BHEL Jhansi unit manufactures locomotives and power transformers. It has modern CNC machinery for fabrication such as a CNC cropping line machine and vapor phase drying system. The unit produces diesel-electric locomotives up to 2600 HP, AC/DC locomotives up to 5000 HP, and power transformers up to 400 KV class and 250 MVA. BHEL Jhansi has facilities for fabrication, copper winding, and testing of transformers. Key operations include cutting, welding, grinding, winding, and non-destructive testing of transformers.

1. BHARAT HEAVY
ELECTRICALS
LIMITED, JHANSI (U.P.)
ROTATION REPORT
&
SUMMER TRAINING PROJECT REPORT ON
LOCOMOTIVE MANUFACTURING
FOR A PERIOD OF FOUR WEEKS
UNDER GUIDANCE OF: Submitted by:
MR. Yogyesh Tripathi Gaurav Singh
Production Engg. (loco) B.Tech. (Mechanical)
Bhel Jhansi JNIT, Jaipur

2. ACKNOWLEDGEMENT
I am extremely thankful & indebted to the numerous BHEL Engineers and technical
staffs who provided vital information about the functioning of their respective
departments thus helping me to gain an overall idea about the working of organization.
We are highly thankful for the support & guidance of each of them.
I am extremely thankful to Mr. Dhruv Bhargava (Manager-HRD) for providing me
the opportunity to undergo this training and to work on my project. We also express my
thanks all the members of HRD for their help & cooperation.
I am highly indebted and thankful to my project guide, Y R TRIPATHI for giving me
their valuable time and helping me to grasp the various concepts of locomotive
manufacturing and their various parts and assembly processes and testing. We would
also like to thank all other members of LME Dept. for providing enough support and
cooperation.
Last but not the least, We would like to thank my parents & all my fellow trainees
who have been a constant source of encouragement & inspiration during my studies &
have always provided me support in every walk of life.

3. BHEL – AN OVERVIEW
BHEL is the largest engineering and manufacturing enterprise in India in the energy
related infrastructure sector today. BHEL was established more than 40 years ago when
its first plant was setup in Bhopal ushering in the indigenous Heavy Electrical
Equipment Industry in India a dream which has been more than realized with a well-
recognized track record of performance it has been earning profits continuously since
1971-72.
BHEL caters to core sectors of the Indian Economy viz., Power Generation's &
Transmission, Industry, Transportation, Telecommunication, Renewable Energy,
Defense, etc. The wide network of BHEL's 14 manufacturing division, four power Sector
regional centers, over 150 project sites, eight service centers and 18 regional offices,
enables the Company to promptly serve its customers and provide them with suitable
products, systems and services – efficiently and at competitive prices. BHEL has
already attained ISO 9000 certification for quality management, and ISO 14001
certification for environment management.
POWER GENERATION
Power generation sector comprises thermal, gas, hydro and nuclear power
plant business as of 31.03.2001, BHEL supplied sets account for nearly 64737 MW or
65% of the total installed capacity of 99,146 MW in the country, as against nil till 1969-
70.
BHEL has proven turnkey capabilities for executing power projects from
concept to commissioning; it possesses the technology and capability to produce
thermal sets with super critical parameters up to 1000 MW unit rating and gas turbine
generator sets of up to 240 MW units rating. Co-generation and combined-cycle plants
have been introduced to achieve higher plant efficiencies to make efficient use of the
high-ash-content coal available in India, BHEL supplies circulating fluidized bed
combustion boilers to both thermal and combined cycle power plants.
The company manufactures 235 MW nuclear turbine generator sets and has

4. commenced production of 500 MW nuclear turbine generator sets.
Custom made hydro sets of Francis; Pelton and Kaplan types for different head
discharge combination are also engineering and manufactured by BHEL.
In all, orders for more than 700 utility sets of thermal, hydro, gas and nuclear have been
placed on the Company as on date. The power plant equipment manufactured by BHEL
is based on contemporary technology comparable to the best in the world and is also
internationally competitive.
The Company has proven expertise in Plant Performance Improvement through
renovation modernization and updating of a variety of power plant equipment besides
specialised know how of residual life assessment, health diagnostics and life extension
of plants.
TRANSPORTATION
BHEL is involved in the development design, engineering, marketing, production,
installation, and maintenance and after-sales service of Rolling Stock and traction
propulsion systems. In the area of rolling stock, BHEL manufactures electric
locomotives up to 5000 HP, diesel-electric locomotives from 350 HP to 3100 HP, both
for mainline and shunting duly applications. BHEL is also producing rolling stock for
special applications viz., overhead equipment cars, Special well wagons, Rail-cum-road
vehicle etc., Besides traction propulsion systems for in-house use, BHEL manufactures
traction propulsion systems for other rolling stock producers of electric locomotives,
diesel-electric locomotives, electrical multiple units and metro cars. The electric and
diesel traction equipment on India Railways are largely powered by electrical propulsion
systems produced by BHEL. The company also undertakes retooling and overhauling of
rolling stock in the area of urban transportation systems. BHEL is geared up to turnkey
execution of electric trolley bus systems, light rail systems etc. BHEL is also diversifying
in the area of port handing equipment and pipelines transportation system.

5. INTERNATIONAL OPERATIONS
BHEL has, over the years, established its references in around 60 countries of the
world, ranging for the United States in the West to New Zealand in the Far East. These
references encompass almost the entire product range of BHEL, covering turnkey
power projects of thermal, hydro and gas-based types, substation projects, rehabilitation
projects, besides a wide variety of products, like transformers, insulators, switchgears,
heat exchangers, castings and forgings, valves, well-head equipment, centrifugal
compressors, photo-voltaic equipment etc. Apart from over 1110MW of boiler capacity
contributed in Malaysia, and execution of four prestigious power projects in Oman,
Some of the other major successes achieved by the Company have been in Australia,
Saudi Arabia, Libya, Greece, Cyprus, Malta, Egypt, Bangladesh, Azerbaijan, Sri Lanka,
Iraq etc.

6. VISION, MISSION AND VALUES OF BHEL
VISION
A WORLD-CLASS ENGINEERING ENTERPRISE COMMITTED TO ENHANCING
STAKEHOLDER VALUE.
MISSION
TO BE AN INDIAN MULTINATIONAL ENGINEERING ENTERPRISE
PROVIDING TOTAL BUSINESS SOLUTIONS THROUGH QUALITY PRODUCTS,
SYSTEMS AND SERVICES IN THE FIELDS OF ENERGY, INDUSTRY,
TRANSPORTATION, INFRASTRUCTURE AND OTHER POTENTIAL AREAS.
VALUES
 ZEAL TO EXCEL AND ZEST FOR CHANGE.
 INTEGRITY AND FAIRNESS IN ALL MATTERS.
 RESPECT FOR DIGNITY AND POTENTIAL OF INDIVIDUALS.
 STRICT ADHERENCE TO COMMITMENTS.
 ENSURE SPEED OF RESPONSE.
 FOSTER LEARNING, CREATIVITY AND TEAMWORK.
 LOYALTY AND PRIDE IN THE COMPANY

7. VARIOUS UNITS OF BHEL ACROSS THE COUNTRY
FIRST GENERATION UNITS
Bhopal : Heavy Electrical Plant.
Haridwar : Heavy Electrical Equipment Plant.
Hyderabad: Heavy Electrical Power Equipment Plant.
SECOND GENERATION UNITS
Tiruchy : High Pressure Boiler Plant.
Jhansi : Transformer and Locomotive Plant.
Haridwar : Central Foundry and Forge Plant.
Tiruchy : Seamless Steel Tube Plant.
UNITS THROUGH ACQUISTION & MERGER
Bangalore : Electronics Division
Electro Porcelain Division.
NEW MANUFACTURING UNITS
Ranipet : Boiler Auxiliaries Plant.
Jagdish : Insulator Plant.
Govindwal : Industrial Valve Plant.
Rudrapur : Component and Fabrication Plant.
Bangalore : Energy Systems Division

8. BHEL is growing concern to meet the changing needs of the nation has taken it
beyond power into the total gamut of energy, industry and transportation BHEL is able
to offer a service in each of this fields. Its manufacturing capability is supported by a
corporate R&D division at Hyderabad works closely with the research and development
cells at various units and Welding Research Institute at Tiruchinapalli.
ACTIVITY PROFILE OF BHEL
POWER SECTOR PROJECTS
 Thermal sets and Auxiliaries.
 Steam generators and Auxiliaries.
 Industrial fans.
 Electrostatic precipitators.
 Air pre heaters.
 Nuclear power equipments.
 Hydro sets and Auxiliaries.
 Motors.
 Transformers.
 Rectifiers.
 Pumps.
 Heat Exchangers.
 Capacitors.
 Porcelain/Ceramics insulators.
 Seamless steel tubes.
 Casting and forging.

9. SYSTEMS/SERVICES
 Turnkey power station.
 Data acquisition Systems.
 Power systems.
 HVDC Commissioning systems.
 Modernization and Rehabilitation.
TRASPORTATION SECTOR
 Diesel Electric generators.
 AC/DC locomotives.
 DC locomotives and loco shunters.
 Traction system for railways.
 Electric trolley buses.
INDUSTRY SECTOR
 Boilers.
 Valves.
 T.G. sets.
 Power devices.
 Solar Cells.
 Photo Voltaic cells.
 Gas Turbines.
 Compressors.
 Drive Turbines.
 Oil rigs.
 Blow out preventers.
 Wind mills.
 Control systems for electric devices.

10. MODERN MACHINARY IN BHEL JHANSI:-
 CNC CROPPING LINE MACHINE
 VAPOR PHASE DRYING SYSTEM
 COMPUTER ICM 6040 AND 6080 AND IRISII 40/20 WITH GRAPHIC
FACILITIES
 BOGIE FRAME MACHINE CENTER
 CNC AXLE TURNING LATHE
 FACING AND CENTERING MACHINE
 WHEEL FORCING PRESS
 CNC PIPE BENDING MACHINE

11. PRODUCT PROFILE OF BHEL JHANSI UNIT
1. Power transformer up to 400 KV class 250 MVA.
2. Special transformer up to 180 KV.
3. ESP transformer 95 KVp, 1400 mA.
4. Freight Loco transformer 3900 to 5400 KVA & 7475 .
KVA for 3 phase.
5. ACEMU transformer up to 1000 KVA (1-phase).
1385 KVA (3 phase). .
6. Dry type transformer up to 6300 KVA 33 KV class
7. Instrument transformer VT & CT up to 220 KV class.
8. Diesel electric locomotives up to 2600 HP.
9. AC/DC locomotives 5000 HP.
10. Over Head Equipment cum Test Car
11. Well wagon 200 tone.
12. Rail cum road vehicle
13. Dynamic track stabilizer

12. BHEL PERFORMANCE (CORPORATE LEVEL)
MAJOR UNITS TURNOVER (In Rs. /Crores)
PARAMETER 2011 - 12 2012 - 13
Turnover (Rs. /Cr.) 49510 50015
Order Inflow (Rs. /Cr.) 22096 31528
Net Profit (Rs. /Cr.) 7040 6485
Net Worth (Rs. /Cr.) 25373 30315
Megawatts Commissioned 9270 10340
R & D Investment (Rs. /Cr.) 1199 1248
Patents/Copyrights Filed (Nos.) 351 385
DIVISION 2011 – 12
(Actual)
2012 – 13
(Provisional
JHANSI 1300 1365
CFFP HARDWAR 506 523
HEEP HARDWAR 5415 6375
BAP RANIPET 4210 3703
HPBP TRICHY/SSTP 14571 14970
EDN BANGALORE 2301 1650
BHOPAL 4790 4703
HEEP HYDERABAD 7072 6408
BHEL NET 49301 50015

13. FABRICATION:
Fabrication is nothing but production. It comprises of 3 bays i.e., Bay0, Bay1 &Bay 2.
BAY-0
It is the preparation shop while the other two bays form the assembly shop.
This section has the following machines:
1. Planner machine – To reduce thickness
2. Shearing machine
3. CNC / ANC Flame Cutting machine – To cut complicated shaft items
using Oxy-Acetylene flame
4. Bending machine
5. Rolling machine
6. Flattening machine
7. Drilling machine
8. Nibbling machine
9. Pantograph flame cutting machine
BAY-1
It is an assembly shop where different parts of tank come from bay 0.Here
welding processes are used for assembly, after which a rough surface is
obtained Grinder operating at 1200 rpm, is used to eliminate the roughness.

14. BAY-2
It is an assembly shop dealing with making different objects mentioned below:-
1-Tank assembly 5-cross feed assembly
2-Tank cover assembly 6-core clamp assembly
3-End Frame assembly 7-pin and pad assembly
4-foot assembly
Before assembly, short blasting (firing of small materials i.e., acid pickling) is
done on different parts of jobs to clean the surface before painting.
After assembly some tests are done known as NON DESTRUCTIVE TEST
1. Ultrasonic test: to detect the welding fault on the CRO at the fault place
high amplitude waves are obtained.
2. Die Penetration test: Red solution is put at the welding and then
cleaned. After some time white solution is put. Appearance of a red spot
indicates a fault at the welding.
3. Magnetic crack detection: Magnetic field is created and then iron
powder is put at the welding. Sticking of the iron powder in the welding
indicated a fault.
4. X-Ray Test: It is same as human testing and the fault is seen in X-ray
film.

15. BAY-3
Here are basically three sections in the bay:
1. Machine section
2. Copper section
3. Tooling section
MACHINE SECTION:
The operations to form small components of power and traction transformer are
done in this section. The shop consist of following machines:
CENTRAL LATHE: it consist one tailstock, headstock, lower part of tailstock is
fixed and tail stock spindle is moving. On this machine facing, turning and
threading is done
TURRET LATHE: its function is same as central lathe but it is used for mass
production. Here turret head is used in presence of tailstock because turret
head contains many tailstocks around six.
CAPSTAN LATHE: It is belt drive.
RADIAL ARM DRILLING MACHINE: It is used for drilling and boring.
HORIZONTAL BORING MACHINE: It is computerized and used for making
bore, facing etc.
MILLING MACHINE:-
a) Horizontal milling machine: It is used for making gear and cutting operations.
b) Vertical milling machine: By the machine facing cutting, and T-slot cutting is
done

16. COPPER SECTION:
All the processes related to copper are done here.
Machines used in this section are:-
TUBE SLITTING MACHINE: This machine is developed here and is used for
cutting the tube along its length and across its diameter. Its blade thickness is
3mm.
SHEARING MACHINE: It is operated hydraulically and its blade has V-shape
and a thickness of 15mm
DIE AND PUNCHING MACHINE: It is also hydraulically operated and has a die
and punch for making holes.
HYDRAULIC BENDING MACHINE: It is used for bending the job upto 90°.
SHEARING MACHINE: It is fully mechanical and is used to cut the job along its
width.
FLY PRESS MACHINE: It is used to press the job. It is operated mechanically
by a wheel, which is on the top of the machine.
BEND SAW MACHINE: This machine is used for cutting job having small
thickness. It has a circularly operated blade, around 5.1 meters long.
WATER COOLED BRAZING MACHINE: It contains two carbon brushes. The
sheet is put along with a sulfas sheet and the carbon brushes are heated. A
Lap Joint is formed between the sheets as the sulfas sheet melts.
LINCING BELT MACHINE: It creates a smooth surface.
HYDRAULIC PRESS MACHINE: To press the job.
SOLDER POT MACHINE: It has a pot that contains solder. Solder has a
composition of 60% Zn and 40% Pb.

17. TOOLING SECTION:
In this section the servicing of tools is done.
Machines used for servicing and maintenance are
BLADE SHARP MACHINE: It sharpens the blade using a circular diamond
cutter. Blade of CNC cropping line machine is sharpened here.
MINI SURFACE GRINDER MACHINE: It serves grinding purposes. It has a
grinding wheel made of “Aluminum Oxide”.
TOOL & SURFACE GRINDING MACHINE: This is specially used to grind the
tools used in Bay 7.
DRILL GRINDING MACHINE: To grind the drills.
BAY 4:
This is the winding section.
TYPES OF WINDING : 1. Reverse section winding.
2. Helical winding
3. Spiral winding
4. Interleaved winding
5. Half sectional winding

18. There are four TYPES OF COIL fixed in a transformer, they are:
1. Low voltage coil (LV)
2. High voltage coil (HV)
3. Tertiary coil
4. Tap coil
The type of winding depends upon job requirement. Also, the width and
thickness of the conductors are designed particulars and are decided by design
department. Conductors used for winding is in the form of very long strips
wound on a spool, the conductor is covered by cellulose paper for insulation.
For winding first the mould of diameter equal to inner diameter of required coil
is made .The specification of coil are given in drawing. The diameter of mould is
adjustable as its body is made up of wooden sections that interlock with each
other. This interlocking can be increased or decreased to adjust the inner
diameter of coil.
The moulds are of following types.
1. Belly types
2. Link types
3. Cone type

19. BAY-5
It is core and punch section. The lamination used in power, dry, ESP
transformer etc. for making core is cut in this section.
CRGO (cold rolled grain oriented) silicon steel is used for lamination, which is
imported in India from Japan, U.K. Germany. It is available in 0.27 and 0.28
mm thick sheets, 1mt wide and measured in Kg .The sheets are coated with
very thin layer of insulating material called “carlites”.
For the purpose of cutting and punching the core three machines are installed
in shop
1. SLITTING MACHINE: It is used to cut CRGO sheets in different width. It has
a circular cutter whose position can be changed as per the requirement.
2. CNC CROPPING LINE PNEUMATIC: It contains only one blade, which can
rotate 90° about the sheet .It is operated pneumatically.
3. CNC CROPPING LINE HYDRAULIC: It is also used to cut the CRGO sheet.
It contains two blades, one is fixed and the other rotates 90° above the sheet. It
is operated hydraulically .M4 quality sheet 0.23-0.33 mm thickness is used
BAY-6
Single-phase traction transformer for AC locomotives is assembled in this
section. These Freight locomotive transformers are used where there is
frequent change in speed. In this bay core winding and all the assembly and
testing of traction transformer is done.

20. Three-phase transformers for ACEMU are also manufactured in this section.
The supply lines for this transformer is of 25 KV and power of the transformer
is6500 KVA.
The tap changer of rectifier transformer is also assembled in this bay. Rectified
transformer is used in big furnace like the thermal power stations / plants (
TPP).
BAY-7:
This is the insulation shop. Various types of insulations are
1- AWWW: All Wood Water Washed press paper.
The paper is 0.2-0.5mm thick cellulose paper and is wound on the
conductors for insulation.
2-PRE-COMPRESSED BOARD: This is widely used for general insulation &
separation of conductors in the forms of blocks.
3-PRESS BOARD: This is used for separation of coils e.g. L.V. from H.V. It is
up to 38 mm thick.
4-UDEL: UnDemnified Electrical Laminated wood or Permawood
This is special type of plywood made for insulation purposes.
5-FIBRE GLASS: This is a resin material and is used in fire prone areas.
6-BAKELLITE

21. 7-GASKET-It is used for protection against leakage.
8-SILICON RUBBER SHEET-It is used for dry type transformer.
The machines used for shaping the insulation material are
1-Cylindrical machines
2-Circle cutting machine
3 Scarping machines
4-Punching press machine
5-Drilling machine
6-Guilletin machines
7-Bench saw (spl for OD)
8-Jig saw (spl for ID)
9-Circular saw
10-Linesin machines
BAY 8:
It is the instrument transformer and ESP transformer manufacturing section.
INSTRUMENT TRANSFORMER -
These are used for measurement. Actual measurement is done by measuring
instruments but these transformers serve the purpose of stepping down the

22. voltage to protect the measuring instrument. They are used in AC system for
measurement of current voltage and energy and can also be used for
measuring power factor, frequency and for indication of synchronism. They find
application in protection of power system and for the operation of over voltage,
over current, earth fault and various other types of relays.
They are of two types.
1-Current transformer (CT)
2-Voltage transformer (VT)
CURENT TRANSFORMER-
It is a step down transformer. High current is not directly measured by the CT
but is stepped down to lower measurable voltages.
BODY:
The main body is a bushing, which houses the winding and also acts as an
insulator.
 The CT has a bottom and top chamber.
 The top chamber is a cylindrical tank of mild steel. It has
terminals for connection of HV coils. It also has a glass window to
indicate the oil level.
 Below the top chamber is the bushing made of porcelain. It
has several folds or “rain sheds” to provide a specific electric field
distribution and long leakage path. Some bushings are cylindrical
while modern ones are conical as amount of oil porcelain used is
reduced without any undesirable defect.

23.  Bottom chamber houses the secondary winding. There is
also connection box to which the connection of the low voltage
(LV) coil is made.
WINDINGS:
The primary winding consists of hollow copper/aluminum pipe bent in form of a
‘U’. Aluminum is used for low rating. For higher rating a set of wires is passed
through the pipe. For still higher ratings, a copper pipe is used and for highest
rating copper pipe with copper wires passing through it is used. This
arrangement depends on the current carrying capacity. The bent portion of
primary as in the bottom chamber whereas the free end is the top chamber. The
straight portion lies inside the bushing.
The primary is wound with crepe paper insulation. The thickness of the insulation
goes in increasing as we go downwards in the bottom chamber. The free ends
are provided with ‘ferrules’, which are, small hollow cylinders through which wires
can pass connection to the primary are made through these ferrules.
The secondary is divided in a number of coils for different set of tapings.
Connections are different tapings are made in connection box. Each coil has an
annular core of CRGO (silicon steel). The wire use is insulated copper wire. The
winding may be done both manually and by machine. After winding the coils are
covered with paper tape insulation. The coils are then slipped into both the legs
of the primary winding and connections are made in connection box for different
tapping.
VOLTAGE TRANSFORMERS:
This is also a stepped down transformer. The outer construction is same as that
of the CT that is this also has a top chamber, bushing and a bottom chamber.
The difference is only in the winding.

24. WINDINGS:
The primary winding is of the thick wire having a few turns. The winding is heavily
insulated with paper insulation. It has a hollow cylinder passing centrally through
it, which houses the secondary winding. The clean and painted with either
enamel or epoxy paint. The customer gives the choice of paint. Epoxy paint is
generally used in chemical plants and seashore installation. Terminals are then
mark and ratings and diagram plate is fixed.
The job is then sent to the shipping department, which takes care of its dispatch
by packing it in the wooden boxes.
ESP TRANSFORMER:
The Electrostatic Precipitator transformer is used for environmental application. It
is used to filter in a suspended charge particle in the waste gases of an industry.
They are of particular use in thermal power stations and cement industry.
The ESP is a single-phase transformer. It has a primary and secondary. The core
is laminated and is made up of CRGOS. It is a step up transformer. An AC
reactor is connected in series with primary coil. The output of the transformer
must be DC that is obtained by rectifying AC using a bridge rectifier (bridge
rectifier is a combination of several hundred diodes). A radio frequency choke
(RF choke) is connected in series with the DC output for the protection of the
secondary circuit and filter circuit. The output is chosen negative because the
particles are positively charged. The DC output from the secondary is given to a
set of plates arrange one after the others. Impurity particles being positively
charged stick to these plates, which can be jerked off. For this a network of
plates has to be setup all across the plant. This is very costly process in

25. comparison with the transformer cost. A relive vent is also provided to prevent
the transformer from bursting it higher pressure develops, inside it. It is the
weakest point in the transformer body. An oil temperature indicator and the
secondary supply spark detector are also provided. One side of the transformer
output is taken and other side has a ‘marshalling box’ which is the control box
of the transformer.
BAY-9
In this bay power transformer are assembled. After taking different input from
different bays 0-9 assembly is done.
Power transformer is used to step and step down voltages at generating and
sub-stations. There are various ratings –11KV, 22KV, manufactured, they are
Generator transformer.
System & Auto transformer.
A transformer in a process of assemblage is called a job. The design of the
transformer is done by the design department & is unique of each job; depends on
the requirement of customer. The design department provides drawing to the
assembly shop, which assembles it accordingly.
The steps involved in assembly are:
1. Core building
2. Core Lifting.
3. Unlacing.
4. Delacing and end-frame mounting.
5. High voltage terminal gear and low volt terminal gear mounting.
6. Vapor phasing and oil soaking

26. 7. Final servicing and tanking.
8. Case fitting.
TECHNOLOGY
This department analyses the changes taking place in the world and suggest changes
accordingly. This is very important because the products must not get obsolete in the
market otherwise they will be rejected by the customer.
FUNCTIONS:
Technology functions can be classified as:
 Processing Sequence: The sequence of process of manufacturing is decided
for timely and economic completion of the job.
 Operation time estimate : It includes incentive scheme management
 Allowed operation time: It includes incentive amount
 Facilities identification: It includes looking for new equipment or plant or tools
to increase productivity
 Special process certification: Special processes are the ones requiring
expertise for example identifying errors, cracks, air bubbles in welding
 Special tools requirement: Special tools are allotted, if possible, when required
else the design has to be reconsidered.
 Productivity projects compilation: It includes the initial analysis of the problem
and their appropriate solution to enhance productivity.
The principle of working is that
“IF YOU DO NOT MAKE THE CHANGES IN YOUR COMPANY, THE CUSTOMER
WILL CHANGE YOU”.

27. QUALITY CONTROL
CENTRAL QUALITY SERVICE
Few terms concerning this department are:-
QUALITY
It is the extent to which products and services satisfy the customer needs.
QUALITY ASSURANCE
All those plants and systematic action necessary to provide adequate confidence that a
product or service will satisfy the given requirement is called quality assurance.
QUALITY CONTROL
The operational technique and activities that are used to fulfil requirement for quality are
quality control.
QUALITY INSPECTION
Activities such as measuring, testing, gauging one or more characteristics of a product
or service and comparing these with specified requirement to determine conformity is
termed quality inspection.
OTHER TRACTION DEVICES MANUFACTURED AT BHEL
BHEL is not only into manufacturing electric locomotives but also some various other
devices required to cater the need of transportation sector. We would be discussing
these devices in brief here as the next section would be dedicated to electric
locomotive’s technical know-how completely.

28. OHE Inspection Car (Tower Wagon)
This is the recording cum test car for the overhead equipment used for maintenance of
OHE and for attending to break downs. It carries necessary tools for maintenance and
break downs such as tackles, straining screws, clamps, ropes, ladders, adequate stock
of insulators, length of contact and catenary wires and other OHE fittings.
These are of two types:
– Four Wheeler (speed potential upto 75 KMPH)
– Eight Wheeler (speed potential upto 110 KMPH)
RRV
RRV stands for Rail cum Road Vehicle. It is a type of track equipment which can be run
both on rail and the road.

29. BALLAST CLEANING MACHINE
This is used for cleaning of the tracks after some accident or incident has occurred on
the railway tracks.
DYNAMIC TRACK STABILIZER
This is used for track stabilization after ballast cleaning.

30. OTHER USEFUL EQUIPMENTS
The various other useful equipments are shown below with their descriptions just below
them
a) UTILITY VEHICLE

31. b) WELL WAGON
Well wagon are manufactured at BHEL Jhansi for BHEL Haridwar for the transportation
of turbines manufactured there. Presently, two types of well wagons have been
manufactured and they are:

32. PROJECT REPORT ON

33. LOCOMOTIVES
A locomotive or engine is a railway vehicle that provides the motive power for a train.
The word originates from the Latin loco – "from a place", ablative of locus, "place" +
Medieval Latin motivus, "causing motion", and is a shortened form of the
term locomotive engine,[1] first used in the early 19th century to distinguish between
mobile and stationary steam engines.
BHEL deals with the two types of locomotive-
1. Diesel locomotive
2. Electric locomotive
BHEL has subsequently diversified into manufacturer of rolling stock products-
1. Diesel Electric loco
2. Electric locomotive (AC,AC/DC)
3. Special wagon (200 T well wagon)
OHE Recording Cum Test Car
Diesel loco further classified as follows-
1. Diesel Electric
2. Diesel Hydraulic
In diesel electric an alternator is used where as in diesel hydraulic a torque converter is
used.
The report is concerned with an electric loco i.e. WAG- 7A
Which is a crew friendly loco.
W - Broad Gauge
A - Running in AC mode
G - Hauling goods train
BHEL Jhansi has got order to develop WAG-7 of 5000 HP in quantity of 50 by Indian
Railways.

34. LOCOMOTIVE MANUFACTURING
A locomotive can be broadly classified as:
a) Superstructure
b) Under frame
c) Bogie
FABRICATION
This shop does not come under Loco Unit but manufactures all the basis parts
necessary for locomotive manufacturing like Shell, Traction Transformer etc.
PARTS MADE IN THE SHOP
To manufacture the structure following Machines are used in fabrication shop.
STRUCTURE
SHELL
UNDERFRAME SUPERSTRUCTURE
CABIN SIDEWALL ROOF
BOGIE FRAME

35.  BUTLER Milling Machine: It is a PLANO Milling machine with multiple cutting
tools. It is used for milling operation. Its milling head is universal which does
angular movement for chamfering.
 Bending Machine: It performs bending operation on thick metallic sheets of
thickness up to 32mm and of length up to 3200mm approx. tonnage of capacity
is 500 tones stroke of machine (height up to which tool is lifted) is 15mm.
shut height from top is 250. max pressure which can be applied is 140kg/cm2
 Rolling Machine: It contains one power generating roller, below two are driving
rollers. This is used to roll the sheet.
 Roller arm drilling machine: it has a fixed bed. If job cannot be fixed on the bed it
can be rotated to work directly on the job. Its movement is controlled hydraulically
in vertical direction.
 Hydraulic press Machine or flattening Machine: It flattens the thick metal sheets
in the shop. It has a max. capacity of 100 tones.
 CNC Flame Cutting Machine: It is used to cut various shapes on thick sheets of
metal. This is done by suitable program feed in machine.
WELDING PROCESS IN FABRICATION SHOP
Welding is a process of joining together of two metal pieces to produce essentially a
single piece of metal.
BASIC ARC WELDING PROCESS
1. Shielded Metal Arc Welding(SMAW)
2. Gas Tungsten Arc Welding(GTAW)
3. Gas Metal Arc Welding(GMAW)
4. Flux Cored Arc Welding(FCAW)
5. Submerged Arc Welding(SAW)

36. Two types of Welding used in BHEL Jhansi:-
 GMAW
 SUBMERGED ARC WELDING:-
• Submerged Arc Welding is an arc welding process where weld is produced by
heating with an electric arc between a bare metal electrode and the work.
• The welding zone is shielded by a blanket of granular fusible material on the
work.
• Pressure is not used.
• Filler metal is obtained from the electrode wire.

37. ELECTRODES
Electrodes classification as per AWS A 5.1.
1. The prefix E refers to Arc welding electrodes.
2. The first two digit indicate minimum tensile strength in psi,
Ex: E60XX indicate minimum tensile strength 60,000 psi.
3. Second last digit indicates the welding position.
1- All position.
2- Flat position and horizontal fillets.
4. The last two digit together indicate the welding position giving coating type current
and polarity.
POLARITY
• When the power source is DC the work is connected with positive pole of the
machine, it is called Straight Polarity or DCEN(DC Electrode Negative).
• When the work is connected with negative pole of machine it is called Reverse
Polarity or DCEP(DC Electrode Positive)
• The Positive Pole generates two third of heat produce.
CommonElectrode used in BHEL, Jhansi:-
• E6013 suitable for all welding position can be used with AC and DC negative.
• E7018 low hydrogen electrode suitable for all welding position can be used with
AC and DC(+)
• E7024 iron powder electrode suitable for flat position can be used DC and AC
both.
• E309 for welding mild steel and stainless steel.
• E308 for welding stainless steel.
WELDING CHECKS & TESTS
• LPT/DPT ( Liquid/dye penetrant test)
• MCD / MPI ( Magnetic Crack Detection/ Magnetic particle detection)
• UT ( Ultrasound Testing)
• RT ( Radiographic test )

38. WAG-7:
INTRODUCTION:-
WAG-7 built by CLW to RDSO specifications, these represent the next indigenous
design step up from the WAG-5 locomotives. Used primarily for goods haulage, these
locos have a co-co wheel arrangement with high adhesion bogies (shared with WCAG-
1, WCAM-3, and WDG-2/3A) and Hitachi motors providing 5000HP. The higher tractive
effort compared to the WAG-5 locos allows them to attain higher balancing speeds
under load. The first 71 of these all went to the mughalsarai shed, Kanpur was the
second shed to get these locos.
Traction motors are permanently coupled in parallel and speed control through the use
of transformer taps. Maximum speed is 100 km/hr. Air brakes and dynamic brakes for
loco, dual train brakes. MU operation with up to 4 units is possible. Traction equipment
such as the smoothing reactor etc. are all higher rated than in WAG-5 due to the higher
currents this loco draws. A number of these locos have been retrofitted with static
converters to power the auxiliaries, replacing the older Arno rotary converters. These
static converters are more efficient and require less maintenance, besides having self-
diagnostic systems to make troubleshooting easier.
NEED & SPECIFICATIONOF WAG-7AC
With the ever increasing freight traffic and the need for hauling heavier loads in 1in 200
grades at increased balancing speeds, BHEL JHANSI went into for the design of an
upgraded version of WAG-5 locomotive with high capacity transformer, rectifier, traction
motor, compressor and other matching associated equipment.
These are six axels loco with axel and nose suspended drive. DC series motors,
controlled by a tap changer are used in this locomotive. Indian Railway is going to
achieve 700Million tones of traffic; WAG-7 is the stay of loco main. In the locomotive
vehicle market WAG- 7 is more economical option and one of the cheapest in the world.

39. SPECIFICATION
TRACTION MOTORS: Hitachi HS15250-G. Motors built by CLW and BHEL.
GEAR RATIO: 65:18(65:16)
TRANSFORMER: CCL India, type CGTT-5400, 5400 KVA, 32 TAPS.
RECTIFIERS: Two silicon rectifiers, cell type S18FN350 (From Hind Rectifier), 64 per
bridge, 2700A/1050V per cubicle.
AXLE LOAD: 20.5T
BOGIES: Alco High-adhesion bogies, fabricated bogie frame assembly with
unidirectional mounting of traction motors, primary and secondary suspension.
HAULING CAPACTIY: 3010 T
PANTOGRAPHS: Two stone India (Kolkata) type AN-12.
CURRENT RATINGS: 1350A/2MIN, 1200/10MIN, 960A,HR, 900A continuous.

40. LOCOMOTIVE MANUFACTURING UNIT
Here is the locomotive manufacturing unit .It has been divided in two shops:
1) Bogie shop
Step by step process carried out in Bogie shop:
Machining of axle:
Axle is prepared in bogie shop out of thick cylindrical raw material.
 Facing and drilling operation is done on the axle.
 Turning operation is done on the axle to get the required diameter, by
CNC machine.
 Grinding operation is done on the axle to make the surface smooth.
1. Preparation of collar and wheel
The collar and wheel are machined to get the desired accuracy. Collar
contains a small hole inside which helps in releasing of oil. It is provided
across the gears so that it doesn’t move on axle and forms a firm grip.
2. After machining these parts are assembled on pressing machine. The
collar, gear, wheel are pressed on the axle via pressing machine.
3. Tube is fitted on the axle and traction motor is assembled on it. Tube
supports the traction motor and keeps it stationary while axle is rotating.
The gear and pinion (gear of traction motor) are meshed together (the
teeth’s are in ratio 64:16 respectively).
4. Axle box is assembled. It has tapered bearing system.
5. After the assembly is complete following test is performed as per the
specification:
Wheel Testing:
In this process the testing of the assembly of traction motor and
wheel (with gears and axle box) on axle is done. This test is called
traction motor run test. In this test servo-57 or ENCLO-68 oil is used.
It ensures clean commutater.
Specification:
 Axle caps of TM-4906 and TM-4605 AZ

41.  Traction motor supply-
Voltage 30-40 V DC
Current 70-90 Amps
Duration 2hrs
Backlash test:
Any backlash if occurred is recorded and any abnormality like
bearing noise is also noted. Backlash limits 0.3-0.8mm.
1. Bogie frame is prepared by achieving desired accuracy. Accuracy is achieved by
machining it through CNC machine (COOPER machine).
2. After final machining bogie fitting is done. Bogie fitting includes following steps:
 Liner mounting. It is done so that the shell of the bogie can be
mounted at this place. The shell structure is pivoted at this place, and
liner provides a smooth joint.
 Pneumatic brake system is installed.
a) Bush brake system is assembled.
b) Brake rigging is done.
 Wheel axle system is mounted.
 Suspension arrangement is done which includes mounting of springs
and linkages.
 Beam mounting is carried out by mounting two equalizer beams.
These beams maintain the alignment of the train by transmitting the
suspension motion equally.
 Bogie trail load is applied for coupling of Axle with Bogie by
tightening of Horn Stay to the Bogie. By applying load the vertical
gap between the axle box and padstle reduces and thus the gap can
also be maintained. Horn stay provides a support to the axle
mounted in the padestle, so that if frame assembly is lifted the Wheel
Axle arrangement does not run out.
 Rubber is mounted on the frame which is connected to the Traction
motors for giving a vibration absorbing support caused due to the
suspension of Wheel and Axle system.
 After bogie frame is ready it is send to the assembly shop.

42. 2. Assembly shop:
 The shell is received from fabrication shop.
 Dismantling of roof
 Transformer marking drilling
 Main reservoir &Aux. reservoir mtg.
 Battery box mtg.
 After cooler mtg.
 SL-30 1st,2nd mtg.
 Cattle guard mounting at both end.
 Pivot mtg.
 AC-2 panel mtg.
 MVMT 1st mtg.
 Roof sub. Assy.
a) Roof line & Panto insulater mtg.
b) Lightening Arrester
c) Earthing on roof.
 Compressor (MCP)-1,2,3 mounting.
 Baby Compressor mtg. with its oil tray.
 AC transformer mtg
 Power cable termination
 Painting
 Chequred plate in cabin-1&2
 Cable laying
 General Inspection
 Testing

43. TESTING
Testing is carried out after all the assembly is complete. Following steps are performed
in testing:
1. HV & IR (High Voltage and Insulation Resistance) Test: In this testing the insulation
of the cabling is tested. Whether there is any leakage of current and its
resistance fits the required limit.
2. Sequence Test: This is to check whether the wiring is done accordance with the
drawing or not and supply circuit is working properly.
3. Under Catenary Test: 100V supply is provided through battery to baby compressor (8
kg/cm2) then Pantograph is lifted. VCB (Vacuum Circuit Breaker) is closed so that
the supply gets transferred. Supply goes to the Rectifier, SL etc. and the circuit is
thus tested completely.
4. Axillary Run Test: MVMT (for cooling of motors), MVRH (cooling of circulated oil),
MVSL (cooling of smoothening reactor), MVSI (cooling of rectifier), MVMP
(cooling of motors) run test.
5. Pneumatic Test: This is to check the working of brake system.
6. Traction Motor Test: To check the direction of rotation of traction motor.
7. Rain Test.
8 Long Run Test: Final Bogie is tested by running 4-5 km in nearby station and DBR
test is performed during the run.

44. Various machines employed in the shop:
1) HOESC –pressing machine –wheel, axle, collar, and gears are pressed
together on
this machine. Pressing limit (95 – 132 tones)
2) Cooper machine: wheel turning CNC machine.
Specification
 Travel along x-axis – 1000mm
 Travel along z-axis – 3000mm
 Swing over bead – 760mm
 Spindle nose – 5mm
 Spindle power – 20 kw
3) Asquith CNC machine (bogie machining center): Bogie after being prepared
from fabrication shop comes to bogie shop for machining. In machining of bogie,
various processes like boring drilling, milling, facing etc. is done through
ASQUITH CNC MACHINE
Specification:-
travel in x –axis 8000 mm
travel in y- axis 4000 mm
travel in z- axis 800 mm
spindle dia. - 180 mm
spindle power 40kw
auto tool changer 40 tools
4) Hydraulic arm drilling machine
5) Radial arm drilling machine
6) Turret lathe:

45. Specification:
 Swing over saddle- 596mm (max)
 Swing over cross
 Slide-317mm
 Flange to turret
 Face – 1500mm
7) Axle drilling machine
8) Centre drilling and facing machine:
Specification:
 Work holder – 160*3000 HID
 Stock removal – 5.5mm
 Gang drilling – 3no UNC 98mm PCD/100mm PCD
 Motor power – 10.5 – 5.5 HP
9) Axle turning machine
10) Churchill machine tool: CNC vertical milling m/c
Specification:
1. Travel in x-axis – 1200mm
2. Travel in y-axis – 600mm
3. Travel in z-axis – 400mm
4. Spindle dia – 180mm
5. Spindle nose – ISO 50
6. Spindle power - 30 kw

46. 7. System – SINUMARIL 80Omm
11) Hydraulic Pipe Bending Machine: This machine is in Assembly Sop and it is
used to bend pipe of various diameter at various angles.
Specification:
 Max. capacity 65mm OD*6mm thick ferrous tube
 Max. bend radius - 300mm
 Length over mandrel - 6mtr
 Hyd. Tank capacity - 200 ltr
 Total H.P- 100
Typesand productranges:
a) Electric Locomotives :WAG-9,WAG-7,WAG-5,WCAM-2,WCAM-3,WCAG-1
b) Diesel Electric Shunting Locomotives :350 hp,450 hp,700 hp(TPP),1150
hp(SPP),1350 hp(SPP),1400 hp(SPP),2600 hp(SPP)
c) New Products :
1. OHE (Recording and Testing car)
2. UTV (Utility vehicle)
3. RRV (Rail cum Road vehicle)
4. DETV (Diesel Electric Tower car)
5. BPRV (Battery powered road vehicle)
6. BCM (Ballast cleaning machine)
7. Metro Rake-Kolkata Metro Railways
8.200 T Well wagon for BHEL Haridwar

47. The main parts of the locomotive are
 Under frame: The frame on which a locomotive is built
 Super structure: The body of locomotive is called superstructure or Shell and
is made of sheet of Mild steel
 DC motor
 Alternator
 Compressor
 Flower
 Static Rectifier-MSR
 Static Converter-SC
 Exchanger
 Bogie-The wheel arrangement of a loco is called a bogie. A bogie essentially
contains
1-wheel axle arrangement
2-Suspension
3-Brake rigging
Traction transformer: It is fixed on under frame and gets supply from an overhead
line by equipment called pantograph. The type of pantograph depends on supply.
This transformer steps down voltage and is fitted with a tap changer. Different taps
are taken from it for operating different equipment. One tap is taken and is rectified
into DC using MSR and is fed to the DC motor.
Railways has two types of power supplies – 25 KV, 1 Phase, 50 Hz AC
-1500 V DC
An AC/DC loco is able to work on both of these supplies. For e.g. WCAM-3.

48. EQUIPMENTS AT A GLANCE
Figure 1.1 BLOCK DIAGRAM OF ENGINE ROOM LAYOUT
CAB-1
 Compressor
↓
 MVMT Blower: Cooling of traction motors.
↓
 BA-1 Panel: Speeding control through shunt resistance.
↓
 Triplate pneumatic console
↓
 RS-1 {Rectifier}

49. ↓
 DBR {Dynamic Brake Resistance}
↓
 SL-42 {Smoothing Reactor}: Removes pulses from DC signal.
↓
 Transformer
↓
 SMGR{Tap Changer}
↓
 SL-42{Second}
↓
 ATFEX Transformer
↓
 BA-3 Panel
↓
 BA-2Panel
↓
 RSI-2
↓
 RC Damping
↓
 Static Converter: Converts single phase current to 3 phase.
↓
 MVMT Blower-2
↓
 Baby Compressor

50. The above flowchart clearly gives us a handy look at the equipments used in the
locomotive WAG-7.
BROKEN code for the present locomotive.
W- BROAD GAUGE A- RUNNING IN AC MODE G- HAULING GOODS TRAIN
So, this locomotive is basically made for hauling goods train or we can say its freight
carrier.
1. COMPRESSOR(MCP):-
Three compressors are used to produce compressed air to transmit force in an
air brake system. Compressor is designed to pump air into reservoir, which result
in pressurized air. The compressor in constant drive with engine. A governor
controls the maximum & minimum air pressure in the system. The compressor is
of reciprocating type. The compressor must be able to build reservoir air
pressure 50-90 P.s.i within three minutes.
SPECIFICATION:-
It is reciprocating type compressor.
a. It has three cylinders.
b. 14 HP
c. 900 RPM
d. Working pressure 18.5kg/cm2.
e. Air supply 1000 liter/minute.
2. BLOWER:-
Three types of centrifugal blowers are used in the engine room for cooling purpose.
(i)MVMT BLOWER-
They are two in numbers & one is assigned for each bogie to cool the three traction
motor mounted on each bogie.

51. (ii)MVSL BLOWER-
They are small in size & two in numbers. They are used in cooling of smoothing reactor
i.e. SL-30.
(iii)MVRS BLOWER- It is a single unit mounted in a transformer assembly. Its
purpose is to provide forced in air for cooling of radiator in which hot transformer oil is
circulated.
3. BA PANEL:-
The WAG-7 consists of three BA panels i.e. BA panel 1, 2&3.
It is controlling device of traction motor, sl-30 &other minor equipments.
It controls the traction motor.
4. TRIPLATEPNUMATIC CONSOLE (TPC):-
It is system of valves which is responsible for braking in bogie of locomotive engine. This
system of console takes the compressed air from air reservoir 1 & 2 and supply further to
different valves for various operations to be occurred.
It contains various types of valves having different characteristic.
Some of them are-
(i) SA9 valve
(ii)C2W valve
(iii)F 1 Selector valves
5. RECTIFIER (RSI1&2):-
Locomotive is provided with two set of air cooled silicon rectifier connected in Graetz
Bridge. Each of these rectifier shall be supplied by separate secondary of main transformer. Its
job is to convert AC current to DC current.
6. DYNAMIC BRAKE RESISTNCE (DBR):-

52. A locomotive shall be equipped with rheostat braking arrangement capable of breaking
during event of failure of electric brake on the train & air brake on locomotive. It shall be
applied automatically. Braking effort regulating shall be obtained by adjustment of
traction motor excitation.
The field of all the motor will be connected in series & lead by one of the two
silicon rectifier bridge connected by mean of intermediate transformer to one of the two
secondary winding of transformer. The control of excitation shall be provided by tap
changer.
7. SL-42:-
It is a smoothing reactor and it is two in number. It is located blow under frame.
Converted by its casing. Its function is to smoothen the DC current.
8. TRANSFORMER:-
The main transformer shall be oil submerged type. The oil will be forced circulate
through winding by an electric pump & cooled in a radiator with a blower the
transformer will have the combined winding on a combined core in a same tank.
(i). A variable order transformer winding incorporates various tap changer, the
normal voltage being 22.5 to 27.5kv.
(ii). A fixed ratio transformer the primary winding of which it is connected to auto
transformer, tap changer heaving a variable voltage from 0 to 22kv. This transformer
will have 2 separate secondary winding.
Transformer consist mainly 5 parts
1. Radiator
2. Conservator
3. Rps
4. Blower
5. Smgr
(I)RADIATOR:-

53. In radiator hot oil circulate for cooling purpose for increasing surface area for
heat transformer.
(II)CONSERVATOR: - Its role is to maintain the level of oil in the transformer tank.
(III)RPS: - It is a resistance parallel to a motor winding.
(IV)BLOWER: - Blower blows the cooling air through the radiator cool the oil through it.
(V)SMGR: - It is a panel which helps in tap changing.
9. ATFEX TRANSFORMER:-
Its main purpose is to provide electric braking. Low voltage supply is received from
this transformer. Secondary winding which is feed to the field winding of traction motor.
As soon as current flows in secondary winding the motor works as a generator & the
voltage produced is consumed by a resistance due to loading (resistance) on the motor.
Its speed decrease & finally it stops in this way it acts like an electric brake.
10. RC DAMPING:-
The main purpose of RC damping is to remove voltage dampness i.e. to produce pure
dc.
11. STATIC CONVERTOR:-
It is an electric device used to convert single phase as to 3 phase ac. This 3 phase
supply is used for running for the auxiliary devices.
12. BABY COMPRESSOR:-
It is compressor used to develop air pressure to lift the pantograph. It operates at
110 volt provided by a battery supply.
13. TRACTION MOTOR:-

54. (A) The traction motor shall be series d.c. pulsating current. The motor shall be
designed as to fit properly in the bogie having adequate margin and reliability
levels.
(B) Traction motor armature shall be vacuum pressured impregnated solvent less
resins per procedure adopted for manufacture of traction motor by BHEL.
(C) The motor shall be taken for manufacture only after the manufacture of design
by R.D.S.O.
(D) The motor shall fulfill the following parameters broadly.
Mounting: - Axel hung nose suspended
Rating: - RPM =895; VOLTAGE=750
CURRENT=900; O/P=630Kw
(MADE IN BHEL BHOPAL)
14. PANTOGRAPH:-
The locomotive shall be equipped with two pantographs. Normally the trailing end
pantograph shall be used. The pantograph selector switch shall be provided in the
driver’s desk. For raising, either of pantograph or both of the pantograph at a time.
Raising &lowering of the pantograph with locomotive in motion will not cause any un-
due disturbance to OHE.
(A) It shall be possible for each of these pantograph to be disconnected from the
roof equipment &earthed in case of damage.
(B) The metallized carbon strips to be used as pantograph as is being used in IR.

55. 15. TAP CHANGER:-
(i) The tap changer shall be of on load type oil immersed with circulating
pump and filter and shall have 32 running taps controlled by an electro
pneumatic servo motor.
(ii) In case of failure of the tap changer control circuit it shall be possible to
operate the electro valve of tap changer directly from the driver’s cab. Also
a manually operated handle shall be provided to move the tap changer.
(iii) A notch repeating device in each cab shall be indicated the position of the
tap changer.
(iv) The tap changer shall be complete with switching contractors and
resistance.
PANTOGRAPH
The pantograph is the collector used to slide along the contact wire as has been
explained in section 3.6.3.1. It has a conducting strip which is pressed against the
contact wire by springs. The collector strips are usually of steel with grease lubrication,
or of carbon, in which case no lubrication is needed. Function of the pantograph is to
maintain as constant a pressure as possible between the collector strip and contact wire
and to prevent any vertical oscillation of the collector strip; as these will produce arcing
due to braking of electric contact. When the pantograph is not in use, it is maintained in
lower position with the help of stiff springs. The collector strip is raised by compressed
air when it is to be used.

56. As per the specifications, the WAG-7 locomotive shall be equipped with two
pantographs having the metallized carbon strips. Normally, the trailing end pantograph
will be used but a selector switch should be provided on the driver’s desk so that either
or both of the pantographs can be raised. The raising up or down of the pantograph
while in motion should not cause any disturbance in the OHE.
MAIN CIRCUIT BREAKER
An electro pneumatically operated single bottle vacuum circuit breaker is mounted on
the roof of the locomotive to connect the transformer to 25 KV AC overhead line
through the pantograph and to clear any fault in traction power circuit. The breaker
should be operational via a switch located in the driver’s cab. The circuit breaker should
have a rupturing capacity of 400MVA and a continuous rating of 1000Amps at 25 KV.
The suitable interlocks are provided for tripping the circuit breaker in case the air
pressure becomes low to a value at which the raised pantograph leaves the contact
wire.
LIGHTENING ARRESTOR
A gapless lightening arrestor of proven design similar to those working in three phase
locos is provided for protection against the line voltage transients caused by lightening
or system switching.

57. TRACTION MOTOR
Traction motor refers to an electric motor providing the primary rotational torque of a
machine, usually for conversion into linear motion i.e. traction.
Traction motors are used in electrically powered rail vehicles such as Electric multiple
units and Electric locomotives, other electric vehicles such as electric milk floats,
elevators and conveyors as well as vehicles with electrical transmission systems such
as diesel-electric and electric hybrid vehicles. Additionally the electric motors in other
products such as the main motor in washing machines are described as traction motors.
Before the mid-20th century, a single large motor was often used to drive multiple
driving wheels through connecting rods that were very similar to those used on steam
locomotives. It is now standard practice to provide one traction motor driving each axle
through a gear drive.
Usually, the traction motor is simply suspended between the truck (bogie) frame and the
driven axle; this is referred to as a "nose-suspended traction motor". The problem with
such an arrangement is that a portion of the motor's weight is unsprung, increasing
forces on the track.

58. In WAG-7 the traction motor used is of series DC pulsating current type. The
armature is vacuum pressure impregnated solvent less resin. The motor fulfils the
following parameters broadly:
Mounting: Axle hung nose suspended
Rating: One hour: 750V, 960A, 870RPM, 670 kW
Continuous: 750V, 900A, 895RPM, 630kW
Weak field: 40%
Maximum permissible Ripple 28%
at continuous current of 900A
Starting current: 1350A for 2 minutes
Short time rating: 1200A for 10 minutes
RHEOSTATIC BRAKING
Dynamic braking is the use of the electric traction motors of a railroad vehicle as
generators when slowing the vehicle. It is termed rheostatic if the generated electrical
power is dissipated as heat in brake grid resistors and regenerative if the power is
returned to the supply line. Dynamic braking lowers the wear of friction braking
components and additionally regeneration can also lower energy consumption.
During braking the motor fields are connected across either the main traction
generator (Diesel-electric loco) or the supply (Electric locomotive) and the motor
armatures are connected across either the brake grids or supply line. The rolling
locomotive wheels turn the motor armatures, and if the motor fields are now excited, the
motors will act as generators. For a given direction of travel, current flow through the
motor armatures during braking will be opposite to that during motoring. Therefore, the
motor exerts torque in a direction that is opposite from the rolling direction. Braking
effort is proportional to the product of the magnetic strength of the field windings, times
that of the armature windings.

59. The locomotive WAG-7 is equipped with rheostatic braking arrangement
capable of braking effort of around 20T over a speed range of 25 to 50 km/h. In the
event of failure of the electric brake brakes on the train the air brake on the locomotive
will be applied automatically. Braking effort regulation are obtained by adjustments of
the traction motor excitation. The field of all the motors are connected in series and fed
by one of the two silicon rectifier bridge connected by means of an intermediate
transformer to one of the two secondary windings of the transformer. The control of the
excitation is provided by the tap changer. The dynamic braking resistance is forced cool
by AC motor blower set (AC MVRF). In case of emergency brake application by the
driver, the electric brake, if applied will be automatically cut off.
BATTERY
Batteries of adequate capacity are provided on the locomotive to feed the equipment for
three hours starting with a half charged battery when the locomotives are coupled in
multiple. The battery can be of lead acid type or latest with PPCP containers.
CONTROL EQUIPMENT & SAFETY DEVICES
The LED flashers light are provided in the locomotive. The microprocessor based
control and fault diagnostic systems are there which can even indicate the availability of
OHE power supply through capacitive coupling.
The safety devices include a new feature in the locomotives manufacturing. The
Vigilance Control Device (VCD) has been installed on WAG-7. The driver has to
acknowledge to periodic vigilance check by pressing a push button. In case the driver is
not vigilant with the first step then the device will flash an indication. If even now, the
driver does not respond then an audio-visual warning will be played and in case of no
response automatically the emergency brakes will be applied and the whole loco has to
be started all again.

60. PNEUMATIC BRAKING SYSTEM
In the air brake's simplest form, called the straight air system, compressed air pushes
on a piston in a cylinder. The piston is connected through mechanical linkage to brake
shoes that can rub on the train wheels, using the resulting friction to slow the train. The
mechanical linkage can become quite elaborate, as it evenly distributes force from one
pressurized air cylinder to 8 or 12 wheels.
The pressurized air comes from an air compressor in the locomotive and is sent from
car to car by a train line made up of pipes beneath each car and hoses between cars.
The principal problem with the straight air braking system is that any separation
between hoses and pipes causes loss of air pressure and hence the loss of the force
applying the brakes.
SPECIAL FEATURES OF WAG- 7AC
1. Air conditioned driver’s cab.
2. Vigilance control device to monitor driver’s alertness.
3. Stick type master controller for operation by driver in sitting position.
4. Ergonomically designed driver’s desk in FRP.
5. Improved aesthetics using FRP panels for walls, roof & floors.
6. Fire retardant paint for engine room interior.
7. State of art-cable management system-epdm modules.