Welcome

ATraining Report on

ELECTRIC LOCOMOTIVE WORKSHOP

BHUSAWAL (P.O.H.)

Submitted By: DHIRAJ U. MAHAJAN

Prof. B.A.WANI Prof: K. R. Patil (GUIDE) (H.O.D)

KCE SOCIETY COLLEGE OF ENGINEERING & INFORMATION TECHNOLOGY

JALGAON (2012-13)

Submitted To DEPARTMENT OF ELECTRICAL ENGINEERING.

CONTENT History of Railway

Introduction of POH

Types of loco

Loco contents

Section of ELW

Functions of the equipments used in loco

Conclusion

HISTORY OF INDIAN RAILWAY :-

On 16th April, 1853, the first train service was started in India.

The first train consisting of steam engine and some coaches. It travel between Bombay and Thane in about 1:25 hours time. The railway track was 56 kms stretched.

On 15th August, 1854, the 2nd train service commenced between Howrah and Hubli.

The Indian railway about 11,000 trains every day, serving 6,990 railway station and carry about 411 million tonnes of good traffic in the year.

On the 1st July, 1856, the 3rd train service in India and first in South India commenced between Vyasarpadi and Walajah Road

DIFFERENT GAUGES ON THE WORLD RAILWAY

Sr. no. Types of gauges Gauge in mm

Names of Country

1 Standard Gauge 1434 England, USA, Canada Europe

2 Broad Gauge (W) 1676 India, Pakistan, Brazil, Argentina

3 Cap gauge 1067 África, Japan, Java, Australia, New Zealand

4 Meter Gauge 1000 India, France, Switzerland, Argentina

5 Narrow Gauge 762 India

INTRODUCTION TO P.O.H. Bhusawal

On year 1974, Electric Locomotive Workshop was set up in Bhusawal.

Electric locomotive workshop Bhusawal was set up at a cost of Rs.3.52 corers in the year 1974

This P.O.H second workshop of electrical locomotives .

The biggest locomotives workshop Bhusawal.

CAPACITY OF E.L.W. BHUSAWAL

As newly establishment ELW bhusawal carry out 5 loco per month but now a days they carry out 12 loco per month.

Every locomotive brought here every six year or 600000 of run for periodic overhauling (POH).As new locomotive comes after 9 years on 900000 KM of run.

The production and designing of new loco had done only in Chittranjan locomotive workshop (CLW)

TYPES OF LOCO AND GEAR RATIOType of loco Gear ratio

WAM4 58/21

WAG5 62/15

WAP1/3 58/21

WAP4 58/23

WAM4 TAO 58/21

WCAM-1/2 58/21 or 61/16

WAG5-HITACHI 64/18

WAG7-HITACHI 65/17

WCG2 74/18

WAG9 77/15

Where W- Broad GaugeA- A.C. Electric locoM- Mixed ServiceG- Goods LocoCA- AC & DC LOCO

All these loco comes in (ELW) Bhusawal for periodic overhauling.

WAM4

WAG5

WAP1/3

WAP4

WCG2

WCG9

ONE LOCOMOTIVE CONTAINS MAIN EQUIPMENTSr. No. Name of Equipment Quantity

1 Body 1

2 Bogie 2

3 Wheel set 6

4 Traction Motor 6

5 Transformer 1

6 D.I. 1

7 B. A. panel 2

8 Rectifier 2

9 Compressor 2/3

10 Exhauster (except air break)2

11 SMGR 1

12 MVMT(Blower for T.M.) 2

13 RPS 1

14 DBR 1

15 MPS(Blower for SL) 216 S.L. 2

17 S.J. 3 set

18 Arno 1

19 Baby Compressor 1

20 Battery Charger 1

21 Batteries 10

22 RTPR 2

23 Main reservoir 5

24 M.P. 2

25 Buffers 4

26 C.B.C. 2

27 Pantograph 2

28 CABS 2

29 Brake arrangement 5

30 H o m 2

31 Head light 2

32 Marker Height 4

33 Parking Light 4

34 Flasher 2

35 Total valves 40

36 Brake cylinder 8/12

37 R.C. Panel 1

38 Sand boxes 8/10/12/16

39 HOM Switch 1

Sr. No. Name of Equipment Quantity

SHORT DESCRIPTION, FUNCTIONS OF THE EQUIPMENTS USED IN A LOCO

1) Arno - In loco there are many three phase induction motor because at their advantages then single phase motor but OHE supply 25 KV is single phase. To convert single phase supply into three phases Arno is used. The Arno converter is designed a type of three phase squirrel cage induction motor.

2) Transformer – To provide different voltage supply to TM transformer with tab changer is used. In this transformer laminated core is magnetic circuit is made having three legs. One of the leg having auto winding and with this tab changing connector having laminated core. Another leg is low voltage winding in their auxiliary circuit is supplied (380 V) constantly to drive 12 auxiliaries in loco. And others are primary and secondary winding.

CAPACITY - 3469 KVWEIGHT - 6880 KGTOTAL - 11.5 TONNESTAP CHANGER WEIGHT - 0.5 TONNESOIL WEIGHT - 1.7 TONNESOIL CONTAIN - 2000 LITRES

3) Pantograph –The most important function of pantograph is to make contact with OHE or cater nary wire and collect all supply from OHE (I.e. 25 KV)Full panto is made up of hallow aluminium pipe and strips and it can be hold easily with 7 Kg contact pressure. The whole panto is controlled by two spring. The springs are fitted at the piston at servomotor.

The time period of touching should 65 to 19 sec. And lowering time for panto is max. 10 sec. The height of OHE from base of panto is between 1.75 to 2 meter

4) Rectifier –Rectifier is used for converting AC into DC and the process is known as rectification. The rectifier uses silicon and germanium diode. It is a bridge rectifier and have simply p-n junction.

5) Body -This is the main convert at locomotive. This is made of very high strength of metal sheet. It is also called as spinal cord of loco. It protects all the equipment in loco form air. Rain or dust etc. It contains 2 cabs and all lighting system.

6) M.P. - It is called as master controller. We may call it as brain of loco. When complete loco is ready and it doesn’t move without M.P.

M.P. contains control switches driver handle, shunting handle, panto switch, R.F switch and etc. It has 32 notches. As the notches are increased the speed of loco is also increased.

7) T.M. - Traction motor is the main part of the loco. Without T. M. loco is unable to move. Traction motor wants pure D.C. supply. It has two main parts- 1) Armature 2) Winding

Following are the sections in ELW Bhusawal :-

Erection Section

Bogie Section

Wheel Section

Recalling Section

Traction motor Section

Transformer Section

Test room Section

Pneumatic Section

Machine shop Section

R & M Section

B.A Panel Section

Mill Wright Section

Static Section

White metal Section

Inspection Section

Test Laboratory

Test room (Relay)

E.P Contactor section

Rewinding Section

DIFFERENT SECTIONS AND RESPECTIVE FUNCTION OF ELW

•Erection Section :- When loco comes in ELW for POH it is comes to erection for dismantle. Assembling and dismantling of all loco parts is carried out in this section. After dismantling all parts are dispatched to respective section for maintenance after completing all maintenance work assembling of loco is done.

•R and M section – When loco is damaged or burned then repair and maintenance is carried out in this section. It contain – i] Press machine for bending ii] Sharing machine for cutting

• Pneumatic Section – There are 40 different valves are fitted in a loco. All leakage or any problem are removed in this section and make them fully efficient. In this section also overhauling of horn is done. As all loco circuit is electro pneumatic. Pneumatic section is the heart of loco and ELW.

• Bogie Section :-

After dismantling loco bogie is send to this section by erection section. In this section all parts are attached from bogie frame is send for inspecting cracks. Here wheels and traction motor are detached from bogie and send them to respective section, where overhauling of parts is done.

•Wheel Section :- In this section wheel comes from bogie sections. Here axle box and set are dismantle and necessary operation are done on wheel disc and axle box, with help of different machines.

• Traction Motor Section :- In this section relating traction motor all maintenance including bearing and armature maintenance is carried out. Different test are carried out on T.M. in this section.

H.V. Test :- In this test 2.5 KV voltage applied to T.M. see the leakage current.

Run Test :-

In this test rated supply is given to motor and run it for 2 hours. In between these vibration in motor, temp. And motor, noise in rotor are observed. After completing tests if armature and field winding are found OK. Then they are assembled. If there is any disturb in field winding replacement A] Same resistance B] Same inductance C] No one winding open D] No winding grounded

• Transformer section – In this section maintenance of transformer is done. following function are done in this section.

I] dismantling all parts of transformerii] Checking insulation of windingiii] Breaking down voltage test on insulating oilIV] Cleaning bushingv] Cleaning windingvi] Replacement oilvii] Cleaning fins of coolingviii] H.V. test

In HV test 380 V supply is given to auxiliary winding so 25 KV we get across primary and by changing taps the voltage across each tap is taken and check for temperature rise.

•Test Lab - Test lab is the most important part of ELW, Bhusawal when the new equipment comes in ELW. All testing of sample piece is done here. After certification of this department all stock is distributed to respective section.Various tests are done in this section some of them are as follows:•Non destructive Testing (NDT) –•Ultrasonic testing•RPDT (Red, penetrate dye test)

Ultrasonic Testing – It is carried with the help of ultrasonic flow detector machine used. This principle behind ultrasonic testing is based on piezoelectric effect.

RPDT - The kit is having 3 can –•Cleaner•Red dye•Developer Principle based on capillary action.

CONCLUSION

The Industrial training helps student to experience working environment of industry & evoked in yourself technical thinking and develop ability to understand basic factor. So this training taught many new technique & procedure of such a big organization. It helped me to learn co-ordination between department, organizations and communication between different levels of organization.

THANK YOU