BHILAI INSTITUTE OF TECHNOLOGY

Bhilai House, G.E. Road, Durg – 491001 (C.G.), India

A
PROJECT REPORT
ON
SUMMER VOCATIONAL TRAINING
AT
ELECTRIC LOCOSHED, BHILAI
DURG, CHHATTISGARH

Submitted By: Guided By:

Name - Sameer Bara Shikha choudhary

Branch – Mechanical Engineering

Semester – 6tH
 CERTIFICATE

This is to certify that SAMEER BARA, of 6thSEMESTER, MECHANICAL

ENGINEERING BRANCH, has done the SUMMER VOCATIONAL TRAINING
in the ELECTRIC LOCO SHED BHILAI, DURG, CHHATTISGARH.

Signature
Shikha Choudhary

Ch. Office Superintendent

 CONTENTS

1. INTRODUCTION OF INDIAN RAILWAY

2. INTRODUCTION OF ELECTRIC LOCO SHED
BHILAI
a. Purpose of electric loco shed, Bhilai
3. INTRODUCTION OF LOCOMOTIVE
4. POWER SUPPLY SYSTEM OF ELECTRIC
LOCOMOTIVE
5. MECHANICAL PARTS OF LOCOMOTIVE
INTRODUCTION OF INDIAN RAILWAY
Indian Railways, a historical legacy, are a vital force in
our economy. The first railway on Indian sub-continent
ran from Bombay to Thane on 16th April 1853, fourteen
railway carriages carried about400 guests from Bombay
to Thane covering a distance of 21 miles (34 KM). Since
then there has been no looking back. Today, it covers
6,909 stations over a total route length of more than 63,028 KM. The track
kilo meters in broad game (1676 mm) areas, 526 kms, meter gauge (1000
mm) are 18, 529 kms and narrow game (762/610 mm) are 3,651 kms. Of
the total route of 63.028 kms, 16,m1 kms are electrified. The railways have
8000 locomotives, 50,0“) coaching vehicles, 222,147 freight wagons, 6853
stations, 300 vards,2300 good sheds, 700 repair shops, and 1.54 million
work force. Indian Railways runs around 11,000 trams every day, of which
7,000 are passenger trains. Pres envy, 9 pairs of Rajdhani and 13 pairs of
Shatabdi Express Trains run on the rail tracks of India.

It is interesting to note that though the railways were introduced to facilitate

the commercial Interest of the British, It played an important role in unifying
the country. Railways are ideally suited for long distance travel and
movement of bulk commodities. Regarded better than road transport In
terms of energy efficiency, land use, environment impact and safety It Is
always in for efront during national emergency.

Indian railways, the largest rail network in Asia and the world’s second
largest under one management are also credited with having a multi gauge
and multi traction system. The Indian Railways have been a great
integrating force for more than 150 years. It has helped the economic life of
the country and helped in accelerating the development (1 Industry and
agriculture. Indian Railways Is known to be the largest railway network In
Asia.

The Indian Railways network binds the social, cultural and economic fabric
of the country and covers the whole of country ranking from north to south
and east to west removing the distance barrier for its people. The railway
network of India has brought together the whole of country hence creating
a feeling of unity among Indians.
 INTRODUCTION OF ELECTRIC LOCO SHED
BHILAI

BRIEF HISTORY
The inception of Electric Loco
Shed, Bhilai dates back to the
year 1970 when it was
commissioned consequent
upon Rourkela-Durg
Electrification. Electric Loco
Shed, Bhilai started its journey
to excellence, in the field of
Electric Locomotive
maintenance, by taking up IOH
work of WAG-4 Locomotives of
Electric Loco Shed, Tata
Nagar. Initial success of the Shed in carrying out the assignment
to the perfection got instant recognition and all the WAG-4 and
WAM-4 Locomotives of Electric Loco Shed, Tata Nagar were
transferred to Electric Loco Shed, Bhilai.
Since that time, Electric Loco Shed, Bhilai
has left no stone unturned in providing
trouble-free Locomotives for hauling
heavier loads at prescribed speed.
The region of Central India has been
blessed with abundance of rich minerals
and vast coal deposits, extremely vital for
the industrial & economic growth for a
developing nation like ours. These vast
resources are the backbone of rapid
industrialization process and to add infrastructural facilities in the
overall growth of nation. Industrial activities are being undertaken
at a very fast pace in this region which is further increasing day by
day.

SECR is situated in the heartland of Central India & serving the

states of Chhattisgarh, Orissa, Madhya Pradesh and Maharastra,
with proud privilege. This Railway plays a paramount role in the
transportation of Minerals and Coals to different Power Plants &
Industrial Units all over the country. Performance of SECR over
last eight consecutive financial years has been appreciated. The
main commodities being transported are Coal, Iron & Steel, iron
ore, cement and fertilizers. When we look at the indices of SECR,
amazingly we find that even though it has only 3.78% Railway
track kilometers of Indian Railways, SECR carries about 15.01%
of total volume of freight traffic on Indian Railways. At the same
time, it has the minimal strength of the employees i.e. only 3% of
the total work force of Indian Railways, whereas the operating
ratio on this railway has been extremely good i.e. only 50% which
is the best on Indian Railways. SECR has focused more on
capacity utilization, reduction in unit costs, energy conservation
and quality improvement of service which yielded remarkable
results
The freight traffic and the number of originating passengers have
increased on SECR.
 Purpose of electric loco shed Bhilai

01. The main purpose of electric loco shed is maintenance

of locomotive.
02. Improved Safety in Train Operation.
03. Improved Timely &quality of Servicing of locomotive.
04. Improved passenger Amenities.
05. Improved terminal Management.
06. Decrease profitability of the system failure of
locomotive.
07. Develop Infrastructure to meet future traffic potential.
08. Extensive effective use of Information Technology.
09. Effective cost management by the maintenance of
locomotive.
10. To improve quality Efficiency of electric locomotive.
11. Improved safety system in locomotive.
 INRODUCTION OF LOCOMOTIVE
An electric locomotive is a locomotive powered by electricity from
an external source. Sources include overhead lines, third rail, or
an on-board electricity storage device such as a battery, flywheel
system, or fuel cell. One advantage of electrification is the lack of
pollution from the locomotives themselves. Electrification also
results in higher performance, lower maintenance costs, and
lower energy costs for electric locomotives.

Electric locomotives are also quiet compared to diesel

locomotives since there is no engine and exhaust noise and less
mechanical noise. The lack of reciprocating parts means that
electric locomotives are easier on the track, reducing track
maintenance.

Electric locomotives can have a higher power output than diesel

locomotives and they can produce even higher short-term surge
power for fast acceleration. Electric locomotives are ideal for
commuter rail service with frequent stops.

Electric locomotives benefit from the high efficiency of electric

motors, often above 90%. Additional efficiency can be gained
from regenerative braking, which allows kinetic energy to be
recovered during braking to put some power back on the line.
Newer electric locomotives use AC motor-inverter drive systems
that provide for regenerative braking.
01. Main Reservoir
02. Scavenge Blower to TM blower/oil cooling unit.
03. Traction motor blower bogie 2
04. Vigilance control equipment
05. Control electronics pneumatic manifold.
06. Pneumatic panel
07. Auxiliary compressor
08. Oil cooling unit, transformer/ convter 1
09. Oil pump converter 1
10. Traction converter 1
11. Scavenge blower capacitor to machine room blower 1
12. Scavenge blower to machine room blower 1
13. Machine room blower 1
14. Auxiliary converter box 1
15. Cubical auxiliary circuits 1
16. Cubical control circuits 1
17. Central electronics 1 (cell -1)
18. Main reservoir
19. Main reservoir
20. Central electronics 1 ( cell -2 )
21. Cubical control circuits 2
22. Cubical auxiliary circuits 2
23. Auxiliary converter box 2
24. Machine room blower 2
25. Scavenge blower to machine room blower 2
26. Scavenge blower capacitor to machine room blower 2
27. Traction converter 2
28. Oil pump converter 2
29. Oil cooling unit, transformer, convector 2
30. Filter cubical
31. Traction motor blower bogie 1
32. Scavenge blower to TM blower/ oil cooling unit 1
33. Pneumatic horn
34. Vacuum circuit barker
35. Pantograph
36. Lightening arrester
37. High voltage transformer
38. Transformer
39. Battery box
40. Compressor
 POWER SUPPLY SYSTEMS FOR ELECTRIC
LOCOMOTIVE
Indian Railway has adopted 25 KV industrial frequencies (50 Hz)
A.C supply system for traction purposes. The power supplies are
derived from 220 KV / 132 KV 3 phase transmission system from
the various grids. The basic arrangement constitutes incoming
supply to Railway traction substation at a voltage level of 220 KV/
132 KV, which normally feeds power along the track for 35-40
Km. Adjacent traction substation are fed from different phases in
rotation in order to balance the 3 phase load in its entirety. Neutral
sections are provided in between two adjacent substations to
prevent the bridging of different phases while passing the electric
locomotive. Level of voltage is reduced to 25 KV for the end use
of locomotives by 21.6 MVA signal phase power transformers
placed at traction sub stations which are located at every 30-35
Kms distance along the track.
LOCOMOTIVES IN INDIA
Syntax

• First letter (gauge):

W-Broad gauge (wide)
Y -metre gauge (yard)
Z -2 ft. 6 in (762 mm) narrow gauge
N -2 ft. (6|0 mm) narrow (toy) gauge.

• Second letter (motive power):

D- Diesel
C- DC electric (DC overhead line)
A- AC electric (AC overhead line)
CA- DC and AC (AC or DC overhead line); CA is considered
one letter
B- Battery (rare).

• Third letter (job type):

G- Goods
P- Passenger
M- Mixed (goods and passenger)
S- Shunting (switching)
U- Multiple units (electric or diesel)
R- Railcar

AC electric
A 25 kV AC system with overhead lines is used throughout the
country.

• Mixed locomotives are:

WAM-l, WAM-2,WAM-3,WAM-4.
• Passenger locomotives are:
WAP-1, WAP-2, WAP-3, WAP-4, WAP-5, WAP-6, WAP-7,
WAG-9.

• Goods locomotives are:

WAG-l,WAG-2,WAG-3,WAG-4,WAG-5,WAG-6B and -6C,
WAG- 7H, WAG-8,WAG-9, WAG-9i and WAG-9Hi,WAG-12.

Dual (AC and DC)

These locomotives are used only in the Mumbai. Their main
purpose is to prevent the need to change engines. Mixed
locomotives are:

1) WCAM 1: - Designed by Chittaranjan Locomotive Works,

total 53 were built between 1975 and 1979.
Decommissioned by Western Railway, it is the only
locomotive with reverse pantographs.

2) WCAM 2/2P: - Designed by BHEL, 20 were built in 1995-96

and tested at 135 km/h (84 mph) on AC.

3) WCAM 3: - Fifty were designed by Bharat Heavy Electricals,

rated at 4,600 hp (3,400 kW) on DC traction and 5,000 hp
(3,700 kW) on AC. Owned by Central Railway; they are the
most widely-used locomotive on the Mumbai-Pune section.

The WCAG 1 is a goods locomotive, with 12 designed by BHEL in

1999-2000. Similar to the WCAM 3 in outer structure, it is rated 4,
600 hp (3, 400 kW) on DC and 5,000 hp (3, 700 kW) on AC.
 MECHANICAL PARTS OF LOCOMOTIVE
01. BODY
02. PANTOGRAPH
03. COMPRESSORS
04. BABY COMPRESSOR
05. BOGIES& IT’S MAIN PARTS
I. WHEELS
II. AXLES
III. TRACTION MOTOR
IV. MOTOR SUSPANTION UNIT
V. BULL GEAR
VI. SPLITE GEAR
VII. BEARINGS
VIII. BRAKE SYSYEM (LEVERS, LINKS, BRAKE
SHOE)
IX. SUSPENTION UNITS ( SPRINGS)
X. DAMPER
XI. SAND BOX
 01. BODY
The upper part of locomotive is called body. All electrical
and electronics part is inside the body.
There is a different shape of body of locomotive:-
WAM-4 front plan shape & WAP-7 front inclined shape
(which is aerodynamic shape) this shape increase the
efficiency of the locomotive.

WAM-4 WAP-7

Body
 02. PANTOGRAPH

Pantograph is mechanism which is made by the

links, levers, nut bolt etc. The pantograph is a
system of articulated arms, fixed to the roof of the
locomotive. It unfolds & extends along a vertical
axis. The horizontal end – piece of the pantograph
is called the
head. This
head is fitted
with carbon
strips (30%
copper &
70% carbon).
These carbon
strips slide along the over head catenaries wire
thus capturing the
Electricity required
to power
the train’s
traction
motors.
Failure of pantograph –
1. Brakeage of pantograph arm due to high speed of
train or
2. Tear in carbon strip.
3. Wear in the joints.

Maintenance of pantograph –

1. Repair the pantograph arm or replace it.

2. Do welding is crake occur in any point of
pantograph as possible or replace by new parts of
pantograph.
3. Repair the carbon strip or replace by the new
carbon strip.
 03. COMPRESSOR
A compressor is a mechanical device that increases the
pressure of a gas by reducing its volume.
The compressor intake the air from atmosphere and
compress it. The compressed air is store in main reservoir,
this compressed air is use for the air braking system.

1. Conventional
compressor
generates 10KG
of air in 5 minutes.
2. New (WAP-7 or
WAG-9)
compressor
generates
10KG of air
Conventional Compressor
in 3 minutes.

New Compressor
In different locomotive there are a different number of
compressors which is following -

Locomotive No. of compressor

WAG-9 2
WAG-7 3
WAP-7 2
WAM-4 3

ABOUT COMPRESSOR –
DELEVERY PRESSURE – 10 bar
POWER CONSUMPTION – 15 KW
COMPRESSOR SPEED –730 RPM
AIR DELEVERY- 1745 L / Min.
DISPLACEMENT - 2330 L / Min.
COMPRESSOR OF DEFFECT & REMIDIES

DEFFECT REASON OF REMADIES

DEFFECT
More time 1. Linkage in 1. Wash the oil
take to make pipe line bath mesh
the pressure 2. Wear & tear by petrol
in the piston 2. Change
rings. cylinder
3. Spoilage of head & do
disk valve. free from
carbon in
disk valve.
3. Measures
the ring gap
if necessary
then change
the ring.

Safety valve Safety valve is Check the parts

operate in not working of safety valve &
low pressure properly set in right
position & reset
it.
 04. BABY COMPRESSOR
A compressor is a mechanical device that
increases the pressure of a gas by
reducing its volume.
“This baby compressor is also called as
auxiliary compressor”.
The baby compressor is use for operate
the pantograph.
There is only one baby compressor in
locomotive.
ABOUT BABY OR AUXILIARY COMPRESSOR WITH
D.C. MOTOR
OUTPUT POWER – 1HP
VOLTS – 110 V
CURREN - 8.5 A
RATING – S1 DUTY
FRAME SIZE - 112mm
SPEED – 1500 RPM
DISP. T. – 150 Lts / Min.
WORK PR. – 7 Kg / Sq cm
BABY COMPRESSOR OF DEFFECT & REMIDIES-

DEFFECT REASON OF REMADIES

DEFFECT
More time 1. Chock happens 1. Change the air
taking to full fill in air filter. filter.
the reservoir 2. Linkage in air 2. Check the
line joints. joints.
more heating or 1. Insufficient 1. Fill the oil level
sage of piston lubrication. & change it in a
2. Piston cylinder particularly
is not properly dates.
fix
 05. BOGIE
The bogie frame & components are of all welded
light comstruction with the wheel base. The lower
part of locomotive is called as body, each
locomotive there is a 2 bogies. The wheels, traction
motors, damper & springs are present in the Bogie.

TYPE OF BODIES –
• ON THE BASES OF Casting Bogie
MANUFACTURING –
1. Casting Bogie – These
bogies made by casting
operation.
2. Fabricated Bogie –
These bogies made by
fabricate operation.

Fabricated Bogie
• ON THE BASES OF NUMBER OF MOTOR

TYPE OF BOGIE NUMBER OF MOTOR

B-B Type 1
Bi-Bi Type 2
Co-Co Type 3

The Bi-Bi type of bogie use in memu trains.

The Co-Co type of bogie use in good and passenger
trains.
I. WHEELS
The wheels provide the forward & backward motion of
the locomotive.
Wheel of a rake is a specifically made cylindrical portion
having outer edge shape to fit in the rail track. It is made of
Stainless Steel.
In one locomotive there is
12 wheels.
One bogie there is 6
wheels.

Wheel
DAIMENTION OF WHEEL

Loco New Wear Limits

Wheel
Diameter Root Flange Tread
WAG-9 1092(+5/- 6.0 3.0 6.5
0)
WAG-7 1092(+5/- 6.0 3.0 6.5
0)
MAINTENANCE OF WHEEL

• By the tear turning process reduction of diameter of

wheel occur.
• Always maintain the wear limit of the root, flange &
tread.
II. AXLE
Axle is the mail long cylindrical bar on which wheels are
fixed with the help of bearings. This is also made of
stainless steel like wheels. Each Axle contains two
wheels

The brake cylinders are also attached to it and the braking

discs are fixed on the axle.

Length of axle is 1596(+0.5 to -0.5) to 1599.

• A central shaft for a rotating wheel or gear.

• Axle may be fixed to the wheels rotating with them, or

fixed to its surroundings.

• Bearing or bushing provided at mounting points.

• Bearing or bushing sits inside the hole in the wheel.

AXLE
 III. TRACTION MOTOR
Traction motor refers to a type of electric motor.
A traction motor is used to make rotation torque on a
machine. It is usually changed into a straight line
motion. Traction motors are used in electrically powered
rail vehicles such as electric multiple units and electric
locomotives.

ABOUT DERECT CURRENT TRACTION MOTOR

Rating / RPM Volts AMPS Shaft

Value Output
power in KW
Continuous 895 750 900 630
Rating
One Hour 877 750 960 670
Rating
MAX VALUE 2150 900 1350
IV. MOTOR SUSPENSION UNIT

Motor Suspension Unit

The motor suspension

unit is nothing but it is a
frame of metal which is
attached with the axle
and the traction motor is
sets in motor suspension
unit.

MAINTENANCE OF MOTOR SUSPENSION UNIT

• If the crack is occur in the motor suspension unit then

the welding is done by the worker.
V. BULL GEAR
The term bull gear is used to refer to the larger of two spur
gears that are in engagement in any machine. The smaller
gear is usually referred to as a pinion.
Passenger AC electric loco comparison (WAP series).
See the freight ... Gear Ratio, 1:3.95, 1:3.95, 15:62, 16:62,
16:65, 15:77/ 18:64, 15:77 ... 1997 issue
of Indian Railways

THERE IS TWO TYPE OF GEAR -

Bull Gear

Inclined Bull Gear

LOCO CLASS AND ITS GEAR TEETH –

Loco Class Pinion No. of Teeth No. of teeth

Gear ‘k’
WAG-5 Gear 62 8
Wheel
WAM-4 Gear 58 7
Wheel
WAG-7 Gear 65 8
Wheel
WAG-9 Gear 107 15
Wheel

MAINTENANCE OFBULL GEAR

• If the Brakeage of tooth is occur then replace the gear
with the new gear.
• If Crack in develop is the gear then welding is done
up to the permissible limit other - wise replace it.
VI. BEARING
Bearing is use for support the shaft. Double roller bearing
is use in bogie of locomotive.

MAINTENANCE OF BEARING

• The roller bearings are inside the axle

box so that do properly lubrication.
• Check the service limit of the bearing
and after replace the old roller
bearing to new roller bearing.
VII. BRAKE SYSTEM

An air brake or, more formally, a compressed air brake

system, is a type of friction brake for vehicles in which
compressed air pressing on a piston is used to apply the
pressure to the brake pad needed to stop the train. He
patented a safer air brake on March 5, 1872.

AIR BREAK SYSTEM OF ELECTRIC LOCOMOTIVE

VIII. SUSPENSION UNIT

The all kind of springs and damper which is presence in

the locomotive that is comes into the suspension unit.
There is the some parts of the suspension unit are –

a) SPRINGS
Spring resist the sock in the locomotive.
The name of the spring use in the
electric locomotive is helical spring.

Following is the type of the spring

which is use in bogie are –
➢ Outer spring
➢ Inner spring
➢ Sunber spring
 b) DAMPERS
Damper is a mechanical part which is use to absorb the
shock.
Inside the damper there is a high viscous fluid present.

Damper
IX. SAND BOX

Sand box is use for the create the friction in between rail
line and wheel.
Sand release from the sand box in high pressure in the rail
line.
This sand box is mainly use in the rain season and in
turning time.
MAINTENANCE OF SAND BOX –
• Change the sand flow pipe.
• If crack occur in the sand box then welding has to be
done by the worker.
CONCLUSION

This Project report gives brief information about the

electric Locomotive and its various mechanical
components and it maintenance. In this report we can see
progress of conventional locomotive to new generation
locomotive. We can also see the various mechanical
component of electric locomotive and it use in locomotive.
This report is just focused on the mechanical component
of electric locomotive and it use and it maintenance.