Summer training report on electric loco shed ghaziabad

1. SUMMER TRAINING
REPORT
FOUR WEEKS INDUSTRIAL TRAINING
NORTHERN RAILWAY
ELECTRIC LOCO SHED
GHAZIABAD (2017-18)
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2. ABES INSTITUTE
OF TECHNOLOGY
SUBMITTED BY :
TARANG MITTAL
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3. CONTENT
• INTRODUCTION
• HISTORY
• OVERVIEW OF TRAINING
• TYPES OF LOCO HOLDING
• SYNTAX USED IN LOCO’S
• TYPES OF INSPECTION
• DEPARTMENTS OF MECHANICAL
WORKSHOP
• CONCLUSION
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4. 1. INTRODUCTION
Ghaziabad electric loco shed is a government organization.
Ghaziabad electric loco shed is situated in
vijay nagar just behind of the railway station of
Ghaziabad. It is expanded over a area of 45000
square meter. The purpose of establishing this
loco shed was to minimize the traffic in Delhi
for the maintenance of locos.
More than 1000 employees including government and non
government are are working here.
The work force is as following-
SHED OFFICERS
• Sr.DEE – 1
• DEE – 1 (Mr. K.K. Rastogi )
• ADEE - 2
SHED STORES DEPOT
• SMM – 1
SUPERVISORS, ANCILLARY AND OTHER STAFF
• ELS/GZB:- SS-992, OR-871
RSO:- SS-166, OR-172
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5. 2.HISTORY
Ghaziabad Elecric Loco Shed was established & inaugurated in
1976 by the hon’ble MR Shri Kamlapati Tripathi.It’s main
purpose is of maintenance of WAP1 WAP4, WAP5, WAP7,
WAG5, WAM4 engines.
Ghaziabad electric loco shed serves the Delhi area. It houses
and maintains India's fastest locomotives which are mostly
used in Rajdhani, Shatabdi and Duronto Expresses. It holds 47
WAP-1 locos as of 2008. It also has WAM-4, WAP-4, WAP-5,
WAP-7 and WAG-5HA locos.
Ghaziabad (for Delhi) Electric WAM-4, WAP-1, WAP-4, WAP-5,
WAP-7 Built to cater to passenger traffic in the Delhi area.
Received the first WAP-1s. Some WAP-1 and WAP-4s were
transferred to Arrakonam shed. Retains 31 WAP-1 locos. Also
the home for the WAP-3 locos which have been converted back
to a WAP-1. Also homes WAP-4, WAP-5 and WAP-7 and one
WAM-4 for departmental duties. Has largest fleet of 3 phase
passenger locos Or, in "WAP 5".
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6. The initial cost of the establishment was 1.5 crore and in
starting it was serving for the total number of 34 locos but at
present it has ability of maintenance 184 locos.
3.OVERVIEW OF TRAINING
I have attended the summer training programme held by loco
shed from 19th june 2017 to 15th
july 2017.
During a month of this programme I had gone through various
departments of loco shed and got precious knowledge.thereare
various departments such as M1,M2,M3,M4.These various
departments are performing the activities as listed below-
M1: Wheel maintenance and material inspection
M2 : Body repairing
M3 : Pantograph installation and maintenance
M4 : Pnuematics and braking system
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7. 4.TYPES OF LOCOS HOLDING
• WAP1 (Traction motors:3900hp,18 coaches)
• WAP4 (Traction motors:5350hp,750V,26 coaches)
• WAP5(Traction motor: 3 phase squirrel cage induction
motors) 5450hp,2180V
• WAP7(Traction motor: 3 phase squirrel cage induction
motors) 6250hp,2180V
Excluding these locos it also take the maintenance work of
WAM and WAG type of locos. All these locos are either used
for the transportation of passengers, transportation of goods or
transportation of both goods and passengers depending upon
the specifications that they have and the name they have given.
Each alphabet of WAM, WAP and WAG has a specific and
different meaning that differentiate all locos from one another.
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8. 5.SYNTAX USED IN LOCOS
The first letter (gauge)
• W – Indian broad gauge (the "W" Stands for Wide Gauge -
5 ft 6 in)
• Y – metre gauge (the "Y" stands for Yard Gauge - 3 ft or
1000mm)
• Z – narrow gauge(2 ft 6 in)
• N – narrow gauge (toy gauge) (2 ft)
The second letter (motive power)
• D – diesel
• C – DC electric (can run under DC overhead line only)
• A – AC electric (can run under AC overhead line only)
• CA – both DC and AC (can run under both AC and DC
overhead line); 'CA' is considered a single letter
• B – Battery electric locomotive (rare)
The third letter (job type)
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9. • G – goods
• P – passenger
• M – mixed; both goods and passenger
• S – shunting (also known as switching engines or
switchers in the USA and some other countries)
• U – electric multiple unit (used to carry commuters in city
suburbs)
• R – Railcars
• For example, in "WDM 3A":
• "W" means broad gauge
• "D" means diesel motive power
• "M" means suitable for both goods and passenger service
• "3A" means the locomotive's power is 3,100 hp ('3' stands
for 3000 hp, 'A' denotes 100 hp more)
• Or, in "WAP 5":
• "W" means broad gauge
• "A" mean AC electric traction motive power
• "P" means suitable for Passenger service
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10. • "5" denotes that this locomotive is chronologically the
fifth electric locomotive model used by the railways for
passenger service.
6.TYPES OF INSPECTION AND THEIR PLACES
Inspection name Place
Trip Inspection Outstation shed or
homing loco shed as
convenient
Monthly Inspection Homing or nominated
Electric Loco Shed
Two-monthly Inspection Homing Electric Loco
Shed
Four monthly Inspection Homing Electric Loco
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11. Shed
Annual overhaul Homing Electric Loco
Shed
Intermediate overhaul Homing Electric Loco
Shed or Nominated
Workshop.
Periodical overhaul Workshop nominated for
the purpose
7.WHEEL AND AXLE ASSEMBLY
Wheel and axle assembly is the main part of an loco it is the
wheel which takes the complete load of the loco and also
makes a loco to run. In this way we can say that this is also the
main supporting part of the traction system.
It basically consists of four main parts.
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12. • Wheel
• Axle
• Bearing and Housing
7.a.WHEEL
Wheel is the member of wheel and axle assembly which takes
the complete load of the loco and rolls on the railway track to
move the whole locomotive. Wheel is generally made up of
stainless steel and at its inner side a flange is provided which
helps wheel to make in proper contact with the track.
The method of production of wheels is casting but due to some
defects of casting such as inclusions, nonproper cooling and
solidification there are some chances of failure to avoid this
there should be use of forging as in case of metro wheels.
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13. 7.b.AXLE
Axle is the main long cylindrical bar on which wheels are fixed
with the help of bearings. This is also made of stainless steel as
above. Each axle contains 2 wheels, the brake cylinders are
also attached to it, braking discs are fixed on to the axle.
7.c.COMPONENTS OF WHEEL AND AXLE
ASSEMBLY
The components of wheel and axle assembly are given below
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14. • Two brake disks (4), diameter 640 mm and width 110 mm.
• In built slack adjusting brake cylinder fitted
• Two wheel discs
7.d.AXLE BEARING
A taper roller cartridge type bearing is used and it makes up a
preassembled unit. The axle bearings on the bogie are fitted
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15. with sensors for detecting speed (whose signal is elaborated by
the ant slipping system) and a current return device.
The ends of the control arms are fitted with centering devices
for the primary suspension spring assembly. The bearing
lubricating plug is fitted in the lower part.
7.e.SOME SPECIFICATIONS OF WHEEL AND
AXLE
• Width of wheel 65-27mm
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16. • Flange thickness 32-29.5mm and for
WAP729
• Distance between two wheels 1596 approx.
• Flat thickness 6.5mm
• Root wear 4.0 -6.0m
8.BOGIE
• Solid welded Bogie Frame made up of two longitudinal
components connected by two cross beams. The bogie
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17. frame rests on the primary suspension spring units and
supports the vehicle body by means of Bolster beam. The
Bolster beam is connected to the bogie frame by
secondary suspension.
• Primary suspension consist of two steel coil springs
(internal/external) laid out on the Control Arm upper part.
• Secondary suspension consists of two spring packs
which sustain the bolster beam over the bogie frame.
Each spring pack is made up by an internal and external
spring. An Anti roll bar fitted on the bogie frame realizes a
constant, reduced inclination coefficient during running.
The bogie frame is linked to the bolster beam through two
vertical dampers, a lateral damper, four safety cables and
the traction rods. The bogie frame is linked to the coach
body through two yaw dampers.
• Traction Centre - The traction Centre transmits traction
and braking forces between bogie frame and body by a
traction lever on the bolster beam pin and two rods.
• Disk Brakes – The FIAT bogie is fitted with pneumatic
disk brakes. The pneumatically operated brake cylinders
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18. are fitted with automatic device for taking up the
clearances.
• Taper Roller Cartridge Bearing – Fiat Bogie is fitted with
130 mm Cartridge type roller bearings.
8.a.BOGIE FRAME
The bogie frame is a solid welded frame made by steel sheets
and forged or cast parts.
The frame is made up of two longitudinal components (1)
connected by two cross-beams (2) which also support the
brake units. The various supports which connect the different
bogie components are welded to the frame. The bogie frame
rests on the primary suspension spring units and supports the
vehicle body by means of a bolster beam. The bolster beam is
connected to the bogie frame by the secondary suspension.
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19. 1.Bogie frame longitudinal component
2. Cross-beam
8.b.PRIMARY SUSPENSION
Primary suspension is implemented by two units of two steel
coil springs (internal (4) and external (5)) laid out on the control
arm upper part (13) by a centering disk (8) and adjustment
shims, (if required).
The suspension is also completed by the following
components:
A control arm (13), fitted with twin-layer elastic joints (12),
connecting the axle bearing to the bogie frame and
transmitting, not stiffly, lateral, longitudinal and part of the
vertical forces;
A vertical damper (14).
Rubber elements (2) separate the primary suspension from the
bogie to realize noise reduction.
Stops and protections are mounted on the bogie frame for the
lifting.
1. Bogie frame
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BOGIE FRAME

20. 2. Rubber disks
3. Centering disk
4. Internal spring
5. External spring
6. Bump stop
7. Shim
8. Centering disk
9. Control Arm Lower Part
10. Plate
11. Block
12. Rubber joint
13. Control Arm Upper Part
14. Damper
8.c.SECONDARY SUSPENSION
The secondary suspension enables lateral and vertical
displacements and bogie rotation with respect to body when
running through curves.
It is implemented by two spring packs which sustain the bolster
beam (1) over the bogie frame (6). Each spring pack is made
up by an internal (3) and an external spring (4), mounted and
positioned through the centering discs (5).
An anti-roll bar (2), fitted on the bogie frame (6), realizes a
constant, reduced inclination coefficient during running.
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21. The bogie frame is linked to the bolster beam through two
vertical dampers (7), a lateral damper (8), four safety cables (9)
and the traction rods (10).
The bogie frame is also linked to the coach body through two
yaw dampers (11).
1. Bolster beam
2. Anti- roll bar
3. Internal spring
4. External spring
5. Centering disc
6. Bogie frame
7. Vertical damper
8. Lateral damper
9. Safety cables
10. Traction rod
11. Yaw dampe
9.BODY
Body is basically the coach itself without the braking
mechanisms and suspensions. It has the following constituents.
They are discussed below:
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22. • The Carriage is the main structure of the coach. This
contains a floor which is called Turf. There are Arch
Levers which maintain the weight distribution throughout
the whole coach. And then there is the roof which is of a
typical aero dynamical shape.
• At the bottom of the carriage there are two kinds of bars
made of stainless steel which transfers the weight from
the carriage to the wheels.
The Sole Bar is throughout the whole body of the coach
vertically. These are at the bottommost position of the
body.
The Cross Bar is the horizontally arranged bars across the
body. They get their support from the sole bar.
9.a.CENTER PIVOT ASSEMBLY
Center Pivot is welded to the upper bolster plank and passes
through the supporting frame which is rectangular in shape.
This is a pivoting system used in transportation of force through
a mechanically advantageous system of pivot. At the bottom of
the center pivot there is a traction lever. A traction rod is also
connected at the end of traction lever having its other end
connected with the cross bar.
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23. 9.b.BOGIE
BODY
CONNECTION
In coaches, there are a special kind of bolts called swing bolts,
which are four numbered in each trolley. These connect the
body to the bogie to the body. Each bolt is fastened with a pin
which can swing in the direction of the motion.
10.PANTOGRAPH
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24. A pantograph is a device that collects electric current from
overhead lines for electric trains or trams. It is spring loaded
and pushes a contact shoe up against the contact wire to draw
the electricity needed to run the train. Pantographs are typically
operated by compressed air from the vehicle's braking system,
either to raise the unit and hold it against the conductor.
Now a days all locos are running through Electricity with the
help of OHE line Pantograph is used to connect the loco with
OHE line Loco contains 2 Bogies, each Bogie consist of 6
wheels. So totally loco consists of 12 wheels. Pantograph
draws 25 KV of electricity from OHE line, which is very high AC
voltage.
10.a.HOW DOES PANTOGRAPH WORK
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25. A pantograph is operated by the compressed air of compessor
which is located nearby the compressed air cylinder of braking
system. when brakes are applied there is no need of the
electricity for running of the loco so the pantograph get down
and after release of break when need of tractive power arises
then once again the pantrograph get raised and collects the
electricity .
Pantograph has some parts such as
• Upper arm
• Lower arm
• Coupling rod
• Carbon strips (initially made up of mild steel)
• Lifting mechanism
• Collector panel
• Frame
• Guiding rod etc.
When the pantograph slides in contact with the OHE line then it
collects electricity and sends it to a collecting device where it is
stored and then it goes to the batteries and get stored there
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26. .there is also a transformer which converts this dc into ac for
the traction purpose.
11.PNUEMATICS OR AIR BRAKE SYSTEM
In Air Brake system compressed air is used for operating the
brake system. The locomotive compressor charges the feed
pipe and the brake pipes throughout the length of the train. The
feed pipe is connected to the auxiliary reservoirs and the brake
pipe is connected to the brake cylinders through the distributor
valve. Brake application takes place by dropping the pressure
in the brake pipe. The schematic arrangement of the brake
equipment is shown as in figure.
11.a.COMPONENTS OF AIR BRAKE SYSTEM
• Brake Container (Brake Equipment Panel)
• Distributor valve
• Pressure Tanks (125 litres, 75 litres, 6 litres)
• Indicators
• B.P./F.P. Couplings and Hoses
• Emergency Brake Pull Box
• Emergency Brake valve
• Bogie Brake Equipment, consisting of-
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27. • Brake Discs
• Brake Caliper Units (consisting of Brake Cylinder,
Brake Calipers, Brake Pads)
• Wheel Slide Control System, consisting of-
• Microprocessor Control Unit
• Speed Sensor/Pulse Generator
11.b.BRAKE APPLICATION
• The driver lowers the BP pressure by engaging the A-9
valve in the engine.
• This loss in pressure is transmitted from one bogey to the
next.
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28. • Since CR pressure remains same, the main diaphragm
(above the CR) moves up in response to the pressure
drop in DV.
• As a result the ‘three pressure valve’ opens the AR-BC
port
• Thus the AR pressure of 6 kg/cm^2 flows into the BC
through pressure limiters which reduces BC pressure to
3.8.
11.d.BRAKE RELEASE
• BP pressure is again increased to 5 kg/cm2.
• Consequently, main diaphragm move down and the
‘three pressure valve’ closes the AR-BC port and opens
the BC-atm port.
• BC pressure is released and the brake caliper is
disengaged.
11.e.3.BRAKE DISCS
The axle –mounted brake disc consists of a gray cast iron
friction ring and a cast steel hub, connected by means of
radially arranged elastic resilient sleeves which are secured in
the hub by means of hexagon screws. The friction ring is
manufactured as a solid component or in a split version. In the
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29. latter case, the two halves are held together by two tight –fit
screws.
Axle Mounted Brake Discs Wheel Mounted
Brake Discs
11.e.4.BRAKE SHOE
The brake shoe is provided with a brake pad holder carrying
replaceable pads. The brake shoe consists of the brake pad
holder, the vertical pins and the brake pad. The brake pad
holder is provided with a dovetail guide into which the pad is
slipped. The pad is held in place by a captive gate, which is
pivoted at the pad holder. To lock the gate a locking spring of
spring steel has been provided which is pre-tensioned such that
in one position it secures the gate in the pad holder and in the
other (released) position it holds the gate open. For each brake
disc a right and a left hand brake shoe are required.
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30. 12.CONCLUSION
In this way I have learnt a lot of things at electric loco shed
Ghaziabad during my summer training which would be very
much useful in my future. There I have learnt the advantages of
electric locomotives such that they can save fossil fuels which
are limited in amount and the pollution induced due to them
also reduced by using a neat and clean resource electricity as
the power source for locomotives.
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