project report of vocational training at chittaranjan locomotive workshop

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PROJECT REPORT OF VOCATIONAL TRAINING AT CHITTARANJAN LOCOMOTIVE WORKS, CHITTARANJAN NAME- Sagardwip Das Bachelor in Engineering Mechanical Engineering Department I.D NO. 111011012 Bengal Engineering And Science University, Shibpur Howrah-3

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Page 1: Project report of vocational training at Chittaranjan locomotive workshop

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PROJECT REPORT OF VOCATIONAL TRAINING AT CHITTARANJAN LOCOMOTIVE WORKS, CHITTARANJAN

NAME- Sagardwip Das

Bachelor in Engineering

Mechanical Engineering Department

I.D NO. – 111011012

Bengal Engineering And Science University,

Shibpur

Howrah-3

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ACKNOWLEDGEMENT

Sub : Short term practical training

Ref.: your Office Order No.353 dated. 10.6.2013

Even after completing of two weeks in vocational training at - Chittaranjan

locomotive works; it was a great pleasure to undergo training with this company. It is

very difficult to express in a few words the gratitude towards people so near to my

heart. Yet, I consider myself privileged in doing so. What can I say, but a big

‘THANK YOU’ to CHITTARANJAN LOCOMOTIVE WORKS; to which I shall

always remain indebted for the faith it has placed in me by letting me to pursue and

complete my Industrial in vocational training of Mechanical Engineering course on

loco works .

I am grateful to express my heart full thanks to Mr. B C Ghosh ,

principal TTC /CLW/Chittaranjan for allowing me to undertake short term practical

training at TTC, C-D& D, TMDO etc. as per Office Order No. 353. Dated 10.6.2013.

I am also grateful to all supervisor‟s , Senior Section Engineer‟s and

worker‟s regarding rendering their all assistant to me during this training .

I would also like to express my sincere thanks to Mr. S.K.SAHA, the HOD

of our Mechanical Engineering Department for arranging for the training in

CHITTARANJAN LOCOMOTIVE WORKS.

SAGARDWIP DAS

21st JUNE, 2013

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INTRODUCTION: - Chittaranjan locomotive works is the first step after our independence

towards self sufficiency in the field of manufacture of locomotives for Indian railways. 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.

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 inaugural production of WG class of steam locomotive commenced on 26th January, 1950. Smt.

Basanti Devi wife of Deshbandhu Chittaranjan Das inaugurated the production. The first president of

India Dr. Rajendra Prasad dedicated the first steam locomotive christened as “Desh Bandhu “ on 1st

November, 1950 and on the same day the factor was named as “Chittaranjan Locomotive Works”

after the great patriot Chittaranjan Das.

It manufactured 2351 steam locomotives of five types. The production of steam locomotives

was discontinues from 1973-74. The production Diesel Hydraulic Locomotives was taken up during

1968 and after manufacturing 842 Diesel Hydraulic

Locos of 7 types the production was discontinued

from 1993-94.

CLW was entrusted for the manufacture of

Electric Locomotives in the year 1961. The first

1500V DC Electric Locomotive named

“LOKMANYA” was commissioned and dedicated to

the nation by Pt. Jawaharlal Nehru, the first prime

minister of India on 14th October, 1961. 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. Since then CLW has

continuously updated and upgraded the technology towards the manufacture of Electric Locomotives.

So far 3006 Electric Locomotives of different types have been manufactures till the year 2001-02,

upgrading its horse power from 2840HP to 6000HP and maximum speed from 60 Km/h to 160 Km/h.

LOKMANYA WCM

5

During pre-construction days

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CLW has become the first production unit in developing countries, second in Asia and fifth in

the world to manufacture 3-phase, state of the art GTO Thyrister controlled electric loco with the

inauguration of 6000HP freight type WAG-9 Loco christened as “NAVYUG” on 14th November,

1993. CLW is also manufacturing the passenger version of the three phase loco type WAP-5 with the

maximum speed of 160 Km/h and having a potential up to 200 Km/h. By indigenization of three

phase technology CLW has been successful in bringing the towering imported cost of Rs 35 crores to

12.5 crores. In addition to the two new versions of the three phase locomotives viz. WAP-7 and

WAG-9H has been started from the year 2000-01. Today CLW has the capacity to produce 150

locomotives in a year.

The production of traction motor and control equipment commenced on April 1967 and steel

foundry was set up on 1962-63 for manufacturing cast steel loco components. Currently DC and 3-

phase AC traction motors are being manufactured. Apart from manufacturing CLW has machining of

bogies, machining and assembly of wheel set which includes modern CNC machines, plasma cutting

machines, MIG welding sets, inert gas welding sets etc.

CLW has never been behind in the field of quality assurance also. It acquired 1SO-9001 certification

for loco works on 13th July, 1996 and ISO-9002 certification for steel foundry on 8

th August, 1996.

CLW has been awarded with ISO-14001 certification also on 26-04-2002.

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.

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. River Ajay flows past CLW along

its northern side. Its serene environment, lush green fields and plethora of unknown birds welcome

all visitors. Every winter, migratory birds, after covering thousand miles come to the seven lakes

within the township.

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 enters its Diamond Jubilee year w.e.f 26th January, 2009. Yearlong 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. Now ShriRadheyShyam is General Manager of CLW.

HOW TO REACH CLW: - 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. River Ajay flows past CLW along its northern side.

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MEMORABLE EVENTS OF CLW: -

• INAUGURATION OF PRODUCTION – 26 JAN, 1950

• FIRST STEAM LOCOMOTIVE COMISS1ONED – 1st NOV, 1950

• FIRST 1500V DC ELECTRIC LOCO "LOKMANYA" COMMISSIONED - 14th OCT, 1961

• FIRST 25KV AC ELECTRIC LOCO "BIDHAN" COMMISSIONED - 16th NOV, 1963

• FIRST DIESEL HYDRAULIC LOCO WDS-4 "INDRAPRASTHA" COMMISSIONED - 6th

JAN, 1968

• FIRST RAJDHANI ELECTRIC LOCO WAP-1 COMMISIONED 1st OCT, 1980

• AWARDED ISO-9001 CERTIFICATION FOR LOCO WORKS - 13TH JUL, 1996

• FIRST 3 PHASE 6000 HP WAG 9 LOCO (SKD) DISPATCHED TO RAILWAYS- 27th

DEC, 1996.

• FIRST 3 PHASE 6000 HP STATE OF THE ART WAG 9 FREIGHT ELECTRIC

LOCOMOTIVE "NAVYUG" INAUGURATED BY HONURABLE MINISTER OF

RAILWAYS – 14th NOV, 1998.

• 5000 HP MICROPROCESSOR CONTROL FREIGHT ELECTRIC LOCO WAG 7

"SAMARPAN" INAUGURATED BY SRI. JYOTI BASU, HON‟BLE CHIEF MINISTER

OF WEST BENGAL- 21st NOV, 1998.

• 1000 HP PHASE STATE OF THE ART MATOR INDEGINEOUSLY BUILT AT CLW

AND INAUGURATED BY STAFF MEMBER JAN, 1990.

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.

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1952 1st to 2

nd

March

Prime Minister of India, Pandit Jawaharlal Nehru visits

Chittaranjan accompanied by Dr. B.C.Roy, Chief Minister of

West Bengal

1952 21st Oct 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 200

th

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 Jan 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

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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 dispatched

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.

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1988 First batch of Hitachi traction motors dispatched

1989 Collaboration agreement signed with Rockwell International

Corporation .

1990 31st March 105

th Electric Loco KIRTIMAN inaugurated by Mr.

R.D.Kitson, Member Mechanical, Railway Board

1991 7th January Flagging off of 1500

th 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 2500

th 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

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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 Jan CLW completes 50 years of service to the nation

2000 24th Febr 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

Sept ISO-9001-2000

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Milestone6

2003 28th Oct 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 Jan “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 9thJune 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 Jan CLW steps into its Diamond Jubilee year

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QUALITY POLICY OF CLW: - Quality policy of CLW is to manufacture electric

loco and spares meeting railways requirement of performance and maintain ability.

1. Adopted quality management system, which

ensures conformance to designees and

specification of every stage of manufacture.

2. Constantly reviewing and updating design,

specification and process to improve product

performance.

3. Ensure quality of purchase material by establishing an effective system of vendor

product performance.

4. Having an effective system of communication and training to make every employee

of quality policy of CLW and motivate him or her to implement and maintain the

quality system.

5. CLW will constantly strive for cost effectiveness to ensure the sales price is "at cost”

basis.

It is intention of CLW to remain the leader in manufacture of electric locomotives in India in

terms of both quality and cost.

Recently CLW has achieved an ISO 9001 certificate.

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 OF CLW: -

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.

Recently CLW has achieved an ISO 14001 certificate.

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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.

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.

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.

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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

INDIAN RAILWAY ORGANIZATION STRUCTURE: -

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GENERAL DESCRIPTION OF A LOCO: -

1. Roof equipments. 2. Driver's cab.

3. Machine room. 4. Bogie

1. ROOF EQUIPMENTS:- The high tension current for feeding of loco is taken from

catenary lines by means of Pantographs. The locomotive is equipped with two pneumatically

controlled pantographs PT-1 and PT-2

Pantographs: - Power at 25KV Is taken from the catenary by means of two

pantographs, only one works at a time. The main functions of pantographs are to maintain a link

between the overhead line and power circuit of the loco at varying speeds and wind. The min. air

required for complete extension is 4.5Kg/cm2.

Pantograph selection switch (ZPT):- The ZPT is fitted on driver's desk, one in

each cab. The switch controls the working of the pantographs. The selector switch has three positions-

Position 0 => Both pantograph are down.

Position I => Rear pantograph is raised.

Position 2 => Front pantograph is raised.

Rating voltage of ZPT =1 WV.

Double pole earthings switch (H0M):- For securing the safety of the operations

during maintenance that is carried out in the loco a hand operated switch HOM makes it possible to

earth simultaneously the entire roof line HV 1/p terminals of the loco lock after lowering the

pantograph when HOM cuts the compressed air supply of the pantograph.

ET Surge arrester: - The protection of loco against, surge voltage is secured by

means of two surge arresters with spark discharger ET-1 mounted on support of the isolator of HT

connection and ET-2 mounted on HT 1/p terminals of the loco.

2. DRIVER’S CAB: - Since a loco consists of two cabs i.e. cab- 1 and cab-2 and usually

one cabin is used by the driver which are fitted with driver's desk, by means of which the driver

performs different operations to run a loco.

3. MACHINE ROOM: - The machine room constitutes the entire important equipments

and they are as follows-

a) B.A Panel.

b) A.C Panel-2.

c) Loco Transformer.

d) Arno converter.

e) Rectifier.

f) Smoothing Reactor.

g) Inductive shunt.

h) Air compressor.

i) Exhauster.

j) Battery.

k) Traction Motor.

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15

B.A Panel: - B.A Panel stands for "Block Aparture Panel". There are tree B A panels in a

loco viz. BA-1.BA-2.BA-.3.1t is also called as the heart of loco.

B A panel has following parts:

1. Various rating resistors.

2. Shunting Contactors:- These are used to increase the speed of the loco. These are kept in

parallel with the field of the traction motor. As these contactor introduced in the circuit the

field gets weakened and there by the flux reduces hence increases the speed. All shunting

contactors are pneumatically controlled. This pneumatic control is done by electro valve

assembly.

3. Relay QD- 1 (Differential Relay).

4. CTF-1 Inverter TR/BR or change over switch: - These are two electro valves assembly for

CTF-1, one for TR (traction) side operation and another for BR (Breaking) side operation.

5. J-1 (Reverser):- The electro valve assembly for J-1 reverser one for forward direction (-->)

operation of J-1 and another for reverse direction (<---) side operation of J-1.

BA-2 and BA-3 contains the following accessories:-

1. Field weakening resistance.

2. 2 Line contactor-All are pneumatically controlled.

3. Shunting contactor.

4. CTF-2(BA-2), CTF-3(BA-3).

5. J-2 reverser.

6. QD-2: Differential relay for slipping.

7. Q-20: Relay o/p voltage.

Reverser: - The direction of rotation of a series motor can be changed when the direction of

current is changed in either the armature or the field. It is usually the direction of the field current

which is changed. This is because voltage across field coil is less as compared to the voltage across

armature terminals. The function of the reverser is to control the direction of current in the field of

traction motor and therefore its direction of rotation. Reverser is usually operated electro

pneumatically when the motor is on no load i.e. traction circuit is energized only when reverser has

been put in the desired direction. It can be manually operated in the event of failure of pneumatic

operation.

Contactor: - It is a switch which makes and breaks a power circuit on load and is controlled

by means of a remote switch. Contactor consists of a fixed contact and a movable contact both

insulated from rest of the mechanism.

Loco-Transformer: - The main transformer of the electric loco is an auto transformer with

32 taps and a step down transformer with two separate secondary windings. The primary winding of

the step down transformer is connected to one of the 32 taps by means of tap changer GR, which is

driven by pneumatic servometer. The main transformer comprises more over of an auxiliary winding

TEWA for winding feeding the auxiliary circuit; the circuits for auxiliary are connected to 400+/-22%

voltage AC supply. The main transformer are protected by capacitors CAPTFP-1-2 against over fault

voltage. The two secondary winding of the step down TFP are protected against excess voltage by

means of surge arresters ETTFPT-2 condensers CAPTFP-3-4 and recombinations.

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Arno-Converter: - Since the main supply of the traction overhead catenary is at single

phase and the auxiliaries are required to have 3-phase because the motors required for auxiliary drives

are 3-phase induction motors. The main function of the Arno-converter is to convert 1-phase to 3-

phase supply. Arno-converter is basically an induction motors. The single phase supply of 400V AC

is fed directly to the 'U‟ and „V' phase of the Arno, since the Arno is connected to single phase supply

no torque is developed. For starting Arno the split phase has been employed. The W-0 phase winding

is connected to the supply through a starting resistor R-118 and starting contactor C-118. Thus the

unbalanced 3-phase voltage is impressed to each phase winding of Arno and starting torque is

developed. Arno picks up speed within 5 secs. After Arno has gained sufficient speed the phase W-0

is opened from the starting circuit by starting circuit by starting contactor.

Rating of Arno-converter: -

Single phase 1/p Three phase 0/p

150 KVA 120 KVA

380 V 380 V

395A 190A

Revolutions/min- 1495, Connection-Star. Frequency-50 Hz.

Three phase AC o/p of Arno-converter is supplied to the auxiliary circuit. The o/p of one

reactor is fed to three motor and the o/p of the second reactor are fed to the rest of the three traction

motors. The rectifiers are arranged in bridge connection.

Smoother Reactor: - The dc o/p of rectifiers specially from a single phase supply is

pulsating and contains ripples. The magnitude of ripples which is alternating component at 100Hz has

to be limited to 20% to 30% from 40% to 50%. These a.c harmonics besides producing heating in the

magnetic circuit of the motor produces commutation troubles. Smoothing reactor is introduced in

between o/p terminals of the reactors and d.c motors and its main job is to smoothen out ripples in the

d.c o/p of the rectifiers. It is made of rectangular Cu-conductors wound over a laminated core. Spaces

are put in between turns to help cooling the reactor by blower air cooled type mounted usually on the

under frame.

Smoothing Reactor for Higher H.P Loco: -

Technical Features SL-30

Current Rating 1350 A

Inductance at 50Hz 3.6mH

No. of turns/coil 30*3

C/s of coil conductor (3*35*5.35)min

Class of insulation "Class F"

Rectifier: - There are two rectifiers for rectification of the single phase ac supply fed from

the transformer to the d.c output. The supplies to the two rectifiers are from the secondary of the

transformer through the terminals. The rectification is needed to feed the traction motors which are d.c

operated i.e. the o/p of the rectifiers are fed to the d.c motor through SL.

Rating of the Rectifiers is

AC l/p DC 0/p

Voltage-1222 Amperes-3300

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Cycles- 50 Hz Voltage-750

Phase- 1

Inductive Shut: - This is a device to restore the bypassing current used through the field

weakening resistance to active designed per formation from the traction motor. This also reduces the

wear on the fringe contacts of the field weakening shunting contactors, due to arching. The inductive

shunt controlled in series with the resistances connected in parallel with the field coil of the traction

motor. The field of traction motor can be controlled by changing the resistance in 3-steps.

Salient features for inductive shunt (S.J): -

Rated voltage- 750V

Insulation- Class H

Cooling - Natural

Traction motor: - CLW started Traction Motor manufacture from 1969 with Alsthom

design of MG-1580 motors and TAO-659 motors and switched over to HS15250A, 850 HP Traction

Motors for which technology was received from Hitachi, Japan. HS15250A Traction Motor

production started in 1988-89. Now with the advent of three phase technology of locomotives from

Bombardier Transportation, Switzerland, CLW has geared up to manufacture 1000 HP and 1500 HP

state-of-the-art 3- Phase Traction Motors for freight (WAG-9) and passenger (WAP-5 & WAP-7)

locomotives. 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.

The different types of Traction Motors manufactured at CLW are following:-

I. 3-PHASE TRACTION MOTOR TYPE 6FRA6068 & 6FXA7059: - 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.

II. 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.

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Salient Features of Different Types of Traction Motors: -

4. BOGIE: - A bogie is a wheeled wagon or trolley. In mechanics terms, a bogie is a chassis

or framework carrying wheels, attached to a vehicle, thus serving as a modular subassembly of wheels

and axles. Bogies take various forms in various modes of transport. A bogie may remain normally

attached or be quickly detachable; it may contain a suspension within it; it may be mounted on a

swivel, as on a railway locomotive, or additionally jointed and sprung.

At CLW two types of bogie are manufactured – Cast Bogie & Fabricated Bogie. For WAP -4

cast bogies are used & for other type of LOCO fabricated bogies are used.

In the basis of axle arrangement bogies are of two types – COCO type & BOBO type. Only

WAP -5 are of BOBO type & other are of COCO type.

Description HS15250A 6FXA7059 6FRA6068

Application Freight/Passenger Passenger Freight/Passenger

Suspension Axle hung Nose

suspension

Fully suspended Axle suspended

Power Output 630 KW 1150 KW 850 KW

Voltage 750 V 2180 V 2180 V

Current (Nom./Max.) 900A 370/540 A 270/370 A

Speed (Nom./Max.) 895 RPM 1585/3174 RPM 1283/2584 RPM

Efficiency 0.93 0.96 0.95

Power to Wt. ratio 0.18 KW/Kg 0.555 KW/Kg 0.4 KW/Kg

Temp. class of

Winding insulation

System

200º C 250º C 250º C

Varnish for

impregnation

Epoxy Silicon Silicon

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COCO type bogies are consist of:-

Equipments No.

Bogie Framre 2

Wheel 12

Axle 6

Motor 6

Gear 6

MSU (Motor Suspension Unit ) 6

Axle Box 6

Brake Gear Arrangement 2 set

Gear Case 6

Suspension Spring Coil (Outer) 16

Suspension Spring Coil (Inner) 16

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.

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(vi) 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.

LOCO ASSEMBLY SHOP: -

Flow Chart for LOCO Assembly Shop-19

(For Conventional LOCO)

Stage Description of stage work Parallel job

Stage-1

(LOCO shell from shop 26 to

assembly shop 16 & 19)

SSE-ELA-16

SSE-ELA-19

Drilling, tapping, welding of

stiffness, brackets or clamps,

slotted channel etc.

_

Stage-2

Shop-16

SSE-ELA-16

Painting SL assembly

Stage-3

Shop-16 & 19(Combined)

SSE-ELA-16

SSE-ELA-19

SE-ELA-19

Laying of power cables, control

cables and underframe,

pneumatic pipe lines, SL

mounting

BA panel manufacturing, RPS

manufacturing

TB panel assembly

AC-1 panel assembly by shop-

16

AC-2 panel assembly

LOCO ASSEMBLY SHOP

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TFP assembly

Stage-4

Shop-16 & 19(combined)

SSE-ELA-16

SSE-ELA-19

SE-ELA-19

SSE-St.v

All equipments mounting in

machine room (eg:- TFP, RSF,

DBR, SE-I & II panels, BA

panels, auxiliary motors,

pneumatic panels etc.) and

pneumatic piping of shell & cab

D/Desk assembly

Roof preparation

Stage-5

SSE-NIL

SE-NIL

Cable connection of all

equipments, Bd, cab-5B etc.

D/Desk mounting, MP on

mounting

Roof mounting and final

assembly of roof equipments

Stage-6

Shop-16 & 19(Combined)

SSE-ELA-16

SSE-ELA-19

SE-ELA-19

Mounting of cab equipments

driver desk MP, motorised

bogie, brake panels etc, cab

ceiling ,driver‟s desk

connection, PC-I & II

connection

Battery base fitting by shop -16,

battery box connection fixing

Stage-7

(Proposed)

General inspection by CQAM

_

Stage-8

(proposed)

Rectification by concerned

section supervisors and re

inspections

_

Stage-9

Shop-19

SSE/T&C-ELA-19

LT test testing &

commissioning section

_

Stage-10

Shop-16

SSR-ELA-16

Pneumatic testing _

Stage-11

Shop-16 & 19(Combined)

SSE-ELA-16

SSE-ELA-19

Rain test, driver‟s seat fitment,

cab painting

_

Stage-12

Shop-19

SSE-T&C-ELA-19

Joint commissioning and final

testing inclusive of pneumatic

valve setting

_

Stage-13

Shop-16

SSE-ELA-16

Final painting _

Stage-14

Shop-19

SSE/ELA-19

SE/ELA-19

Final rectification & despatch _

Steel Foundry Shop: - 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

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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.

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.

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.

Product mix of Steel Foundry: -

A) CAST Items: -

o HS Casnub Bogie for BOXNHL wagons.

o Flexicoil Bogie for WAP-4 loco.

o Flexicoil Bolster for WAP-4 loco.

o Co-Co Bogie BG for WAG-5 & WDM-2 Loco.

o Casnub Bolster.

o Casnub Side Frame.

o Centre Pivot Top and Bottom for Casnub Bogies.

o Suspension tube for Hitachi TM.

o Suspension tube for BHEL TM.

o Suspension tube for WDM-3D loco.

o Rotor Clamp for Hitachi TM.

o Commutator Spider for Hitachi TM.

o Centre Pivot for WAP-4 loco.

o Ballast Blocks for WAG-9 loco.

o Ballast Weights for WAG-7 loco.

o Wheels for Tower Car.

o Wheels for Power Car.

o Wheels for Narrow Gauge Coaches.

o Wheels for Narrow Gauge loco.

o Knuckle for CB Coupler.

o Coupler Body for CB Coupler.

o Yoke for Cd Coupler.

o Striker Castings for CB Coupler.

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o Counter Weight Slabs for 140T Slabs for 140T Breakdown

Cranes.

o Wooden Cleats, Wedges, Battery Boxes, etc.

B) FABRICATED ITEMS: -

o Long Beams & End Structure for WAP-4 Loco.

o End Structure & End Box for WAG-7 loco.

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 casting are as follows: -

Grade 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

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 sets. The

Suspension Tubes and Axle Box housings are cast in Steel Foundry and machined in-house. CLW

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assembles wheel sets not only for our current range of locomotives, but also for the Zonal Railways

for their spares requirements in respect of our current and also

former range of locomotives. Besides, the machining of major

items such as Bolster, Hitachi T.M Magnet Frame, &

3 phase TM Stator is done in-house.

Facilities also exist for manufacturing a wide range

of light items required for Electric Loco production

.Besides, the regular production of Electric loco and related

items ,CLW has a well established Steel Foundry shop which

caters to the need of the entire Electric loco steel castings items and also supply spares to the zonal

railways.

Salient Features of Wheel: -

Specification of Locomotive: -

First letter (Gauge): - W – Broad Gauge (1.676 m)

Y – Meter Gauge (1 m)

Z – Narrow Gauge (0.71 m; 0.76 m)

Middle Letter (Motive Power): - A – Overhead AC (25 kv)

C – Over head DC (1500 v DC)

CA – Overhead AC or DC

D – Diesel

Last Letter (Job Type): - P – Suitable for passenger carry

G – Suitable for carrying goods

S – Shunting low HP locomotives

M – Mixed purpose

Suffix (Model No): - 4,5,7,9 – Model No.

H – Rectified model no.

Example: - "WAP 5": -

"W" means broad gauge

"A" mean AC electric traction motive power

"P" means suitable for Passenger service

"5" denotes that this locomotive is chronologically the fifth electric

locomotive model used by the railways for passenger service.

Type Of LOCO No. Of Gear

Teeth

Gear Pressure

Force(Tons)

Collar Pressure

Force(Tons)

Wheel Cut Of

Pressure

Force(Tons)

WAG 7 65 89 - 117 80 – 100 95 - 132

WAP 4 58 89 - 117 80 – 100 95 - 132

WAG 9 107 90 -106 86 – 104 -

WAP 7 72 90 -106 86 – 104 -

WAP 5 67 88 -108 86 – 104 -

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Gallery: -

Locomotive: -

Different types of Locomotive & its salient details: -

WAG 9: - The “Heavy Haul” Freight locomotive of IR. Rail Freight market which is

registering a remarkable growth since 2000, has also triggered 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. The cabin of this locomotive is air conditioned.

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.

WAG 7

WAG 9

WAP 7

WAP 4

WAP 5

WG

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26

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.

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.

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.

WAG- 7: - WAG-7 is the name of a type of electric locomotive used in India. It is a very

powerful locomotive in Indian Railways' fleet. Its maximum speed is 100 km/h and it used DC

traction motor.

SALIENT FEATURES OF DIFFERENT TYPE OF ELECTRIC LOCOMOTIVES: -

Description WAG-7 WAP-4 WAG-9 WAP-7 WAP-5

Type of service Freight Passenger Freight Passenger Passenger

Gauge 1676 mm 1676 m 1676 m 1676 m 1676 m

Power Supply 25 KV

AC,50Hz

25 KV

AC,50Hz

25 KV

AC,50Hz

25 KV

AC,50Hz

25 KV

AC,50Hz

Whell

Arrangement Co-Co Co-Co Co-Co Co-Co Bo-Bo

Total Wt of

Loco 123t 112t 123t 123t 78t

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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 along with

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.

Continuous

H.P 5000 5000 6000 6000 6000

Max. Speed 100 Km/h 140 Km/h 100 Km/h 140 Km/h 160 Km/h

Starting

Tractive Effort

402 KN

(41t) 30.8t

460 KN

(52t)

460 KN

(52t)

258 KN

(26.3t)

Continnuous

Tractive Effort

235 KN

(24t) 19t

325 KN

(33t)

325 KN

(33t)

180 KN

(18.3t)

Type of Bogie Fabricated Cast Fabricated Fabricated Fabricated

Great ratio 16.65 23.58 15.77 20.72 17.67

No.of T.M &

Type

6 No.-

HS15250AH

(Hitachi)

6 No.-

HS15250AH

(Hitachi)

6 No.-

FRA6068

3-Phase AC

6 No.-

FRA6068

3-Phase AC

4 No.-

FXA7059

3-Phase AC

Brake System Air and

Rheostatic

Air and

Rheostatic

Air and

Regeneration

Air and

Regeneration

Air and

Regeneration

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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 have come down to 12.5

cr.

(d) Advantages of three phase Traction Technology: -

Low maintenance due to absence of commutators/brush gears in

traction motor of switch gears in power circuits.

Availability of full power up to maximum speed.

Better power to weight ratio of traction motor.

Heigher overall efficiency of operation due to regenerative braking

system.

Minimum wear on rails and disturbances to track geometry due to low

unsprung masses

Higher reliability of TM due to use of induction motors.

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

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29

converts single phase 25

KV AC supply into 3

phase AC with variable

voltage (maximum

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

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30

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 ventilated by

one traction motor

blower. Each traction

motor is equipped with

two temperature sensors

and two motor speed

sensors

SN ITEM QUANTITY PER LOCO FUNCTIONS

6 Primary voltage

transformer

1 1 1 It is a potential

transformer situated on

the loco roof reduces

the Catenary voltage

approx. 25 KV to 200

volts for metering

purpose.

7 Surge Arrestor 1 1 1 It is for high voltage

protection for the

Locomotive situated on

the roof of the Loco.

8 Pantograph 2 2 2 The Pantographs collect

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31

the power from the

overhead 25 KV supply

to the Loco.

9 Vacuum Circuit

Breaker

1 1 1 It is protective circuit

breaker of Locomotive

for any abnormal

situation in the Loco

and disconnects the loco

from the supply.

10 Speedometer 1 1 1 For indicating speed of

the Loco memotel type

speedometer is provided

in both cabs. Speed is

indicated by needle as

well as LCD screen of

Speedometer.

11 Transformer oil

pump

2 2 2 It is a pump to circulate

oil from Transformer to

Oil Cooling unit and

back.

12 Converter oil pump 2 2 2 It is a pump to circulate

oil from Converters to

Oil Cooling unit and

back.

13 Oil Cooling Unit 2 2 2 It is a oil cooling

system for cooling

Transformer oil and

Power Converter Oil by

taking air from air.

14 Temperature Sensor 2 2 2 It is a temperature

sensing equipment for

detecting temperature

of Transformer oil

(maximum allowable

oil temperature is 150

degree Celsius).

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32

15 Pressure Sensor 2 2 2 It is a pressure sensing

equipment for detecting

pressure of Transformer

oil pump. .

16 High Voltage

Bushing

1 1 1 It is a bushing for

tapping high voltage

power from overhead to

Main Transformer

situated just beneath

roof.

17 Resistance for

Harmonic Filter

1 1 1 It is the resistance

connected in the

harmonic filter circuit

of the loco to suppress

the high frequency

harmonics to avoid

disturbances in

signaling.

18 Machine room

blower

2 2 2 It is a blower to cool

machine room( to keep

temperature below 70

degree Celsius) by

ducting and limit the

temperature of control

Electronics below 70

degree Celsius.

19 Machine room

scavenge blower

2 2 2 It is a blower to clean

dust from air filters of

Machine Room.

SN ITEM QUANTITY PER LOCO FUNCTION

20 Traction motor

blower

2 2 2 It is a blower for

ventilation of the

Traction motors

(connected with bogie

1&2) by forced air.

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33

21 TM / oil cooling

scavenge blower

2 2 2 It is a blower to clean

dust from Traction

Motors and oil cooling

units.

22 Fire Detection Unit

(FDU)

1 1 1 The loco is equipped

with a fire detection

system in the machine

room. Through a ring

line with apertures at

regular distances air in

the machine room is

extracted with a fan and

checked for traces of

smoke by a detector.

The unit is equipped

with two smoke

sensors.

23 Battery 1 set 1 set 1 set It is a NI-Cd

accumulator, which

consists of 78 cells,

which are connected in

series. The nominal

capacity is 199 Ah. It is

in two halves which are

located on each side of

the loco. All electrical

components in the

control current circuit

are designed for a

nominal voltage 110V

DC.

24 Main Compressor 2 2 2 It is a pressure creating

equipment for necessary

pressure for entire

Pneumatic circuit of the

loco.

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34

25 Auxiliary

Compressor

1 1 1 It is a pressure creating

equipment for raising

the Pantograph.

26 Master Controller 2 2 2 It is a device used by

Driver of the loco for

controlling loco during

motion in the forward

and reverse direction .

27 Contactor filter on

off and adaption

2 2 2 It is a Contactor for

connecting and

disconnecting filter

winding circuit during

filter operation of Loco

for filtering undesirable

harmonics.

28 Oil cooler radiator

for transformer

/Converter Cooling

2 2 2 It is a radiator for

dissipating heat from

the oil of Transformer

and Converter by

passing air from Oil

cooling Blower through

it.

29 Emergency Flasher

light

2 2 2 It is a flasher light

(amber colour) glow

during Emergency

condition (during

Emergency Chain

Pulling and during

Emergency Braking).

30 Capacitor Bank

Harmonic filter

1 set 1 set 1 set It is a bank of

Capacitors used for

filtering high frequency

harmonics in the

filtering circuit of the

loco.

31 Front & Rear 4 4 4 It is the light for making

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35

Marker Light the presence of Loco

during stop condition of

the in the rail track to

avoid accident.

SN ITEM QUANTITY PER LOCO FUNCTION

32 Head light 2 set 2 set 2 set It is the light used for

clear visibility of rail

track during loco

movement in the night

time.

33 Fire Extinguisher 4 4 4 The loco is equipped

with 4 Fire

Extinguishers, one in

each Driver Cab and

two in Machine Room.

The Fire Extinguishers

are to be operated

manually to extinguish

fire.

34 Auxiliary

Transformer

(415/110V)/

Transformer

Tranela

1 1 1 This transformer is

located in HB-1 cubicle

and supply power to

415 V single phase

power to two machine

room blowers, two

scavenge blowers to Mr

blowers, 110V AC to

crew fans.

35 Contactor for

discharging resistor

1 1 1 It is an item of Filter

cubicle used for

connecting for

discharging the resistor

of Capacitor Bank.

36 Air drier 1 1 1 It is used for purifying

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36

and separating moisture

from air at intake. It is

actuated when one of

the main compressors is

switched on.

37 Hydraulic Damper 4 4 4 To dampen the rebound

rate of springs.

38 Side buffer 4 4 4 To take care the buffing

load.

39 E-70 Brake System 1set 1set 1set It controls the main

pneumatic brake system

of loco.

40 Axle box complete 12 12 8 It is component MSU. It

is housing for axle

bearing.

41 Gears & Pinions 6 6 4 It transmits traction

power to the wheels.

42 CBC 2 2 2 It is mainly used for

coupling. It also take

care the draw and draft

load.

43 Spring Secondary

spring -16

nos (9H) , 8

nos.(G-9)

Primary

Spring-48

nos (9H) ,

32 nos.

(G-9)

Secondary

spring -8

nos.

,Primary

Spring-32

nos

Secondary

spring -8

nos

,Primary

Spring-16

nos

It is a suspension from

axle to bogie and bogie

to body. Suspension

system minimise the

shock caused by

vibration of the track

and also carry weight of

the loco body.

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37

CONCLUSION: -The two weeks of training at Chittaranjan locomotive works has greatly

benefited me in several ways. I have witnessed the immense power of technology and how it

can be put to productive purposes for the benefit of mankind. I also became aware of my role

as a Mechanical Engineer in making this possible.

During my stint at Chittaranjan locomotive works, I have learnt several things besides

engineering which include, but are not limited to the working of a giant organization,

interaction and communication skills, analytical skills, importance of safety in industry, time

management and the most important fact that no work is small.

The training has also inculcated in me professionalism and dedication to work. No

textbook would have been able to do all this just within a span of two weeks. It has proved to

be an important milestone in my academic life.

REFERENCE: -

Production Technology… By R.K. Jain.

Manufacturing science.......By A.Ghosh & A.K.Mallick

www.google.co.in

http://en.wikipedia.org

www.Clw.indianrailways.gov.in

www.railway-technical.com

http://www.indianrailways.gov.in