This training report summarizes information about Chittaranjan Locomotive Works (CLW) in India. CLW is one of the largest locomotive manufacturers in the world. It produces various types of electric locomotives for Indian Railways, including freight locomotives like the WAG-9 and WAG-7, and passenger locomotives such as the WAP-7, WAP-5, and WAP-4. The report describes the key components of electric locomotives, CLW's manufacturing process across its various shops, and provides specifications for different locomotive types.

1. TRAINING REPORT SUBMITTED BY: KANHAIYA
KUMAR
STD.- B.TECH 7th SEM
BRANCH:- MECHANICAL
IT-GURU GHASIDAS UNIVERSITY, BILASPUR, C.G

2. CONTENTS
1. BASIC INFORMATION ABOUT CLW
2 .WHAT IS LOCOMOTIVES?
3.SOME BASIC INFORMATION ABOUT LOCOMOTIVES
4. IMPORTANT PARTS OF LOCOMOTIVES
5. TYPES OF LOCOMOTIVES PRODUCED BY CLW
6. MANUFACTURING SHOPS IN CLW
7. FLOWCHART of LOCO MANUFACTURING

3. BASIC INFORMATION ABOUT CLW
 Chittaranjan Locomotive Works is a goverment-owned electric locomotive manufacturer based in India.
It is located at Chittaranjan in Burdhwan. It is one of the largest locomotive manufacturers in the world.
 Founded in 1950 the Indian Railway owned industrial unit is named after the Indian freedom-fighter
Chittaranjan Das.
 The factory commenced the production of steam locomotives on the 26 January 1950 ,in collaboration
with the North British Locomotive Company. On November 1, 1950 Indian first steam rail-engine
produced by the company (a WG class locomotive) to the freedom fighter Deshbandhu Chittranjan Das.

4. WHAT IS LOCOMOTIVE?
 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.
 A ELECTRIC LOCOMOTIVE is a type
of railway locomotive in which the prime
mover is a electric .

5. SOME BASIC INFORMATION ABOUT LOCOMOTIVES
► TYPES OF TRACK ► NAMING SYMBOLS
Broad gauge (Length=1.76m,denoted by
W)
Meter gauge(Length=1m, denoted by Y)
Narrow gauge(Length=2ft 6in,denoted by
Z )
Narrow gauge(Length = 2ft,denoted by N)
A-ac
C-dc
D-diesel
M-mixed (Both goods and passenger)
AC-Both ac and dc
S-Shunting
U-Multiple unit
3A-3100hp
4B-4200hp

6. IMPORTANT PARTS OF LOCOMOTIVES
The entire ELECTRIC LOCO is divided into
mainly two sections :(1) Mechanical
Section(2) Electrical Section
1. WHEEL AND AXLE
 Wheels and axle are manufactured of cast steel.
 Railway wheels sit on the rails without guidance.
 the flanges should not touch the rails.
 The wheel tire is coned .
 Rail head slightly curved as shown in the diagram.
 the dia. of wheel is 1092 mm

7. 2. TRACTION MOTOR
 A traction motor is an electric motor used for propulsion of a
vehicle, such as an electric locomotive or electric roadway vehicle.
 These motors were traditionally DC but the development of modern
power and control electronics has led to the introduction of 3-phase
AC motors.
 Electric locomotives generally have two or more dc or ac motors.
In these locomotives , power is collected from an electric trolley
which is running on an overhead wire. The overhead wire can carry
both types of supply ac as well as dc. Indian railway also uses both
types of supply systems :
(a) AC system- 25 kv single phase 50 hz ac supply
(b) DC system- 1500 V dc supply
Only western zone and central zone of railway

8. 3. PANTOGRAPH
 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 BABY compressor system, either to raise
the unit and hold it against the conductor

9. 4. BRAKES
Mainly three types of brakes are used-
(a). Air Brake System
(b). Regenerative Brake System.
(c). Parking type

10. (a). AIR BRAKES
This braking systems use compressed air as the
force to push blocks on to wheels or pads on to
discs.

11. (b).REGENERATIVE
BRAKES
During braking, the traction motor connections
are altered to turn them into electrical
generators.
The motor fields are connected across the main
traction generator and the motor armatures are
connected across the load.
The rolling locomotive or multiple unit wheels
turn the motor armatures, and the motors act as
generators, either sending the generated
current back into the supply.
Regenerative braking will be working up to
speed of 15 km/hr.

12. (c). PARKING BRAKES
 In 3 phase loco hand brake are not provided.
For parking the loco new type of brakes are
available on this loco called parking brake.The
great feature of parking brake is that it remain
applied to indefinite time as per the
requirement in absence of air pressure .It's
function is just opposite to that of
conventional brakes i.e it remains released

13. 5. BOGIE FRAMES
 The Bogie is not, as many people wrongly say it
to be, a railway passenger vehicle unit. That is a
coach, compartment, carriage or car. A bogie is a
unit under a coach or a locomotive body which
houses the wheels, suspension etc. Usually there
are be two bogies for a coach and two or three
for a locomotive with each bogie housing four or
six wheels
 Bogies serve a number of purposes
-Support of the rail vehicle body
-Stability on both straight and curved track
-Minimizing generation of track irregularities
and rail abrasion

14. 6. SHELL AND CABIN
 Shell – The housing body of the
locomotive.Where all equipment is kept under
shell body like IGBT, compressor, etc.
 Driving Cab – The “Cockpit” of the locomotive,
where the loco pilot (driver) and assistant and
any other sit and drive the loco. All controls
are located here. The cluster containing the
controls to drive the locomotive is called a
“Control Stand”.

15. Some other Components of an ac locomotive
CATENARY:- This is the Over head Wire of Special Cross section of area.
CIRCUIT BREAKER:- To disconnect the engine from the line side in case of
some fault.
POWER CONVERTER:- Power convertor converts the single phase 25KV AC
supply into 3 phase AC with variable voltage (max. 2150v) and variable
frequency (65 to 132 Hz) feed to the traction motor.
AUXILIARY CONVERTER:- Auxiliary converter converts single phase 1000 volts
supply into three phase 415 volts to different three phase auxiliaries.
RECTIFIERS:- Conversion of AC power into DC power.
SMOOTHING REACTORS:- Any ripple found on the output side of the rectifier
are eliminated by this fitted after the rectifier.
TRANSFORMER:- It is installed in locomotive for step down the voltage
according to threquirement of motor.
TRACTION MOTOR BLOWER:- It is a blower for ventilation of traction motor
(connected with bogie 1&2) by forced air.
MAIN COMPRESSOR :- It is a pressure creating equipment for necessary
pressure for entire pneumatic circuit of the loco.

16. TYPES OF LOCOMOTIVES PRODUCED BY CLW
1. WAG-9 - The “Heavy Haul” Freight locomotive of IR
2.WAP–7- The “Heavy Haul” Passenger locomotives of IR
3. WAP-5 - Advanced control , light weight, disc brakes (used in
RAJDHANI, SHATABDI, DURANTO )
4. WAP-4
5. WAG -7

17. SALIENT FEATURES OF DIFFERENT TYPE OF ELECTRIC
LOCOMOTIVES:
DESCRIPTION WAG-9 WAG-7 WAP-7 WAP-5 WAP-4
Type of service Freight Freight Passenger Passenger Passenger
Gauge 1676 mm 1676 mm 1676 mm 1676 mm 1676 mm
Power Supply 25 KV AC,50Hz 25 KV AC,50Hz 25 KV AC,50Hz 25 KV AC,50Hz 25 KV AC,50Hz
Wheel
Arrangement
Co-Co Co-Co Co-Co Bo-Bo Co-Co
Total Wt of Loco 123 t 123t 123t 78t 112t
Continuous H.P 6000 hp 5000 hp 6000 hp 5400 hp 5000 hp
Max. Speed 100 kmph 100 kmph 140 kmph 160 kmph 140 kmph
Starting Tractive
Effort
460 KN 402 KN 323 KN 258 KN 273 KN
Continuous
Tractive Effort
325 KN 235 KN 325 KN 180 KN 187 KN
Great ratio 15:77 15:77 20:72 17-35-67 20:72

18. Description WAG-9 WAG-7 WAP-7 WAP-5 WAP-4
Brake System air and
regenerative
air and
regenerative
air and
regenerative
Disc brake air and
regenerative
No.of T.M & Types 6 no.& 3- phase
AC IM(850KW)
6 no. & 3-Phase
AC IM(850KW)
6 no.& 3- phase
AC IM(850KW)
4 no. & 3-phase
AC
IM(1150KW)
6 no.& 3- phase
AC IM(750KW)
Length over buffer 20562 mm 20562 mm 20562 mm 18162 mm 20562 mm

19. MANUFACTURING SHOPS IN CLW
1. WHEEL AND AXLE 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.
2. HMS: - 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.
3. 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.
4.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.
5.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. 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.

21. FLOWCHART OF ELECTRIC LOCO MANUACTURING
WHEEL AND AXLE
FITTING AT
SHOP NO. 09
MACHINING AT
SHOP NO. 08
MOTOR PREPARED AT
SHOP NO. 23
BOGIE
FABRICATION AT SHOP NO. 5,
15, 25
BOGIE MACHINING IN SHOP
NO. 1FF8
SHELL
CAB FAB AT SHOP
NO. 12
UNDERFRAME
ASSEMBLED AT SHOP
NO.15
SIDE WALL AND ROOF IS
PREPARED AT SHOP NO.
26
BOGIE ASSEMBLY AT
SHOP NO. F18
ENTIRE UNDERRAME AND ROO IS ITTED AT
SHOP NO. 26, 16
ELECTRICAL TESTING IN SHOP NO. 19
PAINTING AT SHOP NO. 16
DISPATCH