A Training Report on

2. ATraining Report on ELECTRIC LOCOMOTIVE WORKSHOP BHUSAWAL (P.O.H.)

3. Submitted By: Amit S. chavan Guided By: Prof: K. R. Patil S.R. Maheshri (H.O.D) KCE SOCIETY COLLEGE OF ENGINEERING. & INFORMATION TECHNOLOGY JALGAON (2012-13) Submitted To DEPARTMENT OF ELECTRICAL ENGINEERING.

4. CONTENT • History of Railway • Introduction of POH • Types of loco • Loco contents • Section of ELW • Functions of the equipments used in loco • Wheel section • Bogie section • Conclusion • Reference

5. HISTORY OF RAILWAY • In 15th century stone slabs wooden bulks were laid flush with the road surface for carriage of heavy goods loaded on the carts and drawn by animal’s .these were called “Tramways’. These Tramways were extensively used in 16th century. • It was only in the year 1804 when Richard Trevithickdesigned and constructed a steam locomotive how ever could be used for tractions on roads only

6. The credit of panicking the design finally goes to George Stephenson who in the year 1814 produce the steam locomotive used for traction Railways. • The first railway opened in India in 1853 • The maiden trips of Indian soil at the first train consisting of steam engine and for coaches was made on 16april 1853.When it travel 21 mile stretch between Bombay and Thane in about 1:25 hours time.

7. Starting from this humble beginning the Indian railways system becomes Giant networking at 62,000 route KM and crisis crossing the great country from Himalaya foot hill in the north to Kanyakumari in the south. • 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.

8. DIFFERENT GAUGES ON THE WORLD RAILWAY

9. INTRODUCTION TO P.O.H. Indian railway now a day’s largely are locomotives of electrical variety because at their large advantages over locomotives The electrical locomotive workshop (E.L.W.) repairs and does the necessary maintains at these engine. The locomotive comes to E.L.W. for P.O.H. (periodic overhauling).

10. In India there are two P.O.H. workshops 1) Kacharpara (near Kolkata) • Kanchrapara Workshop came into existence in 1863. • It caters to P.O.H.requirment at central, western and northern railways.

11. 2) Bhusawal(M.S.) • Electric locomotive workshop Bhusawal was set up at a cost of Rs.3.52 corers in the year 1970 to cater to P.O.H second workshop of electrical locomotives . • The biggest locomotives workshop Bhusawal.

12. 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. • FURTHER PLANS (ELW BHUSAWAL):- • 1) POH capacity extension to 15 loco per month . • 2) POH of three phase loco • 3) Up gradation at EDP centre • 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.

13. Mainly drawback of that POH Bhuswal is that only do maintenance of the loco • THE production and designing of new loco had done only in Chittranjan locomotive workshop (CLW)

14. TYPES OF LOCO AND GEAR RATIO • Where • W-Broad Gauge • A.A.C.-Electric loco • M-Mixed Service • G-Goods Loco • CA-AC & DC LOCO • All these loco comes in (ELW) Bhusawal for periodic overhauling.

15. WAM4 WAG5

16. WAP1/3 WAP4

17. WCG2 WCG9

18. ONE LOCOMOTIVE CONTAINS MAIN EQUIPMENT

20. 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.

21. 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 KV WEIGHT - 6880 KG TOTAL - 11.5 TONNES TAP CHANGER WEIGHT - 0.5 TONNES OIL WEIGHT - 1.7 TONNES OIL CONTAIN - 2000 LITRES

22. 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 to19 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

23. 4) HOM – Indian Railway has a great safety policy. For this HOM switch is designed in loco. It is a main switch of loco • When any maintenance is done in H>T> Compartment HOM switch is used. • Compartment are closed and the keys are not placed in B.V. Box pantograph key cannot be taken out. There are 4 H.T. Compartment keys.

24. 5) D.J. – D.J. is most important circuit breaker at loco D.J. helps in supplying single phase 25 KV from pantograph to transformer. This circuit breaker having specially that is takes very less time to open the loco circuit. To eliminate the major fault in a loco DJ is used. • There are two types of D.J. – • i) Air blast circuit breaker • ii) Vacuum blast circuit • The time for DJ closed in 4 sec. • The time for DJ trimming is 0.02 to 0.03 sec

25. 6) 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.

26. 7) S.L. (Smoothing reactor) – D.C. voltage obtained from rectifier is not pure. It contain little amount of A.C. pulse. It directly supply is given to T.M. the eddy current will generate and motor get heated and also spark and flashing occur between brush and commentator therefore by smoothing reactor (S.L.) is provided which absorbs A.C. pulse and gives D.C. to T.M

27. 8) S.J. (Inductive Shunt) – When we increased voltage with increase in tab T.M. get sudden voltage and increases speed suddenly and loco get jerking. To avoid this S.J. or inductive shunt which provide smooth current and constantly to T.M. for proper running.

28. 9) 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.

29. 10) RPS (Permanent Field Resistance) It is called as permanent field resistance. The current coming from S.L.also not 100% pure D.C. It contain very little amount of A.C. pulses. To absorb this pulses RPS is in parallel with T.M. Also in case of shunting for increasing speed after 24 notches these acts as resistance and lowers current and increases speed at loco. • RPS should form a current and voltage in stator windings specially.

30. 11) D.B.R. When the locomotive on the sloping track then voltage given is zero but the motor is revolving and becomes as generator and emf is induced in a T.M.This generated emf is directly gone to the D.P.R. for rheostat braking(electric braking).It is given with the help of M.P.in a braking side.

31. 12) 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 increased.

32. 13) 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

33. 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

34. 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.

35. 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.

36. 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. • Recalling Section :- When whole body is checked and certificate from erection section, it comes to recalling section. There are 15000 central cables so many power cables. All the cables have number on both sides so that they can be connected after overhauling at proper places. Elastomeric cables used for these purpose of different diameter.

37. 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. • Tan θ Test :- It is used for finding condition of insulation and is angle between inductive and capacitive current. So value tan θ must be minimum. • Surge Voltage Test :- In this test momentarily high voltage of applied to T.M. and graph observed on CRO. • H.V. Test :- In this test 2.5 KV voltage applied to T.M. see the leakage current.

38. H.V. Test :- In this test 2.5 KV voltage applied to T.M. see the leakage current. • Balancing Test :- Any rotor with an uneven distribution of mass about its axis of rotation has an unbalance. It deteriorates the bearing. So balancing test done on motor. The balancing machine directly gives the weight to be added and angle at which weight added. • 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

39. Growler test- There is half stator when supply is given to stator it produce flux. As rotor shorted close circuit formed so it acts as electromagnet. If rotor is OK it attracts iron parts so it tests rotor.

40. Transformer section – In this section maintenance of transformer is done following function are done in this section. I] dismantling all parts of transformer ii] Checking insulation of winding iii] Breaking down voltage test on insulating oil IV] Cleaning bushing v] Cleaning winding vi] Replacement oil vii] Cleaning fins of cooling viii] 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.

41. Test Room (DJ &S.M.G.R.) section – The maintenance and overhauling of main component of loco DJ and S.M.G.R. is done. i] Checking of opening and closing time for DJ at particular air pressure. ii] Checking S.M.G.R.

42. 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.

43. Machine Shop Section – In this section all little and small quantity work is done. Such as turning, drilling, tapering, shaping milling, threading, etc. I] Centre lathe 5 ii] HMT machine 3 iii] Turrelathe machine 3 iv] Drilling machine 2 v] Milling machine 5 vi] GD2 lathe 2 vii] Surface grinder 1 viii] Shaper machine 2 ix] Sloter machine 2

44. 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 • BA panel section - In this section BA panel in the loco are overhauled. Total maintenance of reversal switch and other equipment is done.

45. Mill Wright section- All machine in machine shop, cranes are under mill weight section. So maintenance of all these are done in this section. It is very important section as it maintains all machines in good condition. • Static section – It involves maintenance of rectifier RPS, DBR, MSR, R118. After doing all overhauls they send equipment to erection section

46. White Metal Section – This section includes casting of white metal to suspension bearing brass bearing and other equipments. • Inspection section – Whenever any locomotive comes to POH for overhauling. First incoming test are done and seen all equipments and test them. After that each equipment is dispatched to particular section. After complete assembly first HL tests are done and then H.T. tests done on locomotive. After inspection loco dispatched to customer.

47. 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.

48. Test Room - In test room (relay) section all relays which are used in loco first inspected and then necessary overhauling is done on that relay. • Rewinding section - In rewinding section winding of aux motors and traction motors field winding if damaged or burned are rewound or replaced

49. E.P. contactor section – E.P. contactor means electro pneumatic contactor. In this section different tests conducted on E.P. contactor like – • Checking operation by electrical • Checking operation pneumatically • M.V. drop test This test is used to see how perfectly the contact of contactor makes contacts. This voltage drop is to leakage current If contacts are perfect then there is no leakage current so voltage drop across contactor reduced permissible limit of voltage drop. In case line contactor - 4 to 6 mV Shunt contactor - 12 mV

50. 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.