dlw summer training report

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A VOCATIONAL TRAINING REPORT

ON

IN PARTIAL FULFILMENT OF THE REQUIREMENT FOR THE DEGREE OF BACHELOR OF TECHNLOGY TO DEPARTMENT OF MECHANICAL ENGINEERING

MAULANA AZAD NATIONAL INSTITUTE OF TECHNOLOGY BHOPAL , MADHYA PRADESH

SUBMITTED TO; SUBMITTED BY;

Eshver Chandra

Mr. B.tech , 4th YEAR

Mechanical engineering Sch. no. 131116244

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ACKNOWLEDGEMENT

This Project Report is combined effort of many people who have contributed in their own ways in making this report effective and purposeful. In my report, I would like to take the opportunity of thanking all those who have been instrumental in preparing this report.

I would sincerely like to thank the employees and the officers of DLW, Varanasi for their help and support during the vocational training. Despite their busy schedule, they took out time for us & explained to us the various aspects of the working of the plant, from the production shops.

I would sincerely like to thank Mr. Ashutosh Singh (JE/E.E.S.) ,Mr. P.K. Shukla (SSE/E.T.S.) and Mr. Jitendra yadav (JE/L.T.S.), Mr. Shyam Prajapati (JE/L.A.S. ) who was instrumental in arranging the vocational training at DLW Varanasi, and without whose help and guidance the training could not have materialized.

I express my deep sense of gratitude to Mr. Gyanesh tripathi (Principal, TTC) for given me such a great opportunity.

I expressed my thanks to the lecture Mr. J.L. Bhagoria & HOD of department, I would also thank my institution & my faculty members without whom this report would have been a distant reality.

I also extend my heartfelt thanks to my family & well wishers.

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Preface

The objectives of the practical training are to learn something about industries practically and to be familiar with the working style of a technical person to adjust simply according to the industrial environment.

It is rightly said practical life is far away from theoretical one. We learn in class room can give the practical exposure or real life experience no doubt they help in improving the personality of the student in long run of life and will be able to implement the theoretical knowledge. As a part of academic syllabus of four year degree course in Mechanical Engineering, every student is required to undergo a practical training.

I am student of the Final Year Mechanical Engineering & this report is written on the basis of practical knowledge of acquired by me during the period of practical training taken at Diesel Locomotive Works, Varanasi.

This report is presented in very simple & understanding language on the basis of Primary and Secondary data.

Eshver chandra

M.E. (4th Year)

131116244

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DECLARATION

I Eshver Chandra, Sch. No-131116244, student of B.Tech (Mechanical Engineering) 4th year of Maulana azad National Institute of Technology hereby declare that my project report on “ DIESEL LOCOMOTIVE WORKS ” is an original and authenticated word done by me.

I further declare that it has not been submitted elsewhere by any person in any of the institutes for the degree of bachelor’s of technology.

Eshver chandraMechanical Engineering Final year 131116244

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TABLES OF CONTENTS

Acknowledgement

Preface

Declaration

Introduction of D. L W.

Identification of locomotives

Product

EMD Specification

ALCO Specification

Vision & Mission

Line Diagram of Diesel Locomotive

Engine erection Shop

Engine testing Shop

Loco assembly Shop

Loco testing Shop

Finding & Conclusion

Learning Experience

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INTRODUCTION

Background

Diesel Locomotive Works (DLW) is 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 general 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.

Brief History

Set up in 1961 as a green-field project in technical collaboration with LCO/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 locomotive. Indian Railways is the state-owned railway company of India.

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It comes under the Ministry of Railways. Indian Railways has one of the largest and busiest rail networks in the world, transporting over 18 million passengers and more than 2 million tonnes of freight daily. Its revenue is Rs.107.66 billion. It is the world's largest commercial employer, with more than 1.4 million employees. It operates rail transport on 6,909 stations over a total route length of more than 63,327 kilometres (39,350 miles).The fleet of Indian railway includes over 200,000 (freight) wagons, 50,000 coaches and 8,000 locomotives. It also owns locomotive and coach production facilities. It was founded in 1853 under the East India Company. Indian Railways is administered by the Railway Board. Indian Railways is divided into 16 zones. Each zone railway is made up of a certain number of divisions. There are a total of sixty-seven divisions. It also operates the Kolkata metro. There are six manufacturing plants of the Indian Railways. The total length of track used by Indian Railways is about 108,805 km (67,608 mi) while the total route length of the network is 63,465 km (39,435 mi). About 40% of the total track kilometer is electrified & almost all electrified sections use 25,000 V AC. Indian railways uses four rail track gauges.

The broad gauge (1670 mm)The meter gauge (1000 mm)Narrow gauge (762 mm)Narrow gauge (610 mm).Indian Railways operates about 9,000 passenger trains and transports 18 million passengers daily .Indian Railways makes 70% of its revenues and most of its profits from the freight sector, and uses these profits to cross-subsidies the loss-making passenger sector. The Rajdhani Express and Shatabdi Express are the fastest trains of India.

CLASSIFICATION

Standard “Gauge” designations and dimensions:-W = Broad gauge (1.67 m)Y = Medium gauge ( 1 m)Z = Narrow gauge ( 0.762 m)N = Narrow gauge ( 0.610 m)

“ Type of Traction” designations:-D = Diesel-electric traction

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C = DC tractionA = AC tractionCA=Dual power AC/DC tractionThe “ type of load” or “Service” designations:-M= Mixed serviceP = PassengerG= GoodsS = Shunting

“ Horse power ” designations from June 2002 (except WDP-1 & WDM-2 LOCOS)‘ 3 ’ For 3000 horsepower‘ 4 ’ For 4000 horsepower‘ 5 ’ For 5000 horsepower‘ A ’ For extra 100 horsepower‘B’ For extra 200 horsepower and so on.

Hence ‘WDM-3A’ indicates a broad gauge loco with diesel-electric traction. It is for mixed services and has 3100 horsepower

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SALIENT FEATURES:

Annual production capacity 125 Locomotives

Annual turn-over (Rs) 5000 million

Total number of staff 7223

Workshop land 89 Hectares

Township area 211 Hectares

Covered area in shops86300 Sq.m

Covered area of other service buildings 73700 Sq.m

Electrical power requirement 3468 KVA

(Average maximum demand)

Electrical energy consumption (units/year) 19.8 million

Standby power generation capacity 3000 KW

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IDENTIFICATION OF LOCOMOTIVES AT DLW

Following types of diesel loco are being produced in the DLW:-

WDM- Wide Diesel Mixed

WDP- Wide Diesel Passenger

WDG- Wide Diesel Goods

WDS- Wide Diesel Shutter

The First Letter (Gauge)

W- Indian broad gauge(The “W” stand for wide Gauge-5ft)

Y- Meter gauge(The “Y” stands for Yard gauge-3ft )

Z- Narrow gauge(2ft 6 inch)

N- Narrow gauge (2ft)

The Second Letter (Motive Power)

D- Diesel

C -DC Electric(can run under DC traction only)

A- AC Electric(can run under AC traction only)

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CA- Both DC & AC(can run under both AC & DC tractions)

B- Battery Electric locomotive (rare)

The Third Letter (Job Type)

G- Goods

P- Passenger

M- Mixed, both goods & passenger

S- Shunting(also known as switching engines)

U- Electric multiple units (used as commuters in city suburb

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Products

EMD(Electro Motive Division)

WDG-4000 HP GOODS LOCOMOTIVE

Broad Gauge free ght traffic Co-Co diesel electric locomotive with 16 Cylinder 4000 HP, AC-A C transmission, microprocessor controlled propulsion and braking with high traction high speed cast steel trucks.First turned out i n 1999 with transfer of technology from General Motor (USA), this locomotive has exceptional fuel efficiency and very lo w maintenance requirements. It is specific ally designed for heavy haul freight traffic requirements of Indian Railways for the 21st Century.The heart of loco Traction Control Converter uses the GT O devices (obsolete technology). Now the IGBT devices, has been introduced from Oct 2006. It is the latest technology and will be cost effective and gives higher reliability .The locomotive power has been upgraded to 4500 BCV an d the first Loco (Loco No 12114) was manufactured in May 07.

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General Characteristic

Installed Power Axle Load

Gauge

Wheel arrangement Wheel diameter

Height Width

Overall Length (Over Buffer Beam)

Weight

Max tractive effort Maximum speed

Fuel tank capacity Locomotive Control

4000 HP 21 T

1676 mm Co-Co

1092 mm 4201 mm 3127 mm 19964 mm 126 T

54 T

100 Kmph 6000 lts

EM 2000 with SIBAS-16 Traction Control

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WDG4-4000 HP GOODS TRACTIVE EFFORT & POWER CHARTLOCOMOTIVE

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2. WDP4-4000 HP PASSENGER LOCMOTIVE

State-of-Art, Microprocessor controlled AC-AC, Passenger Locomotive Powered with 16-710G3B 4000HP Turbo charged Two stroke Engine. Fabricated rigid design Under frame, two stage suspension, High Traction High Speed 3 axle (HTSC) light weight cast truck frame attribute to high adhesion performance. First turned out in 2003, this locomotive has exceptional fuel efficiency and very low maintenance requirements. It is specifically designed for heavy haul passenger traffic requirements for Indian Railways.The WDP4 fleet is being upgraded by provision of hotel load feature along with power up gradation to 4500 HP. The prototype will be manufactured in the year 2007.

Diesel Engine Transmission

16 Cylinder 710 G3B, 2 stroke, Electrical AC-ACturbocharged after cooled

4 Traction motor ( 3 in parallel perFuel Efficient Engine bogie)

Injection System Direct Unit Suspension Axle hung / taperInjector roller bearing

Governor Woodward Gear Ratio 77:17

Compression Ratio- 16:1

Lube Oil Sump Capacity 1073 Lts

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Truck Brakes

High adhesion HTSC ( High Electronic Air Brake System (Tensile Steel Cast) truck or bogie KNORR-NYAB-Computer Controlled

Adhesion 0.42Braking)

Air , hand , dynamic brake with fullyblended with automatic brakesPure air brake

General Characteristic

Installed Power 4000 HPAxle Load 19.5 TGauge 1676 mmWheel arrangement A-A-I I-A-AWheel diameter 1092 mmHeight 4201mmWidth 3127 mmOverall Length (Over 19964 mmBuffer Beam)

117 TWeight

27 TMax tractive effort

160 KmphMaximum speed

4000 ltsFuel tank capacity

EM 2000 with SIBAS-16 Traction ControlLocomotive Control

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ALCO(AMERICAN LOCOMOTIVE COMPANY)

1350 HP CAPE GAUGE LOCOMOTIVE VDM 4

TECHNICAL INFORMATION

1350 HP Locomotive having fabricated cape gauge Co-Co bogie. These locomotives have been supplied to Angola and Sudan.

Track Gauge

1067 mm Cape gauge

Weight

72 t

Overall Length

15600 mm

Wheel Diameter

921 mm

Gear Ratio

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18: 93

Maximum Speed

90 Kmph

Diesel Engine Type : ALCO 251 D 6 Cyl.

1350

Transmission

Electrical AC/DC

Brake

28LAV-1 system

Loco

Air, dynamic, parking

Train Air & Vacuum

Fuel Tank Capacity 3000 ltr

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2. 2300 HP CAPE GAUGE LOCOMOTIVE


2300 HP Main Line Locomotive, having fabricated cape gauge Co-Co bogies. These are provided with two driver’s cabs, one at each end. These locomotives have been supplied to Angola and Sudan.

Wheel Arrangement Co-Co

Track Gauge 1067 mm Cape Gauge

Weight 102 t

Overall Length 17620 mm

Wheel Diameter 921 mm

Gear Ratio 18 : 93

Maximum Speed 100 Kmph

Diesel Engine Type: ALCO 251-B 12 Cyl. V- Engine

HP 2300

Transmission Electrical AC/DC

Brake IRAB-1

Loco Air, Dynamic, parking

Train Air

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3. 2300HP METER GAUGE LOCOMOTIVE

TECHNICAL INFORMATIO2300 HP Main Line Locomotive, having fabricated meter gauge Co-Co bogies. These are provided with two drivers cabs, one at each end. These locos have been supplied to Malaysia, Senegal and Mali.


Track Gauge 1000 mm Meter Gauge

Weight 102 t

Overall Length 17620 mm


Gear Ratio 18 : 93


Diesel Engine Type: ALCO 251-B 12 Cyl. V- Engine

HP 2300

Transmission Electrical AC/DC

Brake IRAB-1

Loco Air, Dynamic, parking

Train Air

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4. BROAD GAUGE MAIN LINE FREIGHT LOCOMOTIVE

WDG 3A


Diesel Electric main line, heavy duty goods service locomotive, with 16 cylinder ALCO engine and AC/DC traction with micro processor controls.


Track Gauge 1676 mm

Weight 123 t

Length over Buffers 19132 mm


Gear Ratio 18 : 74

Min radius of Curvature 117 m


Diesel Engine Type : 251 B,16 Cyl.- V

HP 3100

Brake IRAB-1

Loco Air, Dynamic

Train Air

Fuel Tank Capacity 6000 liters

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VISION & MISSION

Our Vision -”To be a world class manufacturer of Diesel - electric locomotives."

Our Mission - "We shall achieve our vision through Continuous Improvement in the areas of Product Quality, Research and Development, Supplier Partnership, Human Resource Development and Team Work with emphasis on Core Competence leading to Customer Satisfaction and Business Excellence."

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LINE DIAGRA M OF DIESEL LOCMO TIVE

Main Alternator:-

The diesel engine drives the main alternator which provides the power to move the train. The alternator generates AC electricity which is used to provide power for the traction motors mounted on the trucks. In older locomotives, the alternator was a DC machine, called a generator. It produced direct current which was used to provide power for DC traction motors. Many of them machines are still in regular use. The next development was the replacement of the generator by the alternator but still using DC traction motors. The AC output is rectified is give the DC required for the motors.Auxiliary Alternator:-Locomotive used to operate passenger trains are equipped with an auxiliary alternator. This provides AC power for lightening, heating, air conditioning, dining facilities etc on the train .The output is transmitted along the train through an auxiliary power line.

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MOTOR BLOWER

The diesel engine also drives a motor blower. As its name suggests , The motor blower provides the air which is blown over the traction motors to keep them cool during periods of heavy work. The blower is mounted inside the locomotive body but the motors are on the trucks, so the blower output is connected to each of the motors through flexible ducting.

The blower output also cools the alternators. Some design s have separate blowers for the group of motors on each truck and others for the alternators. Whatever the arrangement , a modern locomotive has a complex air management system which monitors the temperature of the various rotating machines in the locomotive and adjust the flow of air accordingly.

AIR INTAKE.

The air for cooling the locomotives motors is drawn in from outside the locomotive . It has to be filtered to remove dust and other impurities and its flow regulated by temperature , both sides and of the locomotive. The air temperature system has to take account of the wide range of temperatures from the possible +40°C of summer and to the possible -40°C of winter.

ELECTRONIC CONTROLE

Almost every part of the modern locomotive equipment has some of electronic control. These are usually collect d in a control cubicle near the cab for easy access.

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Cab :

The standard configuration of US- designed locomotive is to have a cab at one end of the locomotive only.

Batteries

Just like automobile , the diesel engine needs a battery to start it and to provide electrical power for the lights and controls when the engine is switched off and the alternator is not running.

Traction motor

Since the diesel- locomotive uses electric transmission , traction motors are provided on the axles to give the final drive .These motors were traditionally DC but the development of the modern power and control electronics has led to the introduction of 3Φ AC motors.

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PINION/GEAR ;-

The traction motor drives the axles through a reduction gear of a range between 3 to1 and 4 to 1 (passenger)

Fuel tank;-

A diesel locomotive has to carry its own fuel around with it and there has to be enough for a reasonable length of trip. The fuel tank is normally under the loco frame and will have a capacity of say 1000 imperial gallons .the new AC 6000s have 5500 gallon tanks .In addition to fuel , the locomotive will carry around , typically about 300US gallon of cooling water and 250 gallon of lubrication oil for the diesel engine.

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Air compressor :-

The air compressor is required to provide a constant supply of compressed air for the locomotive and train brakes.

Drive shaft;- The main output from the diesel engine is transmitted by the drive shaft to the alternators at one end and the radiator fans and compressor at the other end.Gear box :- The radiator and its cooling fan are often located in the roof of the locomotive . Drive to the fan is therefore through a gearbox to change the direction of the drive upwards.

Turbo charger;-

The amount of the power attained from a cylinder in a diesel engine depends on how much fuel can be burn it in. the amount of fuel which can be burnt depends on the amount of air available in the cylinder .So turbocharger is used to increase the amount of air pushed into each cylinder . The turbocharger is driven by exhaust gas from the engine . This gas drives a fan which in turn , drives a small compressor which pushes the additional air into the cylinder. The turbo charging gives a 50% increase in engine power.

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Sand box:_

Locomotives always carry sand to assist adhesion in bad rail conditions.

Truck frame :-

This is part (called the bogie in the UK) carrying the wheels and traction motors of the locomotive.

MECHANICAL TRANSMISSION:-

As the name suggests, a mechanical transmission on a diesel locomotive consists a direct link between the diesel engine and the wheels. In the example given below , the diesel engine is in the 350-500HP range and the transmission is similar to that of an automobile with a four speed gearbox

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STARTING :-

A diesel engine is started(like an automobile) by turning over the crankshaft until the crankshaft until the cylinders fire or begin combustion .The starting can be done electrically or pneumatically .Pneumatic starting was used for some engines. Compressed air was pumped into the cylinders of the engine , until it gain sufficient speed to allow the ignition , than fuel was applied to fire the engine. The compressed air was supplied from a small auxiliary engine or by high pressure air cylinders carried by the locomotive. Electric starting is now standard . It works same way as for an automobile, with batteries providing the power to turn a start motor which turns over the main engine. In older locomotives fitted with DC generators instead of AC alternators, the generator was used as a starter motor by applying battery power to it.Governor:- Once a diesel engine is running , engine speed is monitored and controlled through a governor . Governors ensures that the engine speed stays high enough to idle at right speed and that the engine speed will not raised to high when full power is demanded. The governors is simple mechanical device which first appeared on steam engines . It operate on the diesel engine as shown in the diagram below .

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Cooling:-

Like an automobile engine , the diesel engine need to works at an optimum temperature for best efficiency .when it starts , it is too cold , and when working ,it must not to be allowed to get too hot. To keep the temperature stable , a cooling system is provided

.this consist of a water based coolant circulating around the engine block, the coolant being kept cool by passing it through a radiator. Another reason for keeping diesel engines running is that the constant heating and cooling caused by produce leaks.

Lubrication:- Like an automobile engine , a diesel engine needs lubrication. In an arrangement similar to the engine cooling system, lubrication oil is distributed around the engine to the cylinder ,crankshaft and other moving parts .The radiator is sometimes design as a heat exchanger ,where the oil passes through pipes encased in a water tank which is connected to the engine cooling system .The oil has to be filtered to remove impurities and it has to monitored for low pressure if oil pressure falls to a level which could cause the engine to size up ,a “low oil pressure switch” will shut down the engine .There is also a high pressure relief valve ,to drain off excess oil back to the sump.Transmissions:- Like an automobile, a diesel locomotive cannot start itself directly from a stand. It will not develop maximum power at idling speed, so it needs some form of transmission system to multiply torque when starting. It will also be necessary to vary the power applied according to the train weight or the line gradient. There are three methods of doing this: mechanical, hydraulic or electric . Most diesel locomotive use electric transmission and are called “diesel-electric” locomotive . Mechanical and hydraulic transmission are still used but are more common on multiple unit trains or lighter locomotives.

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engine erection shop

This shop mainly deals with the fabrication of the engine block and base (B.G. & M.G.) Turbo support. There are many components which are assembled . some of them are listed below-

Assembly of the major component of the locomotive engine 1. Lube oil container ( base ) 2. Crankshaft and crankcase3. Governor and double fuel filter 4. Strainer 5. Double water circulator 6. Flywheel 7. OST shaft 8. Rocker arm 9. Alternator 10. Turbo super charger11. Air intake and exhaust system

1. Inspection standard 2. Proper materials 3. Proper electrodes and flux 4. proper welding technique 5. welfare of staff

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ENGINE TESTING SHOP

The testing of the engine is done for 3 hours in this shop In this shop testing of the engine performed

1. Initial filling of the lube oil and fuel

2. Observation of the vibration

3. Sensing and controlling the temperature 4. Controlling the pressure

5. soak valve pump

6 . Circulation of water and sensing of temperature

7. Initial supply of the 72 V for starting

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LOCO ASSEMBLY SHOP Assembly of the major component of the locomotive on the locomotive frame

1. Driver cabin 2. Fins , cooler and fan 3. Rack positioning 4. Water circulation tube and tank 5 . Major lube oil filter 6. Governor system 7. Engine assembly 8 . Alternator and auxiliary generator 9. Air filter and blower

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10 . ECC 1, ECC 2.

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LOCO TESTING SHOP

When all the perform are done then finally engine come in ETS, for the first inspection report and after this it will be agreed for the performance

Testing of the final locomotive on the basis of several performance

1. Initial filling of lube oil ( approx 4200 ltr)

2. Filling of all fuel ( approx 3000 ltr)

3. Load testing

4. Testing of MR1 and MR2

5. Air brake testing

6. Water circuit check

7. Testing of dynamic brake 8. Lightning inspection

9. testing of speed

10. testing of alignment

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FINDING AND CONCLUSION:-

After completing my project I familiarize with DLW, and I get that diesel locomotive works is a famous technological temple, which came in existence, in 1964 by Late Shri Lal Bahadur Shastri. DLW export to the following countries like Sri Lanka,

Bangladesh, Angola, Tanzania, Vietnam ,Sengal Mozambique, Malaysia, Sudan, Myanmar etc.

There are many facilities for the employees as hospital, health club, sports club, school and college, sewing center, technical training center etc. In short we can say that all the facility which the ordinary employee needed is provided by welfare department and the entire employee are very well aware with welfare programmers. They take advantage with programme in any form. Very few improvement but important improvement, which mentioned above, is needed in welfare programmes, which make the employees more satisfied.