A PRESENTATION ON

CHITTARANJAN LOCOMOTIVE WORKS

PRESENTED BY : - NAME : - ANKAN DEY

BRANCH : - MECHANICAL INSTITUTE ROLL NO : - 131961028UNIVERSITY ROLL NO – 27300713010

NSHM KNOWLEDGE CAMPUS , DURGAPUR

ACKNOWLEDGMENTMR. SUBRATA GHOSH, Principal, TTC/CLW/CHITTARANJAN

MR. NAG, VOCATIONAL TRAINING INCHARGE, TTC/CLW/CHITTARANJAN

ALL SENIOR SECTION ENGINEERS, JUNIOR ENGINEERS, SUPERVISORS AND EMPLOYEES OF CLW CHITTARANJAN

ABOUT CHITTARANJAN LOCOMOTIVES WORKSFIRST LOCOMOTIVE BUILDING WORKSHOP IN INDIA

PREMIER PRODUCTION UNIT OF INDIAN RAILWAYS

PRODUCTION INAGURATED ON 26TH JANUARY 1950 BY SMT. BASANTI DEVI, W/O OF GREAT PATRIOT DESHBANDHU CHITTARANJAN DAS.

ABOUT CHITTARANJAN LOCOMOTIVES WORKS

• 26TH JANUARY 1950 - PRODUCTION INAGURATED BY SMT. BASANTI DEVI, W/O OF GREAT PATRIOT DESHBANDHU CHITTARANJAN DAS.

SOME SPECIAL MOMENTS

• 14TH OCTOBER 1961 – FIRST CLW BUILT WCM-5 ELECTRIC LOCO “LOCKMANYA”• 16TH NOVEMBER 1963 – FIRST CLW BUILT WAG-1 25KV AC ELECTRIC LOCO “BIDHAN”• 1968 – FIRST CLW BUILT DIESEL HYDRAULIC LOCOMOTIVES “INDRAPRASTHA”• 1971 – LAST STEAM ENGINE PRODUCED “ANTIM SITARA”

• 1992 –FIRST 5000HP HIGH ADHESION WAG-7 ELECTRIC LOCOMOTIVE “SHANTIDAN” PRODUCED• 1980 – FIRST RAJDHANI ELECTRIC LOCO WAP-1 PRODUCED

• 1994 – WAP-1 ELETRIC LOCO “PRAGATISHEEL” PROVIDED WITH HITHACHI TRACTION MOTOR

• 1996 – ISO-9001 & 9002 CERTIFIED• 1998 – FIRST 3ɸ 6000HP WAG-9 LOCOMOTIVE “NAVYUG” INAGURATED BY HONARABLE MINISTRY OF

INDIAN RAILWAYS SHRI NITISH KUMAR

• 1994 – FIRST 5000HP WAP-4 PASSENGER TRAIN “ASHOK” FAGGED OFF

• 2000 – “NAVKIRAN” FIRST WAP-7 LOCO ROLLED OUT• 2000 – “NOVODIT” FIRST WAP-5 LOCO ROLLED OUT• 2000 – “NAVASAKTI” FIRST WAG-9H LOCO ROLLED OUT

• 2002 – ISO-14001 CERTIFICATION AWARDED TO CLW

• 2003 – ISO-9001-2000 CERTIFICATION AWARDED TO CLW • 2006 – CLW IS CONFERRED WITH THE GOLDEN PEACOCK AWARD FOR ENVIRONMENT MANAGEMENT BY

THE WOLD ENVIRONMENT FOUNDATION• 2006 – CLW AWARDED WITH SAFETY INNOVATION AWARD 2006 BY THE INSTITUTE OF ENGINEERS• 2008 – CLW WEBSITE LAUNCHED • 2008 – CLW ADOPTED ORACLE BASED FINANCIAL APPLICATION • 28TH JANUARY 2009 STEPS INTO DIAMOND JUBILEE YEAR

Quality Policy Of Chittaranjan Locomotive WorksCLW has well-established Quality System.

The quality policy adopted by CLW are as follows : - • To meet customer’s need by establishing a quality

management system and reviewing the quality policy and quality objective for continual improvement.

• Quality Policy is communicated and understood by all in the organisation and reviewed periodically.

• Ensure quality of purchase material by establishing an effective system of vendor product performance.

• Constantly reviewing and updating design specification and progress to improve product performance.

• Having an effective system of communication, proper training and motivate to every employee of CLW to implement and maintain the quality policy

Environmental Policy Of Chittaranjan Locomotive Works

• 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.

LOCOMOTIVE ENGINE NOMENCLATURE

W - Broad Gauge(1.676 m)

Y - Meter Gauge(1m )

Z – Narrow Gauge(2’6’’)

N – Narrow Gauge(2’)

1, 2, 3,4……. Denotes Model No

M – Mixed TrafficG – GoodsP – PassengerS – ShuntingL – Light DutyR – Rail Car

Alphabets like E, H etc.Denotes rectified locos.

A – AC Power (25KV)

C – DC Power (1500V)

D – Diesel Loco

CA – AC/DC Traction

Locos except older steam ones have classification codes that identified them. The code is as follows : - [Gauge] [Power] [Load] [Series]

[Suffix]

EXAMPLE

[W] [A] [P] [4] [E]

WAP 4E

W Means Broad Gauge i.e. the track width is 1.676m

A Means this is AC powered loco

P Stands for Passenger Train

4 Stands for Model No

E Stands for Rectified loco

DIFFERENY TYPES OF ENGINES PRODUCED BY CLW

1. WAG-92. WAP-73. WAP-5

4. WAP-45.WAG-7

3 Phase Drive

Single Phase/ DC Drive

01. WAG-9 Salient Details :-

Track Gauge - 1676mmTotal HP - 6000Starting Tractive effort - 460KN (47t)Max. Service Speed - 100 KMPHBreaking - Air, Regenerative & ParkingWheel Arrangement - Co-CoSystem Voltage - 25KV AC, 50 HzWeight of loco - 123t 1%Type Of Bogie - FabricatedWheel Dia. - 1092mmNo Of Traction Motor & Type - 6 No Type-FRA 6068Total Width Of Locomotive – 3130mmMinimum Radius Curve Negotiable - 174m

02.WAP-7 Salient Details :-Track Gauge - 1676mmTotal HP - 6000Starting Tractive effort - 460KN (47t)Max. Speed - 140 KMPHBreaking – Air Regenerative & Parking Wheel Arrangement - Co-CoSystem Voltage - 25KV AC, 50 Hz.Weight of loco -123t 1%Type Of Bogie - FabricatedWheel Dia. - 1092mmNo Of Traction Motor & Type - 6 No Type-FRA 6068Total Width Of Locomotive – 3130mmMinimum Radius Curve Negotiable - 174m

03. WAP-5 Salient Details :-Track Gauge - 1676mmTotal HP - 5450Starting Tractive effort - 258KN Max. Service Speed - 160 KMPHBreaking - Air, Regenerative & ParkingWheel Arrangement - Bo-BoSystem Voltage - 25KV AC, 50 HzWeight of loco - 78t 1%Type Of Bogie - FabricatedWheel Dia. - 1092mmNo Of Traction Motor & Type - 4 No & Type- FXA 7059Total Width Of Locomotive – 3130mmMinimum Radius Curve Negotiable - 174m

04. WAP-4 Salient Details :-

Track Gauge - 1676mmTotal HP - 5000Starting Tractive effort - 294KN (30t)Max. Service Speed - 140 KMPHBreaking – Air & Hand BrakeWheel Arrangement - Co-CoSystem Voltage - 25KV AC, 50 HzWeight of loco – 112.8t 1%Type Of Bogie - CastingWheel Dia. - 1092mmNo Of Traction Motor & Type - 6 No Type- HS-15250 AHTotal Width Of Locomotive – 3050mmMinimum Radius Curve Negotiable - 174m

05. WAG-7Salient Details :-

Track Gauge - 1676mmTotal HP - 5000Starting Tractive effort - 412KN (30t)Max. Service Speed - 140 KMPHBreaking – Air & Hand BrakeWheel Arrangement - Co-CoSystem Voltage - 25KV AC, 50 HzWeight of loco – 123t 1%Type Of Bogie - FabricatedWheel Dia. - 1092mmNo Of Traction Motor & Type - 6 No Type- HS-15250 AHTotal Width Of Locomotive – 3055mmMinimum Radius Curve Negotiable - 174m

BRIEF SUMMARY OF IMPORTANT ITEMS USED IN 3-PHASE LOCO01. Main Transformer

Function- To convert the overhead line voltage(25KV) to the lower operating voltage.

02. Power Converter Function- To convert single phase 25KV AC supply into 3-Phase AC with variable voltage and variable frequency and feed it to Traction motor.

03. Auxiliary Converter Function- To convert 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.

04. Control Electronics Function- All the functions of the Locomotive are controlled by the Control Electronics .

05. Traction Motor Function- There are total 6 traction motors in WAG-9/WAP-7 loco .TM 1-2-3 are mounted in bogie -1 and are fed from Power Converter 1 where as TM 4-5-6 are fed from Power Converter -2. In case of WAP-5 Loco there are 4 Traction motors in which Power Converter -1 feeds to TM-1-2 and Power Converter 2 feeds power to TM-3-4. Traction Motors are asynchronous squirrel cage Induction Motor. Power converter providing the power sources.

06. Primary voltage transformer Function - Potential transformer situated on the loco roof reduces the Catenary voltage approx. 25 KV to 200 volts for metering purpose.

07. Surge Arrestor Function- It is for high voltage protection for the Locomotive situated on the roof of the Loco.

08. Pantograph Function- To collect the power from the overhead 25 KV supply to the Loco.

09. Vacuum Circuit Breaker Function- It is protective circuit breaker of Locomotive for any abnormal situation in the Loco and disconnects the loco from the supply.

10. Speedometer Function- For indicating speed of the Loco

11. Transformer oil pumpFunction- To circulate oil from Transformer to Oil Cooling unit and back

12. Converter oil pumpFunction- To pump to circulate oil from Converters to Oil Cooling unit and back.

13. Oil Cooling UnitFunction- For cooling Transformer oil and Power Converter Oil by taking air from air.

14. Temperature SensorFunction- For detecting temperature of Transformer oil (maximum allowable oil temperature is 150 degree Celsius).

15. Pressure SensorFunction- For detecting pressure of Transformer oil pump.

16. Machine room blowerFunction- To cool machine room( to keep temperature below 70 degree Celsius) by ducting and limit the temperature of control Electronics below 70 degree Celsius.

17. Machine room scavenge blower Function- To clean dust from air filters of Machine Room.

18. Traction motor blower Function- For ventilation of the Traction motors (connected with bogie 1&2) by forced air.

19. TM / oil cooling scavenge blower Function- To clean dust from Traction Motors and oil cooling units.

20. Fire Detection Unit (FDU) Function- 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.

21. Fire Extinguisher Function- 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.

22. Battery Function- It is a NI-Cd Battery, which consists of 78 cells, which are connected in series. 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.

23. Main Compressor Function- It is a pressure creating equipment for necessary pressure for entire Pneumatic circuit of the loco.

24. Auxiliary Compressor Function- It is a pressure creating equipment for raising the Pantograph

25. Master Controller Function- It is a device used by Driver of the loco for controlling loco during motion in the forward and reverse direction .

26. Emergency Flasher light Function- It is a flasher light (amber colour ) glow during Emergency condition (during Emergency Chain Pulling and during Emergency Braking).

27. Front & Rear Marker Light Function- It is the light for making the presence of Loco during stop condition of the in the rail track to avoid accident.

28. Head light Function- It is the light used for clear visibility of rail track during loco movement in the night time.

29. Auxiliary Transformer Function- To supply 415 V single phase power to two machine room blowers, two scavenge blowers etc.

30. Air drier Function- It is used for purifying and separating moisture from air at intake. It is actuated when one of the main compressors is switched on

31. Hydraulic Damper Function- To dampen the rebound rate of springs.

32. Side buffer Function- To take care the buffing load

33. Brake System Function- To control the main pneumatic brake system of loco.

34. Axle box complete Function- It is housing for axle bearing.

35. Gears & Pinions Function- It transmits traction power to the wheels.

36. CBC Function- It is mainly used for coupling.

37. Spring Function- 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.

SHOPS VISITED DURING TRAINING

1. WS-092. TR-523. ELF-174. ELB-125. SFS-036. HMS-087. ELB-188. ELF-269. ELDO10.ELA-1611.ELF-15

01. WHEEL SHOP-09 (WS-09)

AXLE FORMATION

WHEEL PRESS

WHEEL SURFACE FINISHING

AXLE SURFINISHING

GEAR FACE RUN OUT

GEAR PRESS

SUSPENSION TUBE ADDED

BEARING AND AXLE BOX ADDED

02. TOOL ROOM – 52TOOL ROOM IS NOT BASICALLY A PRODUCTION UNIT FOR RAILWAYS. THIS IS THE PLACE WHERE• TOOLS ARE MADE UP• DAMAGED TOOLS ARE REPAIRED • BASIC MACHINING OPERATIONS ARE CARRIED OUT

➢ LATHE OPERATION➢ FITTING➢ MACHINING➢ REPAIRING➢ MILLING

SMALL COMPONENTS MANUFACTURED IN TOOL ROOM• HOLDER• FORK HEAD• SUPPORT• SUSPENSION EYE• SUSPENSION PLATE• GUIDE PLATE• AXLE HOLDER• AXLE GUIDE BEARING• HOLDERSEAL PLATE• SUSPENSION EYE• SUSPENSION PLATE• WEB

03. ELECTRIC LOCO FABRICATION SHOP-17

Fabrication Of Different Parts• Fabrication Of Head Stock (2 Nos.)• Fabrication Of Central Under Frame (1 Nos.)• Fabrication Of Bolsters (2 Nos.)• Fabrication Of Central Sill (1 Nos.)• Fabrication Of Side Sill (2 Nos.)

04. ELECTRIC LOCO BOGIE-12 (ELB-12)Different stages are-1. Underframe of loco For WAP-42. Manipulator

➢ For turning the underframe➢ And welding of different positions

3. RWU-1➢ Corridor angle and corridor plate

4. USD (Upside down position)➢ Central pivot➢ Reservoir/Draft Gear

5. Shell ➢ Cab+ side wall+ roof➢ CBC

 

05. SMITY & FORGE SHOP-03 (SFS-03)Mainly operation done for➢ Ducting parts➢ Head Stock manufacturing➢ Production of Handle, Operating Rod, resting hook, pipe plate bending➢ Oxy-cutting Profile machine ➢ Bending & forging done by Pneumatic Hammer.

HEAD STOCK PRODUCTION➢ Take bottom plate – Tagging with a rigid table➢ Front plate tagging➢ Tagging of web plate & collision plate to the bottom plate and welding➢ Rear plate tagging and weld with webs and collision plate.➢ Top plate placed after the manipulator operation and welding➢ Side top plate➢ Buffer and triangle plate set-up➢ Coupler plate positioning

06. HEAVY MACHINE SHOP-08 (HMS-08)

MAINLY PRODUCED –1. Magnet Frame2. Suspension Tube3. Stator4. Equilizer

07. ELECTRIC LOCO BOGIE -18 (ELB-18)Mainly Operation done• Motor with wheel assembly• Running test• Bogie assembly with bogie wheel

TRACTION MOTORS

3-PHASE TRACTION MOTOR TYPE 6FRA6068 3-PHASE TRACTION

MOTOR TYPE 6FXA 7059

HITAHI TRACTION MOTOR

TYPE HS15250A

08. ELECTRIC LOCO FABRICATION-26ELF-26

01. RWU-1 (Right Way Up-1) 03. RWU-2 (Right Way Up-2)

• Cab• Partition plate• Side wall (Tightening & Centring)• Roof guarder• Corner angle• Cable tray bracket & angle• Cable tray assembly• Rear wall• CBC & Cattle guard & Striker casting

• Jig fitment for placing Brackets • Blower fitment• Minor works

➢ Trail of roofs 1, 2, 3➢ Matching or not with roof guarder➢ Tacking operation of inside threads➢ Strip, Caliper & Square bar welding➢ Rain guard fitment➢ Final Inspection

➢ Main stages of RWU-2

04. Roofing work

➢ Shell stage➢ Machine Room

➢ Air Ventilation Assembly➢ End fill plate➢ Channel➢ Drilling operation for CBC➢ Reservoir base fitment

02. USD (Upside Down)

➢ Compressor leg➢ Battery mounting leg➢ Junction box➢ Central pivot➢ Housing work➢ Manipulator guide➢ Spring box➢ Draft gear➢ Inspection

09. ELECTRIC LOCO DESIGN OFFICE (ELDO)

There are four sections in ELDO (mechanical ) –

Here Mainly design of loco works are done.

➢ Pneumatic Section

➢ PPO Section

➢ Bogie Section

➢ Superstructure Section

10. ELECTRIC LOCO ASSEMBLY-16 (ELF-16)Here work has been done in two ways-

➢ Mechanical work➢ Electrical work

In mechanical basically following assemblies are done➢ Buffer fitment➢ Window fitment➢ Transformer fitment➢ Final wheeling on Motor bogie➢ Front glass, final window fitment, door fitment&

other various operations are done.➢ Pipeline fitment➢ Assembly of a lot of parts

11. ELECTRIC LOCO FABRICATION-15 (ELF-15)

Four Operation are done-

1. Shearing operation➢ Nibbling➢ Punching etc.

2. Bending operation➢ Cold bending up to 25mm

3. Fabrication➢ Small fabrication- ducting, security panel➢ Heavy fabrication- Headstock

4. Welding➢ MMAW done for single phase loco➢ MIG done for three phase loco

ADVANTAGES OF THREE- PHASE LOCO∙ Low cost of manufacturing, running and maintaining locomotives and multiple units∙ Higher power-to-weight ratio resulting

∙ Less noise pollution∙ Faster acceleration clear lines quicker to run more trains on the track of urban areas∙ Reduced power loss∙ Independence of running cost from fluctuating fuel prices∙ Service to underground stations where diesel engines cannot work properly∙ Reduced environmental pollution∙ More comfortable ride on multiple units∙ High energy efficiency

➢ Fewer locomotives➢ Faster locomotives➢ Higher practical limit of power➢ Higher speed

NEW PROJECTS➢ Electric Locomotive Factory at Dankuni, West BengalThe unit will work as an ancillary unit of CLW. Initially state of art 3-phase high HP locomotive with regenerative breaking of 6000 HP (WAG-9) electric locomotive will be turned out. Subsequently, the infrastructural facilities shall be utilized for the production of 9000 HP locomotives in future. ➢ Centre of excellence for design, development & evaluation of advanced technology

system for electrical rolling stock.The purpose of establishing the Centre of Excellence is to develop capability for designing, development and evaluation of advanced technology systems for Electric Rolling Stock. The idea is to become a technology exporter from present status of technology importer in Rolling Stock equipment. The main benefit that will accrue from this project is that we shall become self-reliant in the field of development of Electric Rolling Stock equipment which will come in a big way not only for the domestic requirement of adoption of new technology in rolling stock but we shall be in a position to cater to the emerging world market as per the customized requirement of different countries.