BHARAT HEAVY ELECTRICALS LIMITED, JHANSI

Submitted To:- Submitted By :-

Under The Guidance Of; RAVINDRA DEV RAWAT Dr.Dhruv Bhargav B.Tech 3rd Year Er.Y.R.Tripathi (Instrumentation Engg) (Sr.DGM,HRD) I.E.T. B.U Jhansi(U.P) (prod.Engineer, LMM) M.No-8858039861 BHEL, Jhansi (U.P) ravindrarawatjhansi@gmail.com

FOUR WEEKS INDUSTRAIL TRAINING AT

Emai- ajay.ranawat10@gmail.com 1.Introduction 2.Diesel Locomotive Department 3.Locomotive definition 4.Diesel locomotive 5.Parts of Diesel-Electric locomotive 6.Another View 7.Diesel Engine 8.Engine View 9.Traction Motor 10.Other Parts Of Engine 11.Turbo Charging 12.Breaking System Locomotive 13.Air Breaking System 14.Pneumatic Control System 15.Twine Power -Pack 700HP Diesel Engine 16.Single Power –Pack 2400HP Diesel Engine 17.Locomotive Data 18.Maximum Overall Dimension 19.Axiliary Horse Power Requirement 20.Booge Shop Assembly 21.Part Of Bogi

CONTENT

22.Asquith CNC Machine 23.Result And Conclusion 24.References

Bharat Heavy Electricals Limited, Jhansi was founded on 9 January 1974 and is one of the 14 manufacturing units of the Bharat Heavy Electricals Limited (BHEL) Corporation. It is located on NH-26, 15 km away from Jhansi city. The Jhansi unit is spread in 1064 acres, which includes 519 acres of township having large green cover and excellent amenities. BHEL Jhansi started production of Transformers in the year 1976. BHEL Jhansi is in the business of two product groups namely, Transformer and Locomotive. Marketing of products and services is done at the corporate level by Power sector, Industry sector, International operation division and Regional Office Divisions spread all over India.

Products Power Transformers up to 400 kV class/Traction trfr/ESP trfr./Special

trfr/Dry TypeTrfr./Inst trfr up to 400 kV class and voltage transformer and current transformers are also produced.

Locomotive WAG 7 AC locomotive for Indian railway/diesel locos. all application 3300 hp/wagons up to 300 MT 27 axle/railway track equipment/metro for Kolkata/emu coaches.

Certifications & recognitions

BHEL Jhansi has been certified for ISO 9001:2001 for Quality Assurance.

INTRODUCTION

DIESEL LOCOMOTIVE DEPARTMENT

A locomotive or engine is a railway vehicle that provides the motive power for a train. The word originates from the Latin loco – "from a place", ablative of locus, "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 in 1804.

LOCOMOTIVE

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).

The hybrid diesel locomotive is an incredible display of power and ingenuity. It combines some great mechanical technology, including a huge, 12-cylinder,two-stroke diesel engine, with some heavy duty electric  and generators, throwing in a little bit of computer technology for good measure.

DIESEL LOCOMOTIVE

BLOCK DIAGRAM OF DIESEL ENGINE

PARTS OF DIESEL-ELEC TRIC LOCOMOTIVE

LAYOUT OF DIESEL LOCOMOTIVE ENGINE

This is the main power source for the

locomotive.

ANOTHER VIEW

DIESEL ENGINE

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.

It comprises a large cylinder block, with the cylinders arranged in a straight line or in a V.

The diesel engine has the highest thermal efficiency of any  standard internal or external combustion engine due to its very high compression and inherent lean burn which enables heat dissipation by the excess air

Diesel engines are manufactured in two-stroke and four-stroke versions

ENGINE VIEW

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 locomotive, the alternator was a DC machine, called a generator.

MAIN ALTERNATER

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.

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.

AUXILIARY ALTERNATER

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.

 There are between four and six motors on most diesel-electric locomotives.  A modern AC motor with air blowing can provide up to 1,000 hp.

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).

Air Compressor• The air compressor is required to provide a

constant supply of compressed air for the locomotive and train brakes.

TRACTION MOTOR

FUEL TANK

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.

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.

AIR RESERVOIRS 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.

OTHER PARTS OF ENGINE

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.

Turbocharging gives a 50% increase in engine power.

RADIATOR AND RADIATOR FAN

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 radiator blown by a fan driven by the diesel engine.

DYNAMIC BRAKING SYSTEM

Dynamic braking is the use of the electric traction motors of a railroad vehicle as generators when slowing the locomotive. It is

BRAKING SYSTEM IN LOCOMOTIVE

termed rheostat if the generated electrical power is dissipated as heat in brake grid resistors, and regenerative if the power is returned to the supply line. Dynamic braking lowers the wear of friction-based braking components, and additionally regeneration can also lower energy consumption. Dynamic braking can also be used on railcars multiple vehicles, units lights rails vehicles, trams and PCC streetcars

Principle of operationDuring braking, the motor fields are connected across either the main traction generator (diesel-electric loco) or the supply (electric locomotive) and the motor armatures are connected across either the brake grids or supply line. The rolling locomotive wheels turn the motor armatures, and if the motor fields are now excited, the motors will act as generators.During dynamic braking, the traction motors, which are now acting as generators, are connected to the braking grids (large resistors), which put a large load on the electrical circuit. When a generator circuit is

loaded down with resistance, it causes the generators to slow their rotation. By varying the amount of excitation in the traction motor fields and the amount of resistance imposed on the circuit by the resistor grids, the traction motors can be slowed down to a virtual stop (approximately 3-5 MPH).For permanent magnet motors, dynamic braking is easily achieved by shorting the motor terminals, thus bringing the motor to a fast abrupt stop. This method, however, dissipates all the energy as heat in the motor itself, and so cannot be used in anything other than low-power intermittent applications due to cooling limitations. It is not suitable for traction applications.

A railway air brake is a railway brake power braking system with compressed air as the operating medium. Modern trains rely upon a fail-safe air brake system that is based upon a design patented by George Westinghouse on March 5, 1868.

OVERVIEWIn the air brake's simplest form, called the straight air system, compressed air pushes on a piston in a cylinder. The piston is connected through mechanical linkage to brake shoes that can rub on the train wheels, using the resulting friction to slow the train. The mechanical linkage can become quite elaborate, as it evenly distributes force from one pressurized air cylinder to 8 or 12 wheels.

The pressurized air comes from an air compressor in the locomotive and is sent from car to car by a train line made up of pipes beneath each car and hoses between cars. The principal problem with the

AIR BRAKING SYSTEM

straight air braking system is that any separation between hoses and pipes causes loss of air pressure and hence the loss of the force applying the brakes. This could easily cause a runaway train. Straight air brakes are still used on locomotives, although as a dual circuit system, usually with each bogie (truck) having its own circuit.

Pneumatics is a Greek which means "breath", "breath") is a branch of physics applied to technology that makes use of gas or pressurized air.Pneumatic systems used extensively in industry are commonly powered by compressed air or compressed inert gases. A centrally located and electrically powered compressor powers cylinders, air motors, and other pneumatic devices. A pneumatic system controlled through manual or automatic solenoid valves is selected when it provides a lower cost, more flexible, or safer alternative to electric motors and actuators.Pneumatics also has applications

in dentistry, construction, mining, and other areas. Advantages of pneumatics Simplicity of design and control—Machines are

easily designed using standard cylinders and other components, and operate via simple on-off control.

PNEUMATIC CONTROL SYSTEM

Reliability—Pneumatic systems generally have long operating lives and require little maintenance. Because gas is compressible, equipment is less subject to shock damage. Gas absorbs excessive force, whereas fluid in hydraulics directly transfers force. Compressed gas can be stored, so machines still run for a while if electrical power is lost.

Safety—There is a very low chance of fire compared to hydraulic oil. Newer machines are usually overload safe.

Twin Power-Pack 700HP Diesel Engine

Single Power-Pack 2400HP Diesel Engine

General Data Of Locomotive:- Model No. : WDM2 Specification : 16 cylinder V-type 4 stroke

Diesel Engine Type : Co-Co Power : 700hp, 1400hp, 2400hp Maximum Speed : 120 kph Gear Ratio : 68/18 Compression Ratio : 16:1 Cylinder Bore : 230mm

Wheel Base:- Wheel Dia : 1092mm Wheel Base : 12834mm Traction Motor : Bhel 165 Track Gauge : 1676mm Brake Equipment : Vaccun/Air

Locomotive Data

Height : 4185mmWidth : 3010mmLength : 17120mm

Capacity:-Fuel : 5000 ltCooling Water : 1210 ltLube Oil : 910 ltWater Expansion : 155 ltSand : 0.4 m3

Maximum Overall Dimension

Auxiliary Generator Maximum : 17HPExciter Maximum : 12HPTraction Motor : 400HPBlower at full speed : 62HPRadiator Fan : 80HPExpresser Unloaded at 1000 rpm :13 HP

Auxiliary Horse Power Requirement

BOOGY SHOP ASSEMBLY

PARTS OF BOGI

Bogie Shop

The locomotive bogies are rebuilt with new wheel sets, suspension bearings

and remanufactured traction motors. Separate shop has been set up for

machining of wheel sets and assembly of locomotive bogies.

Computer Numeric Control machines is a closed loop machine.

As the name depicts these machines use computer for their operation.

Computer Numeric Control machines are controlled by a set of different ISO codes that helps in proper controlling of the

machine.

In modern CNC systems, end-to-end component design is highly automated using CAD/CAM programs.

ASQUITH CNC MACHINE

View Of ASQUITH CNC Machine

In this machine all the operation which is essential for bogi is performances. Mainly these operation are following-

Cutting

Milling

Finishing

Drilling

Fillit

Grinding

Radial Arm Drilling Machine In radial arm drilling machine there is a one

column on which radial arm is fixed. Radial arm are horizontal arm this is movable

around the column. This is main advantage of this machine.

In drilling machine different type drill can be fixed. But twist drills are very common in use. Holes of different diameter can be done by using drills of different diameter.

View Of Radial Arm Drilling Machine

Axle turning machine is also called lathe machine.

• In this machine material is removed by the single point cutting tool. Turning of axle, grinding of axle operation are performed on this machine.

•

Axle Turning Machine

The BHARAT HEAVY ELECTRICALS is the most widely used transport system in India. The production of the parts and units of rails forms an important and integral part of the proper functioning of the railway system in India.

Its World's largest manufacturer of ALCO diesel loco spares such as Gears, Cams, Con rods, Pins, Carbon Brushes etc.

DCW manufactures large components such as traction motors and locomotive power packs, rebuilds engine blocks, traction generators, etc.

http://www.google.co.in/

www.bhel.com

http://en.wikipedia.org

RESULT AND CONCLUSION

REFERENCES

http://www.railway-technical.com

http://www.howstuffworks.com/

Manual Report of BHEL

thanks

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