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.

3. o TYPE Departmental undertaking of the ministry of
Railways ,Government of India
o INDUSTRY Railway & Locomotive
o FOUNDED 16 April 1853
o HEADQUARTERS New Delhi , Delhi , India
o KEY PEOPLE Mamata banerjee (ministry of railway)
vivek sahai( chairman, railway board)
o SERVICE Rail transport
o 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 India
o DIVISION 16 Railway Zones(excluding konkan Railway)
o WEBSITE indianrailway.gov.in

4. 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.

5. • 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

6. 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.

7. 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.

8. 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

9. MRS LTS
My four week training was confined
to three different sections
EMS

10. 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.

11.  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

12. Single line diagram

13. 33 kv of feeder from UPPCL
11KV feeder
supply from
P.T.
UPPCL
L.A.
G.O. SWITCH
C.T.
OCB
B.C.
MRS SUB-
STATION

14. 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

15. 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

16. COOLING SYSTEM
• There is a RADIATOR COOLING
system:-
in this system
Mobile
( gets cooled by)
Chromate water
(gets cooled by)
Raw water

17. Control Panel
Control panel is a flat , often
vertical area where control or
monitoring instruments are
displayed.
PROTECTION
METERING & INDICATION
BREAKER

18. 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

19. 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

20. 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

21. 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
• Numerical Control (NC)
• Computerized Numerical Control (CNC)

22. 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 Run by paper tape and Run by paper tape or
complex is not possible complex machine is memory and complex
partially possible machine is possible
Prone to human error, Flexibility to some extent High degree of flexibility
design modification is design, modification and
difficult editing
Repeatability depends on Depends only a little on Very high repeatability,
operator operator independent of operator
No facility of storing Though not available in all Program storage, editing
diagnostic of designed machines, some NCS have and fault diagnostics is
algorithm back up memory for limited possible
input
Limitation in selecting specific Selection of optimum speed Selection of specific parameters
cutting parameters and feed is possible to some is possible
extent

23. C.N.C. MACHINE
Control system further energized with a mini-computer or post-
processor.
C.N.C machines have the ability to edit or alter the existing
program in no time .

24. 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
• Preventive maintenance

25. Continued……
This area consists of large
number machines which are used
for many purposes like:-
• Boring
• Drilling
• Tapping
• Reaming
• Cutting
• Milling

26. 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.

27. 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

28. 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)

29. Plasma cutting & welding machine(made in china)
Nitrogen & oxygen (plasma gas) at 6000 degree are used as cutting
media

30. Stako machine (dry cutting) (made in neither land)
Oxygen & acetylene are used as cutting media at 3100deg -
3500deg

31. 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

32. 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

33. 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 Fully microprocessor controlled
only)
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 AC traction motor having less cost, portability
and hard maintenance and maintenance free

34. MAIN COMPONENT OF DIESEL-ELECTRIC LOCOMOTIVE

35. 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