This is six week training report at DLW Varanasi .

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A Summer Training Report
at
Diesel Locomotive Works Varanasi (221004)
Submitted by
GYANENDRA PRAKASH MAURYA
ROLL NO. 1583920033
in partial fulfillment for the award of the degree
of
B. Tech
Department of Electrical Engineering
Rajkiya Engineering college
Kannauj- (209732) U.P.

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CONTENT
 INTRODUCTION .........................................................................................
 MAIN RECEIVING SUBSTATION...........................................................
 COLONY...........................................................................................................
 SCADA..............................................................................................................
 AC PLANT.......................................................................................................
 TRACTION ASSEMBLEY SHOP..............................................................
 CENTRAL TRANSFORING SHOP...........................................................
 CONCLUSION...............................................................................................

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INTRODUCTION
Diesel Locomotive Works (DLW) is a production unit under the ministry of railways. This was setup
in collaboration with American Locomotive Company (ALCO), USA in 1961 and the first locomotive
was rolled out in 1964. This unit produces diesel electronic locomotives and DG sets for Indian
railways and other customers in India and Abroad.
Subsequently a contract for transfer of technology of 4000 HP Microprocessor Controlled AC/AC
Freight (GT 46 MAC) / passenger (GT 46 PAC) locomotives and family of 710 engines has been
signed with electro motive division of GENERL MOTORS of USA for manufacture in DLW.
The production of these locomotives has now started and thus DLW is the only manufacturers of
Diesel Electric Locomotives with both ALCO and General Motors technologies in the world.
Fig .No. 01 Front View Of D.L.W

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BRIEF HISTORY
 Set up in 1961 as a green-field project in technical collaboration with ALCO/USA to Manufacture
Diesel Electric Locomotives.
 First locomotive rolled out and dedicated to nation in January, 1964.
 Transfer-of-Technology agreement signed with General Motors/ USA in October, 95 to
manufacture state-of-the-art high traction AC-AC diesel locomotives.
 A flagship company of Indian Railways offering complete range of flanking products in its area of
operation.
 State-of-the art Design and Manufacturing facility to manufacture more than 150 locomotives per
annum with wide range of related products viz. components and sub-assemblies.
 Unbeatable trail-blazing track record in providing cost-effective, eco-friendly and reliable solutions
to ever-increasing transportation needs for over three decades.
 Fully geared to meet specific transportation needs by putting Price-Value Technology equation
perfectly right.
 A large base of delighted customers among many countries viz. Sri Lanka, Malaysia, Vietnam,
Bangladesh, Tanzania to name a few, bearing testimony to product leadership in its category.

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MAIN RECEIVING SUBSTATION (M.R.S)
Substations generally consist of pumps, DG sets, and control panels. The control panel is used to
control the supply of voltage to trip the supply. It is the point where load is monitored; Different
parts of substation are as follows:
 Transformers
 Control panels
 Bus coupler
 Relays
 Circuit Breaker
 Capacitor bank
 Switch board attendant
Different types of transformers used in DLW:
1. Distribution Transformers
2. Power Transformers
3. Potential Transformers
Distribution Transformers:
These transformers are used in distribution purposes. They are basically Step down transformers. The
load on a distribution Transformers varies over wide period of 24 hours. The primary of distribution
Transformers is always energized so core losses always taking place in the transformers .In this
view the distribution transformers are designed to have very low value of core losses.
Main Characteristics of Distribution Transformers:
1. Low core losses.
2. Low on state losses.
3. Good voltage regulation.
4. Low leakage reactance.
5. High all day efficiency.
The rating of different distribution transformers used in DLW is 150KVA, 250KVA, 400KVA,
750KVA. These transformers are used according to their use in shops requirement or Colony
requirement.

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POWER TRANSFORMERS:
Power Transformers are used at the sending and receiving at a long transmission line for Stepping
down and Stepping up voltages.
Main Characteristics of Power Transformers:
1. Low losses at full load.
2. Very poor voltage regulation.
3. High full load efficiency.
4. Low on state losses.
5. Leakage reactance is variable.
The power transformers which are used in DLW get 33KV supply from UPPCL and this supply is
step downed to 11 KV.
This supply is fed to different feeders of DLW .The three phase transformers which is used has
following properties, primary side i.e. HV side the windings are delta connected , secondary side
i.e. LV side the windings are star connected.
POTENTIALTRANSFORMERS:
This is an instrument transformer which is used to measure the voltage of a line mostly they take
record of line voltage whether it is proper or not in DLW .It is used in control panels.
Fig.02 Potential Transformer Rating

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CONTROL PANEL :
This unit controls the charging of the transformers. From here one can control the switching of
transformer and also the charging of transmission line. From control panel the DG set is also
controlled two 2.4MW and one 1750KW DG sets are used in DLW as an alternate source of supply.
There are 25 control panels in the MRS each of capacity 350MVA with each panel there is
wattmeter, ammeter, voltmeter attached.
BUS COUPLER :
This is used to couple two buses incoming and outgoing one. Bus coupler is the main device so it
is generally protected from overloading. The maintenance of the device is not easy so for
maintenance of this duplicate bus coupler is used.
RELAYS AND CIRCUIT BEAKERS :
RELAYS :
Relays and circuit breakers are used for the protection of the power system from different faults
which are occurring in the power system. A relay is simple electromechanical switch made up of
an electromagnet and a set of contacts. Relays are found hidden in all sets of devices .Two types
of relay used in MRS.
1) Definite Time Relay
2) Inverse Relay
Fig.03 Control Panel

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Capacitor Bank :
In the electrical system the power factor play a important role because by improving the power one
can reduce the losses. Generally power factor should not be brought below 0.8 for industrial load. To
improve power factor, capacitor bank are placed in parallel with the power supply. In DLW there are
three capacitor bank are used to improve the power factor 600 KVAR, 1200KVAR and 1800KVAR,
total of 3600KVAR.
Reason for improvement of Power Factor:
Reduced the losses
Reactive power decreased, active power increased
Efficiency of the machine increases
Fig.04 Relays

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COLONY (132/33KV SUBSTATION KANCHANPUR)
A 132/33KV Substation is present in Kanchanpur, which receives power from
UPPTCL. This substation supplies power to colony as well as Main receiving
Substation. Here one 40MVA Transformer is installed for UPPTCL from which supply
is received and two 20MVA (2×20MVA) transformers are installed in the substation
for supplying power to colony and MRS. Here measuring and protection equipment
are installed which helps in proper controlling power supply.
The SCADA (Supervisory Control and Data Acquisition) System helps in controlling
the switch-yard easily.
The switch-yard contains mainly following equipments:
1. Tandem Isolator
2. Bus Isolator
3. Line Isolator
4. Bus Coupler
5. SF6 Circuit breaker (132KV,3150A)
6. Vacuum circuit Breaker (33KV/11KV , 1250A/630A )
7. Lightening Arrester (120KV, 30KV)
8. Potential Transformer (132KV/110V , 33KV/110V)
9. Current Transformer (400/200/100/1A , 800/400/1A , 400/200/1A)
10. Main Bus bar
11. Transfer Bus bar

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ISOLATORS:
In electrical engineering, a disconnect switch or isolator switch is used to ensure that
an electrical circuit is completely de-energized for service or maintenance. Such
switches are often found in electrical distribution and industrial applications, where
machinery must have its source of driving power removed for adjustment or repair.
High-voltage isolation switches are used in electrical substations to allow isolation
of apparatus such as circuit breakers, transformers, and transmission lines, for
maintenance. The disconnecor is usually not intended for normal control of the
circuit, but only for safety isolation. Disconnectors can be operated either manually
or automatically.
Types of Isolator :
Depending upon the position in power system, the isolators can be categorized as:
Bus side isolator – the isolator is directly connected with main bus.
Line side isolator – the isolator is situated at line side of any feeder.
Transfer bus side isolator – the isolator is directly connected with transfer bus.
BUS-COUPLER:
A bus coupler is an integral part of any substation or switch-yard for the purpose of
reliability of power supply & for ease of maintenance & troubleshooting with least
inter option to loads.
In any HT bus there are two or more separate incomers of power .These could be
different lines from same source bus or from different sources. Ideally a bus is
divided into two or more segments connected by bus coupler .Each section may
have its incoming source of power & its set of loads. Normally the bus coupler is
kept off but during fault in any one incoming line it is made on to supply that
section through the other incoming feeder .The purpose of bus coupler is the
following:
If there is a fault in any section, the bus coupler breaker trips to prevent the fault
current from affecting other bus sections .Thus the fault Is limited to particular
section
.
The routine maintenance of a bus can be done taking one section at a time through
manually opening bus coupler breaker without interrupting power supply to other

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sections.
If the load configuration is such that one of the major loads is induction furnaces,
we can dedicate a bus section to this load & segregate it from other normal loads.
If the incoming sources are different e.g. one from grid & one from own captive plant,
then they have to be fed to different sections with bus coupler off .If required they can
be synchronized through bus coupler
So the purpose of bus coupler is to give flexibility of operation for supplying the loads
in the most reliable way possible
CIRCUIT BREAKER:
A circuit breaker is an automatically operated electrical switch designed to protect
an electrical circuit from damage caused by excess current, typically resulting from
an overload or short circuit .Its basic function is to inter upped current flow after a
fault is detected .Unlike a fuse, which operates once and then must be replaced, a
circuit breaker can be reset (either manually or automatically) to resume normal
operation.
Many classifications of circuit breakers can be made, based on their features such as
voltage class, construction type, interrupting type, and structural features.
1) Low–voltage Circuit Breaker
2) Medium-voltage Circuit Breaker
3) High-voltage Circuit Breaker
Low- voltage circuit breakers
Low-voltage (less than 1,000 V AC) types are common in domestic, commercial and
industrial application, and include:
(1).Miniature circuit breaker (MCB)—rated current not more than 100 A.
(2).Molded-Case Circuit Breaker (MCCB)— rated current up to 2,500A.
Medium- voltage circuit breakers

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Medium-voltage circuit breakers rated between 1 and 72kV may be assembled into
metal-enclosed switchgear line ups for indoor use, or may be individual
components installed outdoors in a substation.
Medium-voltage circuit breakers can be classified by the medium used to extinguish
the arc:
Vacuum circuit breakers—with rated current up to 300A, and higher for generator
circuit breakers. These breakers interrupt the current by creating and extinguishing
the arc in a vacuum container – aka "bottle”.
High – voltage circuit breakers
Electrical power transmission networks are protected and controlled by high-
voltage breakers. High- voltage breakers are nearly always solenoid- operated, with
current sensing protective relays operated through current transformers. High-
voltage breakers are broadly classified by the medium used to extinguish the arc.
Tandem Isolator:
It is a isolator where the phases are aligned diagonally ie. all the pole phases are
connected one behind another so that the jumping can be done on the bus bar. It is
double break isolator which isolate both sides and used in all station.

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Fig.05 SINGLE LINE DIAGRAM OF 132/33KV D.L.W. KANCHANPUR
VARANASI

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Fig.06 DLW POWER SUPPLY DIAGRAM

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SCADA
 SCADA system based on latest RDSO Specification no. TI/SPC/RCC/SCADA/0130.
 Dual hot Standby SCADA Servers.
 Two Workstations with dual 32” LCD at SCADA Control Room.
 Remote Terminal at MRS and KANCHANPUR connected over OFC.
 Total no of RTUs: 29.
 Existing telephone network based n IEC standards IEC60870-5-101 Protocol is replaced by OFC
network based on IEC60870-5-104 Protocol o be used for communication with the RTUs.
 Baud rate for various protocol used in railways:
• SPORT ;600bps &120bps (Serial Communication)
• IEC-60870-5-101:9.6KBPS (Serial communication)
• IEC-60870-5-104:10/100mbp (TCP/IP Communication).
 Present sanctioned demand of workshop: 5867KVA.
 As a result of demand monitoring, State Power Utility has been advised to curtail the
workshop sanctioned demand 1000KVA.
 This will result in saving annual saving of Rs5280000.
 Present sanctioned demand of colony: 2889KWA.
 To ensure that the colony demand does not overshoot, the pumping hours of drinking water
pumps have been redistributed.
 Management of ring structure for load distribution has been incorporated.
Important SCADA Functions:
 Acquisition of data from the field through RTUs.
 Intelligent processing of data by Servers:

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• Engineering Value conversion.
• Raising Alarms/Events.
• Dispatch of Data to Operator workstations for display.
• Storage of Historical Data for trending and reporting.
 Control Command Execution by supervisor from operator Workstations.
 Automatic control logics built into the RTUs.
DLW Infrastructure under Monitoring & Control:
Monitoring
 Monitoring of Circuit Breakers.
 Demand and Energy Monitoring.
 PF Monitoring.
 Monitoring of protection Signals.
 Additional features interfaced with SCADA in DLW.
 Monitoring of Pump Running.
 Monitoring of Valve Status.
 Total unit Consumption.
Control:
 CBs:
•For faster restoration of power from alternate feeders.
•Prompt extension of DG supply.
•Additional features interfaced with SCADA.
 Street Lighting (Time Based with manual override)

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Fig. 07 SCADA System Architecture

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Benefits of SCADA System:
 Centralized monitoring & control of all electrical substations.
 Possibility of multiple location of control (SS-1 & MRS)
 Prompts announcement of power outage and its causes(Protection operated)
 Proactive and faster restoration of power using control commands.
 Historical analysis of data.
 Management information system reporting.
Fig.08 DLW Ring Type Supply System

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AC PLANT OFFICE
AC Plant in DLW consists of centralized air conditioning system manufactured by blue star and
another one by Voltas. This plant supply chilled air to the staff rooms and halls of workshop
where diesel engines are being manufactured.
A Central plant with full ducting is best suited for air-conditioning of large buildings, conference
halls, PRS buildings etc. In the central system the Air-Conditioning plant comprising two or
more heavy compressor units including the ancillary equipment like compressors and
evaporators are located at a central point usually at the ground floor or basement. The
conditioned air is delivered through a ducting system to all parts of building. A duplicate ducting
system is required to take the return air from inside , back to the central plant to be dehumidified
cooled and recharged with fresh ventilating air to be circulated once again.
Refrigerants:
Refrigerants are heat carrying medium which during their cycle in the refrigerants system absorb
heat at a low temperature level and discard the heat so absorbed at a higher level. The
refrigerants common used are R-12,R-22,R-11 etc.
The refrigerants have boiling points much below ordinary room temperature, so they exists as
gas and are only held in the liquid state by keeping them under pressure.
Refrigeration can be produced by allowing liquid refrigerants from high pressure vessel to pass
and boil inside a coil or evaporator. The latent heat needed for the boiling is taken from the
surrounding space the evaporator, thereby cooling the space. After passing from evaporator, the
refrigerant is reclaimed with the help of compressor. The compressor compressed the vapor to
the pressure corresponding to a saturation temperature, higher than the temperature of naturally
available air or water. The compressor also circulates the refrigerants through the system.
The refrigeration cycle thus comprise of :
 Absorption of heat by the evaporation of liquid refrigerants in the evaporator at a controlled
lower pressure.

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 Raising the pressure of the low pressure vapor coming from the evaporator by the use of
compressor.
 Removal of heat from the high vapor in the condenser so as to liquidity or condense the
vapor.
 By the use of the throttling device, reducing the pressure of high pressure liquid (from the
condenser) to the level of pressure needed in the evaporator.
Refrigeration system components:
Following figure shows the line diagram of the centralized AC Plant along with the system
components:
Fig.0 9 CENTRAL PLANT AIR- CONDITIONING

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1. COMPRESSOR:
The reclaiming the refrigerant vapor leaving the evaporator, it must be compressed to the
pressure corresponding to saturation temperature higher than the temperature of the naturally
available air or water. A compressor also circulates the refrigerant through the system and its
capacity determines the capacity of the refrigeration system as a whole.
Types of refrigeration compressor used are: reciprocating, rotary, screw, centrifugal and scroll.
Reciprocating compressor are used in central AC Plants. These are available in sizes as small as
1/12hp to 150hp for large capacity installations:
2. CONDENSER:
Condenser works as a heat exchange equipment. The function of condenser is to de-superheat the
high pressure gas, condense it and also subsoil the system.
Heat from the hot refrigerant gas is rejected in the condenser to the condensing medium air or
water. Air and water are chosen because they are naturally available. Their normal temperature
range is satisfactory for condensing refrigerants.
There are three types condensers viz.
i. Air- Cooled
ii. Water-Cooled
iii. Evaporative
Water cooled condenser are used in Central AC Plant.
3. COOLING TOWERS:
The cooling towers used in conjunction with the water cooled condenser. Water in passing
through the condenser water tubes only gets warmed up but does not get contaminated. It can be
therefore be used again, after cooling. The cooling tower cools the warm water for recirculating it
in the condenser. It is thus a water conservation equipment. The heat removed by the refrigeration
system from the space or product to be cooled is ultimately thrown to the atmosphere through the
cooling tower in a water cooled condenser system.
Thus the cooling tower should function efficiently for the refrigeration system to perform well.
4. THROTTLING DEVICE:
The pressure of the liquid refrigerant room the condenser/receiver has to be reduced so that it can

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vaporize at the desired temperature in the evaporator. Also, sufficient liquid has to be fed into
evaporator to meet the refrigeration load. These function are taken care of by the throttling device.
As the rate of the flow of the liquid refrigerants to the evaporator has to be varied according to the
load on the system. Further the pressure of the liquid refrigerants at the higher side has to be
reduced to the evaporator pressure before it is fed to the evaporator.
Fig.10 AC PLANT

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TRACTION ASSEMBLEY SHOP - (TAS)
 This is the main power source for the locomotive.
 The engines mostly used are V type.
 As the transmission is electric, the engine is used as the power source for the electricity
generator or alternator.
This shop consists of following sections:
1) Harness section.
2) Battery section.
3) Assembly section.
4) Sub-Assembly section.
5) Cab section.
1. HARNESS SECTION:
In this section all the Multiple Unit cables are harnessed for making parallel connection
between two locos under overloading condition of single loco.
2. BATTERY SECTION:
• Battery is an electrochemical cell which converts chemical energy into electrical energy.
• In battery section the batteries are charged and discharge for testing purpose.
• Total 8 batteries are connected in series to get output voltage as 72 volt
(i.e.1battery=9volt).
• Lead Acid battery is used here in which concentrated sulphuric acid is used as
electrolyte.

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3. ASSEMBLY SECTION:
In a diesel–electric locomotive, the diesel engine drives an ac generator or alternator whose output
provides power to the traction motors. There is no Mechanical connection between the engine and
the wheels.
Parts of locomotive:
• Air Compressor
• Diesel engine
• Main alternator
• Auxiliary alternator
• Motor blower
• Rectifiers
• Traction control cabinet [TCC-1 & TCC-2]
• Electrical Control Cabinet [ECC-1,ECC-2,ECC-3 & ECC-4]
• Truck frame
• Traction motors
• Fuel tank
• Air reservoir (MR-1&MR-2)
• Gear box
• Radiator and radiator fan
• Turbo charging
• Sandbox

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Traction motor:
Electric motor providing the primary rotational torque of a machine usually for conversion into
linear motion.
The availability of high-powered semiconductors such as thyristors has now made practical the
use of much simpler, higher – reliabilty AC induction motor.
Electric transmission:
The diesel electric locomotive uses electric transmission ,where traction motors are provided on
the axles to give the final drive.
These motors were traditionally dc but the development of modern power and control electronics
has led to the introduction of 3-phase AC motors.
Generally there are six motors on most diesel -electric locomotives. A modern AC
motor with air blowing can provide upto 1000 hp.

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CENTRAL TRANSFERING SHOP - (CTS)
INTRODUCTION
In DLW the CTS shop is one of the vital shop presents in DLW. It main work emphasizes the
maintenance of the vehicle which needs any kinds of repairing on change in parts. Vehicle is very
important in the industries as they are used to transport all the heavy stuff from one place to other,
with the ease of time and effort. As most of the products in DLW are really heavy and almost
impossible for a human being to lift it up. So they use many other machines to transport system to
shits the products from one shop to other. That’s why there is a shop which took care of all the
vehicles in those industries to repair or any kind of adjustment requirement.
Transportation moves goods from one place to another using a variety of vehicles across different
infrastructure system. It does this using not only technology (namely vehicles, energy and
infrastructure), but also people’s time and effort; producing not only the desired output of freight
shipments, but also adverse outcomes such as air pollution, noise.
Different machines used for transportation are:
1. Fork Lift Trucks
2. Cranes
1. FORK LIFT TRUCKS

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2. CRANES
In DLW there is 5/50 Ton, 2/20 Ton capacity crane used. The main parts of overhead carne are:
1. Bridge Girder
2. Trolley Frame
3. Pendant/conductor Track
4. Bridge Drive

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5. Hook block
6. Hoist
The three types of movement that are influenced by a crane’s control system are:
 Crane motion – moving the crane up and down the runway(s)
 Hoist positioning – side-to-side / lateral movement
 Hoist lifting motion – moving the hook up and down
There are two ways that a crane can be operated:
1. An operator can control the crane from an exposed or enclosed cab attached to the crane and
utilize one or two other co-workers on the ground who help guide and position the load using
hand signals.
2. A crane can be controlled by an operator on the floor using a push button pendant system that is
attached to the crane itself, or a wireless control that utilizes a radio transmitter and receiver.

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REFERENCES
www.dlw.indianrailways.gov.in
https://www.slideshare.net/
https://www.scribd.com/

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