diesel electric locomotive : a saga of strength...
TRANSCRIPT
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DIESEL ELECTRIC LOCOMOTIVE : a saga of Strength,
Innovation and Glory
The first diesel electric locomotive (WDM2, no. 18233)
rolled out of Diesel Locomotive Works (DLW) on 3rd
January, 1964. Since then DLW has acquired domain
knowledge and expertise in developing new designs not
only to suit the transport needs of Indian Railways, but also of Non-Railway
Customers (NRCs) in India and abroad. Having produced 7778 locomotives
(up to 31st January, 2017) of various types, DLW now manufactures “More
than one locomotive a day” . DLW produced the ever highest number of
locomotives (330 nos.) during 2015-16 and is well on course to beat the
same during the current financial year i.e. 2016-17. DLW bagged the “Best
Production Unit Shield” for the year 2015-16, awarded by Shri Suresh
Prabhakar Prabhu, Hon’ble Minister for Railways.
5980
110
150
190
231
266249
317300
271163
177
148
117
69
63
38
17
1320
13
222
257 258267
259
294304
266
330 320
284
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17
(Target)
2016-17
(Actual up to
Jan'2017)
No.
of L
ocom
otiv
es (A
ll ty
pes)
ALCO High Horse Power
Ten Years’ Production Performance
Starting from 2600 HP locomotives, DLW moved towards manufacturing
High Horse Power (HHP), 4500
HP locomotives since March,
2002. DLW has in recent years
ramped up the production of HHP
locomotives which can be gauged
from the fact that the first 1000
HHP locomotive took 11years,
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while the next 1000th locomotive took only 3½ years. The 2000th HHP
locomotive was flagged off by Hon’ble Shri Manoj Sinha, Minister of State for
Railways on 10th December, 2016. So far (upto 31.01.2017) DLW has
manufactured 2054 HHP locomotives. This demonstrates the versatility of
the production capability at DLW. This year, DLW added yet another feather
in its cap by manufacturing its first Electric Locomotive WAP7 “Varun”, there
by making it a unique Production Unit manufacturing both Diesel and Electric
locomotives under one roof. This project was alloted to DLW only in
September 2016. Although this being a new product for DLW, with a different
propulsion architecture, “Team DLW” was able to deliver the product in a
record time and the first Electric Locomotive rolled out on 14th February,
2017. DLW will manufacture two
electric locomotives in 2016-17.
Encouraged by response of DLW
and their ability to grasp the
expertise in assimilating new
technology, DLW has been
entrusted with production of 25
Electric Locomotives in 2017-18 and
75 Electric Locomotives in 2018-19.
DLW has not only succeeded in scaling up the production to greater heights,
but has also been
successful in reducing
the unit cost of
locomotive. This has
been achieved with a
concerted effort towards
indigenisation and
multisourcing. The
locomotive cost has been reduced by more than one crore in the current
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financial year as compared the previous year. With a view to give filip to
“Make in India” initiative, the Expansion Project of DLW got underway, in
which the foundation stone was laid by the Hon’ble Prime Minister. Phase-I
of this project has now become functional and was dedicated to the nation
by Shri Narendra Modi, Hon’ble Prime Minister on 24 October’ 2016. Phase-
II of this project is also likely to be completed during 2017-18. With the
Expansion Project in place, the unit cost of locomotive is likely to come down
further besides improved layout and work flow.
DLW has been supplying its locomotives to Non-Railway Customers (NRCs)
in India and abroad as well. With its proven track record and quality of its
product and through increased productivity and better manufacturing
practices, DLW has become a meaningful player in the domestic and
international markets. DLW has till date supplied 694 locomotives to various
customers including 137 locomotives exported to various countries. During
the last five years DLW has earned ` 1,200 Crores by way of revenue
from its NRC business. DLW has orders for supplying 18 export
locomotives to Myanmar and 18 locomotives to NRCs. DLW has recently
entered into MoU with RITES for design and development of prototype of
3000 HP, Meter/Cape Gauge, AC-AC loco for export to South African and
other South East & Middle East Asian countries.
Technical Training :
DLW has a full-fledged Technical
Training Centre (TTC) which has been
engaged in skill development of
DLW’s human resource since 1959. It
imparts training to the newly recruited
staff and Act Apprentices, organizes
refresher courses for staff and
supervisors and gives vocational training to undergraduate engineering and
management students. In addition it organizes quality and industrial safety
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related courses also. Indian Railway Welding Research Institute (IRWRI)
which is also the nodal and coordinating organization for all other Regional
Welding Training institutes has been functioning under its auspices. TTC
provides training to more than 8,000 personnel annu ally.
Safety & Health of Staff :
Safety of staff at DLW has been accorded the highest priority. The safety
organization apart from doing routine inspections also undertake training in
firefighting and first aid. Mock drills are organized for emergency
preparedness. Safety seminars and safety awareness camps highlight the
importance of safety at workplace. These safety measures are also audited
by external agency as DLW is accredited with OHSAS 18001-2007
certification for occupational health and safety.
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25
1311
7
3
0
5
10
15
20
25
30
2013 2014 2015 2016 2017 (till Jan)
Accid
ents
(Nos
.)
Calender Year
Minor Accidents
Major Accidents
Minor Accidents
Major Accidents
No. of Accidents
Recent steps taken for safe working are:
• Provision of wider footsteps on ladders of EOT cranes
• Provision of steel chequered plates on walkways of EOT cranes
• Provision of hand-rails along the walkways in open gantry and
provision of steel platform adjoining the walkways
• Provision of safety belt (body harness) to staff
• Emphasizing the importance and insistence to wear personnel
protective equipment while working
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A hospital having 105 beds with patholigical test facilities & operation
theatre, a health unit and a First Aid post is also available here to extend
required medical attention to Railway personnel
and their families. A Homeopathic and an
Ayurvedic Dispensary have also been provided.
To facilitate DLW employees, online feature has
been added to the Hospital Management
Information System (HMIS). This will enable
online doctor appointment/registration, online
reporting of lab investigation, online position of
running token no. of individual doctor, either
through website or through the App which can
be downloaded from Android application
Google Play Store. This will save time and
energy of the staff by avoiding frequent visit to
hospital.
Environment Improvement :
As a harbinger for environmental protection, way back in late 1980s, DLW
took the lead in the “Clean Ganga” campaign and installed two treatment
plants viz. Sewage Treatment Plant (STP) for treatment of discharged
human waste and Industrial Effluent Treatment Plant (IETP) for treating
contaminated & mixed Petroleum oil and Lubricants (POL). The plants,
besides ensuring that Ganga remains clean, also contribute to significant
recycling of resources. At IETP alone, around 3,000 litres of oil and
grease is separated and sold off, whereas in STP 3 million litres of
water is being recycled every day. The treated water is released for
agricultural and gardening purposes. DLW takes pride in the fact that none
of sewage, whether treated or untreated, is dischar ged into
Holy River Ganga . The digested bio-manure as sludge dried is used as
fertilizer for horticultural purposes. The average water consumption in DLW
is about 17.7 million litres per day. Recognising water as precious resource,
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treated water from STP is used for irrigation of lawns, sports grounds, green
patches and filling of water bodies as Surya-Sarovar and other ponds
existing at DLW, which has resulted in 19 % saving in water consumption
compared, to previous year.
In order to meet environmental obligation, DLW accredited itself with ISO
14001 certification for its Environmental Management Systems, as early as
in 2002. In line with this certification targets have been framed, which are at
par with global norms for water, air, exhaust-emission, work place environs,
hazardous waste, etc. DLW is also one of the units nominated by Railway
Board for Green Co Rating. The work is in advanced stage and Green
Rating is expected to be obtained by March’ 2017.
Stepping towards energy conservation and to tap the benefits of non-
conventional energy resources, 127 solar lights are fitted in the workshop
and colony as well as 40 solar water heaters have been installed in hospital
and officers’ guest house. As a fillip to energy conservation, 3000 energy
efficient LED lights have been fitted at DLW. Roof mounted Grid Connected
Solar power plants of a total 306 kWp have been commissioned at DLW so
far and a further capacity of 1200 KWp solar power plants are planned to be
commissioned. These steps towards energy conservation has resulted in
reduction in electrical energy consumption by 15.3% resulting in a saving of
around ` 44 lakhs in the electricity bill. As per our policy for continual
improvement, process for certification for ISO 50001:2011 for Energy
Management has been initiated and likely to be obtained by March’ 2017.
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Solar equipments at DLW premises
Presently, DLW township area has more than one lakh small & big trees.
Every year thousands of trees are planted religiously. DLW boasts of a
green area of 40% of its total area. The moment one enters DLW, a drop in
temperature of 3-4 degree Celsius from the outside area is palpable.
It is no exaggeration that Varanasi breathes throug h campuses like
DLW.
Clean and green DLW premises
We, at DLW, understand and appreciated that environment is a priceless gift
of nature. To protect our environment and to maintain the ecological
balance, we must bestow our immediate attention to it. The strategy adopted
by DLW is not only to maintain emission norms within its premises but also
equip its locomotives with fuel efficient technology. Introduction of Auxiliary
Power Units (APUs) in the locomotives reduce the emissions by reducing the
engine running when not required. Electronic Fuel Injection system will
further improve fuel efficiency of the locomotive thereby reducing fuel
consumption and exhaust emissions.
Technology Improvement : Since its inception, DLW has gradually shifted its focus from “Systems Integration” to “Systems Engineering” and has been making constant efforts for acquiring domain knowledge about “Know why” rather than “Know how”. The knowledge, expertise and skill set acquired by DLW engineers over a period of time has enabled DLW to upgrade HHP locomotive technology on a continuous basis. Locomotive technology upgrades implemented by DLW with the objective of improving energy efficiency, operational safety and crew comfort include dual cab architecture, Hotel load/HEP (Head End Power) feature, ACES (Auto Control of Engine Stop) with APU (Auxiliary Power
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Unit), DPCS (Distributed Power Control System) feature, Air Conditioned locomotive driving Cabs, Integrated Driver Display system and water-closet onboard with motor driven oil free air compressors. These have been possible with the joint engineering efforts put in by DLW and RDSO.
Current Projects : DLW is working on induction of new traction technologies which would improve energy efficiency and would be environment friendly. These include development of hydrogen based Fuel Cell Hybrid locomotives, Dual Mode locomotives, 3000 HP AC-AC (Meter Gauge) diesel electric locomotives for export and induction of electronic fuel injection system and 3-phase inverter based Motor Driven Oil Free Air Compressors in HHP locomotives. Crew comfort and ergonomics is another focus area where DLW has put in efforts to improve the working environment. Provision of intermediate vacuum type toilet module with on-board bio-digester (sewage treatment system) for crew and improved acoustic insulation treatment of crew cabins to reduce noise levels are steps taken in this direction. The new technologies under development at DLW in the high horsepower (HHP) and new generation locomotive designs are summarized below:
i) Dual Mode Locomotive : Dual mode locomotives, as the name suggests, have the capability to work in electrified as well as non-electrified territories. Such locomotives are already in use on European and American railroads. In addition to operational advantage i.e. reduction in train running time due to elimination of traction change at interchange points of electrified and non-electrified territories etc., there is also reduced net requirement of locomotives as well as of crew of each type (i.e. diesel & electric locomotives separately) for haulage of trains. Railway Board has sanctioned manufacture of five Dual Mode locomotives at DLW. The functional requirements of the intended design targets passenger train operation with power capability of 4500 HP in Diesel mode and electric mode. The locomotive would be manufactured using the existing dual cab version of 4500 HP high horse power WDP4D locomotive and therefore the Dual Mode locomotive would also be equipped with twin cabs. The targeted speed potential for this locomotive would be 135 kmph. The existing high horse power (4500 HP) dual cab passenger locomotive architecture and also broad architectural modifications needed to create dual mode loco architecture are illustrated in the sketch and the 3D model image below:
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Existing WDP4D locomotive layout
Conceptual layout of Dual Mode Locomotive The major challenges involved in design and manufacture of dual mode locomotive include, amongst others, the weight and strength optimization of car body and structural members so as to meet the functional requirements within the existing axle load constraints. This will be the first locomotive of its kind having universal capability for seamless operation on Indian Railways.
DLW is targeting to roll-out first Dual Mode Locomotive in 2017-18.
16 -7 10G 3B E ngine
R adiators
C o m pres sor
T rac tio n A lt ernato r
D B G rid & F an s
E CC -1
T CC
Note: Items indicated in Red are uncommon items w.r.t WDP4D
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ii) Reduction in level of noise emission : DLW has initiated action for achieving substantial reduction in the noise levels in driver cabins as also the external noise being emitted by the locomotive. Implementation plan included:
� Assessment of existing noise levels in HHP locomotives � Benchmarking with International Standards � Identifying critical areas / major contributors to the sound energy � Generating SPL data and understanding noise spectrum � Exploring solutions specific to frequency bands � Trials on a limited number of HHP locomotives to assess the efficacy of
selected solution DLW engaged CMTI / Bangalore (Central Manufacturing Technology Institute, A Govt. of India organization) to measure and map the existing noise levels of a WDP4D locomotive. The existing noise map details provided by CMTI / Bangalore was used to benchmark the WDP4D noise levels with International Standards (49 CFR Part 229) and ranking of noise sources with regard to their contribution to the overall noise spectrum has been defined. The existing overall sound pressure levels (SPL) in the rear cab of 4500 HP dual cab high horse power locomotives (WDP4D/WDG4D) has been recorded as 96 dB(A) while that in the front cab is 88 dB(A). The existing international standard for in-cab noise defines noise exposure limit as 85 dB(A). Standard methodologies of noise control are (a) Source Control (b) Path Control and (c) Receiver Control. Rear cab being the noisiest working zone for the loco pilot, DLW has attempted to bring down the sound pressure levels in the rear cab of 4500 HP dual cab locomotives by adopting “Path Control” and “Receiver Control” methods. New acoustic materials including absorber, dampener, barrier and sealing materials were used to isolate rear cabs from the noise sources onboard and the results achieved are summarized in Table – 2.
Table – 2
Loco No. / Month Results
WDP4D-40207 (Dec-2014)
Noise level in Rear cab reduced from 96 dB(A) to 90 dB(A)
WDG4D-70355 (April-2015)
Noise level in Rear cab reduced from 96 dB(A) to 88 dB(A)
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As a part of continuing efforts to meet the 85 dB(A) benchmark, DLW engaged NVH (Noise, Vibration & Harshness) experts (M/s. Megasorber/Australia, M/s. Henkel/India and M/s. Pyrotech/India) for designing a suitable acoustic insulation scheme for application in dual cab HHP locomotives to bring down the noise levels in both the cabs to within 85 dB(A) in locos being manufactured by DLW. The results achieved are summarized below in Table-3
Table – 3
DLW is now working with RDSO to develop solution for further reducing the sound pressure levels in the HHP Locomotive cabs. RDSO has awarded a consultancy contract to IIT/KGP to suggest measures for reducing sound pressure levels in HHP Locomotive Cabs.
iii) Toilet onboard 4500 HP WDG4D Diesel Electric L ocomotive : Keeping in view the inherent need for improving crew comfort, DLW has provided a vacuum based micro-processor controlled toilet module onboard the HHP Locomotive. This is equipped with environment friendly and self-sustaining bio-digester module for onboard sewage treatment.
Loco No. / Month of dispatch
Results
Front Cab Rear Cab
WDP4D-40340 (August-2016)
Reduced from 88 dB(A) to 86 dB(A)
Reduced from 96 dB(A) to 88 dB(A)
WDP4D-40392 (November-2016)
Didn’t reduce from 88 dB(A)
Reduced from 96 dB(A) to 88 dB(A)
WDG4D-70640 (January-2017)
Reduced from 88 dB(A) to 86 dB(A)
Reduced from 96 dB(A) to 88 dB(A)
Toilet Module
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WDG4D loco fitted with onboard toilet module under manufacture at DLW First WDG4D HHP locomotive No. 70486 fitted with vacuum based toilet system rolled-out of DLW in April-2016 and was flagged off by Hon’ble MR on 6th May’16 at Safdarganj Rly station.
WDG4D-70486 being flagged off by Hon’ble MR on 6th May’16 at Safdarganj Rly . station
Thereafter, three more locomotives provided with onboard toilet module, rolled out from DLW in Nov., Dec. 2016 and Feb.’ 2017 respectively. One more HHP locomotive is planned to be provided with onboard toilet module in March’ 2017. The locomotives provided with onboard toilet module are also fitted with underslung mounted motor driven oil free compressor.
Motor driven oil free compressor The switch-over to inverter based motor driven air compressor was essential to generate space for accommodating toilet module onboard the platform of WDG4D loco. Use of inverter based motor driven unit, in place of the existing shaft driven compressor, saves power over duty cycle when compressor air charging is not required. The added advantage of using oil free compressor is improved air quality entering the computer controlled brake system leading to improved reliability of brake system valves and other critical components in the circuit.
iv) Hydrogen Fuel Cell Hybrid locomotive :
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DLW has been manufacturing locomotives for mainline and shunting operation with conventional power-train onboard. Conventional Power train design for locomotive application utilizes medium speed multi-cylinder compression ignition engine with associated electrics and propulsion control system integrated together for desired functionality. The existing design variants of diesel electric locomotives being manufactured by DLW and other locomotive manufacturers across the world, however, have a definite carbon footprint linked to the exhaust emissions levels. Considering the environmental concerns specifically related to the environmental impact of various technologies and the rising societal awareness for bringing-in more and more environment friendly technologies, design review and adoption of new innovative traction technologies having minimal impact on environment has become inevitable. One of the new unconventional power-trains being tried out worldwide for traction application is hydrogen based fuel cell in hybrid architecture with a battery bank, hydrogen storage and propulsion control system onboard. The hydrogen powered fuel cells have inherent technological advantages like zero carbon emission and reduced dependence on fossil fuel and thereby imports. This makes the hydrogen fuel cell technology attractive for addressing the burning issue of climate change.
Considering the advantages discussed above, Railway Board has sanctioned manufacture of 2 hybrid locomotives having capability to feed the traction power requirement directly from either the hydrogen fuel cell stack or battery bank onboard or both as per the instantaneous power requirement.
DLW is working on manufacture of these locomotives. The locomotive will be a technology demonstrator for creating awareness in establishing use of environmentally sustainable green technology in the field of traction. It will be equipped with 300 KW rating PEM (Proton Exchange Membrane) type fuel cell stack modules and battery bank and have peak transient power capability of 700 KW
A typical hydrogen based fuel cell locomotive layout
A typical hydrogen based fuel cell locomotive under manufacture in USA
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Leveraging IT for indigenization and multisourcing With a view to have more indigenized vendors, DLW has leveraged information technology (IT) for developing more vendors and expediting prototype development. The developed systems are not only transparent but also linked to specific timelines. Two such IT applications being used at DLW and their impact are mentioned below: Web based portal for vendor registration In an effort to create transparency in dealing with the vendors and improve procedural efficiency in processing of their applications, DLW has launched a web-based portal for vendors on its official website www.dlw.indianrailways.gov.in. This portal has many enabling features including facility for the vendors to register their application online. It provides them with login authority which can be used by the vendor to access DLW’s vendor portal for any information related to the status of processing of their application. Each activity related with the processing of vendor application (including scrutiny of documents, physical verification of manufacturing infrastructure etc.) is tied to a specific timeline and the system automatically generates alerts as and when these defined timelines are violated at any stage. The system automatically ensures monitoring of process time and the slacks are eliminated. The advantages of web based portal are summarized as under: • Facility to vendors for online submission of VA form • System generated acknowledgement to Vendor and alerts to DLW
officials at every stage • Paperless transaction • Smart tracking of document / Timeline Monitoring of complete process /
Status of application visible to vendor As a result, the application processing / approval time has reduced from 240 days to 60 days. The module implemented for online vendor application is a scaleable module and can be interfaced with other lateral modules in future. Web based product development monitoring system : In an effort to increase the available vendor base for sourcing locomotive components/assemblies, DLW places developmental purchase orders on vendors against regular and developmental tenders and the typical process time taken from the issue of purchase order to the final acceptance of prototypes was around 34 months. In order to improve the process efficiency and reduce the product development cycle time, DLW has launched a web-enabled “product development monitoring system” . The system was launched on 18th August 2015 and is hosted on DLW’s official website www.dlw.indianrailways.gov.in. The algorithm responsible for running the web enabled product development system has been programmed to ensure that each activity of the complete process work flow, right from the issue of developmental purchase order to
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the final validation and acceptance of prototype(s), is tied to a specific timeline and the system automatically generates alerts as and when these defined timelines are violated at any stage. The system automatically ensures monitoring of process time and the slacks are eliminated. With this system, the product development process time is likely to come down from around 34 months (existing) to 9 months. The advantages of web based portal are summarized as under: • Reduction in process time / Timeline Monitoring of complete process • Paperless transaction , File movements eliminated • System generated alerts /SMS/Emails to all concerned • Real time monitoring of activities, Activity logs / Responsibility for delay • Access to vendors for tracking of stages during development • System generated customized reports • Use of data base for managerial decision making The module is scaleable and can be interfaced with other lateral modules in future. Diesel Mitra - Service Engineering and customer sat isfaction : Zonal railways/Diesel sheds homing diesel electric locomotives manufactured by DLW are treated as valued customers by DLW. Their feedback on quality and design inputs are therefore given due consideration and prompt efforts are made to resolve them. There are currently 33 diesel loco sheds which are homing more than 2000 HHP locomotives. To improve DLW'S co-ordination with the diesel loco sheds across Indian Railways, and to get first hand feedback from the sheds regarding not only the performance of these locos but also issues linked with reliability, maintenance spares, technical and maintenance issues, confidence building in the sheds, concept of Diesel Mitras was introduced. One officer from DLW has been nominated as DLW's co-ordinator for each zone and the sheds therein. This officer also known as ‘Diesel Mitra’ for the zone personally visits the sheds and the HQs of his nominated zone at least thrice a year, personally interacts with the officers and staff and on return to DLW gives his report to the management. Currently there are 16 Diesel Mitras who, in the last year alone have carried out 36 visits across 16 Zones and 29 diesel sheds. DLW has put in efforts to study the feedbacks received and has taken corrective action for resolution of the issues. The analysis and action advisory is being regularly documented in the form of “Design Bulletins” which are being uploaded on DLW official website to enable wide publicity and provide unrestricted access to all concerned. Till date DLW has already issued 76 design bulletins on various service engineering related issues highlighted by various railways. Diesel Locomotive Works is committed to adopt new t echnologies, manufacture new design locomotives, improve quality of HHP locomotives and innovate to achieve new standards o f crew comfort and safety in the coming future .
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रा क सवेा म डीजल रेल इंजन कारखाना
हर दन...... ...... एक रेल इंजन
DLW AT A GLANCE
• 23rd April, 1956 - Foundation stone by the 1st President of India Late Dr. Rajendra Prasad.
• 3rd January, 1964 - 1st BG locomotive WDM2 commissioned by Late Lal Bahadur Shastri.
• February, 1975 - 1st BG shunting locomotive (WDS6) turned out.
• March, 1976 - 1st Export Loco turned out for Tanzania.
• March, 2002 - 1st High Horse Power (4500 HP) locomotive WDG4 turned out.
• July, 2013 – 1000th High Horse Power (4500 HP) locomotive WDP4D turned out.
• December, 2016 – 2000th High Horse Power (4500 HP) locomotive WDP4D turned out.
• February, 2017 – 1st Electric Locomotive (6000 HP) WAP7 rolled out.
• Installed capacity : 200 loco/year
• Ever highest production : 330 (in 2015-16)
• Locomotives produced since inception : 7778 (Up to 31.01.2017).
• Locomotives supplied to other than Zonal Railways : India : 556, Abroad : 137.
• Annual Turnover : ` 4942 Crores (FY 2015-16)
• Total Manpower : 6223 (Up to 01.02.2017).
• No. of Staff Quarters : 3675.
• Total Area : 299.7 hectares. (Workshop: 89.0 hectares Township: 210.7 hectares.)
• Road network : 102 km.
• Boundary perimeter : 10.35 km.
• Green Area : 119.88 hectares (40% of total area of DLW)
• No. of Trees : More than 1 lakh.
• Sewage Treatment Plant (STP) : 12 Million Litres per day (MLD)
• Industrial Effluent Treatment Plant (IETP) : 3 Million Litres per day (MLD)
• Recycling of water : 3.95 Million Litres per day (MLD)
DLW IS NOT DISCHARGING ANY SEWAGE (TREATED OR UNTREATED) INTO GANGES.