TRAINING REPORT SUBMITTED BY: KANHAIYA

KUMAR

STD.- B.TECH 7th SEM

BRANCH:- MECHANICAL

IT-GURU GHASIDAS UNIVERSITY, BILASPUR, C.G

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

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.

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 .

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

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

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

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

4. BRAKES

Mainly three types of brakes are used-

(a). Air Brake System

(b). Regenerative Brake System.

(c). Parking type

(a). AIR BRAKES

This braking systems use compressed air as the

force to push blocks on to wheels or pads on to

discs.

(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.

(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

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

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”.

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.

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

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

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

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.

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.

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