BHARAT HEAVY ELECTRICALS

LIMITED, JHANSI (U.P.)

ROTATION REPORT

&

SUMMER TRAINING PROJECT REPORT ON

Diesel - loco

FOR A PERIOD OF FIVE WEEKS

UNDER GUIDANCE OF: Submitted by:

MR. Abhishek Kumar Kamlakant Rajpoot

Production Engg. (loco) B.E. (Mechanical)

Bhart Heavy Electrical Limitted NRI Institute of technology & management (Jhanasi ) (Gwalior)

1

PREFACE

Vocational training is one of the important parts of the curriculum for the engineering students. Its basic idea is to strength the theoretical concepts of the students through practical training of making them acquainted with the latest technology and development.

The philosophy of this report is to emphasize the practical understanding of basic concept, which has been studied in the class.

I do sincerely hope that this project work wills the BHEL JHANSI in formulating its theory and plan. I tried my best to cover, even if there is any acutance surface, I regret for that.

2

ACKNOWLEDGEMENT

Training is one of the most important aspects for an engineering student’s career. It is to strength the theoretical concepts. Through training a student is acquainted with the latest technology and recent development.

Firstly I convey my sincere thanks to all the B.H.E.L. employees. Their guidance was omnipotent and incompatible throughout the training period.

I also convey our special thanks to Mr. Sr. Manager (H.R.) for providing us this opportunity to undergo this training. We also express our regards to all the member of H.R.D. in B.H.E.L. JHANSI.

I would like to express my thanks to all departments for valuable suggestion, guidance, support, encouragement and providing necessary information for the project.

3

CONTENT

Sl N0. TOPIC PAGE NO.

1 An Overview of BHEL 5

2 Activity Profile of BHEL 8

3 Vision, Mission & values of BHEL 10

4 Various BHEL Units 11

5 Product Profile Of BHEL JHANSI Unit 12

6 Rotation Report 13

7 Project Report On Diesel Loco 24

8 Introduction 25

9 Parts of Diesel Loco 27

10 Locomotive Data 37

11 Wheel Base 38

12 Over All Dimansion 38

13 Capacity 38

14 Auxiliary Horse Power Requirement 39

4

(1) AN OVERVIEW OF BHEL

BHEL is the largest engineering and manufacturing enterprise in India in the

energy/infrastructure sector today. BHEL was established more than 40 years ago

when its first plant was set up in Bhopal ushering in the indigenous Heavy Electrical

Equipment industry in India, a dream that has been more than realized with a well-

recognized track record of performance.

BHEL caters to core sectors of the Indian Economy viz., Power Generation &

transmission, Industry, Transportation, Telecommunication, Renewable Energy,

Defense, etc. The wide network of BHEL’s 17 manufacturing divisions, four Power

Sector regional centers, over 100 project sites, eight service centers and 18 regional

offices, enables the company to promptly serve its customers and provide them with

suitable products, systems and services-efficiently and at competitive prices. BHEL

has already attained ISO 9000 certification for quality management, ISO 27000 for

Information Technology and ISO 14001 certification for environment management.

POWER GENERATION

Power generation sector comprises thermal, gas, hydro, and nuclear power plant

business.

TELECOMMUNICATION

BHEL also caters to Telecommunication Sector by way of small, medium and large

switching systems.

TRANSMISSION AND DISTRIBUTION (T&D)

BHEL offers wide-ranging products and systems for T&D applications. Products

manufactured include: power transformers, instrument transformers, dry type

transformers, series &shunt reactors, capacitor banks, vacuum &SF6 circuit

breakers, gas-insulated switchgears and insulators.

5

INDUSTRIES

BHEL is a major contributor of equipment and systems to industries, cement, sugar,

fertilizer, refineries, petrochemicals, paper, oil and gas, metallurgical and other

process industries. The range of systems & equipment supplied includes: captive

power plants, co-generation plants, DG power plants, industrial steam turbines,

industrial boilers and auxiliaries, waste heat recovery boilers, gas turbines, heat

exchangers and pressure vessels, centrifugal compressors, electrical machines,

pumps, valves, seamless steel tubes, electrostatic precipitators, fabric filters,

reactors, fluidized bed combustion boilers, chemical recovery boilers and process

controls.

TRANSPORTATION

BHEL is involved in the development, design, engineering, marketing, production,

installation, and maintenance and after-sales service of rolling stock and traction

propulsions systems. BHEL manufactures electric locomotives up to 5000 HP, diesel

electric locomotives from 350 HP to 3100 HP, both for mainline and shunting duty

applications. It also produces rolling stock for special applications viz. overhead

equipment cars, special well wagons, and Rail-cum road vehicle.

RENEWABLE ENERGY

Technologies that can be offered by BHEL for exploiting non-conventional and renewable sources of energy include: wind electric generators, solar photovoltaic systems, solar heating systems, solar lanterns and battery-powered road vehicles.

OIL AND GAS

BHEL’s products range includes Deep Drilling Oil Rigs, Mobile Rigs, Work Over

Rigs, Well Heads and X-Mas Trees, Choke and Kill Manifolds, Full Bore Gate

Valves, Mudline Suspension System, Casing Support system Sub-Sea Well Heads,

Block valves, Seamless pipes, Motors, Compressor, Heat Exchangers etc.

6

INTERNATIONAL OPERATIONS

BHEL is one of the largest exporters of engineering products & services from

India, ranking among the major power plant equipment suppliers in the world.

7

(2) ACTIVITY PROFILE OF BHEL

POWER SECTOR PROJECTS

Thermal sets and Auxiliaries.

Steam generators and Auxiliaries.

Industrial fans.

Electrostatic precipitators.

Air pre heaters.

Nuclear power equipments.

Hydro sets and Auxiliaries.

Motors.

Transformers.

Rectifiers.

Pumps.

Heat Exchangers.

Capacitors.

Porcelain/Ceramics insulators.

Seamless steel tubes.

Casting and forging.

SYSTEMS/SERVICES

Turnkey power station.

Data acquisition Systems.

Power systems.

HVDC Commissioning systems.

Modernization and Rehabilitation.

8

TRASPORTATION SECTOR

Diesel Electric generators.

AC/DC locomotives.

DC locomotives and loco shunters.

Traction system for railways.

Electric trolley buses.

INDUSTRY SECTOR

Boilers.

Valves.

T.G. sets.

Power devices.

Solar Cells.

Photo Voltaic cells.

Gas Turbines.

Compressors.

Drive Turbines.

Oil rigs.

Blow out preventers.

Wind mills.

Control systems for electric devices.

9

(3) VISION, MISSION AND VALUES OF BHEL

VISION

A global engineering enterprise providing solutions for a better tomorrow.

MISSION

Providing sustainable business solutions in the fields of Energy, Industry & Infrastructure.

VALUES

GOVERNANCE: We are stewards of our shareholders investments and we take that responsibility very seriously. We are accountable and responsible for delivering superior results that make a difference in the lives of the people we touch.

RESPECT: We value the unique contribution of each individual. We believe in respect for human dignity and we respect the need to preserve the environment around us.

EXCELLENCE: We are committed to deliver and demonstrate excellence in whatever we do.

LOYALTY: We are loyal to our customers, to our company and to each other.

ENTEGRITY: We work with highest ethical standards and demonstrate a behavior that is honest, decent and fair. We are dedicated to the highest levels of personal and institutional integrity.

COMMITMENT: We set high performance standards for ourselves as individuals and our teams. We honour our commitments in a timely manner.

INNOVATION: We constantly support development of newer technologies, products, improved processes, better services and management practices.

TEAM WORK: We work together as a team to provide best solutions & services to our customers. Through quality relationships with all stakeholders we deliver value to our customers.

10

(4) VARIOUS BHEL UNITS

FIRST GENERATION UNITS

Bhopal : Heavy Electrical Plant.

Haridwar : Heavy Electrical Equipment Plant.

Hyderabad: Heavy Electrical Power Equipment Plant.

SECOND GENERATION UNITS

Tiruchy : High Pressure Boiler Plant.

Jhansi : Transformer and Locomotive Plant.

Haridwar : Central Foundry and Forge Plant.

Tiruchy : Seamless Steel Tube Plant.

UNITS THROUGH ACQUISTION & MERGER

Bangalore : Electronics Division

Electro Porcelain Division.

NEW MANUFACTURING UNITS

Ranipet : Boiler Auxiliaries Plant.

Jagdishpur: Insulator Plant.

Govindwal : Industrial Valve Plant.

Rudrapur : Component and Fabrication Plant.

Bangalore : Energy Systems Division

BHEL is growing concern to meet the changing needs of the nation has taken it beyond

power into the total gamut of energy, industry and transportation BHEL is able to offer a

service in each of this fields. It;s manufacturing capability is supported by a corporate R&D

division at Hyderabad works closely with the research and development cells at various units

and Welding Research Institute at Tiruchinapalli.

11

(5)THE PRODUCT PROFILE OF BHEL JHANSI UNIT

PRODUCTS RATINGS

1. Power transformer Up to 220 KV class 250 MVA

2. Special transformer Up to 132 KV

3. ESP transformer 100 KV, 1400 MA

4. Freight Loco transformer 3900 to 5400 KVA & 7475.

KVA for 3 phase.

5. ACEMU transformer Up to 1000 KVA 2(1-phase).

1385 KVA (3 phase).

6. Bus-Duct transformer Up to 5000 KVA.

7. Instrument transformer VT & CT up to 220 KV class.

8. Diesel electric locomotives Up to 2600 HP.

9. AC/DC locomotives 5000 HP.

10. Over Head Equipment cum Test

Car

11. Well wagon 200 tone.

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(6) Rotation Report

TRANSFORMER COMMERCIAL (TRC)

The objective of the department is interaction with the customers. It brings out

tenders and notices and also responds to them. It is this department that bags

contracts of building transformers. After delivery regarding faults, this department

does failures and maintenance. All such snags are reported to them and they

forward the information to the concerning department.

One of the major tasks of this department is to earn decent profits over all

negotiations. Transformer industry has become very competitive. The company

offering the lowest price gets the contract but this process may continue does the

work on very low profits. To avoid such a situation, a body by the name of India

Electrical and Electronics Manufactures Association (IEEMA) was set up. This

association helps to maintain a healthy competitive atmosphere in the manufacturing

of electrical appliances.

TRANSFORMER ENGINEERING (TRE)

The transformer manufactured in BHEL Jhansi range from 10 MVA to 250 MVA and

up to 400 KV. The various transformers manufactured in this unit are:-

POWER TRANSFORMER

a) Generator transformer

b) System transformer.

c) Auto transformer.

SPECIAL TRANSFORMER

a) Freight loco transformer.

b) ESP transformer.

c) Instrument transformer.

d) Dry type transformer.

BAY-00 & 0:

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It is a sub part of Fabrication. It is the preparation shop while the other two bays

form the assembly shop. This section has the following machines:

Planner machine – To reduce thickness

Shearing machine

CNC / ANC Flame Cutting machine – To cut Complicated shaft items using

Oxy-Acetylene flame

Bending machine

Rolling machine

Flattening machine

Drilling machine

Nibbling machine

Pantograph flame cutting machine

BAY-1

It is also a sub part of Fabrication. It is an assembly shop where different parts of

tank come from bay 0.Here welding processes are used for assembly, after which

a rough surface is obtained Grinder operating at 1200 rpm is used to eliminate the

roughness.

BAY-2

It is also a sub part of Fabrication It is an assembly shop dealing with making

different objects mentioned below.

1-Tank assembly 5-cross feed assembly

2-Tank cover assembly 6-core clamp assembly

3-End Frame assembly 7-pin and pad assembly

4-foot assembly

Before assembly, short blasting (firing of small materials i.e., acid pickling) is done

on different parts of jobs to clean the surface before painting.

NON DESTRUCTIVE TEST

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1 Ultrasonic test to detect the welding fault on the CRO at the fault place high

amplitude waves are obtained.

2. Die Penetration test Red solution is put at the welding and then cleaned.

After some time white solution is mixed. Appearance of a red spot indicates a fault

at the welding.

3. Magnetic crack detection Magnetic field is created and then iron powder is

put at the welding. Sticking of the iron powder in the welding indicated a fault.

4. X-Ray Test: It is same as human testing and the fault is seen in X-ray film.

BAY-3

Here are basically three sections in the bay:

Machine section

Copper section

Tooling section

BAY- 4

It is the winding section.

There are four types of coil fixed in a transformer, they are :

1. Low voltage coil (LV)

2. High voltage coil (HV)

3. Tertiary coil

4. Tap coil

The type of winding depends upon job requirement. Also, the width and thickness

of the conductors are designed particulars and are decided by design department.

Conductors used for winding is in the form of very long strips wound on a spool, the

conductor is covered by cellulose paper for insulation.

15

For winding first the mould of diameter equal to inner dia meter of required coil is

made .The specification of coil are given in drawing. The diameter of mould is

adjustable as its body is made up of wooden sections that interlock with each

other. This interlocking can be increased or decreased to adjust the inner diameter

of coil.

The moulds are of following types

1. Belly types

2. Link types

3. Cone type

BAY-5

It is core and punch section. The lamination used in power, dry, ESP transformer

etc for making core is cut in this section.

CRGO (cold rolled grain oriented) silicon steel is used for lamination, which is

imported in India from Japan, U.K. Germany. It is available in 0.27 and 0.28 mm

thick sheets, 1mt wide and measured in Kg.The sheet s are coated with very thin

layer of insulating material called “carlites”.

For the purpose of cutting and punching the core three machines are installed in

shop

BAY-6

Single-phase traction transformer for AC locomotives is assembled in this section.

This Freight locomotive transformer are used where there is frequent

change in speed. In this bay core winding and all the assembly and testing of

traction transformer is done.

Three-phase transformers for ACEMU are also manufactured in this section. The

supply lines for this transformer are of 25 KV and power of the transformer is 6500

KVA. The tap changer of rectifier transformer is also assembled in this bay.

Rectified transformer is used in big furnace like the thermal power stations / plants

(TPP).

BAY-7

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1. This is the insulation shop. Various types of insulations are

2. AWWW - All Wood Water Washed press paper.

3. The paper is 0.2-0.5mm thick cellulose paper and is wound on the

conductors for insulation.

4. PRE COMPRESSED BOARD: This is widely used for general insulation &

separation of conductors in the forms of blocks.

5. PRESS BOARD: This is used for separation of coils e.g. L.V. from H.V. It is

up to 38 mm thick.

6. UDEL(Un Demnified Electrical Laminated) wood or Permawood

7. This is special type of plywood made for insulation purposes.

8. FIBRE GLASS: This is a resin material and is used in fire pron areas.

9. BAKELLITE

10.GASKET- It is used for protection against leakage.

11.SILICON RUBBER SHEET- It is used for dry type transformer.

BAY- 8

It is the instrument transformer and ESP transformer manufacturing section.

INSTRUMENT TRANSFORMER

These are used for measurement. Actual measurement is done by measuring

instruments but these transformers serve the purpose of stepping down the voltage

to protect the measuring instrument. They are used in AC system for measurement

of current voltage and energy and can also be used for measuring power factor,

frequency and for indication of synchronism. They find application in protection of

power system and for the operation of over voltage, over current, earth fault and

various other types of relays.

ESP TRANSFORMER

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The Electrostatic Precipitator transformer is used for environmental application. It is

used to filter in a suspended charge particle in the waste gases of an industry. They

are of particular use in thermal power stations and cement industry.

The ESP is a single-phase transformer. It has a primary and secondary. The core is

laminated and is made up of CRGOS. It is a step up transformer. An AC reactor is

connected in series with primary coil. The output of the transformer must be DC the

is obtained by rectifying AC using a bridge rectifier (bridge rectifier is a combination

of several hundred diodes). A radio frequency choke (RF choke) is connected in

series with the DC output for the protection of the secondary circuit and filter circuit.

The output is chosen negative because the particles are positively charged. The DC

output from the secondary is given to a set of plates arrange one after the others.

Impurity particles being positively charged stick to these plates, which can be jerked

off. For this a network of plates has to be setup all across the plant. This is very

costly process in comparison with the transformer cost. A relive vent is also provided

to prevent the transformer from bursting it higher pressure develops, inside it. It is

the weakest point in the transformer body. An oil temperature indicator and the

secondary supply spark detector are also provided.

One side of the transformer output is taken and other side has an ‘marshalling box’

which is the control box of the transformer.

BAY-9

In this bay power transformer are assembled. After taking different input from

different bays 0-9 assembly is done.Power transformer is used to step and step

down voltages at generating and sub-stations. There are various ratings –11KV,

22KV, manufactured, they are

Generator transformer.

System &

Auto transformer.

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A transformer in a process of assemblage is called a job. The design of the

transformer is done by the design department & is unique of each job; depends on

the requirement of customer. The design department provides drawing to the

assembly shop, which assembles it accordingly.The steps involved in assembly

are:

1. Core building2. Core Lifting.

3. Unlacing.

4. Delacing and end-frame mounting.

5. High voltage terminal gear and low volt terminal gear mounting.

6. Vapour phasing and oil soaking

7. Final servicing and tanking.

8. Case fitting.

STORE

There are three sections in store:

1. Control Receiving Section

2. Custody Section

3. Scrap Disposal Section

LOCOMOTIVE PRODUCTION (LMP)

There are following products are manufactured at Loco shops

Alternating Current Locomotive (ac Loco)

WAG-5H

AC./D.C. Loco

WCAM-2P

WCAM-3

W-broad gauge A-running in AC mode

C-running in DC mode G-hauling goods train

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P-hauling passenger train M-hauling passenger

& goods train

Diesel Electric Locomotive Shunting (DESL)

350 HP

700 HP

Single Power Pack (SPP): One 700 HP m/c is made as a single

Unit. It is a meter gauge locomotive

Twin Power Pack (TPP): 2 350HP m/cs are combined in 1 engine

& can be operated individually or in combination depending on the

load.

450 HP

1400 HP

1150 HP

1350 HP

2600 HP

1150 HP and 1350 HP DESL s are non-standard locomotives and are

modified versions of 1400 HP DESL based on requirement of customer.

Under mention are the new non-conventional products designed and

developed for Indian Railways based on their requirement.

OHE (Overhead electric) recording and testing cars

UTV(Utility vehicle )

RRV(Rail cum road vehicle)

DETV( Diesel electric tower car)

BPRV(Battery power road vehicle)

BCM(Blast cleaning machine)

200 T Well wagon for BHEL Haridwar

Metro Rake-Kolkata Metro Railways

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LOCOMOTIVE MANUFACTURING (LMM)

This section deals with manufacturing of locomotives. The main parts of the

locomotive are

Under frame: The frame on which a locomotive is built

Super structure: The body of locomotive is called

superstructure or Shell and is made of sheet of Mild steel

DC motor

Alternator

Compressor

Flower

Static Rectifier-MSR

Static Converter-SC

Exchanger

Bogie-The wheel arrangement of a loco is called a bogie. A bogie

es sentially contains

– 1-wheel axle arrangement

– 2-Suspension

– 3-Brake rigging

Traction transformer: It is fixed on under frame and gets supply from an

overhead line by equipment called pantograph. The type of pantograph

depends on supply. This transformer steps down voltage and is fitted

with a tap changer. Different taps are taken from it for operating different

equipment. One tap is taken and is rectified into DC using MSR and is fed to the

DC motor

Railways has two types of power supplies – 25 KV , 1 Phase ,50hz AC

-1500 V DC

An AC/DC loco is able to work on both of these supplies. For e.g. WCAM-3.

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WORK ENGINEERING & SERVICES (WE&S)

This department looks after the commissioning and maintenance of all the

machinery used in the factory. It also has 3 two-stage air compressors for

supplying compressed air to the various bays.

The department has 03 different divisions:

Electrical Engg

Electronics Engg

Mechanical Engg

ELECTRICAL ENGINEERING:

This division looks after all the electrical machinery and power distribution of the

factory. Snags detected in the system are immediately reported to this dept by the

concerning dept.WE&S takes prompt action to rectify it.

The factory has a feeder of 11KV .The total load sanctioned for

the factory is 2500MVA But the maximum demand reaches the range of

1700-2000 MVA.

CENTRAL QUALITY SERVICE

First we get acquainted with a few terms concerning this department.

QUALITY

It is the extent to which products and services satisfy the customer needs.

QUALITY ASSURANCE

All those plants and systematic action necessary to provide adequate confidence

that a product or service will satisfy the given requirement is called quality

assurance.

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QUALITY CONTROL

The operational technique and activities that are used to fulfill requirement for quality

are quality control.

QUALITY INSPECTION

Activities such as measuring, testing, gauging one or more characteristics of a

product or service and comparing these with specified requirement to determine

conformity are termed quality inspection.

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PROJECT REPORT

ONDIESEL -LOCO

INTRODUCTION

24

BHEL deals with the two types of locomotive-

1. Diesel locomotive

2. Electric locomotive

Further diesel loco may be classified into two groups i.e.TPP & SPP

BHEL has subsequently diversified into manufacturer of rolling stock products-

1. Diesel Electric loco

2. Electric locomotive (AC,AC/DC)

3. Special wagon (200 T well wagon)

OHE Recording Cum Test Car

Diesel loco further classified as follows-

1.Diesel Electric

2.Diesel Hydraulic

In diesel electric an alternator is used where as in diesel hydraulic a torque converter is used.

The report is concerned with an electric loco i.e. WAG- 7A

Which is a crew friendly loco.

W - Broad Guage

A - running in AC mode

G - hauling goods train

BHEL Jhansi has got order to develop WAG-7 of 5000 HP in quantity of 50 by Indian Railways.

Diesel Locomotive25

A diesel locomotive is a type of railway locomotive in which the prime mover is a diesel engine. Several types of diesel locomotive have been developed, differing mainly in the means by which mechanical power is conveyed to the driving wheels (drivers).

Diesel-Electric Locomotive

Twin Power-Pack 700HP Diesel Engine

26

Single Power-Pack 2400HP Diesel Engine

27

Parts of a Diesel Locomotive

Diesel Engine Main Alternator Auxiliary Alternator Rectifier Motor Blower Air Reservoirs Turbo charger Battery Air Compressor Radiator & Radiator fan Hydraulic Transmission Traction Motor Pinion/Gear Fuel Tank Drive Shaft Gear Box Sand Box

Diesel Engine:-

28

This is the main power source for the locomotive. It comprises a large cylinder block, with the cylinders arranged in a straight line or in a V .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. A diesel engine (also known as a compression-ignition engine) is an internal combustion engine that uses the heat of compression to initiate ignition to burn the fuel that has been injected into the combustion chamber.

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 (bogies). 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 these 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 to give the DC required for the motors.

Auxiliary Alternator :-

29

Locomotives used to operate passenger trains are equipped with an auxiliary alternator. This provides AC power for lighting, heating, air conditioning, dining facilities etc. on the train. The output is transmitted along the train through an auxiliary power line.

Rectifier :-

30

The output from the main alternator is AC but it can be used in a locomotive with either DC or AC traction motors. DC motors were the traditional type used for many years but, in the last 10 years, AC motors have become standard for new locomotives. They are cheaper to build and cost less to maintain and, with electronic management can be very finely controlled. To convert the AC output from the main alternator to DC, rectifiers are required. If the motors are DC, the output from the rectifiers is used directly. If the motors are AC, the DC output from the rectifiers is converted to 3-phase AC for the traction motors.

Motor Blower :-

The diesel engine also drives a motor blower. As its name suggests, the motor blower provides 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 designs have separate blowers for the group of motors on each truck and others for the alternators.

Air Reservoirs :-

31

Air reservoirs containing compressed air at high pressure are required for the train braking and some other systems on the locomotive. These are often mounted next to the fuel tank under the floor of the locomotive.

Turbo charging :-

The amount of power obtained from a cylinder in a diesel engine depends on how much fuel can be burnt in it. The amount of fuel which can be burnt depends on the amount of air available in the cylinder. So, if you can get more air into the cylinder, more fuel will be burnt and you will get more power out of your ignition. Turbo charging 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. Turbocharging gives a 50% increase in engine power. The main advantage of the turbocharger is that it gives more power with no increase in fuel costs because it uses exhaust gas as drive power. It does need additional maintenance, however, so there are some type of lower power locomotives which are built without it.

Battery :-

32

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

Air Compressor :-

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

Radiator & Radiator fan :-

33

The radiator works the same way as in an automobile. Water is distributed around the engine block to keep the temperature within the most efficient range for the engine. The water is cooled by passing it through a radiator blown by a fan driven by the diesel engine.

(Radiator fan) (Radiator)

Hydraulic Transmission :-

Hydraulic transmission works on the same principal as the fluid coupling but it allows a wider range of "slip" between the engine and wheels. It is known as a "torque converter". When the train speed has increased sufficiently to match the engine speed, the fluid is drained out of the torque converter so that the engine is virtually coupled directly to the locomotive wheels. It is virtually direct because the coupling is usually a fluid coupling, to give some "slip". Higher speed locomotives use two or three torque converters in a sequence similar to gear changing in a mechanical transmission and some have used a combination of torque converters and gears.

(Hydrolic tank) Traction Motor :-

34

Since the diesel-electric 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 modern power and control electronics has led to the introduction of 3-phase AC motors.

Pinion/Gear :-

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

Fuel Tank :-

35

A diesel locomotive has to carry its own fuel around with it. The fuel tank is normally under the loco frame and This huge tank in the underbelly of the locomotive holds 2,200 gallons (8,328 L) of diesel fuel.

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 is 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.

Sand Box :-

Locomotives always carry sand to assist adhesion in bad rail conditions. Sand is not often provided on multiple unit trains because the adhesion requirements are lower and there are normally more driven axles.

Locomotive Data

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General Data Of Locomotive:-

Model No. : WDM2

Specification : 16 cylinder V-type 4 strokeDiesel Engine

Type : Co-Co

Power : 700hp, 1400hp, 2400hp

Maximum Speed : 120 kph

Gear Ratio : 68/18

Compression Ratio : 16:1

Cylinder Bore : 230mm

Cylinder Stroke : 279mm

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Wheel Base

Wheel Dia : 1092mmWheel Base : 12834mmTraction Motor : Bhel 165Track Gauge : 1676mmBrake Equipment : Vaccun/Air

Maximum Overall Dimension

Height : 4185mmWidth : 3010mmLength : 17120mm

Capacity

Fuel : 5000 lt Cooling Water : 1210 lt Lube Oil : 910 lt Water Expansion : 155 lt Sand : 0.4 m3

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Auxiliary Horse Power Requirement

Auxiliary Generator Maximum : 17HP

Exciter Maximum : 12HP

Traction Motor : 400HP

Blower at full speed : 62HP

Radiator Fan : 80HP

Expresser Unloaded at 1000 rpm : 13 HP

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