electric locomotive workshop

7/23/2019 Electric Locomotive Workshop.

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In-plant Training

HISTORY OF RAILWAYS

(Electrical point of view)

The first electric train ran between Bombay's Victoria Terminus and Kurla along the

Harbour Line of CR, on February , !"#$, a distance of "%$ miles% &n !"#, Thana and (ahimwere connected% &n !"#), electrification was com*lete u* to Kalyan% &n !"#+, Boriili in the

north was connected -Colaba.Boriili of /R being inaugurated on (ay !0% &n !"#", Kalyan .

&gat*uri section was commissioned% &n !"1, the Kalyan . 2oona trac3s were o*ened to

electric trains%

&t is sometimes stated that the electric train in !"#$ was 4sia's first

electric, or electric suburban, train serice% This is howeer not true, because electric serices

were running in 5a*an since 5an% !, !+"$, on the Kyoto 6lectric Railway -officially listed

under '67*loitation 8e*artment', Kyoto (unici*ality, in the annual re*orts of the

9oernment of 5a*an's 8e*artment of Railways0, but this is sometimes classified as atramway instead of a light rail system% -&nterestingly, this was also the year that the first

5a*anese steam locomotie was manufactured%0 6lectric railcar serices ran on the

9oernment Railways of 5a*an from about !"1$, and -9erman.built0 electric locomoties

were introduced in 5a*an in !"!!% &n !"!" the first the first entirely 5a*anese electric

locomotie was built -a class 68.:10% &n &ndonesia, the first electrified section -!$11V 8C0

of the ;tate Railways o*ened at Bataia -5a3arta0 in !"#$, the same year as in Bombay%

at.2une and Kasara.&gat*uri sections because it wasreali?ed that the heay traffic to and from Bombay would be suitable for electric haulage%

Following this there was a long ga*, and the ne7t electrification *ro>ect

started only !"$ or !"$:, in the Calcutta area -Howrah.Burdwan ia Bandel, ;heora*hulli.

Tara3eshwar0, using 3V 8C traction% 4t this time, the idea of mainline electrification

-Howrah.(ughalsarai0 was seriously mooted% ;u**ort for #$3V 4C traction was also

growing at about this time, es*ecially after some trials of 4C locos from ;=CF, and studies

that concluded that the single.*hase load from electric traction would not seriously unbalance

the .*hase regional grids%

Electric Locomotive Workshop Bhusaval 1


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In-plant Training

4fter a *eriod of about #$ years of aggressie electrification, now

@!#A1: &R has most of the busy routes of its networ3 electrified -although not all0, and this

has resulted in about $ of the traffic being hauled by electric traction% Recently @!#A1:,

therefore, &R has decided to slow down the *ace of electrification .. about #113m of routes

are scheduled to be electrified in the ne7t !1 years, com*ared to $!113m in the *ast !1 years%

The focus will be on consolidating electric traction for the busiest sectionsD some of the

sections that will be conerted to electric traction in the ne7t few years are 2une.9unta3al,

Bina.Kota, and many 'B' sections of =R%



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In-plant Training

ZONAL RAILWAYS

INTRODUCTION TO P.O.H

Electric Locomotive Workshop Bhusaval

Sl. No Name Headquarters Diisio!s

!% =orthernRailway !" 8elhi 8elhi,4mbala,Firo?*ur,Luc3now, (oradabad

#% =orth

6astern

Railway

!E" 9ora3h*ur &??atnagar, Luc3now,

Varanasi

% =ortheast

Frontier

Railway

=FR 9uwahati 4li*urduar,Katihar,

Lumding, Rangia, Tinsu3ia

:% 6astern 6R Kol3ata Howrah,;ealdah,4sansol,

$% ;outh

6astern

Railway

;6R Kol3ata 4dra, Cha3radhar*ur,

Kharag*ur, Ranchi

% ;outh

Central

Railway

;CR ;ecunderabad ;ecunderabad, Hyderabad,

9unta3al, 9untur,=anded,

Vi>ayawada

)% ;outhern

Railway

;R Chennai Chennai, (adurai, 2alghat,

Tiruchchira*alli,Triandrum,

;alem-Coimbatore0

+% Central

Railway

CR (umbai (umbai,Bhusawal, 2une,

;ola*ur,=ag*ur

"% /estern

Railway

/R (umbai (umbai Central, Baroda,

Ratlam,4hmedabad,Ra>3ot,

Bhanagar

!1% ;outh

/estern

;/R Hubli Hubli, Bangalore,(ysore

!!% =orth

/estern

Railway

=/R 5ai*ur 5ai*ur , 4>mer, Bi3aner,

5odh*ur

!#% /est

Central

/CR 5abal*ur 5abal*ur ,Bho*al, Kota

!% =orth

Central

=CR 4llahabad 4llahabad, 4gra, 5hansi

!:% ;outh 6astCentral

Railway

;6CR Bilas*ur, C9 Bilas*ur,Rai*ur,=ag*ur

!$% 6ast Coast

Railway

6CoR Bhubaneswar Khurda Road, ;ambal*ur,

Visa3ha*atnam

!% 6ast Central

Railway

6CR Ha>i*ur 8ana*ur, 8hanbad,

(ughalsarai, ;amasti*ur,

;on*ur

!)%

Kon3an

RailwayE

KR =ai (umbai =one
http://en.wikipedia.org/wiki/Northern_Railway_(India)http://en.wikipedia.org/wiki/Northern_Railway_(India)http://en.wikipedia.org/wiki/Delhihttp://en.wikipedia.org/wiki/Ambalahttp://en.wikipedia.org/wiki/Firozpurhttp://en.wikipedia.org/wiki/Lucknowhttp://en.wikipedia.org/wiki/Moradabadhttp://en.wikipedia.org/wiki/North_Eastern_Railway_(India)http://en.wikipedia.org/wiki/North_Eastern_Railway_(India)http://en.wikipedia.org/wiki/North_Eastern_Railway_(India)http://en.wikipedia.org/wiki/Gorakhpurhttp://en.wikipedia.org/wiki/Izzatnagarhttp://en.wikipedia.org/wiki/Lucknowhttp://en.wikipedia.org/wiki/Varanasihttp://en.wikipedia.org/wiki/Northeast_Frontier_Railwayhttp://en.wikipedia.org/wiki/Northeast_Frontier_Railwayhttp://en.wikipedia.org/wiki/Northeast_Frontier_Railwayhttp://en.wikipedia.org/wiki/Guwahatihttp://en.wikipedia.org/wiki/Alipurduarhttp://en.wikipedia.org/wiki/Katiharhttp://en.wikipedia.org/wiki/Lumdinghttp://en.wikipedia.org/wiki/Rangiahttp://en.wikipedia.org/wiki/Tinsukiahttp://en.wikipedia.org/wiki/Eastern_Railway_(India)http://en.wikipedia.org/wiki/Kolkatahttp://en.wikipedia.org/wiki/Howrahhttp://en.wikipedia.org/wiki/Sealdahhttp://en.wikipedia.org/wiki/Asansolhttp://en.wikipedia.org/wiki/South_Eastern_Railway_(India)http://en.wikipedia.org/wiki/South_Eastern_Railway_(India)http://en.wikipedia.org/wiki/South_Eastern_Railway_(India)http://en.wikipedia.org/wiki/Kolkatahttp://en.wikipedia.org/wiki/Adra_(India)http://en.wikipedia.org/wiki/Chakradharpurhttp://en.wikipedia.org/wiki/Kharagpurhttp://en.wikipedia.org/wiki/Ranchihttp://en.wikipedia.org/wiki/South_Central_Railwayhttp://en.wikipedia.org/wiki/South_Central_Railwayhttp://en.wikipedia.org/wiki/South_Central_Railwayhttp://en.wikipedia.org/wiki/Secunderabadhttp://en.wikipedia.org/wiki/Hyderabad_(India)http://en.wikipedia.org/wiki/Guntakalhttp://en.wikipedia.org/wiki/Gunturhttp://en.wikipedia.org/wiki/Nandedhttp://en.wikipedia.org/wiki/Vijayawadahttp://en.wikipedia.org/wiki/Southern_Railway_(India)http://en.wikipedia.org/wiki/Southern_Railway_(India)http://en.wikipedia.org/wiki/Chennaihttp://en.wikipedia.org/wiki/Maduraihttp://en.wikipedia.org/wiki/Palghathttp://en.wikipedia.org/wiki/Tiruchirapallihttp://en.wikipedia.org/wiki/Trivandrumhttp://en.wikipedia.org/wiki/Salemhttp://en.wikipedia.org/wiki/Coimbatorehttp://en.wikipedia.org/wiki/Central_Railway_(India)http://en.wikipedia.org/wiki/Central_Railway_(India)http://en.wikipedia.org/wiki/Mumbaihttp://en.wikipedia.org/wiki/Bhusawalhttp://en.wikipedia.org/wiki/Punehttp://en.wikipedia.org/wiki/Solapurhttp://en.wikipedia.org/wiki/Nagpurhttp://en.wikipedia.org/wiki/Western_Railway_(India)http://en.wikipedia.org/wiki/Western_Railway_(India)http://en.wikipedia.org/wiki/Mumbaihttp://en.wikipedia.org/wiki/Mumbai_Centralhttp://en.wikipedia.org/wiki/Vadodarahttp://en.wikipedia.org/wiki/Ratlamhttp://en.wikipedia.org/wiki/Ahmedabadhttp://en.wikipedia.org/wiki/Rajkothttp://en.wikipedia.org/wiki/Bhavnagarhttp://en.wikipedia.org/wiki/South_Western_Railwayhttp://en.wikipedia.org/wiki/South_Western_Railwayhttp://en.wikipedia.org/wiki/Hublihttp://en.wikipedia.org/wiki/Bangalorehttp://en.wikipedia.org/wiki/Mysorehttp://en.wikipedia.org/wiki/North_Western_Railwayhttp://en.wikipedia.org/wiki/North_Western_Railwayhttp://en.wikipedia.org/wiki/North_Western_Railwayhttp://en.wikipedia.org/wiki/Jaipurhttp://en.wikipedia.org/wiki/Ajmerhttp://en.wikipedia.org/wiki/Bikanerhttp://en.wikipedia.org/wiki/Jodhpurhttp://en.wikipedia.org/wiki/West_Central_Railwayhttp://en.wikipedia.org/wiki/West_Central_Railwayhttp://en.wikipedia.org/wiki/Jabalpurhttp://en.wikipedia.org/wiki/Bhopalhttp://en.wikipedia.org/wiki/Kotahttp://en.wikipedia.org/wiki/North_Central_Railwayhttp://en.wikipedia.org/wiki/North_Central_Railwayhttp://en.wikipedia.org/wiki/Allahabadhttp://en.wikipedia.org/wiki/Agrahttp://en.wikipedia.org/wiki/Jhansihttp://en.wikipedia.org/wiki/South_East_Central_Railwayhttp://en.wikipedia.org/wiki/South_East_Central_Railwayhttp://en.wikipedia.org/wiki/South_East_Central_Railwayhttp://en.wikipedia.org/wiki/Bilaspur%2C_Chhattisgarhhttp://en.wikipedia.org/wiki/Raipurhttp://en.wikipedia.org/wiki/Nagpurhttp://en.wikipedia.org/wiki/East_Coast_Railwayhttp://en.wikipedia.org/wiki/East_Coast_Railwayhttp://en.wikipedia.org/wiki/Bhubaneswarhttp://en.wikipedia.org/wiki/Khurda_Roadhttp://en.wikipedia.org/wiki/Sambalpurhttp://en.wikipedia.org/wiki/Visakhapatnamhttp://en.wikipedia.org/wiki/East_Central_Railwayhttp://en.wikipedia.org/wiki/East_Central_Railwayhttp://en.wikipedia.org/wiki/Hajipurhttp://en.wikipedia.org/wiki/Danapurhttp://en.wikipedia.org/wiki/Dhanbadhttp://en.wikipedia.org/wiki/Mughalsaraihttp://en.wikipedia.org/wiki/Samastipurhttp://en.wikipedia.org/wiki/Sonpurhttp://en.wikipedia.org/wiki/Konkan_Railwayhttp://en.wikipedia.org/wiki/Konkan_Railwayhttp://en.wikipedia.org/wiki/Navi_Mumbaihttp://en.wikipedia.org/wiki/Delhihttp://en.wikipedia.org/wiki/Delhihttp://en.wikipedia.org/wiki/Ambalahttp://en.wikipedia.org/wiki/Firozpurhttp://en.wikipedia.org/wiki/Lucknowhttp://en.wikipedia.org/wiki/Moradabadhttp://en.wikipedia.org/wiki/North_Eastern_Railway_(India)http://en.wikipedia.org/wiki/North_Eastern_Railway_(India)http://en.wikipedia.org/wiki/North_Eastern_Railway_(India)http://en.wikipedia.org/wiki/Gorakhpurhttp://en.wikipedia.org/wiki/Izzatnagarhttp://en.wikipedia.org/wiki/Lucknowhttp://en.wikipedia.org/wiki/Varanasihttp://en.wikipedia.org/wiki/Northeast_Frontier_Railwayhttp://en.wikipedia.org/wiki/Northeast_Frontier_Railwayhttp://en.wikipedia.org/wiki/Northeast_Frontier_Railwayhttp://en.wikipedia.org/wiki/Guwahatihttp://en.wikipedia.org/wiki/Alipurduarhttp://en.wikipedia.org/wiki/Katiharhttp://en.wikipedia.org/wiki/Lumdinghttp://en.wikipedia.org/wiki/Rangiahttp://en.wikipedia.org/wiki/Tinsukiahttp://en.wikipedia.org/wiki/Eastern_Railway_(India)http://en.wikipedia.org/wiki/Kolkatahttp://en.wikipedia.org/wiki/Howrahhttp://en.wikipedia.org/wiki/Sealdahhttp://en.wikipedia.org/wiki/Asansolhttp://en.wikipedia.org/wiki/South_Eastern_Railway_(India)http://en.wikipedia.org/wiki/South_Eastern_Railway_(India)http://en.wikipedia.org/wiki/South_Eastern_Railway_(India)http://en.wikipedia.org/wiki/Kolkatahttp://en.wikipedia.org/wiki/Adra_(India)http://en.wikipedia.org/wiki/Chakradharpurhttp://en.wikipedia.org/wiki/Kharagpurhttp://en.wikipedia.org/wiki/Ranchihttp://en.wikipedia.org/wiki/South_Central_Railwayhttp://en.wikipedia.org/wiki/South_Central_Railwayhttp://en.wikipedia.org/wiki/South_Central_Railwayhttp://en.wikipedia.org/wiki/Secunderabadhttp://en.wikipedia.org/wiki/Secunderabadhttp://en.wikipedia.org/wiki/Hyderabad_(India)http://en.wikipedia.org/wiki/Guntakalhttp://en.wikipedia.org/wiki/Gunturhttp://en.wikipedia.org/wiki/Nandedhttp://en.wikipedia.org/wiki/Vijayawadahttp://en.wikipedia.org/wiki/Southern_Railway_(India)http://en.wikipedia.org/wiki/Southern_Railway_(India)http://en.wikipedia.org/wiki/Chennaihttp://en.wikipedia.org/wiki/Chennaihttp://en.wikipedia.org/wiki/Maduraihttp://en.wikipedia.org/wiki/Palghathttp://en.wikipedia.org/wiki/Tiruchirapallihttp://en.wikipedia.org/wiki/Trivandrumhttp://en.wikipedia.org/wiki/Salemhttp://en.wikipedia.org/wiki/Coimbatorehttp://en.wikipedia.org/wiki/Central_Railway_(India)http://en.wikipedia.org/wiki/Central_Railway_(India)http://en.wikipedia.org/wiki/Mumbaihttp://en.wikipedia.org/wiki/Mumbaihttp://en.wikipedia.org/wiki/Bhusawalhttp://en.wikipedia.org/wiki/Punehttp://en.wikipedia.org/wiki/Solapurhttp://en.wikipedia.org/wiki/Nagpurhttp://en.wikipedia.org/wiki/Western_Railway_(India)http://en.wikipedia.org/wiki/Western_Railway_(India)http://en.wikipedia.org/wiki/Mumbaihttp://en.wikipedia.org/wiki/Mumbai_Centralhttp://en.wikipedia.org/wiki/Vadodarahttp://en.wikipedia.org/wiki/Ratlamhttp://en.wikipedia.org/wiki/Ahmedabadhttp://en.wikipedia.org/wiki/Rajkothttp://en.wikipedia.org/wiki/Bhavnagarhttp://en.wikipedia.org/wiki/South_Western_Railwayhttp://en.wikipedia.org/wiki/South_Western_Railwayhttp://en.wikipedia.org/wiki/Hublihttp://en.wikipedia.org/wiki/Hublihttp://en.wikipedia.org/wiki/Bangalorehttp://en.wikipedia.org/wiki/Mysorehttp://en.wikipedia.org/wiki/North_Western_Railwayhttp://en.wikipedia.org/wiki/North_Western_Railwayhttp://en.wikipedia.org/wiki/North_Western_Railwayhttp://en.wikipedia.org/wiki/Jaipurhttp://en.wikipedia.org/wiki/Jaipurhttp://en.wikipedia.org/wiki/Ajmerhttp://en.wikipedia.org/wiki/Bikanerhttp://en.wikipedia.org/wiki/Jodhpurhttp://en.wikipedia.org/wiki/West_Central_Railwayhttp://en.wikipedia.org/wiki/West_Central_Railwayhttp://en.wikipedia.org/wiki/Jabalpurhttp://en.wikipedia.org/wiki/Jabalpurhttp://en.wikipedia.org/wiki/Bhopalhttp://en.wikipedia.org/wiki/Kotahttp://en.wikipedia.org/wiki/North_Central_Railwayhttp://en.wikipedia.org/wiki/North_Central_Railwayhttp://en.wikipedia.org/wiki/Allahabadhttp://en.wikipedia.org/wiki/Allahabadhttp://en.wikipedia.org/wiki/Agrahttp://en.wikipedia.org/wiki/Jhansihttp://en.wikipedia.org/wiki/South_East_Central_Railwayhttp://en.wikipedia.org/wiki/South_East_Central_Railwayhttp://en.wikipedia.org/wiki/South_East_Central_Railwayhttp://en.wikipedia.org/wiki/Bilaspur%2C_Chhattisgarhhttp://en.wikipedia.org/wiki/Bilaspur%2C_Chhattisgarhhttp://en.wikipedia.org/wiki/Raipurhttp://en.wikipedia.org/wiki/Nagpurhttp://en.wikipedia.org/wiki/East_Coast_Railwayhttp://en.wikipedia.org/wiki/East_Coast_Railwayhttp://en.wikipedia.org/wiki/Bhubaneswarhttp://en.wikipedia.org/wiki/Khurda_Roadhttp://en.wikipedia.org/wiki/Sambalpurhttp://en.wikipedia.org/wiki/Visakhapatnamhttp://en.wikipedia.org/wiki/East_Central_Railwayhttp://en.wikipedia.org/wiki/East_Central_Railwayhttp://en.wikipedia.org/wiki/Hajipurhttp://en.wikipedia.org/wiki/Danapurhttp://en.wikipedia.org/wiki/Dhanbadhttp://en.wikipedia.org/wiki/Mughalsaraihttp://en.wikipedia.org/wiki/Samastipurhttp://en.wikipedia.org/wiki/Sonpurhttp://en.wikipedia.org/wiki/Konkan_Railwayhttp://en.wikipedia.org/wiki/Konkan_Railwayhttp://en.wikipedia.org/wiki/Navi_Mumbaihttp://en.wikipedia.org/wiki/Northern_Railway_(India)http://en.wikipedia.org/wiki/Northern_Railway_(India)


4/38

In-plant Training

=ow a days indian railways hae largely are locomotie of electric ariety

because at their large adantages oer other locomotie

The electric locomotie wor3sho* -6L/0 re*airs and does the necessary

maintance at these engine %The locomotie comes to 6%L%/%for 2


5/38

In-plant Training

Recabling of aboe class in addition to /C9# loco%

;*ecial re*air to 4ccident damaged and burnt locomotie of c%rly

8ual bra3e conersion of /4(:G/C9# locomoties%

Catering to wheel sets re*airs ,rediscing and regarding reuirement at 4C

locomoties shed on central railway%

CAPACITY OF #.L.W. &HUSA$AL.

4s newly establishment 6L/ Bhusaal carryout $ locos *er month but now a days they carry


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In-plant Training

DIFF#R#NT S#CTION * TH#IR R#SP#CTI$# FUCTION

OF #LW %P.O.H.'

+' #R#CTION S#CTION.

/hen loco comes in 6L/ for 2%


7/38

In-plant Training

0' T.".S#CTION.

&n locomoties the d%c%series motor is used because the d%c% motor hae

starting torue and most suitable characteristic for locomotie% The dg series motor has two

ty*es

!% Tao motor

#% Hitachi motor

&n one locomotie only one ty*e of motor is used on this traction motor some tests are

carried out as follows.

!0 TAN D#LTA T#ST.&t is used for including condition of insulation and is

angle between inductie current% ;o alue of tan delta must be minimum%

#0SUR-# $OLTA-# T#ST()

&n this test momentarily high oltage of a**lied to T%(% and gra*h obsered

on cro %

0H.$. T#ST.

&n this test #%$ Kg 3 oltage is a**lied to T%(% and see the lea3age current%

:0 RUN T#ST.

&n this test rated su**ly gies to motor and run it for # hours in

between these ibration in motor ,tem* and motor noise in rotor are obsered%

4fter com*leting this test its armature and field windings are found o3% Then they

are assembled% &f there is any disturb in field winding re*lacement of winding is

done%

1' TRANSFOR"#R S#CTION.

/hen the transformer is detached from loco then it comes to this section

%&n this section the transformer can change under this section for maintenance%

There is dismantling of transformer to chec3 were the transformer is o3

or not% The following test can be *erformed on the transformer%

!0WINDIN- T#ST.

&n this test resistance of winding can be measured %



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In-plant Training

#0INSULATIN- R#SISTANC# T#ST.

&n this test the insulation resistance of winding &s to be measured by megger %

The test is carries after H%V%test %

'H.$. T#ST.

&n this test high oltage is a**lied to transformer then select the ta*

changer is non ?ero it show the alue of current is :1.$1 4% /hen the current

leel of transformer is increased to !$14 during test the transformer not

suitable for traction%

/' "OISTUR# T#ST.

&n this test the moisture content on coil of transformer is to be chec3ed%

2' PN#U"ATIC S#CTION.

&n this section :$ ty*es of *neumatic ales are re*aired and maintenance the

wor3ers *erform arious test and trial on *neumatic eui*ment if locomotie because of easy

trans*ortability of com*ressed air in *ressure cylinder ,long *i*es and tubes and maintain fire

*roof characteristic medium%

3' AU4ILLARY S#CTION.

4u7illary means the su**orting the au7illary eui*ment used in loco start the

loco freuency without any *rolem and is done in all section%

2articularly the air com*ressor which is source of *neumatic circuit in this

com*ressor %The air can be *roided to com*ressor and this will cool on inter cooler and

after this air will *ass through L2.H2%

The drien motor of com*ressor is J &%( % which &s su**lied from arno

cylinder and any fault occur in com*ressor then first chec3 the reason fault and

Then re*lace it%

5' RSI S#CTION ()



9/38

In-plant Training

The section is nothing but rectifier section it is the most im*ortant section in

*oh 4fter demantaling of loco in erection section the rectifier bloc3 comes to this section %

&t is an electronic deice that conert ac su**ly to dc su**ly the traction

motor used in loco is the dc series motor %;o dc su**ly is su**lied for traction motor%

+6' T#ST ROO")

&n this section the fuction of 85 G ;(9R is to be tested /here the 85 is

nothing but the ta* changer ,@disc >ointer &n this section the whole section of ;(9R is to be

chec3ed@sero motor of gr%

++' "ACHIN# SHOP S#CTION.

Turning ,8riling,Ta*ring,;ha*ing,(illing, Threading, etc%

!0 Center lathe $

#0 H(T machine

0 Turret lathe machine

:0 8riling machine #

$0 (iling machine $

0 surface grinder #

)0 98# lathe #

+,' R" S#CTION.

&= this section the re*aring of accidental loco is done and maintenance of central

*iot%

The central *iot is attached to lower side of loco %The fuction of this is to carry

the loco %;ide mirror is also manufactured in this section in /4(: the side (irror is used%

+' INSP#CTION S#CTION.

/hen the railways comes in L/ for 2


10/38

In-plant Training

0;ander wor3ing

)0(eter wor3ing

+02antogra*h

+/' 7ULITY CONTROL LA&.

&n this the uality of different material, oil insulating material is to be tested% &n

this lab the testing on ferrous and non ferrous material , transformer oil is *erformed on

different material%

;R

=


11/38

In-plant Training

+2' TOOL S#CTION()

/hen any tool is reuired in any section then this need is satisfied by tool room

section &n this section the arious eui*ment are *resent as follows

!0Hydraulic *um*

#0Torue bench

0;oc3et of tighting the nut

:08ifferent meters and gauges

+3' "CO S#CTION.

This is nothing but the material collection section the section is *roide the

material which will reuired for 2


12/38

In-plant Training

d0 2oldi Hardness Test

e0 Brinell Hardness Test

f0 Iltrasonic Test

g0 (agnaflu7 Test

h0 Rubber Tension Test

i0 Transformer oil moisture content test, etc%

;ome of the sections related with (echanical 6ngineering are as follows,

/heel ;ection

Bogie ;ection

CLASSIFICATION OF LOCO"OTI$#S

Locos, e7ce*t for older steam ones, hae classification codes that identify

them% This code is of the form '@gauge@*ower@load@series@subty*e@suffi7'

&n this the first item, '@gauge', is a single letter identifying the gauge the loco runs on

/ Broad 9auge (eter 9auge



13/38

In-plant Training

M =arrow 9auge -#' N0

= =arrow 9auge -#'0

The second item, '@*ower', is one or two letters identifying the *ower source

8 8iesel

C 8C traction

4 4C traction

C4 8ual.*ower 4CA8C traction

B Battery electric-rare0

The third item, '@load', is a single letter identifying the 3ind of load the loco is normally used

for

( (i7ed Traffic

2 2assenger

9 9oods

; ;hunting

L Light 8uty -Light 2assengerO0 -no longer in use0

I (ulti*le Init -6(I A 86(I0

R Railcar -see below0

The fourth item, '@series', is a digit identifying the model of the loco% Intil

recently, this series number was sim*ly assigned chronologically as new models of locos

were introduced%

The fifth item, '@subty*e', is an o*tional letter or number -or two of them0 that

indicates some smaller ariation in the basic model or series, *erha*s different motors, or a

different manufacturer% /ith the new scheme for classifying diesel locos -see aboe0, the fifth

item is a letter that further refines the horse*ower indication in !11h* increments '4' for

!11h*, 'B' for #11h*, 'C' for 11h*, etc% ;o in this scheme, a /8(.4 refers to a !11h*loco, while a /8(.F would be a 11h* loco%

The last item, '@suffi7', is an o*tional indication that indicates something

s*ecial about the loco, such as a different gearing ratio or bra3e system than usual%



14/38

In-plant Training

;R =


15/38

In-plant Training

# (ain Reseroir $

#: (%2% #

#$ Buffers :

# C%B%C% #

#) 2antogra*h #

#+ C4B; #

#" Brea3 4rrangement $

1 Horn #

! Head Light #

# (ar3er Light :

2ar3ing Light :

: Flasher #

$ Total Vales :1

Bra3e Cylinder +A!#

) R%C% 2anel !

+ ;and Bo7es +A!1A!#A!

" H


16/38

In-plant Training

TYP#S OF LOCO"OTI$#S * SP#CIFICATION

WA"9+

"a!u:a;turers(Kraus.(affei, Kru**, ;F4C, La Brugeoise G =ielle -$1 cycles

6uro*ean grou*0

Tra;tio! "otors(;iemensA4C6CA4lstom (9 )!14 -):1h*, !#$1V, :+14, !111

r*m, weight #)$13g0% Fully sus*ended, force.entilated%

Re;ti:iers(Four water.cooled ignitrons from ;9T, each rated for $)$3/ A !#$1V%

Pa!tos(Two Faieley 4(.!#%

WA"9,

"a!u:a;turers((itsubishi

Tra;tio! "otors((itsubishi (B 1:$.4 -):$h*, )#$V, +!$4, !111 r*m, weight

##113g0%

Re;ti:iers((itsubishi water.cooled ignitrons -9I !0, rated at )#$V A "14%


WA"9

"a!u:a;turers((itsubishi

Tra;tio! "otors((itsubishi (B 1:$.4 -):$h*, )#$V, +!$4, !111 r*m, weight

##113g0%

Re;ti:iers(Two ;ilicon , ty*e ;F.1C#1R -)#$V A ##13/0, rectifier cell ;R#11F,

weight #:113g with au7iliaries%


WA"9/

"a!u:a;turers(CL/

Tra;tio! "otors(4lstom T4< $" 4! -$)$3/, )$1V0% ;i7 motors, a7le.hung, nose.

sus*ended, force.entilated%

-ear Ratio(!$# originally -and still for /4(.: #;20, now many ariations,

#!$+ being common for /4(.: 2 locos%%

Tra!s:ormer(Heil B


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In-plant Training

A?le load(!+%+t

&o


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In-plant Training

"a!u:a;turers(CL/

Tra;tio! "otors(Hitachi H;!$#$1 -13/, )$1V, "114% +"$r*m% /eight $113g0%

47le.hung, nose.sus*ended, force entilated, ta*er roller bearings%

-ear Ratio(#$+ -eel diameter(!1"#mm new, !1!mm worn

W>eel ase(!$)11mm

&o(!$#mmn

Ca le!(#::mm

Pa!to lo;Bed do! >eit(:$#$mm



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In-plant Training

4 #:.coach -!:1t0 *assenger ra3e can be accelerated to !!13mAh in #:1 seconds -oer

:%)3m0 by a /42.)D to !#13mAh in 1: sec% -%)3m0D and to !13mAh in ": sec% -"%"3m0%

WA-9+

Tra;tio! "otors(46CA4lstomA;iemens (9!:#1% Two motors -monomotor bogies0,force.entilated, fully sus*ended%

-ear Ratio(%"$!

Tra!s:ormer((F


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In-plant Training

Curre!t Rati!


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In-plant Training

conertor rated at # 7 !#"V S $1H?, with 8C lin3 oltage of #+11V% (otorAdrie

conertor rated at #!+1V *hase to *hase, ")!4 out*ut current *er *hase, motor

freuency from 1 to !#H?%

Hauli!< ;a=a;it@(:#$1t

&oeel ase(!$)11mm

A?le load(#1%$t

U!s=ru!< mass =er a?le(%"+:t

Le! oer u::ers(#1$#mm

Le! oer >eadsto;Bs(!"#+1mm

&od@ idt>(!$#mmn

Ca le!(#::mm

Pa!tos(Two ;echeron 6;!1 !J.#$11%



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In-plant Training

D CONTROL CIRCUIT WITH SI WA- )0



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In-plant Training

'TAP CHAN-#R.

;*eed control of traction motor is by arying the a**lied oltage there are two ty*es of ta*

changer %

4 Low oltage ta* changer

B High oltage ta* changer

&n &ndia high oltage ta* changer is used%

This ta* changer is continuous feeding with oil %Ta* changer is attached with transformer

to reducing weight%

;26C&F&C4T&


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In-plant Training

&LOC8 DIA-RA" OF R#CTIFI#R TRACTI$# DRI$#

Electric Locomotive Workshop Bhusaval 2.


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In-plant Training

$0TRANSFOR"#R(.

The ariation of oltage can be obtained by transformer along with ta* changer% Theoltage of transformer on *rimary side is #$KV limiting alue of starting current and s*eed

control according to reuirement %

&n the most of &ndian locomotie the transformer and ta* changing deice is mounted on

one bloc3% This reduce the weight, maintenance and aoid additional electrical connection%

Ta* changer o*erated freuently there oil is to be changed at regularly interal during

maintenance oil is forced through the closed cooling circuit of transformer by oil circulation

*um*%

;26C&F&C4T&


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In-plant Training

8esirable characteristicsD

!0 2arallel running

#0 (a7% starting torue

0 Ca*able of withstanding oltage fluctuation

:0 (otor should withstand tem*orary interru*tion so 8C series motor are most

suitable for traction duty%

/elded and fabricated frame are used to reduce weight% 8ucts are *roided to allow

radial flow of air through core for cooling *ur*ose% Commutator bar inters*aced with *ure

mica are made of hard dram co**er% These are a7ial hung non.sus*ended ty*e and are

*roided with grease lubrication ta*ered roller bearing for armature as well as for sus*ension%

R4T&=9(


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In-plant Training

AU4ILIARY #7UIP"#NT IN #L#CTRIC

LOCO"OTI$#

A E AU4ILIARY FOR TRANSFOR"#R

Tra!s:ormer Oil Cir;ulati!< Pum= %"PH'

The transformer tan3 is filled with oil which seres two *ur*oses% &t *roides

enhanced insulation to the transformer and its surroundings and the oil absorbs the heat

generated in the transformer and ta3es it away to the Transformer


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In-plant Training

&n /4(.: locos only one (V;L blower is *roided for the cooling of the

;moothing Reactors ;L ! G #% Howeer in /49.$ and other locos two blowers namely

(V;L !G# are *roided for each of the ;L's% Their running is N*roedXNby the J.!!+ relay%

DE AU4ILIARY OF TRACTION "OTOR %"$"T +*,'

&n the course of normal o*eration the traction motors also generate a lot of

heat% This heat is dissi*ated by two blowers namely (V(T ! G # which force air through a

duct into the traction motors of Bogie.! namely T(.!, T(.#, T(. and Bogie.# namely

T(.:, $, res*ectiely% The traction motor cooling blowers reuire a large uantity of air

which is ta3en from ents in the side.wall of the loco% Body.side filters are *roided to

minimise the ingress of dust into the loco% Their running is detected by 4ir.Flow sensing

relay JV(T ! G # -2ic.#0 which in turn gie there feed to the J.!!+ relay%

Air Com=ressors %"CP + "CP), "CP)'

6lectric locos need com*ressed at a *ressure ranging from 3gAcm#to !1

3gAcm#% Com*ressed air is used for the loco's own air bra3e system as also for the train

bra3es, for raising the *antogra*h, for o*erating the *ower switchgear inside the loco such as

the *ower contactors, change.oer switches, windscreen wi*ers, sanders, etc%

This com*ressed air is obtained by *roiding three air com*ressors, each

haing a ca*acity to *um* !111 litres of air *er minute% Howeer de*ending on the current

reuirement, more than two com*ressors are rarely needed%

$a;uum Pum=s %"P$ + * ,'

&n locos eui**ed to haul acuum bra3ed trains, two acuum *um*s are also

*roided of which at least one is running in normal serice and sometimes both may hae to

be run if train bra3es are reuired to be released in a hurry%

D@!ami; &raBi!< resista!;e Cooli!< &loer %"$RF'

&n locos eui**ed with internal dynamic bra3ing resistances, (VRF

blower is *roided for cooling the resistances during bra3ing% /hile all the 4u7iliarymachines run on the *ower su**ly *roided by the 4rno conertor A ;tatic Conertor A (otor.



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In-plant Training

4lternator set, the (VRF blower runs off the su**ly deried from the out*ut of the Traction

(otor itself and is connected in *arallel to the 8ynamic Bra3ing Resistances

"ai! Starti!< Resista!;e

Cooli!< &loers %"$"SR'

These blowers-four in number0are *roided in /C4(.!, /C4(.#, /C4(. locos

and are used during 8C line wor3ing to cool the (ain ;tarting Resistances-(;R0% The (;R

is used for regulating the oltage su**lied to the Traction (otors during 8C line wor3ing %



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In-plant Training

AU4ILIARY POW#R CIRCUIT WA-)0

POW#R F##DIN- CIRCUIT WA-)0



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In-plant Training

THR## PHAS# LOCO"OTI$#S

7. Ho do t>e !e )=>ase AC lo;os orBi!o do t>e@ ;om=are

it> t>e earlier lo;osG

Three.*hase 4C locos such as /42.$ use some fairly new technology ascom*ared to the earlier generations of diesel.electrics and electrics% &n most of the earlier

locos, the traction motors driing the a7les are 8C motors% 8C motors were used because

they afforded -in those days0 far su*erior s*eed and torue control com*ared to 4C motors Y

the latter reuire ariation of in*ut freuency and oltage for effectie control, which was not

an easy matter earlier%

(odern micro*rocessor technology and the aailability of efficient and

com*act *ower com*onents hae changed that *icture% &n .*hase 4C locos, the in*ut

-single.*hase 4C0 from the


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In-plant Training

8uring regeneratie bra3ing this section also has to transfer *ower bac3 to the in*ut conerter

to be fed bac3 to the catenary% The ca*acitor ban3 in this section can also *roide a small

amount of resere *ower in transient situations -e%g%, *antogra*h bounce0 if needed by the

traction motors

Drie Co!erter ( This is basically an inerter which consists of three thyristor.based

com*onents that switch on and off at *recise times under the control of a micro*rocessor

-*ulse.width modulation0% The three com*onents *roduce *hases of 4C -!#1 degrees out of

*hase with one another0% 4dditional circuitry sha*es the waeforms so that they are suitable

for feeding to the traction motors% The micro*rocessor controller can ary the switching of

the thyristors and thereby *roduce 4C of a wide range of freuencies and oltages and at any

*hase relationshi* with res*ect to the traction motors% Various 3inds of thyristor deices are

used to *erform the switching%

Currently *roduced modern locos generally use 9T< thyristors -9ate Turn.


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In-plant Training

/ith the increase of economic actiities and on going electrification

*ro>ects, and because the electric traction will be *laying an im*ortant *iotal role in the

national economy, it was felt necessary that a more s*eedy, strong and cost effectie system

of trans*ortation is necessary in &ndia% Kee*ing this in iew, a decision was ta3en to acuire

.*hase drie technology for &ndian Railways%

4 global search for the *roen technology resulted in a contract with

48tran?- formerly 4BBA;wit?erland0 % The contract had ob>ecties% -!0 To im*ort fully

assembled Locomoties and 3noc3ed down 3its% -#0 To ensure Local warranty serice and -0

to gain transfer of technology -T


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In-plant Training

/hy so much of money and efforts were s*ent O Let us see how are these different from our

*reious ones%

The .*hase system *roides a lot of adantages%

!% 6fficiency )% 4utomated fault isolation%

+% 8is*lay terminal in 8rier's Cab% 8riers get assistance during faults and rectification%

"% 8iagnostic Com*uter to log faults and this can be u*loaded to a 2C in the shedAwor3sho*s

for better fault identification %

7UILITY POLICY

6L/, Bhusawal, renders to carryout designated tas3s of *eriodic oerhauling of

electric locomoties and its com*onents, wor3ing within the framewor3 and guidelines of

&=8&4= R4&L/4% This is carried out with the *rinci*le aim of ensuring the satisfaction ofits customers%

Electric Locomotive Workshop Bhusaval .


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In-plant Training

The management of 6L/ is committed to com*ly with the reuirements of uality

standard, the uality system established by 6L/ and this is achieed there%

!% Carrying out oerhaul wor3 according to designated uality system documentation%

#% 6nsuring a**ro*riate understanding of the uality system and the uality *olicy

within the organi?ation%% 4cting u*on the feedbac3 receied from customer regarding serices *roided%

:% 6stablishment and reiew of uality ob>ecties to *romote uality wor3 and achieed

continuous im*roement%

This *olicy is receied by management for continuous suitability%



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In-plant Training

CONCLUSION

fter 4nishing m, traning in 1. &a,s in 3%*%/%I come to

know that without practical knowle&ge an engineer is of no

use %The entire 'asic fun&amental are clear in training%

B, the help of this training the information a'out the traction

motor 8all section will 'e helpful in future%

I ha& great e9perience in &oing the training% lso I

cannot forget the help of all in charges of respective

&epartment :nless we see the work that we cannot imagine

how

It all goes on%

;o this training teache& man, new techni


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In-plant Training

electric locomotive workshop

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