Industrial Training

1. WINTER VOCATIONAL TRAINING - 2020
SWAMI VIVEKANANDA INSTITUTE OF SCIENCE
&TECHNOLOGY
INDUSTRIAL TRAINING FROM SOUTH EASTERN RAILWAY , KHARAGPUR

2. TEAM MEMBERS
 SOURAV BOSE
 SUBHAJIT MONDAL
 SURAJ BHAKTA
 ANKITA KHARA
 SHREYASI MUKHERJEE
 DIBYENDU MAITY
 SOURAV GHOSAL
 SANDIP SHAW

3. AREA OF INTERESTS
 Introduction
 Kharagpur Railway Workshop
 Total No Of Shops in Workshop
 Visiting Shops
 EMU Shop
 Power House Shop
 Train Lighting Shop
 AC Shop
 Conclusion

4. INTRODUCTION :
 Kharagpur Railway Workshop was established in 1898 as a small repair workshop of Bengal
Nagpur Railway.
 It has the unique distinction of being the only Workshop of the Indian Railways which deals with
all types of Rolling Stock viz. Coaches, EMUs, MEMUs, DEMUs, SP-ART, SP-ARME, Tower
Cars, Diesel Locomotives, Electric Locomotives, Diesel Cranes and Wagons.
 The Workshop also undertakes manufacture of a large number of Rolling Stock components and
spares parts.
 Apart from this, Diesel POH Shop has the facilities for re-winding of traction machines,
including coil manufacturing.

5. Kharagpur Railway Workshop :
Milestones :
1898: Workshop Established
1903: POH of Steam Locomotives
1917: POH of Coach and Wagons
1963: POH of Diesel Locomotives
1985: POH of Electric Locomotives and EMU
2009: IOH of ICF Bogie to Division.
2014: DEMU Factory at Haldia
2019: IOH of LHB bogies to Division

6. Total No Of Shops In Workshops :
Shop No. Description Shop No. Description
1,2,3 Production Unit Shops 19 Wheel Shop
4 Scheduling Shop 20 Production Control
6 Welding Shop 21 Diesel POH Shop`
7 Machining Shop 22-23 Carriage Shop
8 Tool Room 35 Bogie Shop
9 Non-Ferrous Shop 36-49 Wagon Shop
10 Service Shop(Mill Wright) 50
Power House (33 kV DC Wing
Station)
11 Fitting Shop 51
General Electrical Repair
& Train Lightening
12 ERS POH Shop 52
Electrical Maintenance
(Breakdown)
13 Heat Treatment Shop 53 Heavy Motors Repair Shop
14,15 Plate Shop 54
Diesel Electric Locomotive
Shop
16 Mechanical Transport 55 Air-conditioning Shop
18 BTC 56 EMU Machine Shop

7. Visiting Shops :
1. EMU Shop (Shop No - 56 )
2. Power House Shop (Shop No - 50)
3. Train Lighting Shop (Shop No - 51)
4. AC Shop (Shop No - 55)

8. EMU(ELECTRICAL MULTIPLE UNIT) SHOP-
Shop No - 56
 Electric Multiple Unit or EMU is a multiple unit train consisting of self- propelled carriages, using electrically as
motive power. EMU requires no separate locomotive, as traction motor are incorporated within one or a number of
carriages. These types of train are popular on commuter and suburban rail network around the world due to their
fast acceleration.
 A EMU is usually formed of two or more semi – permanently Coupled carriages, but electrically powered signal -
unit railcars are Also generally classed as EMUs

9. Power Circuit of EMU :
1- Tap changer 5 - Switch Group - I (for TM-1+2)
2- Main Rectifier 6 - Switch Group - II (for TM -3+4)
3- SL - Smoothing Reactor 7+8 - Traction Motor (DC Series Motor)
4- ASL - Additional Smoothing Reactor

10. Components :
 Pantograph:
 It is current collecting device mounted on the roof of Locomotive.
 It collects the required power from over head conductor and feds to
Locomotive.
 VCB(Vacuum Circuit Breaker) :
 vacuum circuit breaker is such kind of protecting device for Locomotive
Equipments , it is mounted on the roof of Locomotives.
 The function of circuit Breaker is to make the supply ON & OFF both
in normal and faulty condition.

11.  Transformer :
 The 25 Kv AC Single phase power supply of Over Head Line is fed to the
windings of regulating transformer through main Bushing . The winding is
equally divided into 32 taps. These taps are connected to a TAP CHANGER.
 In EMU, transformers are used for stepping down the voltage from
1 phase 25KV AC to 1 phase 835V AC. Then, 835V is transferred to
converter
 Baby Compressor :
 APU has a baby compressor, which produces compressed air and feeds
to locomotive main reservoir to compensate the formation leakages.
 Baby compressor is start by battery and its actually helps to rise the
pantograph for taking 25kv supply from catenary line.
 Traction Motor (Dc series motor):
The DC Series Motor is similar to any other motor because the main
function of this motor is to convert electrical energy to mechanical
energy. Actually it has a very high starting torque , so that it used Locomotives.

12.  Tap Changer:
 A tap changer is a device fitted to
power transformers for regulation of
the output voltage to required levels.
 This is normally achived by changing
the ratios of the transformer on the
System by altering the numbers of turns
in one winding of the appropriate
Transformer.
 It regulates motor speed by varying voltage from input side of the transformer.
 On load tap changers are used in EMU Loco

13. POWER HOUSE SHOP :
Shop No - 50
 Electric supply to Workshop and Division through 33/11 KV receiving Sub-Station.
 Standby Electric supply through 4 Diesel Generating sets of 1750 KW each.
 Maintenance of cranes, traversers and electrical components of various machines and plants of
the entire Workshop.
 Repair and re-winding of all distribution transformers, pumps, industrial motors, DG sets,
alternators and welding plants of S. E. Railway.
 POH of Electrical portion of coaches.
The Main components of the Power house are-
 Transformer
 Bus Bar
 Isolator
 Lightning Arrester
 Circuit Breaker
 SF6 Circuit Breaker
 Capacitor Bank
 Diesel Generator

14.  TRANSFORMER –
Transformer substations are the key
element of any electrical power system,
and these are the heart of the
transmission network. It can mainly be
classified into four sections such as
Step up substation, Primary grid
substation, secondary substation and
distribution
Name Plate Rating –
Serial No – 5798-1
KVA - 500
Volts At No Load HV- 11000 V , LV – 415 V Oil Temp Rise - 40℃
Amperes – HV – 26.2 , LV – 627 Standard – IEC 60076
Phases – 3 Impedance (%) - 20
Type Of Cooling – ONAN Oil Weight (Kg) - 2200
Frequency - 50 Hz
Vectors – Dyn11
Winding Temp Rise – 50 ℃

15.  BUS BAR:
 It is a type of electrical junction in which all the incoming and outgoing electrical
current meets. Thus the electrical Bus bar collects the electrical power at one location.
 ISOLATOR:
 It is one type of mechanical switch used to isolate a fraction of the electrical circuit
when it is required. Generally, these are employed on circuit breaker both the ends
thus the circuit breaker repair can be done easily without any risk.
 LIGHTNING ARRESTER:
 It is diverts the abnormal high voltage to the ground without affecting the continuity
of supply. It is connected between the line and earth, i.e., in parallel with the equipment
to be protected at the substation.

16.  SF6 CIRCUIT BREAKER:
 Sulpher Hexafluoride possesses very good insulating and arc quenching
properties. These properties are—
 It is colorless, odorless, non-toxic, and non-inflammable gas.
 SF6 gas is extremely stable and insert, and it’s density is five times than of air.
 CAPACITOR BANK:
 It is a combination of numerous capacitors of similar rating that are joined in
parallel or series with one another to collect electrical energy. It is generally use
to- Power Factor correction, Reactive Power compensation.
 DIESEL GENERATOR:
 A diesel generator is the combination of a diesel engine with an electric generator
(often an alternator) to generate electrical energy. This is a specific case of engine
generator In DG room there are three 11kv & one 0.44kva generator. In 11kv
diesel generator there are 16 engines, all are four strokes. It is places without
connection to a power grid, or as emergency power supply if the grid fails.

17. TRAIN LIGHTING SHOP :
Shop No - 51
There are several components which are used for generating electricity in train to
provide air conditioning ,fan ,light ,emergency light e.t.c for passengers comfort.
TRAIN LIGHTING EQUIPMENTS:-
 ALTERNATOR
 RECTIFIER CUM REGULATOR UNIT
 BATTERY
 LEAD ACID BATTERY
 VALVE REGULATED LEAD ACID CELL(VRLA)

18. ALTERNATOR -
It is a source of electricity when
the train is moving. For AC
coaches two alternators of 25KW
power each are used in a single
coach. For general coaches an
alternator of 4.5 KW power, per
coach is used. V – Belts and
Pulleys, connects the shaft of the
alternator to axle
Fig - Alternator

19. BATTERY -
Storage Battery Systems provides
reliable nickel cadmium, as well
as flooded and sealed (VRLA)
lead acid batteries, for
railway/transportation
applications. Common uses of
these batteries include: Line
signaling Emergency lighting and
current supply Auxiliary batteries
Suburban railway and
underground trains Rail cars
(starter battery)

20. AC SHOP :
Shop No - 55
The term 'Air Conditioning' was coined by Mr. S.W. Cramer in 1906 while he was making
efforts in putting the air in a fit condition for the textile industry. The term has since come
into use in its broader sense implying control of any or all of the physical or chemical
properties of air within any enclosure.

21. COMPACT AIR
CONDITIONING UNIT
Compact air conditioning unit consists of
following components:
• Two refrigerant compressors
• Two condensers
• Two axial fans for cooling condensers
• Two evaporators and heating assembly
• Two twin sucking radial fans for the supply
air
• Two air inlets for circulating air
• Two air inlets for fresh air
• Two mixed air filters & fresh air filter
• Control and safety devices
• Servo drive

22. The compressor (which
is controlled by the
thermostat) is the
‘heart’ of the system.
The compressor acts as
the pump, causing the
refrigerant to flow
through the system.
The condenser coil is a
series of piping with a
fan that draws outside
air across the coil.
The evaporator coil is a
series of piping
connected to a furnace
or air handler that
blows indoor air across
it, causing the coil to
absorb heat from the
air.
COMPRESSOR CONDENSER EVAPORATOR

23. CONCLUSION :
 Indian Railway Workshop is one of the best platform for a trainee electrical engineer
who can see the practical application of any machine and how it works and relate
those things what he had taught.
 We have tried study the various electrical and electronics methodology which keep
the Indian railways alive as they work progressively by latest technology.
 Kharagpur Railway Workshop has a lot of employee who are willing to help to make
this training program a success
 During this 21 days training process we analysed the typical manufacturing process
and their testing methods.