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Institution of Railway Electrical Engineers

Institution of Railway Electrical Engineers. Challenges Before CLW to Manufacture New Generation Electric Locomotives to Meet the XI Plan Requirements. R.K. Bansal Chief Electrical Engineer. CHITTARANJAN LOCOMOTIVE WORKS. Meeting the Motive Power Requirements of a Resurgent Nation. Road Map.

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Institution of Railway Electrical Engineers

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  1. Institution of Railway Electrical Engineers Challenges Before CLW to Manufacture New Generation Electric Locomotives to Meet the XI Plan Requirements R.K. Bansal Chief Electrical Engineer Providing Motive Power to a Resurgent Nation

  2. CHITTARANJAN LOCOMOTIVE WORKS Meeting the Motive Power Requirements of a Resurgent Nation Providing Motive Power to a Resurgent Nation

  3. Road Map 1. History of CLW 2. Present Status 3. Why full switchover to new generation 3-phase completely 4. Challenges Providing Motive Power to a Resurgent Nation

  4. History of CLW Providing Motive Power to a Resurgent Nation

  5. CLW AT A GLANCE • Established in 1950 (26-Jan-1950) • 55 years of loco building experience • Expertise in steam / diesel / electric • Experience in BG / MG / NG/ E-NG • Manufactured over 6400 locomotives • Modern production facilities • Robust design for tropical conditions Providing Motive Power to a Resurgent Nation

  6. CLW has Manufactured • 2351 Steam Locomotives: 1950-1974 • 842 Diesel Locomotives: 1968-1994 • > 3000 Electric Locomotives since 1961 • CLW has manufactured all three types of locomotives together between 1968 & 1974 Providing Motive Power to a Resurgent Nation

  7. Types of Electric Locos Built • 1500 V DC: Three Types/Total: 90 • Dual Voltage: One Type/Total: 53 • 25 kV AC, 50 Hz :(3490 – till Dec.’06) (Conventional Tap-Changer Drive) • Product of in-house efforts • 15 Types • Increased power from 2900 HP to 5000 HP • Increased speed from 80 kmph to 140 kmph Providing Motive Power to a Resurgent Nation

  8. DC LOCO WCM5 DC LOCO WCG2 Providing Motive Power to a Resurgent Nation

  9. WAG1 WAM4 Providing Motive Power to a Resurgent Nation

  10. ToTs Absorbed by CLW Technology Area Principals Year • Steam Locomotives M/s.North British Locomotives, Scotland 1950 • Steel Foundry M/s.F.H.Lloyd & Co., UK 1960 • Electric Locomotives(WAG1) M/s.50 Cycles Group(European Consortium) 1960 • Electric Locomotives(WAG4) M/s.50 Cycles Group(European Consortium) 1964 • Diesel Locomotives M/s.MAK-KIEL West Germany 1968 • Traction Motors (TAO-659) M/s.Alsthom, France 1968 • Traction Motors (MG-1580) M/s.Alsthom, France 1968 • Traction Motors (HS-15250A) M/s.Hitachi, Japan 1984 • Steel Foundry M/s.Rockwell, USA 1990 • 3-Phase Electric Locomotives M/s.ADtranz (Switzerland) 1993 (WAG9 & WAP5) Providing Motive Power to a Resurgent Nation

  11. Section IIPresent Status • Present Product Mix • Conventional Tap Changer Locos: 2 Classes • Three-Phase propulsion: 3 Classes • Manpower: Though quite sufficient expertise in conventional loco, skills in handling 3-phase need augmentation • Infrastructure: • Inducted in phases • Re-engineering inputs in production lines is being planned to reduce cycle time Providing Motive Power to a Resurgent Nation

  12. Tap Changer Drive • Uses tap-changer as key control element • Traction Motor-DC series traction motor • Rated at 5000 HP • Of two classes • WAP4 (for 140 kmph passenger service) & • WAG7 (for 100 kmph freight operations) Providing Motive Power to a Resurgent Nation

  13. WAG7 WAP4 Providing Motive Power to a Resurgent Nation

  14. CLW Enters in the era of state-of-the-art Three Phase Drive Technology …first indigenous loco ‘Navyug’ dedicated to the nation on 14-11-1998 Providing Motive Power to a Resurgent Nation

  15. 3-Phase Propulsion in IR • Contract with ABB in 1993 • For WAG-9 & WAP-5 class • Technology transferred to CLW Chittaranjan Locomotive Works Providing Motive Power to a Resurgent Nation

  16. WAG-9 WAP-5 Providing Motive Power to a Resurgent Nation

  17. NEW VARIANT WAG9H NEW VARIANT WAP7 Providing Motive Power to a Resurgent Nation

  18. Assimilation of 3-Phase Drive Technology- Present status • ToT fully assimilated • Serial production of WAG-9 & WAP-5 started since 1998 & 2000 respectively • A new variant WAP-7 developed in 2000 • Major items indigenously developed • Application software administration taken over from M/s Bombardier Providing Motive Power to a Resurgent Nation

  19. Cost Reduction - 3-phase Locos (WAG9)(In Rs Cr.) Providing Motive Power to a Resurgent Nation

  20. Evolution of Power HP WAG9 WAG7 WAG5 WAM4 WAG4 WAG1 Year Providing Motive Power to a Resurgent Nation

  21. Can be upgraded to 200 kmph Evolution of Speed WAP5 WAP4 WAP1 WAM4 WAG1 WAG4 Year Providing Motive Power to a Resurgent Nation

  22. Section-IIIWhy 3-Phase Propulsion Technology • Advantages of the technology platform • Superior mechanical, electrical, electronic and control systems • New Perspective due to regeneration features • Loco becomes generator of electricity • Meets needs of Energy Hungry civilization Providing Motive Power to a Resurgent Nation

  23. 3-Phase Drive-Self Debt Paying Platform Pays Back by Generating Electricity Providing Motive Power to a Resurgent Nation

  24. Salient Features • 5400 HP 4-axle passenger • 6000 HP 6 axle freight • Crew friendly • Better safety features • Better Electronic Control Using State-of-the-art technology • VVVF Control • Hotel load winding Providing Motive Power to a Resurgent Nation

  25. Advantages • Improved Performance - 200kmph (10 coaches/160 kmph (18 coaches) - 100 kmph & 58 BOXN– 4800 t) • Reduced Maintenance • Use of Robust 3-phase Traction Motor • Self diagnostic • Automatic fault isolate • Reduced requirement of brake shoes • Reduced down time • Energy saving • Regenerative braking (Source of non-conventional energy) • Unity power factor Providing Motive Power to a Resurgent Nation

  26. A New Perspective- Self paying wonder Locos of CLW • 3-phase Electric Locos when kept running, automatically becomes Self-debt servicing locos. • Depending on the vast scope for deployment in some of the Railways which have long graded sections, the loco becomes a money spinner- simultaneously engaged in 2 parallel lines of businesses- hauling traffic and incidentally generating free of cost power. Providing Motive Power to a Resurgent Nation

  27. A New Perspective • This complementary/ adventitious gain will actually bring down the cost of a 3-phase loco from Rs. 11.54 crores a piece to just about Rs. 5.67 crores. • Both power generation from the locos and contribution to Central exchequer are likely to go up substantially when the 3-phase loco population increases and its deployments in more and more graded sections. (Regeneration figures taken from users railways) Providing Motive Power to a Resurgent Nation

  28. A New Perspective • Total installed capacity of wind power (Wind Turbines) is 2885 MW (as in Sept. 04) in India. • The plant load Factor of Wind Turbines is just about 15% - 20%. • Total installed capacity of 3-phase electric locomotive power as on date from 120 locos held by IR, adds up to 532.5 MW. • The Plant Load Factor is pegged at 10% as of now. Thus the effective installed capacity would be about 53 MW. • This will help generating approximately 60 million units of electricity from 3-Phase locos of IR in a year, as of now. • The total 3-Phase Electric loco population will jump to 220 locos by 2007-08, i.e. 110 MW effective installed capacity in that year which is totally environment-friendly and zero-cost power generation. Providing Motive Power to a Resurgent Nation

  29. A New Perspective • IR’s own electricity generation from 3-Phase locos will reach 200 million units plus per annum by 2007-08. • As on date the 120 three phase locos held by IR, regenerate/ cogenerate @ 60 million units(kWh) of electricity per annum. • At an All India average purchase price of Rs.4.21 per kWh, these locos may contribute to the exchequer approximately Rs.21 crores in 2005-06, on present indications. This would mean that these locos which have a combined purchase price of Rs.1560 crores (each loco costs Rs.11.54 crores a piece) and a useful economic life of 35 years, would contribute an amount of Rs.880 crores from free power generation alone. Providing Motive Power to a Resurgent Nation

  30. Section-IVChallenges • Increased demand of locos • Vendor Development • Paradigm shift in technology • Infrastructure • Obsolescence • Handling heavier load at higher speeds • Human Resource Development Providing Motive Power to a Resurgent Nation

  31. Momentous Decision Complete Switch-over to Three-Phase Propulsion by 2011-12 Providing Motive Power to a Resurgent Nation

  32. Challenges- Requirement of New Electric Locos Providing Motive Power to a Resurgent Nation

  33. Challenges • Indian Rolling Stock component industry yet to get in to real product development mode • Presently they are licensed manufacturers • Vendors to be further groomed to come to global acceptable levels • Then only the real quality & reliability improvements will take place • More vendors to be developed for about 30-40% of the items • Single Source Items :104 • Imported : 64 • Indigenous : 40 • No Regular Approved Source : 21 • Developmental orders being given to the new sources outside the required (NPQ) quantity • Industry invited to participate • Quality of certain equipments is below acceptable levels • There is design deficiency in certain equipment in view of the Indian conditions. Providing Motive Power to a Resurgent Nation

  34. Challenges-Paradigm Shift in the Technology • Three-phase propulsion represents paradigm shift in locomotive design • No longer hard-wired locomotives • Use of fibre-optic bus • Not possible to troubleshoot using test lamp • Imperative to use sophisticated test & measurement equipment: • Multi-channel storage oscilloscopes • Fibre-optic cable test equipment • GTO test equipment • Diagnostic tool • Offline data analysis tool Providing Motive Power to a Resurgent Nation

  35. Challenges-Infrastructure • CLW started as steam loco builder • All the shops still are the legacy shops of that era • Change in technology overlapped • At one time CLW manufactured steam, diesel and electric together • Since shops carry legacy of steam era, present layouts not very scientific • Infrastructure augmentation has been incremental, resulting in to distributed facilities, hence cycle time could not be brought down to optimum levels • For the first time, CLW has proposed new shops Providing Motive Power to a Resurgent Nation

  36. Challenge-Obsolescence • We can repair & run a 150 year old steam locomotive • But repairing a 10 year old television is a challenge Providing Motive Power to a Resurgent Nation

  37. Challenge-Obsolescence • Challenge to keep existing GTO fleet in running condition • Incremental inputs to have IGBT based solutions ready for retrofitment-GTO production is being phased out • Tender for IGBT based power and auxiliary converters under evaluation • Tender for evaluating new VCU conforming to published standards under evaluation • Some foreign manufacturers no more interested to manufacture certain items due to low volumes-IR specific production Providing Motive Power to a Resurgent Nation

  38. Challenge-Keeping 3-Phase Propulsion Alive • Need to change drive to contemporary technology • Plans underway to have full matching drive chain upgraded to IGBT platform Providing Motive Power to a Resurgent Nation

  39. Challenge-Increasing the Power • Heavier loads call for higher power locomotive • Need to upgrade the propulsion to accommodate higher power on WAG-9 platform • Possible to touch 7000 HP in existing WAG-9 platform Providing Motive Power to a Resurgent Nation

  40. Challenges-HRD • Old skill-sets need augmentation • Mechanical Skills: • New locomotives are designed on much tighter tolerances • Drives, esp. fully suspended drives much more complex • Pneumatic circuits not only different-they use different fittings • TE transmission different • Electrical: • Use of sophisticated test & measurement tools • High level of computer literacy • Handling of electro-static discharge sensitive cards • Fundamentally different mind-set Providing Motive Power to a Resurgent Nation

  41. Challenge-HRD • As fleet of 3-phase locomotives grow, there is need of: • Computer literate workforce • Higher level of skills in handling complex test & measurement equipment • Need to recruit Graduate/Diploma candidates • More intensive training and refresher courses on site Providing Motive Power to a Resurgent Nation

  42. Thank You Providing Motive Power to a Resurgent Nation

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