Download - Trainee Somany
-
8/12/2019 Trainee Somany
1/64
SOMANY INSTITUTE OF TECHNOLOGY
AND
MANAGEMENT
REWARI,(HARAYANA )
SUBMITTED BY:BIPUL BISWAS
AJAY KUMAR,AMOD KUMAR,
ARUN KUMAR,ASHISH KUMAR,ANIL KUMAR,
KAPIL ARORA,LALIT KUMAR,PRADEEP KUMAR
2010
hP
NORHERN RAILWAY;DIESEL SHED
SHAKURBASTI,NEW DELHI.
7!"!#$#
INDUSTRIAL TRAININGREPORT ON BRAKE SYSTEM
IN D.E.M.U
-
8/12/2019 Trainee Somany
2/64
ACKNOWLEDGEMENT
WE ARE VERY THANKFUL TO NORTHERN
RAILWAY FOR PROVIDING US THE 6 WEEKS
SUMMER TRAINING IN DIESEL
SHED,SHAKURBASTI .
SHRI D K BISWAS (SSE \HRB), S R PATHAK
(SE) , S.DHRAMVIR SINGH, VIRENDRA
KUMAR, HARINIWAS, LOKESH(TE!H. "1) .
HAS ASSISTED THE STUDENTS VERY WELL.
THEY !ONDU!TED !LASSES AND MADE
!LARIFI!ATION ON VARIOUS TOPI!S
REGARDING DIESEL LO!OS.
WE ARE ALSO VERY MU!H THANKFUL TO
THE OFFI!ERS, SUPERVISORS AND STAFF
MEMBERS FOR THEIR !O"OPERATIVE AND
HELPFUL SUPPORT .THEY SPENDED THEIR
PRE!IOUS TIME WITH US TO E#PLAINVARIOUS OB$E!TS.
THE PRO$E!T OF BRAKE SYSTEM IN
D.E.M.U HAS PROVED TO BE VERY
KNOWLEDGEABLE. IT HELPED US TO LEARN
THE VARIOUS TYPES OF BRAKE SYSTEM
WORKING IN INDIAN RAILWAYS,THEIRPERFE!T ME!HANISMS.THE KNOWLEDGE
WE HAVE GAINED HERE WOULD DEFINATELY
PROVED TO BE A STEPPING STONE INTO
OUR !AREER.THE TRAINING HAS BEEN
PROVED AS A BIG ADVANTAGE FOR US.
-
8/12/2019 Trainee Somany
3/64
PREFA!E
B"TE!H(ME!H ENGG) IS THE STEPPING"
STONE TO ENGINEERING !AREER. IN
ORDER TO A!HIEVE PRA!TI!AL,
POSITIVE AND !ON!RETE RESULT,THE
!LASSROOM LEARNING HAS TO BE
EFFE!TIVELY SUPPLEMENTED TORELATION OF SITUATION E#ISTING
OUTSIDE THE !LASSROOM FOR
DEVELOPING HEALTHY PRODU!TIVE
AND DESIGNING SKILLS IN PRO$E!T
DEPARTMENT.IT IS NE!ESSARY THAT
THE THEORETI!AL KNOWLEDGE MUST
BE SUPPLEMENTED WITH E#POSURE
TO THE REAL ENVIRONMENT.
THE REPORT !OMPRISES ALL THE
IMPORTANT ASPE!TS OF BRAKE
SYSTEM IN DEMU AND ALL THEASPE!TS HAS BEEN PRESENTED
UNDER DIFFERENT HEADING IN
FORTH!OMING PAGES.
I WOULD LIKE TO E#PRESS MY SIN!ERE
THANKS TO ENTIRE STAFF MEMBER OF
-
8/12/2019 Trainee Somany
4/64
NORTHERN RAILWAY%S DIESEL SHED
SHAKURBASTI WHO HELPED US IN ALL
ENDEVIOURS DURING THE TRAINING.
-
8/12/2019 Trainee Somany
5/64
HISTORY OF INDIANRAILWAYS:
A PLAN FOR A RAIL SYSTEM IN INDIA WAS FIRST PUT
FORWARD IN 1&'2, BUT NO FURTHER STEPS WERE
TAKEN FOR MORE THAN A DE!ADE .IN 1& ,THE
GOVERNOR OF INDIA LORD HARDINGE ALLOWED
PRIVATE ENTREPENURES TO SET UP A RAIL SYSTEM IN
INDIA TWO NEW RAILWAY !OMPANIES WERE !REATED
AND THE EAST INDIA !OMPANY WAS ASKED TO ASSIST
THEM ,INTEREST FROM INVESTORS IN THE U.K LED TO
THE RAPID !REATION OF A RAIL SYSTEM OVER THE
NE#T FEW YEARS .THE FIRST TRAIN IN INDIA BE!AME
OPERATOINAL ON 22 DE!EMBER 1&1 ,AND WAS USED
FOR THE HAULING OF !ONSTRU!TIONAL MATERIAL IN
ROORKEY .A YEAR AND A HALF LATER ,ON 16 APRIL
1& THE FIRST PASSENGER TRAIN SERVI!E WAS
INAUGRATED BETWEEN BORI BUNDER ,BOMBAY AND
THANE.!OVERING A DISTAN!E OF ' *+ (21 +-/),ITWAS HAULED BY THREE LO!OMOTIVES .SAHIB ,SINDH
AND SULTAN.THIS WAS TH E BIRTH OF RAILWAYS IN
INDIA .
-
8/12/2019 Trainee Somany
6/64
THE BRITISH GOVT EN!OURAGED NEW RAILWAY
!OMPANIES BA!KED BY PRIVATE INVESTORS UNDER A
S!HEME THAT WOULD GURANTEE AN ANNUAL RETURN
OF DURING THE INITIAL YEARS OF OPERATIONS.
OMN!E ESTABLISHED ,THE !OMPANY WOULD BE
TRANSFERRED TO THE GOVT. WITH THE ORIGINA L
!OMPANY RETAINING OPERATIONAL !ONTROL . BY
1& ,ABOUT MILLION POUNDS WERE INVESTED BYBRITISH !OMPANIES IN INDIAN GUARANTEED
RAILWAYS.THE ROUTE MILEAGE OF THIS NETWORK WAS
ABOUT 100*+(000+-/)BY 1&&0 ,MOSTLY
RADIATING INWARD FROM THE THREE MA$OR PORT
!ITIES OF BOMBAY(MUMBAI),MADRAS(!HENNAI)AND
!AL!UTTA(KOLKATA). BY 1&, INDIA HAD STARTED
BUILDING IT%S OWN LO!OMOTIVES, AND IN 1&6 SENT
ENGINEERS AND LO!OMOTIVES TO HELP BUILD THEUGANDA RAILWAY.E#TENT OF GREAT INDIAN
PENINSULAR RAILWAY NETWORK IN 1&0 .THE G.I.P.R
WAS ONE OF THE LARGEST RAIL !OMPANIES AT THAT
TIME.
SOON VARIOUS INDEPENDENT KINGDOMS BUILT THEIR
OWN RAILWAY SYSTEMS AND THE NETWORK SPREAD TO
THE REGIONS THAT BE!AME THE MODERN DAY STATES
OF ASSAM ,RA$ASTHAN,AND ANDHRA PRADESH .A
RAILWAY BOARD WAS !ONSTITUTED IN 101, BUT
DE!ISION"MAKING POWER WAS RETAINED BY THRE
VI!EROY ,LORD !UR3ON .THE RAILWAY BOARD
OPERATED UNDER AEGIS OF THE DEPARTMENT OF
!OMMEREN!E AND INDUSTRY AND HAD THREE
MEMBERS 4A GOVT RAILWAY OFFI!IAL SERVING AS
!HAIRMAN ,A RAILWAY MANAGER FROM ENGLAND AN
AGENT OF ONE OF THE !OMPANY RAILWAYS .FOR THE
FIRST TIME IN IT%S HISTORY ,THE RAILWAYS BEGAN TO
MAKE A TIDY PROFIT .IN 10, ALMOST ALL THE RAIL
!OMPANIES WERE TAKEN OVER BY THE GOVT .
THE FOLOWING YEAR,THE FIRST ELE!TRI! LO!OMOTIVE
APPEARED .WITH THE ARRIVAL OF THE FIRST WORLD
WAR ,THE RAILWAYS HAD SUFFERED IMMENSELY AND
WERE IN A POOR STATE .THE GOVT. TOOK OVER THEMANAGEMENT OF THE RAILWAYS AND REMOVED THE
LINK BETWEEN THE FINAN!ING OF THE RAILWAYS AND
OTHER GOVT.REVENUES IN 120, A PRA!TI!E THAT
-
8/12/2019 Trainee Somany
7/64
!ONTINUES TO DATE WITH A SEPERATE RAILWAY
BUDGET.
THE SE!OND WORLD WAR SEVERELY !RIPPLED THE
RAILWAYS AS ROLLING STO!K WAS DIVERTED TO THE
MIDDLE EAST, AND THE RAILWAY WORKSHOPS WERE
!ONVERTED INTO MINITION WORKSHOPS.AT THE TIMEOF INDEPENDEN!E IN 1 ,ABOUT 0OF THE
RAILWAYS THEN WENT TO NEWLY !REATED NATION OF
PAKISTAN .A TOTAL OF FORTY 5TWO SEPERATE
RAILWAYS SYSTEMS IN!LUDING '2 LINES OWNED BY
THE FORMER INDIAN PRIN!ELY STATES,WERE
AMALGAMATED AS A SINGLE UNIT WHI!H WAS
!HRISTENED AS THE INDIAN RAILWAYS.
THE E#ISTING RAIL NETWORKS WERE ABANDONED IN
FAVOUR OF 3ONES IN 11 AND A TOTAL OF SI# 3ONES
!AME INTO BEING IN 12. AS THE E!ONOMY OF INDIA
IMPROVED,ALMOST ALL RAILWAY PRODU!TION UNITS
WEREINDEGENISED (PRODUSED IN INDIA). BY 1&,
STEAM LO!OMOTIVES WERE PHASED OUT IN FAVOUR OF
DIESEL AND ELE!TRI! LO!OMOTIVES.THE ENTIRERAILWAY RESERVATION SYSTEM WAS STREAMLINED
WITH !OMPUTERI3ATION BETWEEN 1& AND 1.
INDIAN RAILWAYS IS ONE OF THE LARGEST EMPLOYERS
IN THE WORLD.
-
8/12/2019 Trainee Somany
8/64
DIESEL SHED SHAKURBASTI:-
ESTABLISHED ON THAPRIL 1.THE TOTAL SHED AREA 111
S7M.TOTAL !OVERED AREA 11
S7MTOTAL STAFF 5SS8& OR86&BERTHING !APA!ITYRUNNING " & LO!OS(WDS)
HRB " LO!OS(WDS)
-
8/12/2019 Trainee Somany
9/64
WB " 6
LO!OS(WDS)NEW REPAIR BAY"
LO!OS(WDM2)HOLDING OF WDS"6 NOSTOTAL WORKING LO!O" & NOSLO!O UNDER !ONDEMNATION 5
0&NOSLO!O UNDER GRS AT ASR "
0'NOS
WORKING POINTS OF WDS"LO!O
DLI DIV " 22LO!OSUMBDIV " 0'LO!OSMB DIV " 0LO!OS
LKO DIV " 02 LO!OSF3R DIV 5 01 LO!OHOLDING OF BG DEMU "10 SETS
-
8/12/2019 Trainee Somany
10/64
HISTORY OFN.RLY. DSL SHED
SHAKURBASTI
164"6NOS METER G9:; 9? ; (I?-9C) 9/ @-C@
? D-"?"L9
-
8/12/2019 Trainee Somany
11/64
T/ -=/ -9?< @ SURI ?
-
8/12/2019 Trainee Somany
12/64
1&4"F
-
8/12/2019 Trainee Somany
13/64
DP! 9@ T!
-
8/12/2019 Trainee Somany
14/64
H; H
-
8/12/2019 Trainee Somany
15/64
-
8/12/2019 Trainee Somany
16/64
F:- =/:+? /
-
8/12/2019 Trainee Somany
17/64
T
-
8/12/2019 Trainee Somany
18/64
1D.P.!. 2 T.!. 1D.T.!.) OR
1 D.P.!. 6 T.!. 1
D.P.!.
T
-
8/12/2019 Trainee Somany
19/64
-
8/12/2019 Trainee Somany
20/64
A--
-
8/12/2019 Trainee Somany
21/64
1. 2 V D! 2 V-? D.!.
2. LLOP 5 L L: O- P
-
8/12/2019 Trainee Somany
22/64
'. E/?+9?@ /
-
8/12/2019 Trainee Somany
23/64
&. P< ?
-
8/12/2019 Trainee Somany
24/64
LEADING PARTI!ULARS OF 100 H.P. DEMU
POWER !AR (D.P.!)
1. L;? < 9@"@C 8
211 ++
2. D/?9= ? ; =?
-
8/12/2019 Trainee Somany
25/64
&. H;?
-
8/12/2019 Trainee Somany
26/64
2 2ndnotch 1000
3 3rdnotch 1200
4 4thnotch 1300
5 5thnotch 1400
6 6thnotch 1500
7 7thnotch 1600
8 8thnotch 1800
IMPORTANT PARAMETRS OF 100
H.P. DEMU/
S.No. Description Capacity
1 Engine oil capacity per DPC 230 Litres approx.
2 Hyra!lic oil capacity per DPC 330 Litres approx
3 "ir co#pressor oil capacity per DPC 0$ Litres approx.
$ Cooling %ater capacity per DPC &$0 Litres approx.
' (!el oil capacity per DPC 2'00 ) 3000 Litres
approx.
E; -: -
-
8/12/2019 Trainee Somany
27/64
!-; 9?< ?+.
-
8/12/2019 Trainee Somany
28/64
Dh-= '* +
C-%/C-%/ ++ B0%1 % 2 '*B0%1 % 2 '*
IOC + S03 *'% + ?
BPC + Bh0= U%'3*
HPC + Y%=0*>?
F4* '* >H; /@ D/- " IS 16041"
A+@+?"2 (F"1)
G0 20 R**0 0'%& +
M9* 9
-
8/12/2019 Trainee Somany
29/64
-
8/12/2019 Trainee Somany
30/64
Th 8-*= 180'-='% 2 E.P. 0@ /= '
E*8=0>-%4='8 0@ /=. I% =h' 0@
/=, 0@ 0 --*'1 0*1 '=h0 /
4'%& '0 0 / *8=0'8'=/. Wh% 0@ 0 --*'1
/ 4'%& *8=0'8'=/, '= ' 8**1 E.P. 0@
--*'8='%. I% =h' --*'8='% (E.P. --*'8='%)
0@ 0 --*'10*1 '4*=%4*/ '% **
88h, =h4 &'3 0 0@ -90 '%
8-0'% = =h0 0@ /=. R*'%& %1
--*'8='% =' 2 E.P. B0@ ' * 30/ h0=.
Th' 0@ /= ' 30/ '-* %1 8='3.
Th '%=%%8 8= 2 =h' 0@ /= '
8-0='3*/ *9. Wh% '0 ' 41 20 0@
--*'8='% '% =h' /=, '= ' 8**1 4= 0@
--*'8='%. F**9'%& 0 '% 8-%%= 2 =h'
/=:>
1. M@:-9< B
-
8/12/2019 Trainee Somany
31/64
Th' 14*0 0@ 8%=0**0 80= BP -040 (6
@&8!) 41 '% =0'%.
2. E. P. B20 2 88h %190@ '% 8%4%8='% 2 14*0 0@ 8%=0**0. I=
--*' E.P. 0 4= '0 0@ 8801'%& = h%1*
-'='% 2 M14*0 B0@ C%=0**0.
-
8/12/2019 Trainee Somany
32/64
'. M.R. 9@ B.P.
-
8/12/2019 Trainee Somany
33/64
. MR 9@ A:-9
-
8/12/2019 Trainee Somany
34/64
-
8/12/2019 Trainee Somany
35/64
TC/
-
8/12/2019 Trainee Somany
36/64
' . E+
-
8/12/2019 Trainee Somany
37/64
. G:9
-
8/12/2019 Trainee Somany
38/64
I= ' *8=0'8**/ 8%=0**1 '%1-%1%= 0@. I% =h'
0@ --*'8='%, MR -040 ' 41. P0@'%& 0@
90@ = =h -040 2 6 K&8!. Wh% --*'8='%
9'=8h 2 -0@'%& 0@ ' -01, '= ' 8='3=1 %1
'0 -040 '% &4& 8 0. F0 0*'%&
-0@'%& 0@, -0 = 0* 4==%, =h% -0@'%&0@ &4& 9'** h9 6 K&8!-040 &'% %1
=h' 0@ 9'** 0*. Th' 0@ ' 41 = =- =0'%
0**'%& 9h% '= ' =='%1. Th' 0@ 90@ %*/ '%
DPC.
NOTE4"
I P9
-
8/12/2019 Trainee Somany
39/64
W
-
8/12/2019 Trainee Somany
40/64
I% =h' /= 0@ 0 --*'1 / h%1* 2 M14*0
B0@ C%=0**0. Wh% =h' h%1* ' -0=1 20 %
-'='% = %=h0 -'='%, =9 &%='8 3*3 ==1 %
EP 0@ 4%'= 0 8='3=1. F'0=*/ h*1'%& &%='8 3*3
' 8='3=1 %1 8*1 = =h 0* -0= 2 EP 0@ 4%'=
=h% --*'8='% &%='8 3*3 ' 8='3=1 %1 -% =
--*'8='% -0= 2 EP 0@ 4%'=, 04*='%& MR -040
%=01 '%= =h EP 0@ 4%'=, 20 =h0 '= ' 01481 =
1'01 -040 2 ".! K&8!. Th' '0 -040 2 ".!
K&8! %=01 '% 0@ 8/*'%10 =h04&h -'-*'%
04*='%& 0@ 0 --*'1 '% 88h =0'%. Wh% h%1*
'% 0==1 '% 0* -'='%, =h &%='8 3*3 0
18='3=1 %1 0@ 0 0*1 = =h -03'4
8%1'='%.
E/:
-
8/12/2019 Trainee Somany
41/64
$. M.R. -040 4= ?7 @&8!.
B.P. -040 4= 6.# @&8!.
!. H%1 -0=1 '*='% 88@ 2 *1'%& DPC 4=
'% O-%-'='% %1 '% C*-'='% 2 ** =0'*'%&
DPC.
".
E.P. 0@ MCB 4= '% ON-'='%.
5. E.P. 9'=8h ==1 % D.C.S 4= '% ON
-'='%.
6. E%40 -0@'%& 0@ 0 24**/ 0*1 20
3'%& =0'%.
-
8/12/2019 Trainee Somany
42/64
VERY IMPORTANT / MUST DO
Check train brake power by conducting 'E.P. brake test'
before moving train to destination.
P/?/ EP B
-
8/12/2019 Trainee Somany
43/64
W
-
8/12/2019 Trainee Somany
44/64
-
8/12/2019 Trainee Somany
45/64
. M3 =0'% 9h% 0@ 8/*'%10 -040 ' 24**/
1'8h0&1 (0).
E/:
-
8/12/2019 Trainee Somany
46/64
!. S9'=8h OFF E.P. 0@ MCB %1 E.P. 9'=8h ==1 %
DCS .
". ''Very Important'' Ch8@ =0'% 0@ -90 20
3'%& = 1='%='% / 8%148='%& A4= B0@T= = 3'1 %/ '>h--%'%&.
E.P. B
-
8/12/2019 Trainee Somany
47/64
. !-/ ? M.R. /-9? ==* E.P.
-
8/12/2019 Trainee Somany
48/64
C%0 MR, BP, P0@'%& B0@ -040 %1 0@ 8/*'%10
-040 20 &401 2 =0'*'%& DPCDTC %1 '%='%1 '=
'% *1'%& %1 =0'*'%& DPCDTC. E3% =h% EP 0@
' %= 90@'%& =h% 90@ % =0'% 9'=h 4= 0@ (F**9
4= 0@ '%=048='%) %1 '%20 = h h1 8%=0*
8.
2. E.P. B
-
8/12/2019 Trainee Somany
49/64
0@ 0 %= 0*1 =h% =h0 ' % *8=0'8* 24*= '%
0@ /=. I% =h' 8%1'='% 9'=8h OFF EP 0@
9'=8h %1 --*/ = A4=P0@'%& 0@ %1 0* =
=0'% =h% 90@ % 4= 0@ %1 '%20 = h h1
8%=0* 8. E%40 =h= -0@'%& 0@ 0 0*1
20 3'%& = 1='%='%.
. S+ =9=/ 9
$. Ch8@ ** BP %&* 88@ %1 %40 =h= =h
0 '% 24**/ -% -'='%.
!. I2 %/ BP %&* 88@ ' 8*1 =h% -% = '=.
". Ch8@ BPFP -'- 20 '0 *@&, '2 =h0 ' %/
*@& =0/ = 08='2/ '=. I2 BP -040 ' 0 '% &401 '1%1 6 K&8!'% 10'30 '1 =h% '= '%1'8= %/ =8*
'% BP -'- *'% 0 BP %&* 88@ 2 %/ 88h ' '% 8*1
-'='%. I% =h' 8%1'='% -% = h%1 -0=1 '*='%&
88@ 2 &401 '1 DPC = 21 BP -040 20 =0'*'%&
DPC. B0@ 9'** 0* 2=0 '%='%'%& BP -040 = 6
K&8!. N9 8%148= = E.P. 0@ == %1 90@ %
=0'%.
-
8/12/2019 Trainee Somany
50/64
6. A /;- =9= / J9+ A:?E.P.
-
8/12/2019 Trainee Somany
51/64
A--*/ 0&%8/ 0@ !" =' %1 =0/ = 0*
0@. I2 0@ 0 %= 0*1 =h% 8h8@ = MRBP
-040. I2 =h0 ' %/ '0 *@& '% 0@ /= =h%
08='2/ = '=. E3% =h% 24*= 0'% =h% '%201
= h h1 8%=0* 8.
. B
-
8/12/2019 Trainee Somany
52/64
I2 /, =h% 8h8@ = EP 0@ 4%'= 20 %/ '0
*@&. I2 =h0 ' %/ '0 *@& '% EP 0@ 4%'=
=h% '*= = =h' 88h %1 90@ % =0'%.
12. MR
-
8/12/2019 Trainee Somany
53/64
-
8/12/2019 Trainee Somany
54/64
AIR
BRAKE
SYSTEMON
DEMU
-
8/12/2019 Trainee Somany
55/64
AIR BRAKE SYSTEM
AIM4"
TO STUDY AIR BRAKE SYSTEMTO STUDY OVERHAULING PRA!TI!E OF
PNEUMATI! VALVES.!OMPARATIVE ADVANTAGES OF E.P
BRAKE SYSTEM OVER !ONVENTIONAL
BRAKE SYSTEM IN DEMU.
INTRODU!TION4"
L=
-
8/12/2019 Trainee Somany
56/64
? 9-=9? <
-
8/12/2019 Trainee Somany
57/64
? SA" . I@@?
-
8/12/2019 Trainee Somany
58/64
-
8/12/2019 Trainee Somany
59/64
/9+ ?+ ,
-
8/12/2019 Trainee Somany
60/64
C =9+/ 9??9=@ ? ?
-
8/12/2019 Trainee Somany
61/64
9-/ :/@ ?
-
8/12/2019 Trainee Somany
62/64
-
8/12/2019 Trainee Somany
63/64
-
8/12/2019 Trainee Somany
64/64