CLW

History : ABOUT CHITTARANJAN LOCOMOTIVE WORKS
Chittaranjan Locomotive Works (CLW) is the dream of the nation’s visionaries,
coming true. The planners of the Nation with their deep insight and foresight set to
build a Loco building Factory in West Bengal and CLW is that vision, coming true. On
the 9th of January 1948, survey of the proposed area was done.
The rocky soil was an advantage in
erecting foundations for heavy structural
work and the undulating terrain solved
the problem of drainage for the
township while the schemes of the DVC
envisaged hydro-electric and thermal
power stations in the vicinity assured
cheap power availability in the near
future. It is the only major Electric
Locomotive builder in the country. It is
situated just at the Border of West
Bengal and Jharkhand and is at about
32 km from Asansol and 237 kms from
Kolkata.
The place where today CLW is situated
was actually a hamlet of small villages.
The locoworks with its ancillary
workshops has a stores purchase office
in Kolkata and inspection cells in New
Delhi, Mumbai, Kolkata and Bangalore.
During pre-construction days
The Workshop has an area of 18.34 Sq. Km. The issue of setting up a loco building
unit continued to be under active consideration of the Central legislature and in the
late thirties, a committee consisting of M/s. Humphries and Shrinivasan was
appointed to investigate the possibility of establishing a locomotive manufacturing
unit and to consider its economic viability. The initial project, at Chandmari, a place
near Kanchrapara, in the state of West Bengal, could not mature due to partition,
which inevitably necessitated a change of site. This present site at Chittaranjan was
selected after a fresh survey and Railway Board’s approval was obtained in the year
1947. The locoworks was initially established for production of 120 average sized
steam locomotives with the capacity to manufacture 50 spare boilers.
The production of Diesel Hydraulic Locomotives was taken up during 1968. After
manufacturing 2351 Steam Locomotives of 5 types and 842 Diesel Hydraulic Locos
of 7 types, production of steam and diesel hydraulic locos were discontinued from
1973-74 and 1993-94 respectively

The production of Electric Locomotives
commenced in 1961. In the process,
fifteen versions of electric locomotives
were produced by CLW and the latest in
that series is the freight locomotive WAG-
7 and passenger locomotive WAP-4.
Pandit Jawaharlal Nehru, the first Prime
Minister of India, commissioned the first
1500 V dc Locomotive named
“LOKMANYA” on the 14th
October, 1961.
The production of 25 kV ac loco
commenced on 16th
November, 1963. The
first Electric Loco turned out from CLW,
christened as “BIDHAN” was a Broad
Gauge 25 kV a.c. Freight Locomotive
(WAG-1) of 2840 hp with maximum speed
of 80 km/hr. Subsequently CLW gradually
upgraded the horsepower of Electric Loco
from 2840 hp to 6000 hp and maximum
speed from 80 Km/h to 160 km/h. CLW
also built 25 kV ac/1500 V dc, ac/dc Loco,
WCAM-1 for hauling Mail / Express Trains
from BRC to BCT on W.Rly.
Lokmanya’ WCM-5
CLW became the first production unit in the developing countries, second in
Asia and fifth in the world to manufacture 3-phase state of the art GTO
Thyristor controlled Electric Locomotive and the first indigenous 6000 hp
freight electric loco WAG-9 christened as “NAVYUG” was turned out on 14th
November, 1998. During the year 2000-01 the first passenger version of three
phase loco WAP-5 called “NAVODIT”, with maximum service speed of 160 km/h
and having a potential upto 200 km/h, has been manufactured. Developments of
sources, indigenisation and cost reduction of three-phase loco have been the
highest priority items. The towering imported cost of Rs. 35 crores for 3 phase loco
has been drastically brought down to about Rs.12.5 crores.
Production of DC Traction Motors and Control Equipment commenced in April, 1967.
Currently both DC & AC traction motors are being manufactured. Steel foundry was
set up in 1962-63 for manufacture of cast steel loco parts. CLW has in house
facilities for machining and assembly of wheel sets, fabrication and machining of
bogies etc. The facilities include modern CNC machines, plasma-cutting machines,
inert gas welding sets etc

River Ajay flows past CLW along its
northern side. Workshops, offices and
quarters are spread over the whole are
with ample space in between –
surrounded by greenery and trees.
There are several water bodies in CLW
exhibiting a lush green environment
which attract a large number of
migratory birds every year. A variety of
flora and fauna can be seen here all the
year round.
Long before others became environment
conscious, CLW administration started
planting trees, thus turning and arid
area into a green one. In 1996 alone
90,000 saplings were planted with the
help of the Social Forestry Division of
Government of West Bengal. In 2005
also 50,000 saplings have been planted
with the help of same agency. The
Administration is regularly educating the
staff and encouraging them to preserve
the environment. Recently, an immense
amount of work has been done, with a
view to conserve the Environment, as
well as using of all the existing natural
resources in an eco-friendly manner.
LOCO ASSEMBLY SHOP
The efforts have been recognized by the World Environment Foundation and the
Golden Peacock award for Environment Management 2006, has been
conferred on 9th
June 2006.
CLW has complied fully with the provisions of the Industrial Safety Act, 1948. CLW
in its safety policy aims to ensure 100% safety for all workers working in
Chittaranjan Locomotive Works. CLW is the proud recipient of the Safety
innovation award 2006. The award was conferred on CLW on 6th
September, 2006 by the Safety and Quality forum of the Institute of
Engineers (India).
CLW has recorded the best ever performance during 2007—08 in terms of outturn
of locos and financial indices. The year 2007-08 culminated with the inventory under
stores at Rs. 161 crores as against the target of Rs. 172 crores communicated
through Final Grant for 2007-08, which has resulted in an all time low stores turn
over ratio of 10.75 as compared to 12.69 of the previous year.The WMS turn over
ratio has also decreased to 5.61 in comparison to that of 2006-07 which was 8.67.
The target of Rs. 284 crores for manufacture of components was surpassed and the
figure was Rs. 315 crores. The target of Rs. 85 crores ,for sale and transfer of
bought out items has been fully achieved. Auction sale proceeds exceeded Rs. 8
crores. Full credit of Rs. 1500 crores has been realized under Board’s RSP for 200
locomotives as per target given by Railway Board. The target of Rs. 19 crores kept
for supply of cast items (HS CASNUB Bogie) has been fully achieved.With all these
the net plan outlay is likely to be Rs. 32 crores only which is much below

the target of Rs. 47 crores communicated by Railway Board in the Final
Grant for 2007-08.
CLW enters its Diamond Jubilee year w.e.f 26th
January, 2009. A year long
celebrations are in the offing. A kite flying Competition was held on March, 2009,
to commemorate CLW’s stepping into its Diamond Jubilee year. The programme
brought together the residents of the township , in celebrating the year.

Milestone1
• 1947 September Site for Chittaranjan Locomotive Works located.
• 1948 March Construction work started.
• 1948 April Workshop Set up
• 1950 26th
January Production inaugurated by Smt. Basanti Devi, Wife of Late Chittaranjan
Das.
• 1950 1st
November Namkaran Ceremony of the works by President of India, Dr. Rajendra
Prasad, when the first steam locomotive was turned out and flagged off
from CLW.
• 1951 12th
February KG Hospital formally opened by his Excellency Dr. K.N.Katju, Governor of
West Bengal.
• 1952 1st
to 2nd
March
Prime Minister of India, Pandit Jawaharlal Nehru visits Chittaranjan
accompanied by Dr. B.C.Roy, Chief Minister of West Bengal
• 1952 21st
October Railway Minister Shri Lal Bhahadur Shastri visits Chittaranjan
• 1953 10th
October Dr. Sarvapalli Radhakrishnan, Vice President of India, visits Chittaranjan .
• 1954 6th
January 100th
Steam Loco “CHITTARANJAN 100” inaugurated by Railway Minister
Shri Lal Bahadur Shastri.
• 1955 27th
April Dr. Rajendra Prasad, President of India, drove the 200th
Locomotive from
the works.
• 1955 28th
November Visit of their Majesties the King ,Tribhuvan Bir Bikram Shah and Queen of
Nepal
• 1955 17th
December Visit of their excellencies Mr. N.A.Bulganin and Mr. N.S.Khruschev from
Russia
• 1956 14th
November Visit of His Imperial Majesty, Mr. Haile Selassie, Emperor of Ethiopia
Milestone2
• 1956 12th
December
Visit of Mr. Chou en lai the Prime Minister of People’s
Republic of China
• 1957 13th
January Visit of their Holinesses , the Dalai Lama and the
Panchen Lama
• 1958 18th
March Visit of Mr. Churu Stoika, Prime Minister of Rumanian
People’s Republic
• 1958 20th
November
Visit of Mr. Marcel Roberts, Chief Occupational Safety &
Health Division, International Labour Organisation
• 1960 25th
January A technical collaboration agreement signed with Messrs.
F.H.Lloyd & Co. Ltd., Wednesbury for establishing the
Steel Foundry at Chittaranjan
• 1960 16th
April Thousandth Locomotive turned out.
• 1960 April Visit of Mr. Gamal Abdul Nasser, the President of the

United Arab Republic
• 1961 January Steel Foundry set up
• 1961 2nd
February Visit of the illustrious daughter of Netaji Subhash
Chandra Bose, Kumari Anita Bose
• 1961 16th
April Opening of Rabindra Manch and open air theatre.
• 1961 14th
October First CLW built WCM-5 DC Electric Loco
“LOKMANYA’ commissioned by Pandit Jawaharlal
Nehru.
• 1962 October Electric Loco Shop Set up
• 1963 16th
November
First CLW built WAG-1 25 KV AC Electric Loco
“BIDHAN’ commissioned by Pandit Jawaharlal Nehru.
• 1966 Traction Motor Shop Set up
• 1967 16th
April Chittaranjan builds its First Traction Motor, the largest in
India, at that time.
• 1968 6th
January First CLW built Diesel Hydraulic Shunter
“INDRAPRASTHA” commissioned by Shri
C.M.Poonacha, the then Railway Minister.
• 1971 Antim Sitara last steam engine …….
• 1972 First batch of TAO-659 traction motor despatched
Milestone3
• 1972 30th
January First CLW Built WCAM-1 AC/DC Dual Voltage electric
Locomotive “Vallabh”commissioned by Shri Sidhartha
Shankar Ray, the then Chief Minister of West Bengal.
• 1980 1st
October First Rajdhani Electric Loco WAP-1 commissioned.
• 1985 3rd
and 4th
July
Flagging of of the 600th
Diesel Loco MOHANDAS by
Shri Madhav Rao Scindia, Minister of Railways
• 1986 2nd
November
Visit of Professor Nurul Hassan, Governmor of West
Bengal
• 1987 6th
April “JAWAHAR” (WAP-3) commissioned and christened by
Shri Madhav Rao Scindia, Minister of State for Railways
for Shatabdi Express services.

• 1988 First batch of Hitachi traction motors despatched
• 1989 Collaboration agreement signed with Rockwell
International Corporation .
• 1990 31st
March 105th
Electric Loco KIRTIMAN inaugurated by Mr.
R.D.Kitson, Member Mechanical, Railway Board
• 1991 7th
January Flagging off of 1500th
Electric loco SUKANYA, to mark
the International year of the girl child
• 1992 3rd
August 1st
5000 hp High Adhesion WAG – 7 Electric Locomotive
“SHANTIDAN” christened by Mother Teresa,
Missionaries of Charity.
• 1993 6th
April Last BG Diesel Shunter “VIRAM” of the year and NG
Diesel Locomotive “ITI” of the year 1992-93.
• 1993 11th
June Inauguration of “Sidhu kanu Setu” a light bridge over the
River Ajoy by R.K.Shukla, GM/CLW
• 1994 23rd
January WAP-1 Electric Loco “PRAGATISHEEL” provided with
Hitachi Traction Motor.
Milestone4
• 1994 27th
August First 5000 hp WAP-4 Passenger Locomotive “ASHOK”
flagged off.
• 1996 13th
July ISO-9001 certification awarded to Loco Works by IRQS.
• 1996 8th
August ISO-9002 certification awarded to Steel Foundry by
IRQS.
• 1996 14TH
September
First Modular WAG-7 Loco KARAMVIR Flagged
• 1996 27th
December
First 3 phase 6000 hp WAG-9 Locomotive (CKD/SKD)
flagged off from CLW.
• 1998 29th
April Flagging off of 2500th
Electric loco SWARNA ABHA by
the Shri Nitish Kumar,Hon’ble MR

• 1998 14th
November
WAG-9, the first CLW built indigenous 3 phase state-of-
the-art 6000 hp Freight Electric Locomotive “NAVYUG”
inaugurated by the Hon’ble Minister for Railways by Shri
Nitish Kumar.
• 1998 21st
November
Inauguration of one WAG-7 500 HP Electric Loco
SAMARPAN by Shri Jyoti Basu Chief Minister of West
Bengal
• 1999 10th
January First batch of 6 nos. of CLW built 1000 hp Traction
Motors for WAG-9 inaugurated by Shri K.Balakesari,
Member Staff.
• 1999 12TH
April Flagging off of NAVJYOTI by his His Excellency the
Governor of West Bengal Mr. A.R.Kidwai
• 2000 25th
January CLW completes 50 years of service to the nation
• 2000 24th
February
The first CLW built 3-phase traction motor type 6 FXA-
7059 for WAP-5 locomotive inaugurated.
• 2000 10th
May “NAVKIRAN” the first WAP-7 locomotive rolled out of
CLW.
• 2000 17th
May “NAVODIT” the first CLW built WAP-5 locomotive
rolled out of CLW.
Milestone5
• 2000 30th
June A first Day Cover on CLW released by Shri
M.K.Banerjee, Post Master General/Kolkata to
commemorate CLW Golden Jubilee (Phase-II).
• 2000 30th
June “NAVSHAKTI” the first WAG-9H locomotive was rolled
out of CLW.
• 2000 18th
November
Commissioning of a new facility for polyurethane
painting of Electric Locomotives with grit blasting and
paint drying oven facility.
• 2001 12th
February
“NAVBHARATI”, the second CLW built WAP-7
locomotive flagged off by the Hon’ble Minister of
Railways Ms. Mamata Banerjee.
• 2001 16th
April H.E.Viren J.Shah, Governor of West Bengal was the
chief Guest at the 46th
Railway Week function. H.E.
also flagged off the 3-phase WAG-9 loco christened
“NAVASHA”.

• 2001 31st
May “NAVJAGRAN”, the CLW built WAP-5 locomotive
flagged off by the Hon’ble MOSR (D) Shri Digvijay
Singh.
• 2002 26th
April ISO-14001 certification awarded to CLW by IRQS.
• 2003 6th
April “NAVCHETAK” the CLW built WAP – 7 type
Locomotive flagged off by Hon’ble MOSR (A)
Shri A.K.Murti.
• 2003 2nd
& 3rd
August
“NAVGHANSHAKTI” the CLW built WAG-9 type
locomotive flagged off by ML/RB,Shri S.C.Gupta.
• 2003 25th
September
ISO-9001-2000
Milestone6
• 2003 28th
October Shri Nitish Kumar,Hon’ble MR inaugurated a book published by the PR
Dept. entitled “STORY OF CLW” written by Shri R. K.Vir, Ex-GM/CLW at
Railway Board, New Delhi.
• 2004 10th
January “NAVGATI”, the CLW built WAP-7 locomotive flagged off by Addl. ML/RB.
• 2004 29th
March “YUGANTAR”, the CLW built WAP-4 loco flagged off by GM/CLW.
• 2005 February Manufacturing of Cast Steel Bogie Frame for DLW for GM Loco WDS-4 by
Steel Foundry
• 2006 9th
June CLW is conferred with the Golden Peacock award for Environment
Management by the World Environment Foundation
• 2006 29th
July CLW built new locomotive type WAG-9 & WAG-9H with Satellite Remote
Diagnosis System “Dr. Silver” inaugurated by Shri Lalu Prasad, Hon’ble
MR.
• 2006 6th
September CLW becomes the proud recipient of the Safety Innovation award 2006, by
the Institute of Engineers
• 2007 23rd
March Flagging off of 100th
WAG-9 loco “NAVPRAGATI”.
• 2007 31ST
March 1st
loco for 2007-08 inaugurated
• 2007 31ST
March 1041st
Traction Motor produced for the year 2006-07
• 2008 25th
May CLW website launched
• 2008 11th
July CLW adopts ORACLE based financial application
2009 26th
January CLW steps into its Diamond Jubilee year

Quality Policy
CLW is an ISO-9001 unit and has a well-established quality system. The locoworks
of CLW obtained its ISO-9001certification on 13.07.96 while the ISO-9002: 1994
certification for Steel Foundry was obtained on 08.08.1996. Upgradation to ISO
9001:2001 for both Loco Works and Steel Foundry was completed on 25.09.2003.
First Surveillance Audit was conducted during 06.10.2004 to 08.10.2004 and the
Second Surveillance Audit was conducted during 06.09.05 to 09.09.05. Renewal
audit was conducted from 28th
August to 30th
August, 2006.
It is worth mentioning that CLW acquired ISO- 9001:2008 certificate on 22nd Oct
2009 for another three years for our commitment to Quality Management system.
The quality policy adopted by CLW is as follows:
· Chittaranjan Locomotive Works, the leader in
manufacture of Electric Locomotives, Traction
equipment and Rolling Stock Castings, is
committed to meet customer’s requirement.
· We are dedicated to ensure customer
satisfaction by establishing a quality management
system and reviewing the quality policy and quality
objectives for continual improvement.
· Our quality policy is communicated and
understood by all in the organisation and reviewed
periodically.
CORRECTIVE/PREVENTIVE ACTIONS:
Since the implementation of the ISO – 9001, CLW has benefited immensely

by way of reduced rejections and re-work. Further, customer feedback i.e.
feedback from the various electric loco sheds of the IR are being given
considerable attention. Based on customer feedback, suitable corrective and
preventive actions are being initiated through Design Modifications and
Correction of manufacturing processes.
Environmental Policy
CLW achieved ISO-14001 on 25th
April, 2002. 1st
surveillance Audit was conducted
from 28th
to 30th
April, 2003. 2nd
surveillance audit was conducted from 20th
to 23rd
June 2004. Renewal audit was conducted during 6th
September to 9th
September,
2005. Updated version of ISO 14001:2004 is also available in CLW.EMS up
gradation audit conducted from 11th
to 12th
May, 2006 successfully.
The Environmental Policy adopted at CLW is:
• Improved Environmental Management
System, prevention of pollution and
continuous improvement of
environment performance.
• Compliance with relevant
environmental legislation and
requirements as determined by
appropriate regulatory and other
corporate bodies.
• Conservation of natural resources and
implementation of fundamentals of
waste management.
• Setting environmental objectives and
Targets and monitoring progress for
sustainable development.
• Ensure awareness of all employees and
contractors regarding their
environmental roles and
responsibilities.
•
Following steps have been taken for protection and improvement
of environment at CLW:

• Waste generated in Shops have been reduced by 5% from the
previous year by improvement of operational procedures.
• Air Pollution Control Device has been installed in Integrated Paint
Shop to reduce air pollution.
• Dust collector has been installed in Sand Plant/SF for reduction of
air pollution.
• To reduce air pollution, stack height of D.G.sets in Central Power
House has been increased.
• Air Pollution Control Device has been installed at GEC Arc
Furnaces in Steel Foundry.
• Consumption of water in plant area has been reduced by 5% by
arresting major leakages and provision of water meters have
been made for regular monitoring of water consumption.
• Consumption of electricity in plant and Township has been
reduced by use of energy efficient lights, installation of capacitor
bank etc.
• 50,000 trees have been planted in the CLW Township. Another
50,000 trees will be planted during the current year.
• Use of polybags has been totally banned inside the Township.
• New Sewage Treatment Plant (Bio-filter Plant) has been
commissioned and under operation for improvement of effluent
quality before discharge to surface inland and nearby water
bodies.

WAG9
WAG-9 - The “Heavy Haul” Freight locomotive of IR:-
Rail Freight market which is registering a
remarkable growth since 2000, has also triggered
a buoyancy in demand for Electric Freight
locomotives. Almost 60 – 65 % of IR’s freight
handling takes place over IR’s Electrified Golden
Quadrilaterals and Diagonals , though it accounts
for only 25 % of its route kilometrage . Golden
Quadrilateral and Diagonals being saturated
routes, need heavy throughput and faster sectional
clearance. This is where these heavy haul and
speedier WAG-9 locos play a significant role. This
Gem of a loco is indeed a rail operator’s
delight.This six axle loco with axle and nose
suspended drive is designed to give a starting
tractive effort of 460 KN and maximum braking
effort of 260 KN. Rated 6000 hp, the loco has also
been successfully adapted to give 508 KN of
starting tractive effort with additional ballast.
This loco also is capable to give 6000 hp on rail
upto its rated speed of 100 kmph which gives
6000 HP, 25 KV, 3- phase Freight Electric
Locomotive WAG-9

superior section clearing capability especially in
handling speed restriction.
Need :-
Due to advanced mechanical design especially those of bogies, the locomotive has low
unsprung masses and is truly track friendly. Presently WAP-5 is the only passenger locomotive
with fully suspended drive. Anti-collision posts give locomotive superior crash worthiness. The
fleet of WAP-5 class locomotives is now being geared up for the proposed 150 kmph services
Salient Details :-
Gauge 1676 mm
Continuous HP 6000
Starting Tractive effort 460KN (47t)
Max, Speed 100 kmph
Breaking Air, Regenerative
Wheel Aggangement Co-Co.
System Voltage 25KV AC, 50 Hz.
Weight of loco 123t.
Type Freight
WAP7
WAP-7 - The “Heavy Haul” Passenger locomotives of IR:-
Intercity and interstate fare friendly
Passenger market has of late shown a strong
and sustained growth in recent times. This
market needs very powerful Electric locos
which can haul 24 to 26 coaches at speeds in
the range of 130/ 140 kmph. To meet the
surging demands of this amazingly exploding
Passenger market segment, CLW has come
out with a 6000 H.P loco premium Electric
loco product – WAP-7.WAP-7 class loco is
based on WAG-9 platform and differs from
WAG-9 in gear ratio and the control software.
Locomotive rated at 6000 hp is design to the
starting tractive effort of 323 KN and
maximum braking effort is 260 KN.
6000 HP 25 KV 3-phase Passenger Electric
Locomotive WAP-7

Need :-
This loco also is capable to give 6000 hp on rail upto its rated speed of 100 kmph which gives
superior section clearing capability especially in handling speed restriction.
Salient Details :-
Horse Power 6000
Supply System 25kV, AC, 50 Hz.
Track Gauge 1676 mm (Broad Gauge)
Total weight 123.0 + 1%t.
Wheel Diameter 1092 mm (New ), 1016 mm (Full Worn)
Length over buffers 20562 mm
Panto locked down height 4255 mm
Type of Traction motors 6FRA 6068, 3-phase Squirrel Cage Induction Motors
Continuous Power at wheel
rim
4500 kW (6000 hp)
Starting Tractive effort 323 kN
Max. Service Speed 140 kmph
Brake System Air, Regenerative & parking
Drive System
3 phase Drive with GTO Thristors and microprocessor
based VVVF Control.
WAP5
WAP - 5 : 5400 hp,25 kV ac, B.G. 160 km/hr. speed,3-phase drive
WAP-5 class locomotives employ advanced
control and propulsion technology and are
capable to deliver 5400 hp on rail. The
locomotive has all the hallmarks of a high-
speed propulsion unit viz. light weight, fully
suspended drive and disc brake. Though
presently, it has been certified for 160 kmph
operation, the locomotive has been designed
to give a service speed of 200 kmph with test
speed potential of 225 kmph. Since IR is
currently facing severe competition in Premium
Passenger business market from commercial
airlines, sooner or later, IR will have to
introduce medium high speed intercity

Passenger Services. This emerging market will
call for powerful Electric locos with 150 kmph
plus speed potential to be deployed in the
immediate future and WAP-5 is the locomotive
of choice for this Passenger Services market of
IR.
5400 HP 25 KV 3 phase Passenger
Electric Locomotive WAP-5
Need :-
Salient Details :-
Horse Power 5400
Supply system 25 kV, AC, 50 Hz.
Axle Arrangement Bo-Bo
Total weight 78+ 1%t
Axle Load 19.5 + 2%t.
Wheel Diameter 1092 mm (new ),1016 mm (Full Worn)
Panto locked down height 4237 mm
Max. Service Speed 160 kmph
Type of Traction motors FXA 7059, 3-phase Squirrel Cage Induction Motors
Traction Motor Mounting Fully suspended
Continuous Power at wheel rim 4000 kW (5450 hp)
Starting Tractive Effort 258 KN
Control System Voltage 110 V dc
Drive System
3 phase Drive with GTO Thyristors and
microprocessor based VVVF Control.
Multiple Unit operation Maximum 2 locos.
Hauling Capacity 26 coaches at 140 km/ hr on level.
Brake System Air, Regenerative & parking

WAG9
WAG-9 - The “Heavy Haul” Freight locomotive of IR:-
Rail Freight market which is registering a
remarkable growth since 2000, has also triggered
a buoyancy in demand for Electric Freight
locomotives. Almost 60 – 65 % of IR’s freight
handling takes place over IR’s Electrified Golden
Quadrilaterals and Diagonals , though it accounts
for only 25 % of its route kilometrage . Golden
Quadrilateral and Diagonals being saturated
routes, need heavy throughput and faster sectional
clearance. This is where these heavy haul and
speedier WAG-9 locos play a significant role. This
6000 HP, 25 KV, 3- phase Freight Electric
Locomotive WAG-9

Gem of a loco is indeed a rail operator’s
delight.This six axle loco with axle and nose
suspended drive is designed to give a starting
tractive effort of 460 KN and maximum braking
effort of 260 KN. Rated 6000 hp, the loco has also
been successfully adapted to give 508 KN of
Need :-
Salient Details :-
Gauge 1676 mm
Continuous HP 6000
Starting Tractive effort 460KN (47t)
Max, Speed 100 kmph
Breaking Air, Regenerative
Wheel Aggangement Co-Co.
System Voltage 25KV AC, 50 Hz.
Weight of loco 123t.
Type Freight
I WAP-4
This 5000 HP locomotive was evolved to meet the
requirement of hauling longer trains of 24 coaches
at higher speed up to 130 kmph over Indian
railways. This loco is presently hauling important
high-speed trains on Indian Railways. These are
six axles loco with axle and nose suspended drive.

5000 HP 25 KV AC WAP 4 Passenger
Electric Locomotive.
Need :-
Salient Details :-
system 25 KV, AC, 50 Hz.
Class of Loco WAP-4
Axle arrangement Co-Co
Brake System Air and Rheostatic
Total weight 112.8 + 1% t.`
Wheel Diameter 1092 mm (New) , 1016 mm (Full worn)
Panto locked down height 4232.5 mm
Traction Motor type HS 15250A, DC Series Motor
Continuous Power at Wheel Rim 5000 HP
Starting Tractive Effort 30.8 t
Control System Voltage 110 V DC
TRACTION MOTORS
I TRACTION MOTORS :
Cumulative production of Traction Motors during the year 2007-08, has touched an
all time high of 1225 Traction Motors .This is the Best ever in the 53 years history
of CLW .CLW has achieved the rare distinction of being the only Production Unit in
the country which can cross 1000 Traction Motors production mark in a year.
I 3-PHASE TRACTION MOTOR TYPE 6FRA6068 & 6FXA7059 : 3-
Phase Traction Motors type 6FRA6068 for WAG-9 and WAP-7 locomotives &
6FXA7059 for WAP-5 locomotive are being manufactured indigenously by CLW since
the financial year 1998-99 & 1999–2000 respectively. With the production of 3 –
phase Traction Motor, CLW has entered the era of State of the art, 3-phase
technology.

I HITACHI TRACTION MOTOR TYPE HS15250A :
Hitachi Traction Motor is one of the most critical and vital equipment in Conventional
Electric Locomotives type WAG–7 & WAP–4 under production at CLW. The
production of Hitachi TM is now completely stabilized.
Steel Foundry
I Steel Foundry :
Steel Foundry, CLW was set up at
CLW in 1963 in collaboration with
M/s F.H. Lloyd of U.K. for production
of steel castings for Steam
Locomotives being produced in
CLW/Chittaranjan. After achieving
self-sufficiency in Steal Loco
production, CLW changed over to
manufacture of Diesel & Electric
Locomotives and Traction Motors.
Consequently, heavy Steam
Locomotive castings gradually
tapered from 1972-73 onwards and
gave way to intricate, lightweight
steel castings for Electric/Diesel

Locomotives, Traction Motors and
High Speed Wagons
I Modernisation of Technology:
Steel Foundry was modernized with the state-of-art technology of M/s Rockwell
International Corporation (now M/s Atchison Castings, USA) a leader in casting
technology for Bogies and has changed over completely to this technology from
1995-96.
I Quality
Steel Foundry is accredited with
prestigious ISO 9001:2000
certification for its quality
system. Steel Foundry has come
up with flying colours,
reassuring our commitments to
quality and dedication to
customer satisfaction.
Steel Foundry has strived
constantly to improve the quality
and developments suggested by its
employees and introduction of new
materials and processes.
Other Items
I Other Items :
Panels :
The Switchgear / Relay panels of the Electric
Locomotives WAP-4 / WAG-7 and drivers desk are assembled in-
house. The frames of these Switchgear / Relay Panels are
partly procured from trade and partly fabricated in house .
For 3-phase AC locos. panels like HB-1/HB-2. SB-1/SB-2. Filter
cubicle and Drivers Desk are assembled and wired in-house.
Static Equipment & Contactors :

CLW also undertakes manufacture of Smoothing Reactor
(SL). Inductive shunt(SJ), Electro Pneumatic/Electro Magnetic
Contactors.
Shell :
CLW undertakes complete manufacture of shell. The
Organisation
CLW is under the direct administrative control of Ministry of Railways. The unit headed by a
General Manager, who is assisted by various Heads of Department responsible for their

individual spheres of activity. The list of the present Administration and their contact telephone
numbers is as follows :-
I Structure upto JAG Level
Administration
Finance
Electrical
Mechanical
Personnel
Material
Medical
Vigilance
Public Relations
Security
Civil Engineering

How to reach CLW
Layout map
Chittaranjan Locomotive Works (CLW), located in the land of Viswa Bharati , a great
educational and cultural seat in the world, is the premier electric loco producer in this country.
Situated at the border of West Bengal and Jharkhand, it is about 32 kms away from Asansol and
237 kms from Kolkata, the state capital. The place where CLW is situated today was a small
unknown hamlet of Santhals in the pre-industrialization era. Once the construction of the loco
unit started, a wave of all round development reached this distant place and gradually it has
become a modern railway township equipped with all modern facilities. Spread over an area of
18.34 sq. kms , CLW houses workshops, offices, schools college, staff quarters, cinema hall,
indoor stadium and auditorium.
Apart from its expertise in rolling out state- of-the-art electric locos and providing Indian
Railways much needed motive power, Chittaranjan is also a hot spot for nature lovers, and all
those who want to soothe their frayed nerves in the lap of mother nature. Its serene
environment, lush green fields and plethora of unknown birds welcome all visitors. It’s ideal to
visit Chittaranjan from November to March every year. Every winter, migratory birds, after
covering thousand miles come to the seven lakes within the township. If you are a nature lover,
you will surely be delighted to get a glimpse of CLW’s flora and fauna. Come and explore this
treasure trove.

INFRASTRUCTURE AVAILABLE AS ON 01.4.2011
1. WORKSHOP
Land area under workshop: 8,93.373 sq. m.
Total plinth area in shops 2,39,843 sq. m.
including stores shed
2
STAFF
GROUP -A 95
GROUP -B 103
GROUP -C 10,495
GROUP -D 2750
Total 12837
3. TOWNSHIP
Total area 18.34 Sq. km
Length of Road 203 km.
Residential Quarters 9,356 nos.
Hospitals 01 nos.
Health Units 07 nos.
Community Halls 08 nos.
Open Air Theatre 01 no.
Cinema Halls 02 nos.
Markets 07 nos.
Clubs 01 no.
Institutes 04 nos.
School (Rly.) 16 nos.
Schools (Non-Rly.) 16 nos.
KendriyaVidyalaya 01 no.
College 01 no.
4.POWER SUPPLY
Maximum Contract demand 11.0 MVA
Consumption of Electricity (p.a.) 462.95970 Million units

New Projects
NEW PROJECTS
Fund under plan head 4200 (Capital)
Augmentation of facilities for enhancement capacity of
Three phase locos to 50 locos per year. (AP-50)
Augmentation of facilities for enhancement capacity of 3 phase locos to 50 locos per year.
In long term perspective, production of 3- phase locos at CLW will increase and production
of conventional locos will reduced gradually.
Project for creation of additional facility for enhancing the
production capacity of CLW up to 200 locos per year.(AP-
200)
Project for creation of additional facility for enhancing the production capacity of CLW up to
200 locos per year. This was required to enhance the production capacity of CLW to 200
locos per annum (including 50 three phase locos per annum) to meet the increased loco
requirement of Indian Railway.
Modernization and augmentation of production capacity
from 200 to 275 locos per year.(AP-275)
Modernization and augmentation of production capacity from 200 to 275 locos per year. The
demand of electric locomotives is going up continuously to cope with the increase in freight
traffic and passenger traffic and to take care of requirements of new routes of electrified.
With increased electric locomotives requirement, CLW shall produce at the rate of 275

locomotives per year.
Electric Locomotive Factory at Dankuni, West Bengal
The unit will work as an ancillary unit of CLW. Initially state of art 3-phase high HP
locomotive with regenerative breaking of 6000 HP (WAG-9) electric locomotive will be
turned out. Subsequently, the infrastructural facilities shall be utilized for the production
of 9000 HP locomotives in future.
Centre of excellence for design , development & evaluation
of advanced technology system for electrical rolling stock.
The purpose of establishing the Centre of Excellence is to develop capability for designing,
development and evaluation of advanced technology systems for Electric Rolling Stock. The
idea is to become a technology exporter from present status of technology importer in
Rolling Stock equipments. The main benefit that will accrue from this project is that we shall
become self reliant in the field of development of Electric Rolling Stock equipments which
will come in a big way not only for the domestic requirement of adoption of new technology
in rolling stock but we shall be in a position to cater to the emerging world market as per the
customized requirement of different countries.
ShriRadheyShyam, General Manager of CLW receives Memento from Shri S. Handa,
Member Mechanical , Railway Board at
9th National Steam Congress at New Delhi on 18.02.2012.
Currently there is no data or record available.
Locomotive
WAP - 7 : 6000 hp, ac, B.G. 140 km/hrs. speed, 3-phase drive.

Intercity and interstate fare friendly Passenger market has of late
shown a strong and sustained growth in recent times. This
market needs very powerful Electric locos which can haul 24 to
26 coaches at speeds in the range of 130/ 140 kmph. To meet the
surging demands of this amazingly exploding Passenger market
segment, CLW has come out with a 6000 H.P loco premium
Electric loco product ? WAP-7.
Details
WAP - 5 : 5450 hp,25 kV ac, B.G. 160 km/hr. speed,3-phase drive
WAP-5 class locomotives employ advanced control and
propulsion technology and are capable to deliver 5450 hp on
rail. The locomotive has all the hallmarks of a high-speed
propulsion unit viz. light weight, fully suspended drive and
disc brake. Though presently, it has been certified for 160
kmph operation, the locomotive has been designed to give a
service speed of 200 kmph with test speed potential of 225
kmph. Since IR is currently facing severe competition in
Premium Passenger business market from commercial airlines,
sooner or later,
Details
WAG - 9 : 6000 hp, 25kV ac, B.G.,freight locomotive,
100 km/hrs. 3-phase drive
Rail Freight market which is registering a remarkable growth
since 2000, has also triggered a buoyancy in demand for
Electric Freight locomotives. Almost 60 ? 65 % of IR?s freight
handling takes place over IR?s Electrified Golden
Quadrilaterals and Diagonals , though it accounts for only 25
% of its route kilometrage .
Details

WAG - 7 :
5000 HP,25 kV ac, Broad Gage (BG)1.676m, speed 100 km/hrs.
(on Indian Rlys.track).Tap changer/ DC Traction Motor
technology
Details
WAP - 4 :
5000 hp,25kV, ac, B.G.1.676 m speed 130 km/hrs. ,Tap
changer / DC Traction Motor technology
Details
Traction Motors
TRACTION MOTORS
I 3-PHASE TRACTION MOTOR TYPE 6FRA6068 & 6FXA 7059: 3-Phase Trcation
Motors type 6FRA6068 for WAG-9 and WAP-7 locomotives & 6FXA7059 for WAP-5
locomotive are being manufactured indigenously by CLW since the financial year
1998-99 & 1999-2000 respectively.With the production of 3-phase Traction
Motor,CLW has entered the era of state of the art,3-phase technology.

(3-phaseTM type 6FRA6068) (3-phaseTM type 6FXA
7059)
II HITAHI TRACTION MOTOR TYPE HS15250A
Hitachi traction Motor is one of the most critical and vital equipment in conventional Electric
locomotives type WAP-7 & WAP-4 under production at CLW.The production of Hitachi TM is

now completely stablized.
Steel Foundry
PRODUCT MIX OF STEEL FOUNDRY:
A) CAST Items:
HS Casnub Bogie for BOXNHL wagons.
Flexicoil Bogie for WAP-4 loco.
Flexicoil Bolster for WAP-4 loco.
Co-Co Bogie BG for WAG-5 & WDM-2 Loco.
Casnub Bolster.
Casnub Side Frame.
Centre Pivot Top and Bottom for Casnub Bogies.

Suspension tube for Hitachi TM.
Suspension tube for BHEL TM.
Suspension tube for WDM-3D loco.
Rotor Clamp for Hitachi TM.
Commutator Spider for Hitachi TM.
Centre Pivot for WAP-4 loco.
Ballast Blocks for WAG-9 loco.
Ballast Weights for WAG-7 loco.
Wheels for Tower Car.
Wheels for Power Car.
Wheels for Narrow Gauge Coaches.
Wheels for Narrow Gauge loco.
Knuckle for CB Coupler.
Coupler Body for CB Coupler.
Yoke for Cd Coupler.
Striker Castings for CB Coupler.
Counter Weight Slabs for 140T Slabs for 140T Breakdown Cranes.
Wooden Cleats, Wedges, Battery Boxes, etc.
B) FABRICATED ITEMS:
Long Beams & End Structure for WAP-4 Loco.
End Structure & End Box for WAG-7 loco.
PRODUCT RANGE:
Grade of Steel:
Steel Foundry manufactures steel castings generally complaint with
grades IS-1030 and AAR-201. To meet the requirements of different
products, Steel Foundry had earlier been processing eight different grades of
metal. Steel Foundry has been successful in rationalizing the same to five
grades only without affecting any metallurgical, chemical or physical
properties. This has resulted in improvement in productivity.
Different grades of steel for castings are as follows:-
Composition in Percentage
Carbon Manganese Sulphur
(max.)
Phosphorus
(max)
Silicon
(Max)
Grade-I 0.22 – 0.26 0.08 – 1.00 0.025 0.025 0.50
Grade-II 0.18 – 0.22 0.70 – 0.90 0.040 0.040 0.50
Grade- III 0.20 – 0.32 1.40 – 1.85 0.030 0.030 0.065

Others
Other Items
I Other Items :

Brief summary of important items used in 3-Phase Loco
SN ITEM QUANTITY PER LOCO FUNCTIONS
WAG9 WAP7 WAP5
1 Main Transformer The main transformer converts
the overhead line voltage (25
KV) to the lower operating
voltage. There are four
secondary traction windings
(two on each converter unit ,
1269 volts), one for feeding the
auxiliary ckts. (1000 volts) and
one for harmonic filter (1154
volts) one Hotel load(750 V)
winding ( only for transformer
7475 KVA)
(i) (LOT
7500)
7475
KVA
0 1 1
(ii) (LOT
6500)
6531
KVA
1 0 0
2 Power Converter 1 set 1set 1 set Power Converter converts
single phase 25 KV AC supply
into 3 phase AC with variable
voltage (maxm 2180 V) and
variable frequency (65 to 132
Hz) and feed it to Traction
Motor.
3 Auxiliary Converter 1 set 1set 1 set Auxiliary Converter converts
single phase 1000 volts supply
(from auxiliary winding of
main transformer ) into three
phase 415 volts (variable
voltage variable frequency) to
different three phase auxiliaries.
4 Central Electronics 2 2 2 All the functions of the
Locomotive are controlled by
the Control Electronics . It
takes the form of Bus Station
with processors.
All processors linked to the
vehicle bus transmit a
monitoring signal to the master
vehicle control unit .
5 Traction Motor 6 6 4 There are total 6 traction motors
in WAG-9/WAP-7 loco .TM 1-
2-3 are mounted in bogie -1 and
are fed from Power Converter
1 where as TM 4-5-6 are fed
from Power Converter -2. In
case of WAP-5 Loco there are
4 Traction motors in which
Power Converter -1 feeds to
TM-1-2 and Power Converter 2
feeds power to TM-3-4.
Traction Motors are
asynchronous squirrel cage
Induction Motor. Power
converter providing the power
sources. All three traction
Motors of one bogie are

ELECTRICAL POWER SUPPLY ( GENERAL SERVICES )
CEE’S MESSAGE:-
" CLW HAS ESTABLISHED ITESLF AS WORLD LEADER IN ELECTRIC
LOCOMOTIVE MANUFACTURING UNIT. ROLE OF POWER SUPPLY IN
THIS ENDEAVOUR IS VERY CRUCIAL. ON ONE HAND POWER SUPPLY
SYSTEM SHOULD BE ROBUST , RELAIABLE AND STATE OF ART, AND
ON OTHER HAND IT SHOULD MEET THE RAILWAY BOARD’S TARGETS
FOR GREEN ENERGY . I WISH THIS DEPARTMENT IS ABLE TO COME
OUT WITH FLYING COLORS TO MEET THIS CHALLENGE. "
This department is conscious of energy efficiency and under the
leadership of Chief Electrical Engineer Shri Shailendra Tripathi is
gradually moving towards green energy.
Electrical ( Power Supply) Department in CLW is responsible for
receiving power supply from DVC and distributing it to Shop and
Town.
An Over view of power supply @ CLW
33 KV power supply is received at MSS from DVC through three
feeders with contract demand of 11MVA. Power is being step down
(33kv/11kv) to feed to Main workshop , Steel Foundry, Township and
Water Supply through following power transformers:-
Sn.No. Transformer
33/11 KV
Make Nos. Year of
installation

1 10MVA GEC 02 1988
2 10MVA Andew Yule 01 2000
3 12.5MVA AREVA 01 2009
4 6MVA Transformer Switchgear
Ltd.
01 1982
• There are 21 indoor type ( 11kv/0.44 kv) substations for Main
Workshop and 43 outdoor type(11kv/.44kv) substations for
township & office buildings. One 11kv/3.3 KV substation
serves for pump house at sidhabari.
• 11 KV transmission line:-32 km (OH), 18 km (UG)
• LT Distribution line :-200 km (OH),6 km (UG)
• Annual Power Consumption :- 4.77 Crores Units (approx.).
Maintenance wing of power and town supply
Sn. Wings Nos.
01 Main Sub Station(MSS) 01
02 Air Conditioning & Refrigeration 01
03 Pump Section 01
04 H.T. & General Section 01
05 DG & Invertor Section 01
06 Area Electric Offices 04
MAIN SUBSTATION MSS:
Power Control room consists of 32 nos. VCB panels along with
energy meters.
• Power supply of Township is being fed through 4 H.T. feeders
namely Eastern, Northern, Western & Southern Rings
connected through partial Ring Main System.
• Dedicated Power Supply system for Sidhabari Pumping
Installation for Raw water supply.

• Dedicated power supply system for steel foundry for induction
furnace etc.
• Power supply to Main Workshop through 4 H.T. feeders
• Capacitor banks to improve Power Factor as per following
details
SN CAPACITOR BANK
RATING
MAKE Nos Year of
installation
01 1500 kvar,11kv CG 02 2008
02 1500 kvar,11kv Alsthom 01 1998
Air Conditioning & Refrigerator Section
· Central air condition Plants:
SN Particulars EDP AC Plant TM AC Plant
01 Capacity of
Plant
55 TR x 3 nos. 42.5 TR x 3 nos.
02 Refrigerant Used R-22 R-22
03 Running
Features
Two unit run at a
time in summer
& rainy season
One unit runs at a
time in summer &
rainy season
04 Type Chiller based indirect
expansion
Natural cooled Direct
Expansion
05 No. of Condenser
Water Pumps
3 (Two run at a time) 2 (Two run at a time)
06 No. of
Chilled
Water Pumps
3 (Two run at a time) ---
07 No. of AHU 04 02
08 Make/year Accel /1986 Frick /1987
Pump Installations:
Sidhabari Pump House:- Pumping of Raw water to Filter House from
Maithan dam discharge water through 12km pipeline.
Pump Typ Capacity PUMPS MOTORS

e (m3/h)
Head
(m)
Make Year
of
mfg.
Power
(kW)
RPM Year of
mfg.
P -1 VT 946 91 WPIL 1991 410 1464 1991
P -2 VT 568 91 WPIL 2003 250 1475 2003
P-3 VT 568 91 WPIL 2003 250 1475 2003
P-4 VT 946 91 WPIL 1991 250 1464 1991
FILTER HOUSE:
Distribution of Filter Water to colonies, service building &
workshops.
Name
of
pump
Type Capacity
(m3
/h)
Head
(Meter)
Pump
Make
Motor
power
(kw)
Motor
RPM
Year of
mfg.
Pump
-1
Centrifugal 189 60 WPIL 75 1460 2011
Pump
-2
Pump
-3
Pump
-4
Pump
-5
Centrifugal 225 60 Voltas 75 1469 2003
Pump
-6
Pump
-7
Pump
-8
Centrifugal 225 60 BECON 75 1460 1986
Pump
-9

Pump
-10
Centrifugal 225 60 BECON 75 1460 1986
Pump
-11
Centrifugal 227.3 60 BECON 75 1470 1986
Pump
-12
Centrifugal 227.3 60 Mather &
Platt
75 1470 2005
Pump-
12A
Centrifugal 227.3 60 BECON 75 1470 1986
DAM PUMP HOUSE
Supply of Raw water from DAM near workshop to Main shop & Steel
Foundry
Name
of
pump
Type Capacity
(m3
/h)
Head
(Meter)
Pump MakeMotor
power
(kw)
Motor
RPM
Year of
mfg.
P -1 Centrifugal 900 -- Voltas 300 1486 1995
P -2 Centrifugal 227.3 60 Mather &
platt.
75 1470 2005
P -3 Centrifugal 227.3 60 Mather &
platt.
75 1470 2005
P –
3A
Centrifugal 273 91.6 Mather &
platt.
110 1475 2003
P-4 Centrifugal 273 91.6 Mather &
platt.
110 1475 2003
P -5 Centrifugal 900 -- Voltas 300 1486 2000

DG & Invertor section
CPH has 6 nos. 1750 KW DG sets for emergency power supply:-
Other DG Sets
Sr.no. Set no. Capicity Location Dt. Of
installation
Voltage Amp/
KVA
Excitation
voltage
Excitation
amps
RPM
1. DG-1 1750kw Main
work
shop
08/1978 425V 2980
KVA
192 44 1000
2. DG-2 1750kw CPH 05/1978 425V 2980
KVA
192 44 1000
3. DG-3 1750kw CPH 05/1986 11000V 115
Amps
80 04 1000
4. DG-4 1750kw CPH 06/1987 11000V 115
Amps
80 04 1000
5. DG-5 1750kw CPH 1994 11000V 114.8
Amps
45 390 1000
6. Mobile
DG
1750kw Work
shop
1979 425V 2980
KVA
192 44 1000

Area Electric office (04nos)
Sn. Particulars SPE&W SPN&F H&H AML TOTAL
01 Nos. of Qtrs. 667 3080 1127 4178 9052
02 Nos. of street
light pole
480 960 430 1024 2894
03 Nos. of Timer
switch
06 04 03 02 15
04 Nos. of Sub Stn. 06 09 04 11 30
05 Shops/Stalls 118 152 06 464 740
06 Schools 07 05 02 07 21
07 BANKS -- -- 02 01 03
08 ATM --- 01 03 02 06
09 Cinema Hall 01 -- -- -- 01
10 Petrol Pump -- -- 01 -- 01
MANUFACTURING, M&P MAINTENANCE, TRANSPORT,
MACHINERY & PLANT PROCUREMENT:
Manufacturing group of shops consist of Heavy machine shop, wheel shop, light machine shop, smithy &
forge shop, Heat treatment shop and tool Room, Millwright and Electrical maintenance shops look after
maintenance of all M&Ps of loco works, power supply and distribution inside loco works.MPP cell deals with
planning and process for procurement of machines sanctioned by Rly. Board under M&P plan Head -4100 &
4200 and also look after TPT shop including road and industrial vehicle maintenance work with shunting
work. M&P section deals with commissioning of new machines and issues PTC.
Manufacturing shops:

(i) Wheel Shop:
The Wheel shop manufactures Wheel Sets for loco production as well as spares to Zonal Railways.
Presently wheel sets for WAP-4, WAP-5, WAP-7, WAG-7 and WAG-9 locos are manufactured.
(ii) Heavy Machine Shop:
Heavy Machine Shop undertakes the machining of components for loco production as well as meeting the
spares required for zonal railways such as suspension tube , 3-phase Stator for WAG 9 & WAP 5 locos,
Hitachi Magnet Frame, Equalizer & Compensating beams etc.
Machining work of Steel castings from Steel Foundry like casnub bogie bolster & side frame, brake beam,
center pivots for UIC/Casnub Bogie are also done in HMS.
(iii) Smithy & Forge shop:
SFS undertakes fabrication of End structure, Head stock of WAG-7 loco, forging of small component of loco
assembly, assembly of casnub bogie.
(iv) Light Machine Shop:
LMS manufactures small components like various types of pins, bushes, traction motor blower holding
plates etc. to meet the requirement of loco production as well as spares required for zonal railways.
(v) Tool Room:
Tool Rooms supplies toolings, gauges, jigs and fixtures for production requirements of various shops and
also carries out calibration of various gauges, fixtures, instruments etc. to meet the ISO requirements.
(v) Heat Treatment shop :
Heat Treatment Shops undertakes heat treatment of bogies manufactured in Loco Shops and other items
e.g. Magnet Frame, Equalizer, Compensating Beams etc. manufactured in Heavy machine shop.
Machinery and Plant Procurement:
MPP & M&P section plans for procurement and commissioning of M & Ps required for production of
components of different types of locos and spares in loco works as well as M&Ps for Steel Foundry,
Hospital, Central Power House, etc.
Transport Shop (TPT):
Transport shop maintains all road vehicles consisting of passenger vehicles like cars, Jeeps, Mini Buses
and industrials vehicles like Truck, forklift, Dumpers, tractors, Platform Trucks/Listers sky lifts for movement
of material.
Yard Organisation:
For movement of traffic wagons, departmental wagon and locomotives/locomotive shell on dummy bogies,
four shunting engines (3WDM2,E.Rly) have been deployed. These locomotives are maintained and
operated by Andal Diesel Shed. Shunting requirement is met in three shifts. Yard organisation also keeps
liaison with the Asansol Division for movement of traffic wagons.
Plant Maintenance Organisation (LOCO WORKS):
CLW has more than 1500nos. M&Ps including 115 nos. EOT Cranes in loco works, out of which about 50%
of M&Ps are over aged. The breakdown as well as preventive maintenance of all M&Ps is carried out by
Plant Maintenance Organisation consisting of Millwright Shop (MTS-56) and Electrical repair shop (Shop-
59).
Plant maintenance organization deals with repairing, reconditioning, re-engineering, retro fitment of
machineries and plant. Installation of new small machineries and Plants, condemnation & uprooting of old
M&Ps are also carried out by these shops.
Other Items
I Other Items :
Panels :

The Switchgear / Relay panels of the Electric Locomotives WAP-4 / WAG-7 and drivers
desk are assembled in- house. The frames of these Switchgear / Relay Panels are partly
procured from trade and partly fabricated in house . For 3-phase AC locos. panels like
HB-1/HB-2. SB-1/SB-2. Filter cubicle and Drivers Desk are assembled and wired in-house.
Static Equipment & Contactors :
CLW also undertakes manufacture of Smoothing Reactor (SL). Inductive shunt(SJ),
Electro Pneumatic/Electro Magnetic Contactors.
Shell :
CLW undertakes complete manufacture of shell. The manufacture of shell involves
major fabrication works and CLW has complete facilities for undertaking the same. Recently,
a modern facility has been installed for grit blasting, spray painting and paint drying ovens
for faster painting of complete loco with polyurethanes painting process. This facility at a cost
of Rs. 80 million has been started from 18.11.2000.
Bogie Frames
CLW has the requisite facilities and undertakes complete fabrication and machining of
fabricated types of bogies for its current range of Electric Loco Production. The Electric
Locomotive types WAG-9, WAP-5 and WAG-7 are equipped with fabricated bogies. CLW has
its own Steel Foundry which turns out cast steel bogies for our current WAP-4 locomotive,
and even for our prestigious range of Electric locomotives on demand from Zonal Railways
and also for Diesel locomotives.
WHEEL SETS , HITACHI T.M., MAGNET FRAME, 3 PHASE T.M. STATOR .

CLW has complete facilities for Axle Machining, Wheel Turning and assembly of the wheel

NEW ELECTRIFICAL ENGINES
THREE PHASE ELECTRIC LOCOMOTIVES
(a) Need
Indian Railways imported 2900 HP passenger and freight locomotives alongwith transfer of
technology from 50 cycles group in France in the year 1960. The indigenous production of locomotive
was taken up at CLW in the year 1965. Indian Railways have been continuing with this technology for
over 30 years and during this period improved it to optimise its use to produce 5000HP freight and
passenger locomotives. Further upgradation was not possible. With the increase in train loads and need
for higher speeds both for passenger and freight to enable hauling of more traffic with existing
infrastructure, it became important to upgrade existing technology of electric locomotives and, thus IR
decided to go for most modern three phase high horse power electric locomotives.
(b) Acquisition
IR have acquired 30 nos (10 passenger and 20 freight) high horse power ?state of the art?
microprocessor controlled GTO thyristor based three phase drive electric locos from M/s Bombardier

Transportation (earlier called ABB), Switzerland alongwith transfer of technology (TOT) to manufacture
them indigenously at Chittaranjan Locomotive Works (CLW). The contract was placed in july?1993.
These locomotives have been received during the period Oct?95 to Oct?97 and have been put in service.
(c) Indigenous manufacturing by Indian Railways:
Through Transfer of Technology (ToT) agreement with Bombardier, Switzerland for 5 major
electrical equipments i.e. Power Converter, Auxiliary Converter, Control Electronics, Transformer and
Traction Motor to Indian Industry and three other items i.e. bogies, shell and traction motors to CLW,
first indigenously built 3-phase electric locomotive was turned out by CLW on 14th Nov., 1998. The cost
of these locomotives has been progressively coming down from the original import cost of Rs. 22 cr.
(excluding custom duties) through indigenisation initiatives. CLW has so far manufactured 40
locomotives with indigenisation of major items and the cost per locomotive has come down to 12.5 cr.
(d) Salient data and sections on which these locomotives are working:
Passenger Locomotive (WAP5)
Base shed : Ghaziabad (Northern Railway)
Power : 4000 KW
Speed Potential : 160 kmph
Operation:
Locomotives are hauling the following prestigious trains mainly Rajdhanis and Shatabdis.
2301/2302 :
New Delhi-Howrah
Rajdhani Exp.
2421/2422 :
New Delhi-Bhubneswar
Rajdhani Exp.
2951/2952 : New Delhi-Mumbai

Rajdhani Exp.
2433/2434 :
HNZM-Chennai Rajdhani
Exp.
2417/2418 :
New Delhi-Allahabad
Paryag Raj Exp.
2003/2004 :
New Delhi-Lucknow
Shatabdi Exp.
2001/2002 :
New Delhi-Bhopal Shatabdi
Exp.
2011/2012 :
New Delhi-Chandigarh
Shatabdi Exp.
Freight Locomotives(WAG9)
Base Shed : Gomoh (East Central Railway)
Power : 4500 KW, 6000 HP
Speed
Potential
: 100 kmph
Operation :
4700 T freight trains from EasternColleries to Northern
India destinations.
(e ) Features
• Regenerative braking leading to higher efficiency and energy conservation.
• Less maintenance due to adoption of electronic controls and 3 phase AC traction motors.

• Saving in power demand due to unity P.F (existing P.F is 0.85).
• Ability to haul heavier trains due to higher adhesion.
• Low wear on rails and disturbance to track geometry due to low unsprung masses.
• Reduced harmonics with exclusive harmonic filter circuit.
• Underslung arrangement of compressors with no oil fumes and oil spillage inside the machine
room.
• Micro processor based fault diagnostic system to facilitate maintenance.
• Crew friendly both in operation and trouble shooting.
• Low consumption of brake blocks on wagons/coaches
• Reduction in consumption of wheel discs of loco due to increased life of wheels.
• Availability of extra line capacity on saturated routes due to higher acceleration and balancing
speeds.
• Higher engine kms /per day due to improved transit time and higher productivity.
• Reduced requirement of rolling stock due to lesser turn around period.

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