This document discusses an internship report on an electric locomotive workshop in Bhusawal, India. It provides background on the history of Indian railways and introduces the periodic overhaul (POH) workshop in Bhusawal. The workshop services various electric locomotive types and has various sections that each perform maintenance, testing, and repair of different locomotive components. The internship helped the student learn about the working of a large organization and technical processes.

2. ELECTRIC LOCOMOTIVE WORKSHOP
BHUSAWAL (P.O.H.)

3. Submitted By:
DHIRAJ U. MAHAJAN
Prof. B.A.WANI Prof: K. R. Patil
(GUIDE) (H.O.D)
KCE SOCIETY COLLEGE OF ENGINEERING &
INFORMATION TECHNOLOGY
JALGAON (2012-13)
Submitted To
DEPARTMENT OF ELECTRICAL
ENGINEERING.

4.  History of Railway
Introduction of POH
Types of loco
Loco contents
Section of ELW
Functions of the equipments used in loco
 Conclusion

5. HISTORY OF INDIAN RAILWAY :-
 On 16th April, 1853, the first train service
was started in India.
The first train consisting of steam engine and
some coaches. It travel between Bombay and Thane
in about 1:25 hours time. The railway track was 56
kms stretched.
On 15th August, 1854, the 2nd train service
commenced between Howrah and Hubli.

6. On the 1st July, 1856, the 3rd train service in India and
first in South India commenced between Vyasarpadi and
Walajah Road
The Indian railway about 11,000 trains every day,
serving 6,990 railway station and carry about 411
million tonnes of good traffic in the year.

7. DIFFERENT GAUGES ON THE WORLD RAILWAY
Sr. no. Types of gauges Gauge in
mm
Names of Country
1 Standard Gauge 1434 England, USA, Canada
Europe
2 Broad Gauge (W) 1676 India, Pakistan, Brazil,
Argentina
3 Cap gauge 1067 África, Japan, Java,
Australia, New Zealand
4 Meter Gauge 1000 India, France, Switzerland,
Argentina
5 Narrow Gauge 762 India

8. INTRODUCTION TO P.O.H.
Bhusawal
On year 1974, Electric Locomotive Workshop
was set up in Bhusawal.
Electric locomotive workshop Bhusawal was set
up at a cost of Rs.3.52 corers in the year 1974
This P.O.H second workshop of electrical
locomotives .
The biggest locomotives workshop Bhusawal.

9. CAPACITY OF E.L.W. BHUSAWAL
 As newly establishment ELW bhusawal
carry out 5 loco per month but now a days
they carry out 12 loco per month.
Every locomotive brought here every six year
or 600000 of run for periodic overhauling
(POH).
As new locomotive comes after 9 years on
900000 KM of run.

10.  The production and designing of new
loco had done only in Chittranjan
locomotive workshop (CLW)

11. TYPES OF LOCO AND GEAR RATIO
Type of loco Gear ratio
WAM4 58/21
WAG5 62/15
WAP1/3 58/21
WAP4 58/23
WAM4 TAO 58/21
WCAM-1/2 58/21 or 61/16
WAG5-HITACHI 64/18
WAG7-HITACHI 65/17
WCG2 74/18
WAG9 77/15
Where
W- Broad Gauge
A- A.C. Electric loco
M- Mixed Service
G- Goods Loco
CA- AC & DC LOCO
All these loco comes in (ELW) Bhusawal for periodic overhauling.

12. WAM4
WAG5

13. WAP1/3
WAP4

14. WCG2
WCG9

15. ONE LOCOMOTIVE CONTAINS MAIN
EQUIPMENT Sr. No. Name of Equipment Quantity
1 Body 1
2 Bogie 2
3 Wheel set 6
4 Traction Motor 6
5 Transformer 1
6 D.I. 1
7 B. A. panel 2
8 Rectifier 2
9 Compressor 2/3
10 Exhauster (except air break)2
11 SMGR 1
12 MVMT(Blower for T.M.) 2
13 RPS 1
14 DBR 1
15 MPS(Blower for SL) 2
16 S.L. 2
17 S.J. 3 set
18 Arno 1
19 Baby Compressor 1
20 Battery Charger 1

16. Sr. No. Name of Equipment Quantity
21 Batteries 10
22 RTPR 2
23 Main reservoir 5
24 M.P. 2
25 Buffers 4
26 C.B.C. 2
27 Pantograph 2
28 CABS 2
29 Brake arrangement 5
30 H o m 2
31 Head light 2
32 Marker Height 4
33 Parking Light 4
34 Flasher 2
35 Total valves 40
36 Brake cylinder 8/12
37 R.C. Panel 1
38 Sand boxes 8/10/12/16
39 HOM Switch 1

17. SHORT DESCRIPTION, FUNCTIONS OF THE
EQUIPMENTS USED IN A LOCO
1) Arno -
In loco there are many three phase induction
motor because at their advantages then single phase
motor but OHE supply 25 KV is single phase.
To convert single phase supply into three
phases Arno is used. The Arno converter is designed a
type of three phase squirrel cage induction motor.

18. 2) Transformer –
To provide different voltage supply to TM
transformer with tab changer is used. In this transformer
laminated core is magnetic circuit is made having three
legs. One of the leg having auto winding and with this tab
changing connector having laminated core. Another leg is
low voltage winding in their auxiliary circuit is supplied (380
V) constantly to drive 12 auxiliaries in loco. And others are
primary and secondary winding.
CAPACITY - 3469 KV
WEIGHT - 6880 KG
TOTAL - 11.5
TONNES
TAP CHANGER WEIGHT - 0.5
TONNES
OIL WEIGHT - 1.7
TONNES
OIL CONTAIN - 2000
LITRES

19. 3) Pantograph –
The most important function of pantograph is to make contact with OHE or
cater nary wire and collect all supply from OHE (I.e. 25 KV)
Full panto is made up of hallow
aluminium pipe and strips and it can be
hold easily with 7 Kg contact pressure. The
whole panto is controlled by two spring. The
springs are fitted at the piston at
servomotor.
The time period of touching should 65 to
19 sec. And lowering time for panto is max.
10 sec. The height of OHE from base of
panto is between 1.75 to 2 meter

20. 4) Rectifier –
Rectifier is used for converting AC into DC and
the process is known as rectification. The rectifier
uses silicon and germanium diode. It is a bridge
rectifier and have simply p-n junction.

21. 5) Body -
This is the main convert at locomotive. This
is made of very high strength of metal sheet.
It is also called as spinal cord of loco. It
protects all the equipment in loco form air.
Rain or dust etc.
It contains 2 cabs and all lighting system.

22. 6) M.P. -
It is called as master controller. We may call it as brain of
loco. When complete loco is ready and it doesn’t move without
M.P.
 M.P. contains control switches driver
handle, shunting handle, panto switch, R.F
switch and etc. It has 32 notches. As the
notches are increased the speed of loco is
also increased.

23. 7) T.M. -
Traction motor is the main part of the loco. Without T. M. loco is unable to
move. Traction motor wants pure D.C. supply.
It has two main parts-
1) Armature
2) Winding

24. Following are the sections in ELW
Bhusawal :-
Erection Section
Bogie Section
Wheel Section
Recalling Section
Traction motor Section
Transformer Section
Test room Section
Pneumatic Section
Machine shop Section
R & M Section
B.A Panel Section
Mill Wright Section
Static Section
White metal Section
Inspection Section
Test Laboratory
Test room (Relay)
E.P Contactor section
Rewinding Section

25. DIFFERENT SECTIONS AND
RESPECTIVE FUNCTION OF ELW
•Erection Section :-
When loco comes in ELW for POH it is
comes to erection for dismantle. Assembling and
dismantling of all loco parts is carried out in this section.
After dismantling all parts are dispatched to respective
section for maintenance after completing all maintenance
work assembling of loco is done.
•R and M section –
When loco is damaged or burned then repair and
maintenance is carried out in this section. It contain –
i] Press machine for bending
ii] Sharing machine for cutting

26. • Pneumatic Section –
There are 40 different valves are fitted in a loco. All
leakage or any problem are removed in this section and make
them fully efficient. In this section also overhauling of horn is
done. As all loco circuit is electro pneumatic. Pneumatic section
is the heart of loco and ELW.
• Bogie Section :-
After dismantling loco bogie is send to this section
by erection section. In this section all parts are attached from
bogie frame is send for inspecting cracks. Here wheels and
traction motor are detached from bogie and send them to
respective section, where overhauling of parts is done.
•Wheel Section :-
In this section wheel comes from bogie sections. Here
axle box and set are dismantle and necessary operation are
done on wheel disc and axle box, with help of different
machines.

27. • Traction Motor Section :-
In this section relating traction motor all maintenance
including bearing and armature maintenance is carried out.
Different test are carried out on T.M. in this section.
 H.V. Test :-
In this test 2.5 KV voltage applied to T.M. see the
leakage current.
 Run Test :-
In this test rated supply is given to motor and run it for
2 hours. In between these vibration in motor, temp. And motor,
noise in rotor are observed. After completing tests if armature
and field winding are found OK. Then they are assembled. If
there is any disturb in field winding replacement
A] Same resistance
B] Same inductance
C] No one winding open
D] No winding grounded

28. • Transformer section –
In this section maintenance of transformer is done.
following function are done in this section.
I] dismantling all parts of transformer
ii] Checking insulation of winding
iii] Breaking down voltage test on insulating oil
IV] Cleaning bushing
v] Cleaning winding
vi] Replacement oil
vii] Cleaning fins of cooling
viii] H.V. test
In HV test 380 V supply is given to auxiliary winding
so 25 KV we get across primary and by changing
taps the voltage across each tap is taken and check
for temperature rise.

29. •Test Lab -
Test lab is the most important part of ELW, Bhusawal when the new
equipment comes in ELW. All testing of sample piece is done here. After
certification of this department all stock is distributed to respective section.
Various tests are done in this section some of them are as follows:
•Non destructive Testing (NDT) –
•Ultrasonic testing
•RPDT (Red, penetrate dye test)
Ultrasonic Testing –
It is carried with the help of ultrasonic flow detector machine
used. This principle behind ultrasonic testing is based on piezoelectric
effect.
 RPDT -
The kit is having 3 can –
•Cleaner
•Red dye
•Developer
Principle based on capillary action.

30. CONCLUSION
The Industrial training helps student to experience working
environment of industry & evoked in yourself technical
thinking and develop ability to understand basic factor.
So this training taught many new technique & procedure
of such a big organization.
It helped me to learn co-ordination between department,
organizations and communication between different levels of
organization.