1

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


2

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 supervisors , Senior Section Engineers and
workers 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
21
st
JUNE, 2013








3

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 nations 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 Boards 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 26
th
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 1
st

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 14
th
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

4

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 14
th
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 13
th
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 9
th
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 6
th
September, 2006 by the Safety and Quality forum of the Institute of Engineers (India).
CLW enters its Diamond Jubilee year w.e.f 26
th
January, 2009. Yearlong celebrations are in
the offing. A kite flying Competition was held on March, 2009, to commemorate CLWs 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.


5

MEMORABLE EVENTS OF CLW: -
INAUGURATION OF PRODUCTION 26 JAN, 1950
FIRST STEAM LOCOMOTIVE COMISS1ONED 1
st
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 1
st
OCT, 1980
AWARDED ISO-9001 CERTIFICATION FOR LOCO WORKS - 13TH JUL, 1996
FIRST 3 PHASE 6000 HP WAG 9 LOCO (SKD) DISPATCHED TO RAILWAYS- 27
th

DEC, 1996.
FIRST 3 PHASE 6000 HP STATE OF THE ART WAG 9 FREIGHT ELECTRIC
LOCOMOTIVE "NAVYUG" INAUGURATED BY HONURABLE MINISTER OF
RAILWAYS 14
th
NOV, 1998.
5000 HP MICROPROCESSOR CONTROL FREIGHT ELECTRIC LOCO WAG 7
"SAMARPAN" INAUGURATED BY SRI. JYOTI BASU, HONBLE CHIEF MINISTER
OF WEST BENGAL- 21
st
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 26
th

January
Production inaugurated by Smt. Basanti Devi, Wife of Late
Chittaranjan Das.
1950 1
st

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 12
th

February
KG Hospital formally opened by his Excellency Dr. K.N.Katju,
Governor of West Bengal.

6

1952 1
st
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 21
st
Oct Railway Minister Shri Lal Bhahadur Shastri visits Chittaranjan
1953 10
th

October
Dr. Sarvapalli Radhakrishnan, Vice President of India, visits
Chittaranjan .
1954 6
th

January
100
th
Steam Loco CHITTARANJAN 100 inaugurated by
Railway Minister Shri Lal Bahadur Shastri.
1955 27
th
April Dr. Rajendra Prasad, President of India, drove the 200
th

Locomotive from the works.
1955 28
th

November
Visit of their Majesties the King ,Tribhuvan Bir Bikram Shah
and Queen of Nepal
1955 17
th

December
Visit of their excellencies Mr. N.A.Bulganin and Mr.
N.S.Khruschev from Russia
1956 14
th

November
Visit of His Imperial Majesty, Mr. Haile Selassie, Emperor of
Ethiopia
Milestone2
1956 12
th

December
Visit of Mr. Chou en lai the Prime Minister of Peoples
Republic of China
1957 13
th
Jan Visit of their Holinesses , the Dalai Lama and the Panchen
Lama
1958 18
th
March Visit of Mr. Churu Stoika, Prime Minister of Rumanian
Peoples Republic
1958 20
th

November
Visit of Mr. Marcel Roberts, Chief Occupational Safety &
Health Division, International Labour Organisation
1960 25
th

January
A technical collaboration agreement signed with Messrs.
F.H.Lloyd & Co. Ltd., Wednesbury for establishing the Steel
Foundry at Chittaranjan
1960 16
th
April Thousandth Locomotive turned out.
1960 April Visit of Mr. Gamal Abdul Nasser, the President of the United
Arab Republic

7

1961 January Steel Foundry set up
1961 2
nd

February
Visit of the illustrious daughter of Netaji Subhash Chandra
Bose, Kumari Anita Bose
1961 16
th
April Opening of Rabindra Manch and open air theatre.
1961 14
th

October
First CLW built WCM-5 DC Electric Loco LOKMANYA
commissioned by Pandit Jawaharlal Nehru.
1962 October Electric Loco Shop Set up
1963 16
th

November
First CLW built WAG-1 25 KV AC Electric Loco BIDHAN
commissioned by Pandit Jawaharlal Nehru.
1966 Traction Motor Shop Set up
1967 16
th
April Chittaranjan builds its First Traction Motor, the largest in India,
at that time.
1968 6
th
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 30
th

January
First CLW Built WCAM-1 AC/DC Dual Voltage electric
Locomotive Vallabhcommissioned by Shri Sidhartha Shankar
Ray, the then Chief Minister of West Bengal.
1980 1
st
October First Rajdhani Electric Loco WAP-1 commissioned.
1985 3
rd
and 4
th

July
Flagging of of the 600
th
Diesel Loco MOHANDAS by Shri
Madhav Rao Scindia, Minister of Railways
1986 2
nd

November
Visit of Professor Nurul Hassan, Governmor of West Bengal
1987 6
th
April JAWAHAR (WAP-3) commissioned and christened by Shri
Madhav Rao Scindia, Minister of State for Railways for
Shatabdi Express services.

8

1988 First batch of Hitachi traction motors dispatched
1989 Collaboration agreement signed with Rockwell International
Corporation .
1990 31
st
March 105
th
Electric Loco KIRTIMAN inaugurated by Mr.
R.D.Kitson, Member Mechanical, Railway Board
1991 7
th
January Flagging off of 1500
th
Electric loco SUKANYA, to mark the
International year of the girl child
1992 3
rd
August 1
st
5000 hp High Adhesion WAG 7 Electric Locomotive
SHANTIDAN christened by Mother Teresa, Missionaries of
Charity.
1993 6
th
April Last BG Diesel Shunter VIRAM of the year and NG Diesel
Locomotive ITI of the year 1992-93.
1993 11
th
June Inauguration of Sidhu kanu Setu a light bridge over the River
Ajoy by R.K.Shukla, GM/CLW
1994 23
rd

January
WAP-1 Electric Loco PRAGATISHEEL provided with
Hitachi Traction Motor.
Milestone4
1994 27
th
August First 5000 hp WAP-4 Passenger Locomotive ASHOK
flagged off.
1996 13
th
July ISO-9001 certification awarded to Loco Works by IRQS.
1996 8
th
August ISO-9002 certification awarded to Steel Foundry by IRQS.
1996 14
TH

September
First Modular WAG-7 Loco KARAMVIR Flagged
1996 27
th

December
First 3 phase 6000 hp WAG-9 Locomotive (CKD/SKD) flagged
off from CLW.
1998 29
th
April Flagging off of 2500
th
Electric loco SWARNA ABHA by the
Shri Nitish Kumar,Honble MR
1998 14
th

November
WAG-9, the first CLW built indigenous 3 phase state-of-the-art
6000 hp Freight Electric Locomotive NAVYUG inaugurated
by the Honble Minister for Railways by Shri Nitish Kumar.
1998 21
st

November
Inauguration of one WAG-7 500 HP Electric Loco
SAMARPAN by Shri Jyoti Basu Chief Minister of West
Bengal

9

1999 10
th

January
First batch of 6 nos. of CLW built 1000 hp Traction Motors for
WAG-9 inaugurated by Shri K.Balakesari, Member Staff.
1999 12
TH
April Flagging off of NAVJYOTI by his His Excellency the
Governor of West Bengal Mr. A.R.Kidwai
2000 25
th
Jan CLW completes 50 years of service to the nation
2000 24
th
Febr The first CLW built 3-phase traction motor type 6 FXA-7059
for WAP-5 locomotive inaugurated.
2000 10
th
May NAVKIRAN the first WAP-7 locomotive rolled out of CLW.
2000 17
th
May NAVODIT the first CLW built WAP-5 locomotive rolled out
of CLW.
Milestone5
2000 30
th
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 30
th
June NAVSHAKTI the first WAG-9H locomotive was rolled out
of CLW.
2000 18
th

November
Commissioning of a new facility for polyurethane painting of
Electric Locomotives with grit blasting and paint drying oven
facility.
2001 12
th

February
NAVBHARATI, the second CLW built WAP-7 locomotive
flagged off by the Honble Minister of Railways Ms. Mamata
Banerjee.
2001 16
th
April H.E.Viren J.Shah, Governor of West Bengal was the chief
Guest at the 46
th
Railway Week function. H.E. also flagged off
the 3-phase WAG-9 loco christened NAVASHA.
2001 31
st
May NAVJAGRAN, the CLW built WAP-5 locomotive flagged
off by the Honble MOSR (D) Shri Digvijay Singh.
2002 26
th
April ISO-14001 certification awarded to CLW by IRQS.
2003 6
th
April NAVCHETAK the CLW built WAP 7 type Locomotive
flagged off by Honble MOSR (A)
Shri A.K.Murti.
2003 2
nd
& 3
rd

August
NAVGHANSHAKTI the CLW built WAG-9 type
locomotive flagged off by ML/RB,Shri S.C.Gupta.
2003 25
th
Sept ISO-9001-2000

10

Milestone6
2003 28
th
Oct Shri Nitish Kumar,Honble 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 10
th
Jan NAVGATI, the CLW built WAP-7 locomotive flagged off by
Addl. ML/RB.
2004 29
th
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 9
th
June CLW is conferred with the Golden Peacock award for
Environment Management by the World Environment
Foundation
2006 29
th
July CLW built new locomotive type WAG-9 & WAG-9H with
Satellite Remote Diagnosis System Dr. Silver inaugurated by
Shri Lalu Prasad, Honble MR.
2006 6
th
September
CLW becomes the proud recipient of the Safety Innovation
award 2006, by the Institute of Engineers
2007 23
rd
March Flagging off of 100
th
WAG-9 loco NAVPRAGATI.
2007 31
ST

March
1
st
loco for 2007-08 inaugurated
2007 31
ST

March
1041
st
Traction Motor produced for the year 2006-07
2008 25
th
May CLW website launched
2008 11
th
July CLW adopts ORACLE based financial application
2009 26
th
Jan CLW steps into its Diamond Jubilee year






11

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.


12

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.

13

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: -

14

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/cm
2
.
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. DRIVERS 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.

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.

16

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

17

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 WAG7 & WAP4 under
production at CLW. The production of Hitachi TM is now
completely stabilized.


18

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
200 C 250 C 250 C
Varnish for
impregnation
Epoxy Silicon Silicon

19

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.

20

(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

21

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 ,drivers 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, drivers 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

22

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.

23

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

24

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 -

25

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 IRs freight handling takes place over IRs 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 operators 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

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

27


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

28

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

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

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

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).

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.

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.

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

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

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.





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