Rohilkhand Railway (O&RR) at Lucknow in 1867.After about sixty years, that is in the year 1925 the O&RR was taken over by the Eastern Indian Railway (EIR) along with all assets and liabilities Subsequently in 1952 the EIR merged with Northern Railway. Currently, the periodical overhauling (POH) and maintenance of diesel locomotives like WDM-2, WDM-3A and WDM-3D is done in the workshop

What is Locomotive?Alocomotiveorengineis arail transportvehicle that provides themotive powerfor atrain.The word originates from theLatinloco "from a place",ablativeoflocus, "place" + Medieval Latinmotivus, "causing motion", and is a shortened form of the termlocomotive engine,First used in the early 19th century to distinguish between mobile andstationary steam engines

Locomotives in IndiaLocomotives in India consist of ELECTRIC and DIESEL locomotives. STEAM locomotives are no longer used, except in heritage trains. Locomotives are also called locos or engines.The first successful Locomotive was built by cornish inventor Richard Trevithick

Tracks And GuagesIndian railways uses four gaugesthe 1,676mm(5ft6in) broad gauge which is wider than the 1,435mm(4ft812in) standard gauge; the 1,000mm(3ft338in) metre gauge; and two narrow gaugesThe total length of track used by Indian Railways was about 114,000 km (71,000 mi) while the total route length of the network was 64,215km (39,901 mi) on 31 March 2011.

Tracks And Guages

Section of LocomotiveLocomotive Engine is divided into five Section* Nose : Small section where Batteries are placed* Drivers Cabin : Next to Nose all controls are in this section* Power Pack Assembly or Engine : Main section of locomotive * Compressor section : Compressor are attached with crank shaft via coupling *Radiator : Last section from where thermal energy in of locomotive discharge outside

Section of Locomotive

Classification of Locomotive

In India, locomotives are classified according to their track gauge, motive power, the work they are suited for and their power or model number. It comprises 4 or 5 letters. The first letter denotes the track gaugeThe second letter denotes their motive power (Diesel or Electric) The third letter denotes the kind of traffic for which they are suited (goods, passenger, mixed or shunting).The fourth letter will denote their horsepower range.The fifth letter generally denotes a technical variant or subclass or subtype. For example WDM 2A

Nomenclature of LocomotiveThe code is of the form [gauge][power][load][series][suffix] GUAGE- W(BROAD) Y (METRE) Z (NARROW,2.6) N (NARROW,2) POWER- D = Diesel C = DC traction A = AC traction CA = Dual-power AC/DC B = Battery electric (rare)

LOAD- M = Multipurpose P = Passenger G = Goods S = Shunting L = Light Duty (Light Passenger) R = Railcar

SERIES- 1 over 1000 hp less than 2000hp 2-over 2000 less than 3000 3--over 3000hp less than 4000hp 4-over 4000 less than 5000

SUFFIX-A-100HP B-200HP C-300HP D-400HP

WDM3A MEANS Broad gauge diesel powered multipurpose 3100hp loco

TRANSMISSION TYPES OF DIESEL LOCOMOTIVES:

Unlike steam engines, internal combustion engines require a transmission to power the wheels. The engine must be allowed to continue to run when the locomotive is stopped.The Transmission are of two types DIESEL-MECHANICAL DIESEL-ELECTRICAL

Diesel-Mechanical A diesel-mechanical locomotive uses a mechanical transmission in a fashion similar to that employed in most road vehiclesThis type of transmission is generally limited to low-powered, low speed shunting (switching) locomotives, lightweight multiple units and self-propelled railcars. There is usually a fluid coupling interposed between the engine and gearbox, and the gearbox is often of the epicyclic (planetary) type to permit shifting while under load.

Diesel-Mechanical

Diesel-Electric In a Diesel-electric locomotive, the Diesel engine drives an electrical generator whose output provides power to the traction motors. There is no mechanical connection between the engine and the wheels. The important components of Diesel-electric propulsion are the Diesel engine (also known as the prime mover), the main generator, traction motors and a control system consisting of the engine governor as well as electrical and/or electronic components used to control or modify the electrical supply to the traction motors, including switchgear, rectifiers and other components.

Diesel-Electric

Working of Diesel LocomotiveMost of the diesel locomotives (including WDM-2) are actually Diesel Electric Locomotives. An internal combustion diesel engine rotates an electric generator first, producing electric current. The electricity thus produced by the generator is fed to different electric motors, placed near to loco axles. This motor output is connected mechanically to the wheels through suitable gear systems.

Working of Diesel Locomotive

Indian Locomotive Class WDM-2

Indian Locomotive Class WDM-2The class WDM-2 is Indian Railways' workhorse diesel locomotive. The first units were imported fully built from the American Locomotive Company (Alco) in 1962. Since 1964, it has been manufactured in India by the Diesel Locomotive Works (DLW), Varanasi. The model name stands for broad gauge (W), diesel (D), mixed traffic (M) engine.

Specifications of WDM-2Builders: Alco, DLW Engine: Alco 251-B, V-16 cylinder, 2600hp (2430hp site rating) with Alco 710/720 turbocharger. 1000rpm max, 400rpm idle; 228mm x 266mm bore/stroke; compression ratio 12.5:1. Direct fuel injection, centrifugal pump cooling system Governor: GE 17MG8 / Woodwards 8574-650. Transmission: Electric, with BHEL TG 10931 AZ generator (1000rpm, 770V, 4520A). Traction motors: GE752 (original Alco models) (405hp), BHEL 4906 BZ (AZ) (435hp) and (newer) 4907 AZ (with roller bearings) Axle Load: 18.8 tonnes, total weight 112.8t.

Specifications of WDM-2Gauge: 1,676mamWheel Diameter: 1,092mmWheelbase: 12,834mmTotal length: 17,120mmWidth: 2,864mmHeight: 4,185mmLength over buffer beams: 15,862mm. Distance between bogies: 10,516mm.

Dimensions of WDM-2

Power Pack Assembly of Diesel LocomotiveThis is the main power source for the locomotive.It comprises a large cylinder block, with the cylinders arranged in a V-shaped arrangement (generally V-12 or V-16). The engine rotates the drive shaft at up to 1,000 rpm and this drives the various items needed to power the locomotive. As the transmission is electric, the engine is used as the power source for the electricity generator or alternator, as it is called nowadays.

Power Pack Assembly of Diesel Locomotive

Cross sectional view of Power Pack

Main Parts & Accessories of Power PackThe POWER PACK (engine) of the diesel locomotive consists of various parts and accessories fitted and attached to it.

The LUBE OIL SUMP, ENGINE BLOCK and HEADER are combined together to form the power pack during the assembling process of the power pack.

Main Parts & Accessories of Power Pack Some of the most important parts and accessories of the power pack are as follows:LUBE OIL HEADER, LUBE OIL SCREEN, LUBE DRAIN PIPE, LUBE OIL PUMP, WATER PUMP, S-PIPE, CRANKSHAFT, CAMSHAFT, CONTROL SHAFT, EXTENSION SHAFT, CYLINDER LINER, PISTONS, CYLINDER HEADS, ROCKER ARMS, PUSH RODS, WATER JUMPER, WATER CHANNEL, WATER RISER, EXHAUST MANIFOLD, COMPRESSION CHAMBER EXHAUSTER MOTOR, GOVERNOR, FIP(FUEL INJECTION PUMP), CAMSHAFT GEAR, SPLIT GEAR, TURBO SUPERCHARGER, AC(AFTER COOLING) CORE, OIL CATCHER, VIBRATION DAMPER, INJECTOR NOZZLES, INLET & EXHAUST VALVES, BUBBLE CRUSHERS, CROSSHEAD and many more

DescriptionLUBE OIL PUMP : This pump helps in the circulation of the lube oil to various parts and accessories of the power pack for the purpose of lubrication. It draws the lube oil from lube oil header and circulates it with required optimum pressure to various parts

WATER PUMP: It is a type of centrifugal pump whose main function is to circulate water through parts and accessories of the power pack necessary to cool and reduce the temperature by absorbing heat.

LUBE OIL SCREEN: It acts as a filter which helps in filtering of the lube oil coming to the sump after circulation to various parts. It separates impurities and metal parts from the lube oil.

DescriptionCRANKSHAFT: It is the important shaft of the power pack. It is connected to the camshaft via split gear which is connected to the camshaft gear. Also, on one end of the crankshaft, the main generator is connected and on the other end an extension shaft is being fitted which drives the expressor.

DescriptionEXPRESSOR: The expressor (Combined compressor and exhauster) unit produces vacuum and the constant supply of compressed air for the locomotive and train brakes and for various accessories.COMPRESSION CHAMBER EXHAUSTER MOTOR:. This motor helps in escaping of these blowby gases from the sump to avoid explosion and other harmful effects. This motor is also known as the CC MOTOR.

DescriptionOIL CATCHER: It is mounted on the generator side to avoid the any lube oil entering the generator parts as it may damage the generator. It catches the lube oil and drain it to the sump.

EXHAUST MANIFOLD: It helps in the collection of burnt exhaust gases from various cylinders of the power pack and transfer it to the turbo supercharger. These exhaust gases drives the turbine of the turbocharger.

VIBRATION DAMPERS: The function of vibration damper is to damp the oscillatory and rotator vibrations that are caused due to the movement of the crankshaft and other rotator parts of the power pack.

DescriptionCAMSHAFT: The two camshafts are driven by the crankshaft by the split gear. The camshafts have three lobes for operating the inlet valves, the exhaust valves and the FIP. They are located on each side of the V- shaped engine cylindersGOVERNOR: Once a diesel engine is running, the engine speed is monitored and controlled through a governor. The governor ensures that the engine speed stays high enough to idle at the right speed and that the engine speed will not rise too high when full power is demanded.The governor consists of a rotating shaft, which is driven by the diesel engine.

DescriptionMAIN GENERATOR: The diesel engine drives the main generator which provides the power to move the train. The generator generates electricity which is used to provide power for the traction motors mounted on the trucks (bogies).

Thankyou