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Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
Project report of vocational training at Chittaranjan locomotive workshop
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Project report of vocational training at Chittaranjan locomotive workshop

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Project report of vocational training at Chittaranjan locomotive workshop

Project report of vocational training at Chittaranjan locomotive workshop

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  • 1. 1 PROJECT REPORT OF VOCATIONAL TRAINING AT CHITTARANJAN LOCOMOTIVE WORKS, CHITTARANJAN NAME- Sagardwip Das Bachelor in Engineering Mechanical Engineering Department I.D NO. – 111011012 Bengal Engineering And Science University, Shibpur Howrah-3
  • 2. 2 ACKNOWLEDGEMENT Sub : Short term practical training Ref.: your Office Order No.353 dated. 10.6.2013 Even after completing of two weeks in vocational training at - Chittaranjan locomotive works; it was a great pleasure to undergo training with this company. It is very difficult to express in a few words the gratitude towards people so near to my heart. Yet, I consider myself privileged in doing so. What can I say, but a big ‘THANK YOU’ to CHITTARANJAN LOCOMOTIVE WORKS; to which I shall always remain indebted for the faith it has placed in me by letting me to pursue and complete my Industrial in vocational training of Mechanical Engineering course on loco works . I am grateful to express my heart full thanks to Mr. B C Ghosh , principal TTC /CLW/Chittaranjan for allowing me to undertake short term practical training at TTC, C-D& D, TMDO etc. as per Office Order No. 353. Dated 10.6.2013. I am also grateful to all supervisor‟s , Senior Section Engineer‟s and worker‟s regarding rendering their all assistant to me during this training . I would also like to express my sincere thanks to Mr. S.K.SAHA, the HOD of our Mechanical Engineering Department for arranging for the training in CHITTARANJAN LOCOMOTIVE WORKS. SAGARDWIP DAS 21st JUNE, 2013
  • 3. 3 INTRODUCTION: - Chittaranjan locomotive works is the first step after our independence towards self sufficiency in the field of manufacture of locomotives for Indian railways. Chittaranjan Locomotive Works (CLW) is the dream of the nation‟s visionaries, coming true. The planners of the Nation with their deep insight and foresight set to build a Loco building Factory in West Bengal and CLW is that vision, coming true. On the 9th of January 1948, survey of the proposed area was done. The rocky soil was an advantage in erecting foundations for heavy structural work and the undulating terrain solved the problem of drainage for the township while the schemes of the DVC envisaged hydro-electric and thermal power stations in the vicinity assured cheap power availability in the near future. It is the only major Electric Locomotive builder in the country. It is situated just at the Border of West Bengal and Jharkhand and is at about 32 km from Asansol and 237 kms from Kolkata. The place where today CLW is situated was actually a hamlet of small villages. The locoworks with its ancillary workshops has a stores purchase office in Kolkata and inspection cells in New Delhi, Mumbai, Kolkata and Bangalore. The Workshop has an area of 18.34 Sq. Km. The issue of setting up a loco building unit continued to be under active consideration of the Central legislature and in the late thirties, a committee consisting of M/s. Humphries and Shrinivasan was appointed to investigate the possibility of establishing a locomotive manufacturing unit and to consider its economic viability. The initial project, at Chandmari, a place near Kanchrapara, in the state of West Bengal, could not mature due to partition, which inevitably necessitated a change of site. This present site at Chittaranjan was selected after a fresh survey and Railway Board‟s approval was obtained in the year 1947. The locoworks was initially established for production of 120 average sized steam locomotives with the capacity to manufacture 50 spare boilers. The inaugural production of WG class of steam locomotive commenced on 26th January, 1950. Smt. Basanti Devi wife of Deshbandhu Chittaranjan Das inaugurated the production. The first president of India Dr. Rajendra Prasad dedicated the first steam locomotive christened as “Desh Bandhu “ on 1st November, 1950 and on the same day the factor was named as “Chittaranjan Locomotive Works” after the great patriot Chittaranjan Das. It manufactured 2351 steam locomotives of five types. The production of steam locomotives was discontinues from 1973-74. The production Diesel Hydraulic Locomotives was taken up during 1968 and after manufacturing 842 Diesel Hydraulic Locos of 7 types the production was discontinued from 1993-94. CLW was entrusted for the manufacture of Electric Locomotives in the year 1961. The first 1500V DC Electric Locomotive named “LOKMANYA” was commissioned and dedicated to the nation by Pt. Jawaharlal Nehru, the first prime minister of India on 14th October, 1961. The first Electric Loco turned out from CLW, christened as “BIDHAN” was a Broad Gauge 25 kV a.c. Freight Locomotive (WAG-1) of 2840 hp with maximum speed of 80 km/hr. Since then CLW has continuously updated and upgraded the technology towards the manufacture of Electric Locomotives. So far 3006 Electric Locomotives of different types have been manufactures till the year 2001-02, upgrading its horse power from 2840HP to 6000HP and maximum speed from 60 Km/h to 160 Km/h. LOKMANYA WCM 5 During pre-construction days
  • 4. 4 CLW has become the first production unit in developing countries, second in Asia and fifth in the world to manufacture 3-phase, state of the art GTO Thyrister controlled electric loco with the inauguration of 6000HP freight type WAG-9 Loco christened as “NAVYUG” on 14th November, 1993. CLW is also manufacturing the passenger version of the three phase loco type WAP-5 with the maximum speed of 160 Km/h and having a potential up to 200 Km/h. By indigenization of three phase technology CLW has been successful in bringing the towering imported cost of Rs 35 crores to 12.5 crores. In addition to the two new versions of the three phase locomotives viz. WAP-7 and WAG-9H has been started from the year 2000-01. Today CLW has the capacity to produce 150 locomotives in a year. The production of traction motor and control equipment commenced on April 1967 and steel foundry was set up on 1962-63 for manufacturing cast steel loco components. Currently DC and 3- phase AC traction motors are being manufactured. Apart from manufacturing CLW has machining of bogies, machining and assembly of wheel set which includes modern CNC machines, plasma cutting machines, MIG welding sets, inert gas welding sets etc. CLW has never been behind in the field of quality assurance also. It acquired 1SO-9001 certification for loco works on 13th July, 1996 and ISO-9002 certification for steel foundry on 8th August, 1996. CLW has been awarded with ISO-14001 certification also on 26-04-2002. The efforts have been recognized by the World Environment Foundation and the Golden Peacock award for Environment Management 2006 has been conferred on 9th June 2006. Apart from its expertise in rolling out state- of-the-art electric locos and providing Indian Railways much needed motive power, Chittaranjan is also a hot spot for nature lovers, and all those who want to soothe their frayed nerves in the lap of mother nature. River Ajay flows past CLW along its northern side. Its serene environment, lush green fields and plethora of unknown birds welcome all visitors. Every winter, migratory birds, after covering thousand miles come to the seven lakes within the township. CLW has complied fully with the provisions of the Industrial Safety Act, 1948. CLW in its safety policy aims to ensure 100% safety for all workers working in Chittaranjan Locomotive Works. CLW is the proud recipient of the Safety innovation award 2006. The award was conferred on CLW on 6th September, 2006 by the Safety and Quality forum of the Institute of Engineers (India). CLW enters its Diamond Jubilee year w.e.f 26th January, 2009. Yearlong celebrations are in the offing. A kite flying Competition was held on March, 2009, to commemorate CLW‟s stepping into its Diamond Jubilee year. The programme brought together the residents of the township, in celebrating the year. Now ShriRadheyShyam is General Manager of CLW. HOW TO REACH CLW: - Chittaranjan Locomotive Works (CLW), located in the land of Viswa Bharati, a great educational and cultural seat in the world, is the premier electric loco producer in this country. Situated at the border of West Bengal and Jharkhand, it is about 32 kms away from Asansol and 237 kms from Kolkata, the state capital. River Ajay flows past CLW along its northern side.
  • 5. 5 MEMORABLE EVENTS OF CLW: - • INAUGURATION OF PRODUCTION – 26 JAN, 1950 • FIRST STEAM LOCOMOTIVE COMISS1ONED – 1st NOV, 1950 • FIRST 1500V DC ELECTRIC LOCO "LOKMANYA" COMMISSIONED - 14th OCT, 1961 • FIRST 25KV AC ELECTRIC LOCO "BIDHAN" COMMISSIONED - 16th NOV, 1963 • FIRST DIESEL HYDRAULIC LOCO WDS-4 "INDRAPRASTHA" COMMISSIONED - 6th JAN, 1968 • FIRST RAJDHANI ELECTRIC LOCO WAP-1 COMMISIONED 1st OCT, 1980 • AWARDED ISO-9001 CERTIFICATION FOR LOCO WORKS - 13TH JUL, 1996 • FIRST 3 PHASE 6000 HP WAG 9 LOCO (SKD) DISPATCHED TO RAILWAYS- 27th DEC, 1996. • FIRST 3 PHASE 6000 HP STATE OF THE ART WAG 9 FREIGHT ELECTRIC LOCOMOTIVE "NAVYUG" INAUGURATED BY HONURABLE MINISTER OF RAILWAYS – 14th NOV, 1998. • 5000 HP MICROPROCESSOR CONTROL FREIGHT ELECTRIC LOCO WAG 7 "SAMARPAN" INAUGURATED BY SRI. JYOTI BASU, HON‟BLE CHIEF MINISTER OF WEST BENGAL- 21st NOV, 1998. • 1000 HP PHASE STATE OF THE ART MATOR INDEGINEOUSLY BUILT AT CLW AND INAUGURATED BY STAFF MEMBER JAN, 1990. Milestone1  1947 September Site for Chittaranjan Locomotive Works located.  1948 March Construction work started.  1948 April Workshop Set up  1950 26th January Production inaugurated by Smt. Basanti Devi, Wife of Late Chittaranjan Das.  1950 1st November Namkaran Ceremony of the works by President of India, Dr. Rajendra Prasad, when the first steam locomotive was turned out and flagged off from CLW.  1951 12th February KG Hospital formally opened by his Excellency Dr. K.N.Katju, Governor of West Bengal.
  • 6. 6  1952 1st to 2nd March Prime Minister of India, Pandit Jawaharlal Nehru visits Chittaranjan accompanied by Dr. B.C.Roy, Chief Minister of West Bengal  1952 21st Oct Railway Minister Shri Lal Bhahadur Shastri visits Chittaranjan  1953 10th October Dr. Sarvapalli Radhakrishnan, Vice President of India, visits Chittaranjan .  1954 6th January 100th Steam Loco “CHITTARANJAN 100” inaugurated by Railway Minister Shri Lal Bahadur Shastri.  1955 27th April Dr. Rajendra Prasad, President of India, drove the 200th Locomotive from the works.  1955 28th November Visit of their Majesties the King ,Tribhuvan Bir Bikram Shah and Queen of Nepal  1955 17th December Visit of their excellencies Mr. N.A.Bulganin and Mr. N.S.Khruschev from Russia  1956 14th November Visit of His Imperial Majesty, Mr. Haile Selassie, Emperor of Ethiopia Milestone2  1956 12th December Visit of Mr. Chou en lai the Prime Minister of People‟s Republic of China  1957 13th Jan Visit of their Holinesses , the Dalai Lama and the Panchen Lama  1958 18th March Visit of Mr. Churu Stoika, Prime Minister of Rumanian People‟s Republic  1958 20th November Visit of Mr. Marcel Roberts, Chief Occupational Safety & Health Division, International Labour Organisation  1960 25th January A technical collaboration agreement signed with Messrs. F.H.Lloyd & Co. Ltd., Wednesbury for establishing the Steel Foundry at Chittaranjan  1960 16th April Thousandth Locomotive turned out.  1960 April Visit of Mr. Gamal Abdul Nasser, the President of the United Arab Republic
  • 7. 7  1961 January Steel Foundry set up  1961 2nd February Visit of the illustrious daughter of Netaji Subhash Chandra Bose, Kumari Anita Bose  1961 16th April Opening of Rabindra Manch and open air theatre.  1961 14th October First CLW built WCM-5 DC Electric Loco “LOKMANYA‟ commissioned by Pandit Jawaharlal Nehru.  1962 October Electric Loco Shop Set up  1963 16th November First CLW built WAG-1 25 KV AC Electric Loco “BIDHAN‟ commissioned by Pandit Jawaharlal Nehru.  1966 Traction Motor Shop Set up  1967 16th April Chittaranjan builds its First Traction Motor, the largest in India, at that time.  1968 6th January First CLW built Diesel Hydraulic Shunter “INDRAPRASTHA” commissioned by Shri C.M.Poonacha, the then Railway Minister.  1971 Antim Sitara last steam engine …….  1972 First batch of TAO-659 traction motor dispatched Milestone3  1972 30th January First CLW Built WCAM-1 AC/DC Dual Voltage electric Locomotive “Vallabh”commissioned by Shri Sidhartha Shankar Ray, the then Chief Minister of West Bengal.  1980 1st October First Rajdhani Electric Loco WAP-1 commissioned.  1985 3rd and 4th July Flagging of of the 600th Diesel Loco MOHANDAS by Shri Madhav Rao Scindia, Minister of Railways  1986 2nd November Visit of Professor Nurul Hassan, Governmor of West Bengal  1987 6th April “JAWAHAR” (WAP-3) commissioned and christened by Shri Madhav Rao Scindia, Minister of State for Railways for Shatabdi Express services.
  • 8. 8  1988 First batch of Hitachi traction motors dispatched  1989 Collaboration agreement signed with Rockwell International Corporation .  1990 31st March 105th Electric Loco KIRTIMAN inaugurated by Mr. R.D.Kitson, Member Mechanical, Railway Board  1991 7th January Flagging off of 1500th Electric loco SUKANYA, to mark the International year of the girl child  1992 3rd August 1st 5000 hp High Adhesion WAG – 7 Electric Locomotive “SHANTIDAN” christened by Mother Teresa, Missionaries of Charity.  1993 6th April Last BG Diesel Shunter “VIRAM” of the year and NG Diesel Locomotive “ITI” of the year 1992-93.  1993 11th June Inauguration of “Sidhu kanu Setu” a light bridge over the River Ajoy by R.K.Shukla, GM/CLW  1994 23rd January WAP-1 Electric Loco “PRAGATISHEEL” provided with Hitachi Traction Motor. Milestone4  1994 27th August First 5000 hp WAP-4 Passenger Locomotive “ASHOK” flagged off.  1996 13th July ISO-9001 certification awarded to Loco Works by IRQS.  1996 8th August ISO-9002 certification awarded to Steel Foundry by IRQS.  1996 14TH September First Modular WAG-7 Loco KARAMVIR Flagged  1996 27th December First 3 phase 6000 hp WAG-9 Locomotive (CKD/SKD) flagged off from CLW.  1998 29th April Flagging off of 2500th Electric loco SWARNA ABHA by the Shri Nitish Kumar,Hon‟ble MR  1998 14th November WAG-9, the first CLW built indigenous 3 phase state-of-the-art 6000 hp Freight Electric Locomotive “NAVYUG” inaugurated by the Hon‟ble Minister for Railways by Shri Nitish Kumar.  1998 21st November Inauguration of one WAG-7 500 HP Electric Loco SAMARPAN by Shri Jyoti Basu Chief Minister of West Bengal
  • 9. 9  1999 10th January First batch of 6 nos. of CLW built 1000 hp Traction Motors for WAG-9 inaugurated by Shri K.Balakesari, Member Staff.  1999 12TH April Flagging off of NAVJYOTI by his His Excellency the Governor of West Bengal Mr. A.R.Kidwai  2000 25th Jan CLW completes 50 years of service to the nation  2000 24th Febr The first CLW built 3-phase traction motor type 6 FXA-7059 for WAP-5 locomotive inaugurated.  2000 10th May “NAVKIRAN” the first WAP-7 locomotive rolled out of CLW.  2000 17th May “NAVODIT” the first CLW built WAP-5 locomotive rolled out of CLW. Milestone5  2000 30th June A first Day Cover on CLW released by Shri M.K.Banerjee, Post Master General/Kolkata to commemorate CLW Golden Jubilee (Phase-II).  2000 30th June “NAVSHAKTI” the first WAG-9H locomotive was rolled out of CLW.  2000 18th November Commissioning of a new facility for polyurethane painting of Electric Locomotives with grit blasting and paint drying oven facility.  2001 12th February “NAVBHARATI”, the second CLW built WAP-7 locomotive flagged off by the Hon‟ble Minister of Railways Ms. Mamata Banerjee.  2001 16th April H.E.Viren J.Shah, Governor of West Bengal was the chief Guest at the 46th Railway Week function. H.E. also flagged off the 3-phase WAG-9 loco christened “NAVASHA”.  2001 31st May “NAVJAGRAN”, the CLW built WAP-5 locomotive flagged off by the Hon‟ble MOSR (D) Shri Digvijay Singh.  2002 26th April ISO-14001 certification awarded to CLW by IRQS.  2003 6th April “NAVCHETAK” the CLW built WAP – 7 type Locomotive flagged off by Hon‟ble MOSR (A) Shri A.K.Murti.  2003 2nd & 3rd August “NAVGHANSHAKTI” the CLW built WAG-9 type locomotive flagged off by ML/RB,Shri S.C.Gupta.  2003 25th Sept ISO-9001-2000
  • 10. 10 Milestone6  2003 28th Oct Shri Nitish Kumar,Hon‟ble MR inaugurated a book published by the PR Dept. entitled “STORY OF CLW” written by Shri R. K.Vir, Ex-GM/CLW at Railway Board, New Delhi.  2004 10th Jan “NAVGATI”, the CLW built WAP-7 locomotive flagged off by Addl. ML/RB.  2004 29th March “YUGANTAR”, the CLW built WAP-4 loco flagged off by GM/CLW.  2005 February Manufacturing of Cast Steel Bogie Frame for DLW for GM Loco WDS-4 by Steel Foundry  2006 9th June CLW is conferred with the Golden Peacock award for Environment Management by the World Environment Foundation  2006 29th July CLW built new locomotive type WAG-9 & WAG-9H with Satellite Remote Diagnosis System “Dr. Silver” inaugurated by Shri Lalu Prasad, Hon‟ble MR.  2006 6th September CLW becomes the proud recipient of the Safety Innovation award 2006, by the Institute of Engineers  2007 23rd March Flagging off of 100th WAG-9 loco “NAVPRAGATI”.  2007 31ST March 1st loco for 2007-08 inaugurated  2007 31ST March 1041st Traction Motor produced for the year 2006-07  2008 25th May CLW website launched  2008 11th July CLW adopts ORACLE based financial application  2009 26th Jan CLW steps into its Diamond Jubilee year
  • 11. 11 QUALITY POLICY OF CLW: - Quality policy of CLW is to manufacture electric loco and spares meeting railways requirement of performance and maintain ability. 1. Adopted quality management system, which ensures conformance to designees and specification of every stage of manufacture. 2. Constantly reviewing and updating design, specification and process to improve product performance. 3. Ensure quality of purchase material by establishing an effective system of vendor product performance. 4. Having an effective system of communication and training to make every employee of quality policy of CLW and motivate him or her to implement and maintain the quality system. 5. CLW will constantly strive for cost effectiveness to ensure the sales price is "at cost” basis. It is intention of CLW to remain the leader in manufacture of electric locomotives in India in terms of both quality and cost. Recently CLW has achieved an ISO 9001 certificate. CORRECTIVE/PREVENTIVE ACTIONS: - Since the implementation of the ISO – 9001, CLW has benefited immensely by way of reduced rejections and re-work. Further, customer feedback i.e. feedback from the various electric loco sheds of the IR are being given considerable attention. Based on customer feedback, suitable corrective and preventive actions are being initiated through Design Modifications and Correction of manufacturing processes. ENVIRONMENTAL POLICY OF CLW: -  Improved Environmental Management System, prevention of pollution and continuous improvement of environment performance.  Compliance with relevant environmental legislation and requirements as determined by appropriate regulatory and other corporate bodies.  Conservation of natural resources and implementation of fundamentals of waste management.  Setting environmental objectives and Targets and monitoring progress for sustainable development. Ensure awareness of all employees and contractors regarding their environmental roles and responsibilities. Recently CLW has achieved an ISO 14001 certificate.
  • 12. 12 Following steps have been taken for protection and improvement of environment at CLW: -  Waste generated in Shops have been reduced by 5% from the previous year by improvement of operational procedures.  Air Pollution Control Device has been installed in Integrated Paint Shop to reduce air pollution.  Dust collector has been installed in Sand Plant/SF for reduction of air pollution.  To reduce air pollution, stack height of D.G.sets in Central Power House has been increased.  Air Pollution Control Device has been installed at GEC Arc Furnaces in Steel Foundry.  Consumption of water in plant area has been reduced by 5% by arresting major leakages and provision of water meters have been made for regular monitoring of water consumption.  Consumption of electricity in plant and Township has been reduced by use of energy efficient lights, installation of capacitor bank etc.  50,000 trees have been planted in the CLW Township. Another 50,000 trees will be planted during the current year.  Use of polybags has been totally banned inside the Township.  New Sewage Treatment Plant (Bio-filter Plant) has been commissioned and under operation for improvement of effluent quality before discharge to surface inland and nearby water bodies. INFRASTRUCTURE (AVAILABLE AS ON 01.4.2011): - 1. WORKSHOP: - Land area under workshop: 8,93.373 sq. m. Total plinth area in shops 2,39,843 sq. m. 2. STAFF: - GROUP -A 95 GROUP -B 103 GROUP -C 10,495 GROUP -D 2750 Total 12837 3. TOWNSHIP: - Total area 18.34 Sq. km Length of Road 203 km. Residential Quarters 9,356 nos. Hospitals 01 nos. Health Units 07 nos. Community Halls 08 nos. Open Air Theatre 01 no. Cinema Halls 02 nos.
  • 13. 13 Markets 07 nos. Clubs 01 no. Institutes 04 nos. School (Rly.) 16 nos. Schools (Non-Rly.) 16 nos. KendriyaVidyalaya 01 no. College 01 no. 4.POWER SUPPLY: - Maximum Contract demand 11.0 MVA Consumption of Electricity (p.a.) 462.95970 million units INDIAN RAILWAY ORGANIZATION STRUCTURE: -
  • 14. 14 GENERAL DESCRIPTION OF A LOCO: - 1. Roof equipments. 2. Driver's cab. 3. Machine room. 4. Bogie 1. ROOF EQUIPMENTS:- The high tension current for feeding of loco is taken from catenary lines by means of Pantographs. The locomotive is equipped with two pneumatically controlled pantographs PT-1 and PT-2 Pantographs: - Power at 25KV Is taken from the catenary by means of two pantographs, only one works at a time. The main functions of pantographs are to maintain a link between the overhead line and power circuit of the loco at varying speeds and wind. The min. air required for complete extension is 4.5Kg/cm2 . Pantograph selection switch (ZPT):- The ZPT is fitted on driver's desk, one in each cab. The switch controls the working of the pantographs. The selector switch has three positions- Position 0 => Both pantograph are down. Position I => Rear pantograph is raised. Position 2 => Front pantograph is raised. Rating voltage of ZPT =1 WV. Double pole earthings switch (H0M):- For securing the safety of the operations during maintenance that is carried out in the loco a hand operated switch HOM makes it possible to earth simultaneously the entire roof line HV 1/p terminals of the loco lock after lowering the pantograph when HOM cuts the compressed air supply of the pantograph. ET Surge arrester: - The protection of loco against, surge voltage is secured by means of two surge arresters with spark discharger ET-1 mounted on support of the isolator of HT connection and ET-2 mounted on HT 1/p terminals of the loco. 2. DRIVER’S CAB: - Since a loco consists of two cabs i.e. cab- 1 and cab-2 and usually one cabin is used by the driver which are fitted with driver's desk, by means of which the driver performs different operations to run a loco. 3. MACHINE ROOM: - The machine room constitutes the entire important equipments and they are as follows- a) B.A Panel. b) A.C Panel-2. c) Loco Transformer. d) Arno converter. e) Rectifier. f) Smoothing Reactor. g) Inductive shunt. h) Air compressor. i) Exhauster. j) Battery. k) Traction Motor.
  • 15. 15 B.A Panel: - B.A Panel stands for "Block Aparture Panel". There are tree B A panels in a loco viz. BA-1.BA-2.BA-.3.1t is also called as the heart of loco. B A panel has following parts: 1. Various rating resistors. 2. Shunting Contactors:- These are used to increase the speed of the loco. These are kept in parallel with the field of the traction motor. As these contactor introduced in the circuit the field gets weakened and there by the flux reduces hence increases the speed. All shunting contactors are pneumatically controlled. This pneumatic control is done by electro valve assembly. 3. Relay QD- 1 (Differential Relay). 4. CTF-1 Inverter TR/BR or change over switch: - These are two electro valves assembly for CTF-1, one for TR (traction) side operation and another for BR (Breaking) side operation. 5. J-1 (Reverser):- The electro valve assembly for J-1 reverser one for forward direction (-->) operation of J-1 and another for reverse direction (<---) side operation of J-1. BA-2 and BA-3 contains the following accessories:- 1. Field weakening resistance. 2. 2 Line contactor-All are pneumatically controlled. 3. Shunting contactor. 4. CTF-2(BA-2), CTF-3(BA-3). 5. J-2 reverser. 6. QD-2: Differential relay for slipping. 7. Q-20: Relay o/p voltage. Reverser: - The direction of rotation of a series motor can be changed when the direction of current is changed in either the armature or the field. It is usually the direction of the field current which is changed. This is because voltage across field coil is less as compared to the voltage across armature terminals. The function of the reverser is to control the direction of current in the field of traction motor and therefore its direction of rotation. Reverser is usually operated electro pneumatically when the motor is on no load i.e. traction circuit is energized only when reverser has been put in the desired direction. It can be manually operated in the event of failure of pneumatic operation. Contactor: - It is a switch which makes and breaks a power circuit on load and is controlled by means of a remote switch. Contactor consists of a fixed contact and a movable contact both insulated from rest of the mechanism. Loco-Transformer: - The main transformer of the electric loco is an auto transformer with 32 taps and a step down transformer with two separate secondary windings. The primary winding of the step down transformer is connected to one of the 32 taps by means of tap changer GR, which is driven by pneumatic servometer. The main transformer comprises more over of an auxiliary winding TEWA for winding feeding the auxiliary circuit; the circuits for auxiliary are connected to 400+/-22% voltage AC supply. The main transformer are protected by capacitors CAPTFP-1-2 against over fault voltage. The two secondary winding of the step down TFP are protected against excess voltage by means of surge arresters ETTFPT-2 condensers CAPTFP-3-4 and recombinations.
  • 16. 16 Arno-Converter: - Since the main supply of the traction overhead catenary is at single phase and the auxiliaries are required to have 3-phase because the motors required for auxiliary drives are 3-phase induction motors. The main function of the Arno-converter is to convert 1-phase to 3- phase supply. Arno-converter is basically an induction motors. The single phase supply of 400V AC is fed directly to the 'U‟ and „V' phase of the Arno, since the Arno is connected to single phase supply no torque is developed. For starting Arno the split phase has been employed. The W-0 phase winding is connected to the supply through a starting resistor R-118 and starting contactor C-118. Thus the unbalanced 3-phase voltage is impressed to each phase winding of Arno and starting torque is developed. Arno picks up speed within 5 secs. After Arno has gained sufficient speed the phase W-0 is opened from the starting circuit by starting circuit by starting contactor. Rating of Arno-converter: - Single phase 1/p Three phase 0/p 150 KVA 120 KVA 380 V 380 V 395A 190A Revolutions/min- 1495, Connection-Star. Frequency-50 Hz. Three phase AC o/p of Arno-converter is supplied to the auxiliary circuit. The o/p of one reactor is fed to three motor and the o/p of the second reactor are fed to the rest of the three traction motors. The rectifiers are arranged in bridge connection. Smoother Reactor: - The dc o/p of rectifiers specially from a single phase supply is pulsating and contains ripples. The magnitude of ripples which is alternating component at 100Hz has to be limited to 20% to 30% from 40% to 50%. These a.c harmonics besides producing heating in the magnetic circuit of the motor produces commutation troubles. Smoothing reactor is introduced in between o/p terminals of the reactors and d.c motors and its main job is to smoothen out ripples in the d.c o/p of the rectifiers. It is made of rectangular Cu-conductors wound over a laminated core. Spaces are put in between turns to help cooling the reactor by blower air cooled type mounted usually on the under frame. Smoothing Reactor for Higher H.P Loco: - Technical Features SL-30 Current Rating 1350 A Inductance at 50Hz 3.6mH No. of turns/coil 30*3 C/s of coil conductor (3*35*5.35)min Class of insulation "Class F" Rectifier: - There are two rectifiers for rectification of the single phase ac supply fed from the transformer to the d.c output. The supplies to the two rectifiers are from the secondary of the transformer through the terminals. The rectification is needed to feed the traction motors which are d.c operated i.e. the o/p of the rectifiers are fed to the d.c motor through SL. Rating of the Rectifiers is AC l/p DC 0/p Voltage-1222 Amperes-3300
  • 17. 17 Cycles- 50 Hz Voltage-750 Phase- 1 Inductive Shut: - This is a device to restore the bypassing current used through the field weakening resistance to active designed per formation from the traction motor. This also reduces the wear on the fringe contacts of the field weakening shunting contactors, due to arching. The inductive shunt controlled in series with the resistances connected in parallel with the field coil of the traction motor. The field of traction motor can be controlled by changing the resistance in 3-steps. Salient features for inductive shunt (S.J): - Rated voltage- 750V Insulation- Class H Cooling- Natural Traction motor: - CLW started Traction Motor manufacture from 1969 with Alsthom design of MG-1580 motors and TAO-659 motors and switched over to HS15250A, 850 HP Traction Motors for which technology was received from Hitachi, Japan. HS15250A Traction Motor production started in 1988-89. Now with the advent of three phase technology of locomotives from Bombardier Transportation, Switzerland, CLW has geared up to manufacture 1000 HP and 1500 HP state-of-the-art 3- Phase Traction Motors for freight (WAG-9) and passenger (WAP-5 & WAP-7) locomotives. Cumulative production of Traction Motors during the year 2007-08, has touched an all time high of 1225 Traction Motors .This is the Best ever in the 53 years history of CLW .CLW has achieved the rare distinction of being the only Production Unit in the country which can cross 1000 Traction Motors production mark in a year. The different types of Traction Motors manufactured at CLW are following:- I. 3-PHASE TRACTION MOTOR TYPE 6FRA6068 & 6FXA7059: - Phase Traction Motors type 6FRA6068 for WAG-9 and WAP-7 locomotives & 6FXA7059 for WAP-5 locomotive are being manufactured indigenously by CLW since the financial year 1998-99 & 1999– 2000 respectively. With the production of 3 – phase Traction Motor, CLW has entered the era of State of the art, 3-phase technology. II. HITACHI TRACTION MOTOR TYPE HS15250A: - Hitachi Traction Motor is one of the most critical and vital equipment in Conventional Electric Locomotives type WAG–7 & WAP–4 under production at CLW. The production of Hitachi TM is now completely stabilized.
  • 18. 18 Salient Features of Different Types of Traction Motors: - 4. BOGIE: - A bogie is a wheeled wagon or trolley. In mechanics terms, a bogie is a chassis or framework carrying wheels, attached to a vehicle, thus serving as a modular subassembly of wheels and axles. Bogies take various forms in various modes of transport. A bogie may remain normally attached or be quickly detachable; it may contain a suspension within it; it may be mounted on a swivel, as on a railway locomotive, or additionally jointed and sprung. At CLW two types of bogie are manufactured – Cast Bogie & Fabricated Bogie. For WAP -4 cast bogies are used & for other type of LOCO fabricated bogies are used. In the basis of axle arrangement bogies are of two types – COCO type & BOBO type. Only WAP -5 are of BOBO type & other are of COCO type. Description HS15250A 6FXA7059 6FRA6068 Application Freight/Passenger Passenger Freight/Passenger Suspension Axle hung Nose suspension Fully suspended Axle suspended Power Output 630 KW 1150 KW 850 KW Voltage 750 V 2180 V 2180 V Current (Nom./Max.) 900A 370/540 A 270/370 A Speed (Nom./Max.) 895 RPM 1585/3174 RPM 1283/2584 RPM Efficiency 0.93 0.96 0.95 Power to Wt. ratio 0.18 KW/Kg 0.555 KW/Kg 0.4 KW/Kg Temp. class of Winding insulation System 200º C 250º C 250º C Varnish for impregnation Epoxy Silicon Silicon
  • 19. 19 COCO type bogies are consist of:- Equipments No. Bogie Framre 2 Wheel 12 Axle 6 Motor 6 Gear 6 MSU (Motor Suspension Unit ) 6 Axle Box 6 Brake Gear Arrangement 2 set Gear Case 6 Suspension Spring Coil (Outer) 16 Suspension Spring Coil (Inner) 16 MANUFACTURING, M&P MAINTENANCE, TRANSPORT, MACHINERY & PLANT PROCUREMENT: - Manufacturing group of shops consist of Heavy machine shop, wheel shop, light machine shop, smithy & forge shop, Heat treatment shop and tool Room, Millwright and Electrical maintenance shops look after maintenance of all M&Ps of loco works, power supply and distribution inside loco works.MPP cell deals with planning and process for procurement of machines sanctioned by Rly. Board under M&P plan Head -4100 & 4200 and also look after TPT shop including road and industrial vehicle maintenance work with shunting work. M&P section deals with commissioning of new machines and issues PTC. Manufacturing shops: - (i) Wheel Shop: - The Wheel shop manufactures Wheel Sets for loco production as well as spares to Zonal Railways. Presently wheel sets for WAP-4, WAP-5, WAP-7, WAG-7 and WAG-9 locos are manufactured. (ii) Heavy Machine Shop: - Heavy Machine Shop undertakes the machining of components for loco production as well as meeting the spares required for zonal railways such as suspension tube , 3-phase Stator for WAG 9 & WAP 5 locos, Hitachi Magnet Frame, Equalizer & Compensating beams etc. Machining work of Steel castings from Steel Foundry like casnub bogie bolster & side frame, brake beam, center pivots for UIC/Casnub Bogie are also done in HMS. (iii) Smithy & Forge shop: - SFS undertakes fabrication of End structure, Head stock of WAG-7 loco, forging of small component of loco assembly, assembly of casnub bogie. (iv) Light Machine Shop: - LMS manufactures small components like various types of pins, bushes, traction motor blower holding plates etc. to meet the requirement of loco production as well as spares required for zonal railways. (v) Tool Room: - Tool Rooms supplies toolings, gauges, jigs and fixtures for production requirements of various shops and also carries out calibration of various gauges, fixtures, instruments etc. to meet the ISO requirements.
  • 20. 20 (vi) Heat Treatment shop: - Heat Treatment Shops undertakes heat treatment of bogies manufactured in Loco Shops and other items e.g. Magnet Frame, Equalizer, Compensating Beams etc. manufactured in Heavy machine shop. Machinery and Plant Procurement: - MPP & M&P section plans for procurement and commissioning of M & Ps required for production of components of different types of locos and spares in loco works as well as M&Ps for Steel Foundry, Hospital, Central Power House, etc. Transport Shop (TPT): - Transport shop maintains all road vehicles consisting of passenger vehicles like cars, Jeeps, Mini Buses and industrials vehicles like Truck, forklift, Dumpers, tractors, Platform Trucks/Listers sky lifts for movement of material. Yard Organisation: - For movement of traffic wagons, departmental wagon and locomotives/locomotive shell on dummy bogies, four shunting engines (3WDM2,E.Rly) have been deployed. These locomotives are maintained and operated by Andal Diesel Shed. Shunting requirement is met in three shifts. Yard organisation also keeps liaison with the Asansol Division for movement of traffic wagons. Plant Maintenance Organisation (LOCO WORKS): - CLW has more than 1500nos. M&Ps including 115 nos. EOT Cranes in loco works, out of which about 50% of M&Ps are over aged. The breakdown as well as preventive maintenance of all M&Ps is carried out by Plant Maintenance Organisation consisting of Millwright Shop (MTS-56) and Electrical repair shop (Shop- 59). Plant maintenance organization deals with repairing, reconditioning, re-engineering, retro fitment of machineries and plant. Installation of new small machineries and Plants, condemnation & uprooting of old M&Ps are also carried out by these shops. LOCO ASSEMBLY SHOP: - Flow Chart for LOCO Assembly Shop-19 (For Conventional LOCO) Stage Description of stage work Parallel job Stage-1 (LOCO shell from shop 26 to assembly shop 16 & 19) SSE-ELA-16 SSE-ELA-19 Drilling, tapping, welding of stiffness, brackets or clamps, slotted channel etc. _ Stage-2 Shop-16 SSE-ELA-16 Painting SL assembly Stage-3 Shop-16 & 19(Combined) SSE-ELA-16 SSE-ELA-19 SE-ELA-19 Laying of power cables, control cables and underframe, pneumatic pipe lines, SL mounting BA panel manufacturing, RPS manufacturing TB panel assembly AC-1 panel assembly by shop- 16 AC-2 panel assembly LOCO ASSEMBLY SHOP
  • 21. 21 TFP assembly Stage-4 Shop-16 & 19(combined) SSE-ELA-16 SSE-ELA-19 SE-ELA-19 SSE-St.v All equipments mounting in machine room (eg:- TFP, RSF, DBR, SE-I & II panels, BA panels, auxiliary motors, pneumatic panels etc.) and pneumatic piping of shell & cab D/Desk assembly Roof preparation Stage-5 SSE-NIL SE-NIL Cable connection of all equipments, Bd, cab-5B etc. D/Desk mounting, MP on mounting Roof mounting and final assembly of roof equipments Stage-6 Shop-16 & 19(Combined) SSE-ELA-16 SSE-ELA-19 SE-ELA-19 Mounting of cab equipments driver desk MP, motorised bogie, brake panels etc, cab ceiling ,driver‟s desk connection, PC-I & II connection Battery base fitting by shop -16, battery box connection fixing Stage-7 (Proposed) General inspection by CQAM _ Stage-8 (proposed) Rectification by concerned section supervisors and re inspections _ Stage-9 Shop-19 SSE/T&C-ELA-19 LT test testing & commissioning section _ Stage-10 Shop-16 SSR-ELA-16 Pneumatic testing _ Stage-11 Shop-16 & 19(Combined) SSE-ELA-16 SSE-ELA-19 Rain test, driver‟s seat fitment, cab painting _ Stage-12 Shop-19 SSE-T&C-ELA-19 Joint commissioning and final testing inclusive of pneumatic valve setting _ Stage-13 Shop-16 SSE-ELA-16 Final painting _ Stage-14 Shop-19 SSE/ELA-19 SE/ELA-19 Final rectification & despatch _ Steel Foundry Shop: - Steel Foundry, CLW was set up at CLW in 1963 in collaboration with M/s F.H. Lloyd of U.K. for production of steel castings for Steam Locomotives being produced
  • 22. 22 in CLW/Chittaranjan. After achieving self-sufficiency in Steal Loco production, CLW changed over to manufacture of Diesel & Electric Locomotives and Traction Motors. Consequently, heavy Steam Locomotive castings gradually tapered from 1972-73 onwards and gave way to intricate, lightweight steel castings for Electric/Diesel Locomotives, Traction Motors and High Speed Wagons. Modernisation of Technology: - Steel Foundry was modernized with the state-of- art technology of M/s Rockwell International Corporation (now M/s Atchison Castings, USA) a leader in casting technology for Bogies and has changed over completely to this technology from 1995-96. Quality: - Steel Foundry is accredited with prestigious ISO 9001:2000 certification for its quality system. Steel Foundry has come up with flying colours, reassuring our commitments to quality and dedication to customer satisfaction. Steel Foundry has strived constantly to improve the quality and developments suggested by its employees and introduction of new materials and processes. Product mix of Steel Foundry: - A) CAST Items: - o HS Casnub Bogie for BOXNHL wagons. o Flexicoil Bogie for WAP-4 loco. o Flexicoil Bolster for WAP-4 loco. o Co-Co Bogie BG for WAG-5 & WDM-2 Loco. o Casnub Bolster. o Casnub Side Frame. o Centre Pivot Top and Bottom for Casnub Bogies. o Suspension tube for Hitachi TM. o Suspension tube for BHEL TM. o Suspension tube for WDM-3D loco. o Rotor Clamp for Hitachi TM. o Commutator Spider for Hitachi TM. o Centre Pivot for WAP-4 loco. o Ballast Blocks for WAG-9 loco. o Ballast Weights for WAG-7 loco. o Wheels for Tower Car. o Wheels for Power Car. o Wheels for Narrow Gauge Coaches. o Wheels for Narrow Gauge loco. o Knuckle for CB Coupler. o Coupler Body for CB Coupler. o Yoke for Cd Coupler. o Striker Castings for CB Coupler.
  • 23. 23 o Counter Weight Slabs for 140T Slabs for 140T Breakdown Cranes. o Wooden Cleats, Wedges, Battery Boxes, etc. B) FABRICATED ITEMS: - o Long Beams & End Structure for WAP-4 Loco. o End Structure & End Box for WAG-7 loco. Grade of Steel: - Steel Foundry manufactures steel castings generally complaint with grades IS-1030 and AAR-201. To meet the requirements of different products, Steel Foundry had earlier been processing eight different grades of metal. Steel Foundry has been successful in rationalizing the same to five grades only without affecting any metallurgical, chemical or physical properties. This has resulted in improvement in productivity. Different grades of steel for casting are as follows: - Grade Composition in Percentage Carbon Manganese Sulphur (max.) Phosphorus (max) Silicon (Max) Grade-I 0.22 – 0.26 0.08 – 1.00 0.025 0.025 0.50 Grade-II 0.18 – 0.22 0.70 – 0.90 0.040 0.040 0.50 Grade- III 0.20 – 0.32 1.40 – 1.85 0.030 0.030 0.065 Other Items: - Panels: - The Switchgear / Relay panels of the Electric Locomotives WAP-4 / WAG-7 and drivers desk are assembled in- house. The frames of these Switchgear / Relay Panels are partly procured from trade and partly fabricated in house. For 3-phase AC locos, panels like HB- 1/HB-2, SB-1/SB-2. Filter cubicle and Drivers Desk are assembled and wired in-house. Static Equipment & Contactors: - CLW also undertakes manufacture of Smoothing Reactor (SL), Inductive shunt (SJ), Electro Pneumatic/Electro Magnetic Contactors. Shell: - CLW undertakes complete manufacture of shell. The manufacture of shell involves major fabrication works and CLW has complete facilities for undertaking the same. Recently, a modern facility has been installed for grit blasting, spray painting and paint drying ovens for faster painting of complete loco with polyurethanes painting process. This facility at a cost of Rs. 80 million has been started from 18.11.2000. Bogie Frames: - CLW has the requisite facilities and undertakes complete fabrication and machining of fabricated types of bogies for its current range of Electric Loco Production. The Electric Locomotive types WAG-9, WAP-5 and WAG-7 are equipped with fabricated bogies. CLW has its own Steel Foundry which turns out cast steel bogies for our current WAP-4 locomotive, and even for our prestigious range of Electric locomotives on demand from Zonal Railways and also for Diesel locomotives. Wheel Sets, Hitachi T.M., Magnet Frame, 3 Phase T.M. Stator: - CLW has complete facilities for Axle Machining, Wheel Turning and assembly of the wheel sets. The Suspension Tubes and Axle Box housings are cast in Steel Foundry and machined in-house. CLW
  • 24. 24 assembles wheel sets not only for our current range of locomotives, but also for the Zonal Railways for their spares requirements in respect of our current and also former range of locomotives. Besides, the machining of major items such as Bolster, Hitachi T.M Magnet Frame, & 3 phase TM Stator is done in-house. Facilities also exist for manufacturing a wide range of light items required for Electric Loco production .Besides, the regular production of Electric loco and related items ,CLW has a well established Steel Foundry shop which caters to the need of the entire Electric loco steel castings items and also supply spares to the zonal railways. Salient Features of Wheel: - Specification of Locomotive: - First letter (Gauge): - W – Broad Gauge (1.676 m) Y – Meter Gauge (1 m) Z – Narrow Gauge (0.71 m; 0.76 m) Middle Letter (Motive Power): - A – Overhead AC (25 kv) C – Over head DC (1500 v DC) CA – Overhead AC or DC D – Diesel Last Letter (Job Type): - P – Suitable for passenger carry G – Suitable for carrying goods S – Shunting low HP locomotives M – Mixed purpose Suffix (Model No): - 4,5,7,9 – Model No. H – Rectified model no. Example: - "WAP 5": -  "W" means broad gauge  "A" mean AC electric traction motive power  "P" means suitable for Passenger service  "5" denotes that this locomotive is chronologically the fifth electric locomotive model used by the railways for passenger service. Type Of LOCO No. Of Gear Teeth Gear Pressure Force(Tons) Collar Pressure Force(Tons) Wheel Cut Of Pressure Force(Tons) WAG 7 65 89 - 117 80 – 100 95 - 132 WAP 4 58 89 - 117 80 – 100 95 - 132 WAG 9 107 90 -106 86 – 104 - WAP 7 72 90 -106 86 – 104 - WAP 5 67 88 -108 86 – 104 -
  • 25. 25 Gallery: - Locomotive: - Different types of Locomotive & its salient details: - WAG 9: - The “Heavy Haul” Freight locomotive of IR. Rail Freight market which is registering a remarkable growth since 2000, has also triggered buoyancy in demand for Electric Freight locomotives. Almost 60 – 65 % of IR‟s freight handling takes place over IR‟s Electrified Golden Quadrilaterals and Diagonals, though it accounts for only 25 % of its route kilometrage . Golden Quadrilateral and Diagonals being saturated routes, need heavy throughput and faster sectional clearance. This is where these heavy haul and speedier WAG-9 locos play a significant role. This Gem of a loco is indeed a rail operator‟s delight. This six axle loco with axle and nose suspended drive is designed to give a starting tractive effort of 460 KN and maximum braking effort of 260 KN. Rated 6000 hp, the loco has also been successfully adapted to give 508 KN of starting tractive effort with additional ballast. The cabin of this locomotive is air conditioned. This loco also is capable to give 6000 hp on rail upto its rated speed of 100 kmph which gives superior section clearing capability especially in handling speed restriction. WAG 7 WAG 9 WAP 7 WAP 4 WAP 5 WG
  • 26. 26 WAP-7: - The “Heavy Haul” Passenger locomotives of IR. Intercity and interstate fare friendly Passenger market has of late shown a strong and sustained growth in recent times. This market needs very powerful Electric locos which can haul 24 to 26 coaches at speeds in the range of 130/ 140 kmph. To meet the surging demands of this amazingly exploding Passenger market segment, CLW has come out with a 6000 H.P loco premium Electric loco product – WAP-7.WAP-7 class loco is based on WAG-9 platform and differs from WAG-9 in gear ratio and the control software. Locomotive rated at 6000 hp is design to the starting tractive effort of 323 KN and maximum braking effort is 260 KN. WAP-5: - 5400 hp, 25 kV ac, B.G. 160 km/hr. speed, 3-phase drive. WAP-5 class locomotives employ advanced control and propulsion technology and are capable to deliver 5400 hp on rail. The locomotive has all the hallmarks of a high-speed propulsion unit viz. light weight, fully suspended drive and disc brake. Though presently, it has been certified for 160 kmph operation, the locomotive has been designed to give a service speed of 200 kmph with test speed potential of 225 kmph. Since IR is currently facing severe competition in Premium Passenger business market from commercial airlines, sooner or later, IR will have to introduce medium high speed intercity Passenger Services. This emerging market will call for powerful Electric locos with 150 kmph plus speed potential to be deployed in the immediate future and WAP-5 is the locomotive of choice for this Passenger Services market of IR. WAP-4: - This 5000 HP locomotive was evolved to meet the requirement of hauling longer trains of 24 coaches at higher speed up to 130 kmph over Indian railways. This loco is presently hauling important high-speed trains on Indian Railways. These are six axles loco with axle and nose suspended drive. WAG- 7: - WAG-7 is the name of a type of electric locomotive used in India. It is a very powerful locomotive in Indian Railways' fleet. Its maximum speed is 100 km/h and it used DC traction motor. SALIENT FEATURES OF DIFFERENT TYPE OF ELECTRIC LOCOMOTIVES: - Description WAG-7 WAP-4 WAG-9 WAP-7 WAP-5 Type of service Freight Passenger Freight Passenger Passenger Gauge 1676 mm 1676 m 1676 m 1676 m 1676 m Power Supply 25 KV AC,50Hz 25 KV AC,50Hz 25 KV AC,50Hz 25 KV AC,50Hz 25 KV AC,50Hz Whell Arrangement Co-Co Co-Co Co-Co Co-Co Bo-Bo Total Wt of Loco 123t 112t 123t 123t 78t
  • 27. 27 THREE PHASE ELECTRIC LOCOMOTIVES: - (a) Need: - Indian Railways imported 2900 HP passenger and freight locomotives alongwith transfer of technology from 50 cycles group in France in the year 1960. The indigenous production of locomotive was taken up at CLW in the year 1965. Indian Railways have been continuing with this technology for over 30 years and during this period improved it to optimise its use to produce 5000HP freight and passenger locomotives. Further upgradation was not possible. With the increase in train loads and need for higher speeds both for passenger and freight to enable hauling of more traffic with existing infrastructure, it became important to upgrade existing technology of electric locomotives and, thus IR decided to go for most modern three phase high horse power electric locomotives. (b) Acquisition: - IR have acquired 30 nos (10 passenger and 20 freight) high horse power “state of the art” microprocessor controlled GTO thyristor based three phase drive electric locos from M/s Bombardier Transportation (earlier called ABB), Switzerland along with transfer of technology (TOT) to manufacture them indigenously at Chittaranjan Locomotive Works (CLW). The contract was placed in July, 1993. These locomotives have been received during the period Oct, 95 to Oct, 97 and have been put in service. (c) Indigenous manufacturing by Indian Railways: - Through Transfer of Technology (ToT) agreement with Bombardier, Switzerland for 5 major electrical equipments i.e. Continuous H.P 5000 5000 6000 6000 6000 Max. Speed 100 Km/h 140 Km/h 100 Km/h 140 Km/h 160 Km/h Starting Tractive Effort 402 KN (41t) 30.8t 460 KN (52t) 460 KN (52t) 258 KN (26.3t) Continnuous Tractive Effort 235 KN (24t) 19t 325 KN (33t) 325 KN (33t) 180 KN (18.3t) Type of Bogie Fabricated Cast Fabricated Fabricated Fabricated Great ratio 16.65 23.58 15.77 20.72 17.67 No.of T.M & Type 6 No.- HS15250AH (Hitachi) 6 No.- HS15250AH (Hitachi) 6 No.- FRA6068 3-Phase AC 6 No.- FRA6068 3-Phase AC 4 No.- FXA7059 3-Phase AC Brake System Air and Rheostatic Air and Rheostatic Air and Regeneration Air and Regeneration Air and Regeneration
  • 28. 28 Power Converter, Auxiliary Converter, Control Electronics, Transformer and Traction Motor to Indian Industry and three other items i.e. bogies, shell and traction motors to CLW, first indigenously built 3-phase electric locomotive was turned out by CLW on 14th Nov., 1998. The cost of these locomotives has been progressively coming down from the original import cost of Rs. 22 cr. (excluding custom duties) through indigenisation initiatives. CLW has so far manufactured 40 locomotives with indigenisation of major items and the cost per locomotive have come down to 12.5 cr. (d) Advantages of three phase Traction Technology: -  Low maintenance due to absence of commutators/brush gears in traction motor of switch gears in power circuits.  Availability of full power up to maximum speed.  Better power to weight ratio of traction motor.  Heigher overall efficiency of operation due to regenerative braking system.  Minimum wear on rails and disturbances to track geometry due to low unsprung masses  Higher reliability of TM due to use of induction motors. Brief summary of important items used in 3-Phase Loco SN ITEM QUANTITY PER LOCO FUNCTIONS WAG9 WAP7 WAP5 1 Main Transformer The main transformer converts the overhead line voltage (25 KV) to the lower operating voltage. There are four secondary traction windings (two on each converter unit , 1269 volts), one for feeding the auxiliary ckts. (1000 volts) and one for harmonic filter (1154 volts) one Hotel load(750 V) winding ( only for transformer 7475 KVA) (i) (LOT 7500) 7475 KVA 0 1 1 (ii) (LOT 6500) 6531 KVA 1 0 0 2 Power Converter 1 set 1set 1 set Power Converter
  • 29. 29 converts single phase 25 KV AC supply into 3 phase AC with variable voltage (maximum 2180 V) and variable frequency (65 to 132 Hz) and feed it to Traction Motor. 3 Auxiliary Converter 1 set 1set 1 set Auxiliary Converter converts single phase 1000 volts supply (from auxiliary winding of main transformer) into three phase 415 volts (variable voltage variable frequency) to different three phase auxiliaries. 4 Central Electronics 2 2 2 All the functions of the Locomotive are controlled by the Control Electronics. It takes the form of Bus Station with processors. All processors linked to the vehicle bus transmit a monitoring signal to the master vehicle control unit . 5 Traction Motor 6 6 4 There are total 6 traction motors in WAG-9/WAP-7 loco .TM 1-2-3 are mounted in bogie -1 and are fed from Power Converter 1 where as TM 4-5-6
  • 30. 30 are fed from Power Converter -2. In case of WAP-5 Loco there are 4 Traction motors in which Power Converter -1 feeds to TM-1-2 and Power Converter 2 feeds power to TM-3-4. Traction Motors are asynchronous squirrel cage Induction Motor. Power converter providing the power sources. All three traction Motors of one bogie are ventilated by one traction motor blower. Each traction motor is equipped with two temperature sensors and two motor speed sensors SN ITEM QUANTITY PER LOCO FUNCTIONS 6 Primary voltage transformer 1 1 1 It is a potential transformer situated on the loco roof reduces the Catenary voltage approx. 25 KV to 200 volts for metering purpose. 7 Surge Arrestor 1 1 1 It is for high voltage protection for the Locomotive situated on the roof of the Loco. 8 Pantograph 2 2 2 The Pantographs collect
  • 31. 31 the power from the overhead 25 KV supply to the Loco. 9 Vacuum Circuit Breaker 1 1 1 It is protective circuit breaker of Locomotive for any abnormal situation in the Loco and disconnects the loco from the supply. 10 Speedometer 1 1 1 For indicating speed of the Loco memotel type speedometer is provided in both cabs. Speed is indicated by needle as well as LCD screen of Speedometer. 11 Transformer oil pump 2 2 2 It is a pump to circulate oil from Transformer to Oil Cooling unit and back. 12 Converter oil pump 2 2 2 It is a pump to circulate oil from Converters to Oil Cooling unit and back. 13 Oil Cooling Unit 2 2 2 It is a oil cooling system for cooling Transformer oil and Power Converter Oil by taking air from air. 14 Temperature Sensor 2 2 2 It is a temperature sensing equipment for detecting temperature of Transformer oil (maximum allowable oil temperature is 150 degree Celsius).
  • 32. 32 15 Pressure Sensor 2 2 2 It is a pressure sensing equipment for detecting pressure of Transformer oil pump. . 16 High Voltage Bushing 1 1 1 It is a bushing for tapping high voltage power from overhead to Main Transformer situated just beneath roof. 17 Resistance for Harmonic Filter 1 1 1 It is the resistance connected in the harmonic filter circuit of the loco to suppress the high frequency harmonics to avoid disturbances in signaling. 18 Machine room blower 2 2 2 It is a blower to cool machine room( to keep temperature below 70 degree Celsius) by ducting and limit the temperature of control Electronics below 70 degree Celsius. 19 Machine room scavenge blower 2 2 2 It is a blower to clean dust from air filters of Machine Room. SN ITEM QUANTITY PER LOCO FUNCTION 20 Traction motor blower 2 2 2 It is a blower for ventilation of the Traction motors (connected with bogie 1&2) by forced air.
  • 33. 33 21 TM / oil cooling scavenge blower 2 2 2 It is a blower to clean dust from Traction Motors and oil cooling units. 22 Fire Detection Unit (FDU) 1 1 1 The loco is equipped with a fire detection system in the machine room. Through a ring line with apertures at regular distances air in the machine room is extracted with a fan and checked for traces of smoke by a detector. The unit is equipped with two smoke sensors. 23 Battery 1 set 1 set 1 set It is a NI-Cd accumulator, which consists of 78 cells, which are connected in series. The nominal capacity is 199 Ah. It is in two halves which are located on each side of the loco. All electrical components in the control current circuit are designed for a nominal voltage 110V DC. 24 Main Compressor 2 2 2 It is a pressure creating equipment for necessary pressure for entire Pneumatic circuit of the loco.
  • 34. 34 25 Auxiliary Compressor 1 1 1 It is a pressure creating equipment for raising the Pantograph. 26 Master Controller 2 2 2 It is a device used by Driver of the loco for controlling loco during motion in the forward and reverse direction . 27 Contactor filter on off and adaption 2 2 2 It is a Contactor for connecting and disconnecting filter winding circuit during filter operation of Loco for filtering undesirable harmonics. 28 Oil cooler radiator for transformer /Converter Cooling 2 2 2 It is a radiator for dissipating heat from the oil of Transformer and Converter by passing air from Oil cooling Blower through it. 29 Emergency Flasher light 2 2 2 It is a flasher light (amber colour) glow during Emergency condition (during Emergency Chain Pulling and during Emergency Braking). 30 Capacitor Bank Harmonic filter 1 set 1 set 1 set It is a bank of Capacitors used for filtering high frequency harmonics in the filtering circuit of the loco. 31 Front & Rear 4 4 4 It is the light for making
  • 35. 35 Marker Light the presence of Loco during stop condition of the in the rail track to avoid accident. SN ITEM QUANTITY PER LOCO FUNCTION 32 Head light 2 set 2 set 2 set It is the light used for clear visibility of rail track during loco movement in the night time. 33 Fire Extinguisher 4 4 4 The loco is equipped with 4 Fire Extinguishers, one in each Driver Cab and two in Machine Room. The Fire Extinguishers are to be operated manually to extinguish fire. 34 Auxiliary Transformer (415/110V)/ Transformer Tranela 1 1 1 This transformer is located in HB-1 cubicle and supply power to 415 V single phase power to two machine room blowers, two scavenge blowers to Mr blowers, 110V AC to crew fans. 35 Contactor for discharging resistor 1 1 1 It is an item of Filter cubicle used for connecting for discharging the resistor of Capacitor Bank. 36 Air drier 1 1 1 It is used for purifying
  • 36. 36 and separating moisture from air at intake. It is actuated when one of the main compressors is switched on. 37 Hydraulic Damper 4 4 4 To dampen the rebound rate of springs. 38 Side buffer 4 4 4 To take care the buffing load. 39 E-70 Brake System 1set 1set 1set It controls the main pneumatic brake system of loco. 40 Axle box complete 12 12 8 It is component MSU. It is housing for axle bearing. 41 Gears & Pinions 6 6 4 It transmits traction power to the wheels. 42 CBC 2 2 2 It is mainly used for coupling. It also take care the draw and draft load. 43 Spring Secondary spring -16 nos (9H) , 8 nos.(G-9) Primary Spring-48 nos (9H) , 32 nos. (G-9) Secondary spring -8 nos. ,Primary Spring-32 nos Secondary spring -8 nos ,Primary Spring-16 nos It is a suspension from axle to bogie and bogie to body. Suspension system minimise the shock caused by vibration of the track and also carry weight of the loco body.
  • 37. 37 CONCLUSION: -The two weeks of training at Chittaranjan locomotive works has greatly benefited me in several ways. I have witnessed the immense power of technology and how it can be put to productive purposes for the benefit of mankind. I also became aware of my role as a Mechanical Engineer in making this possible. During my stint at Chittaranjan locomotive works, I have learnt several things besides engineering which include, but are not limited to the working of a giant organization, interaction and communication skills, analytical skills, importance of safety in industry, time management and the most important fact that no work is small. The training has also inculcated in me professionalism and dedication to work. No textbook would have been able to do all this just within a span of two weeks. It has proved to be an important milestone in my academic life. REFERENCE: -  Production Technology… By R.K. Jain.  Manufacturing science.......By A.Ghosh & A.K.Mallick  www.google.co.in  http://en.wikipedia.org  www.Clw.indianrailways.gov.in  www.railway-technical.com  http://www.indianrailways.gov.in

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