Training Report
Training Report
Industrial Training
On
Electric Loco Shed
Submitted by:
Arshad Alam
11145124
th
5 Sem A1 (ME)
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ACKNOWLEDGEMENT
It is indeed a great pleasure for me to present this summer training report on Electric Loco
Shed, Ghaziabad as a part of the curriculum of the Bachelor of Technology (Mechanical
Engineering) degree.
I take this golden opportunity to thank all my mentors at LOCO SHED who with their support
and venerated guidance made this training a real success. I express my sincere thanks to officers
of LOCO SHED who in spite of their busy schedule have lent their precious time for helping out
me to understand various system used in LOCO SHED.
I will be failing in my duty if I am not mentioning the technical demonstrations as given by the
reverent staff of LOCO SHED. Getting training at such an organization is an exquisite learning
experience that made a mark at the profoundest part of my mind.
ARSHAD ALAM
Roll no. 11145124
B.Tech. 3rd year
Mechanical Engineering
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INDEX
1. INTRODUCTION
2. HISTORY
3. OVERVIEW OF TRAINING
8. BOGIE
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9. BODY
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10. PANTOGRAPH
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13. CONCLUSION
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14. REFRENCES
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1.INTRODUCTION
Ghaziabad electric loco shed is a government organization. Ghaziabad electric loco shed is
situated in vijay nagar just behind of the railway station of Ghaziabad. It is expanded over a
area of 45000 square meter. The purpose of establishing this loco shed was to minimize the
traffic in Delhi for the maintenance of locos.
More than 1000 employees including government and non government are are working here.
The work force is as followingSHED OFFICERS
Sr.DEE 1
ADEE - 2
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2.HISTORY
Ghaziabad Elecric Loco Shed was established & inaugurated in 1976 by the honble MR Shri
Kamlapati Tripathi .Its main purpose is of maintenance of WAP1 WAP4, WAP5, WAP7,
WAG5, WAM4 engines.
Ghaziabad electric loco shed serves the Delhi area. It houses and maintains India's fastest
locomotives which are mostly used in Rajdhani, Shatabdi and Duronto Expresses. It holds 47
WAP-1 locos as of 2008. It also has WAM-4, WAP-4, WAP-5, WAP-7 and WAG-5HA locos.
Ghaziabad (for Delhi) Electric WAM-4, WAP-1, WAP-4, WAP-5, WAP-7 Built to cater to
passenger traffic in the Delhi area. Received the first WAP-1s. Some WAP-1 and WAP-4s
were transferred to Arrakonam shed. Retains 31 WAP-1 locos. Also the home for the WAP-3
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3.OVERVIEW OF TRAINING
I have attended the summer training program held by loco shed from 13nd june 2016 to 09th july
2016.
During a month of this program I had gone through various departments of loco shed and got
precious knowledge. There are various departments such as M1,M2,M3,M5,M5HR etc. These
various departments are performing the activities as listed belowM1: Wheel maintenance and material inspection
M2 : Body repairing
M3 : Pantograph installation and maintenance
M5 : Pnuematics and braking system
M5 HR : Compressors maintenance
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Excluding these locos it also take the maintenance work of WAM and WAG type of locos. All
these locos are either used for the transportation of passengers, transportation of goods or
transportation of both goods and passengers depending upon the specifications that they have
and the name they have given. Each alphabet of WAM, WAP and WAG has a specific and
different meaning that differentiate all locos from one another.
W Indian broad gauge (the "W" Stands for Wide Gauge - 5 ft 6 in)
D diesel
CA both DC and AC (can run under both AC and DC overhead line); 'CA' is
considered a single letter
B Battery electric locomotive (rare)
G goods
P passenger
S shunting (also known as switching engines or switchers in the USA and some other
countries)
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R Railcars
"3A" means the locomotive's power is 3,100 hp ('3' stands for 3000 hp, 'A' denotes
100 hp more)
"5" denotes that this locomotive is chronologically the fifth electric locomotive model
used by the railways for passenger service.
Place
Outstation shed or homing loco shed as
convenient
Monthly Inspection
Two-monthly Inspection
Annual overhaul
Intermediate overhaul
Periodical overhaul
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Wheel
Axle
(axle)
7.a.WHEEL
Wheel is the member of wheel and axle assembly which takes the complete load of the loco and
rolls on the railway track to move the whole locomotive. Wheel is generally made up of
stainless steel and at its inner side a flange is provided which helps wheel to make in proper
contact with the track.
The method of production of wheels is casting but due to some defects of casting such as
inclusions, nonproper cooling and solidification there are some chances of failure to avoid this
there should be use of forging as in case of metro wheels.
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( wheel)
7.b.AXLE
Axle is the main long cylindrical bar on which wheels are fixed with the help of bearings. This is
also made of stainless steel as above. Each axle contains 2 wheels, the brake cylinders are also
attached to it, braking discs are fixed on to the axle.
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Width of wheel
Flange thickness
1596 approx.
Flat thickness
6.5mm
Root wear
4.0 -6.0m
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65-27mm
8.BOGIE
Solid welded Bogie Frame
two cross beams. The bogie frame rests on the primary suspension spring units and
supports the vehicle body by means of Bolster beam. The Bolster beam is connected to
the bogie frame by secondary suspension.
Primary suspension consist of two steel coil springs (internal/external) laid out on
the Control Arm upper part.
Secondary suspension
over the bogie frame. Each spring pack is made up by an internal and external spring.
An Anti roll bar fitted on the bogie frame realizes a constant, reduced inclination
coefficient during running. The bogie frame is linked to the bolster beam through two
vertical dampers, a lateral damper, four safety cables and the traction rods. The bogie
frame is linked to the coach body through two yaw dampers.
Traction Centre - The traction Centre transmits traction and braking forces between
bogie frame and body by a traction lever on the bolster beam pin and two rods.
Disk Brakes The FIAT bogie is fitted with pneumatic disk brakes. The
pneumatically operated brake cylinders are fitted with automatic device for taking up
the clearances.
Taper Roller Cartridge Bearing Fiat Bogie is fitted with 130 mm Cartridge type
roller bearings.
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8.a.BOGIE FRAME
The bogie frame is a solid welded frame made by steel sheets and forged or cast parts.
The frame is made up of two longitudinal components (1) connected by two cross-beams (2)
which also support the brake units. The various supports which connect the different bogie
components are welded to the frame. The bogie frame rests on the primary suspension spring
units and supports the vehicle body by means of a bolster beam. The bolster beam is connected
to the bogie frame by the secondary suspension.
BOGIE FRAME
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COMPONENT OF BOGIE
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8.b.PRIMARY SUSPENSION
Primary suspension is implemented by two units of two steel coil springs (internal (4) and
external (5)) laid out on the control arm upper part (13) by a centering disk (8) and adjustment
shims, (if required).
The suspension is also completed by the following components:
A control arm (13), fitted with twin-layer elastic joints (12), connecting the axle bearing to the
bogie frame and transmitting, not stiffly, lateral, longitudinal and part of the vertical forces;
A vertical damper (14).
Rubber elements (2) separate the primary suspension from the bogie to realize noise reduction.
Stops and protections are mounted on the bogie frame for the lifting.
1. Bogie frame
2. Rubber disks
3. Centering disk
4. Internal spring
5. External spring
6. Bump stop
7. Shim
8. Centering disk
9. Control Arm Lower Part
10. Plate
11. Block
12. Rubber joint
13. Control Arm Upper Part
14. Damper
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8.c.SECONDARY SUSPENSION
The secondary suspension enables lateral and vertical displacements and bogie rotation with
respect to body when running through curves.
It is implemented by two spring packs which sustain the bolster beam (1) over the bogie frame
(6). Each spring pack is made up by an internal (3) and an external spring (4), mounted and
positioned through the centering discs (5).
An anti-roll bar (2), fitted on the bogie frame (6), realizes a constant, reduced inclination
coefficient during running.
The bogie frame is linked to the bolster beam through two vertical dampers (7), a lateral damper
(8), four safety cables (9) and the traction rods (10).
The bogie frame is also linked to the coach body through two yaw dampers (11).
1. Bolster beam
2. Anti- roll bar
3. Internal spring
4. External spring
5. Centering disc
6. Bogie frame
7. Vertical damper
8. Lateral damper
9. Safety cables
10. Traction rod
11. Yaw dampe
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9.BODY
Body is basically the coach itself without the braking mechanisms and suspensions. It has the
following constituents. They are discussed below:
The Carriage is the main structure of the coach. This contains a floor which is called
Turf. There are Arch Levers which maintain the weight distribution throughout the
whole coach. And then there is the roof which is of a typical aero dynamical shape.
At the bottom of the carriage there are two kinds of bars made of stainless steel which
transfers the weight from the carriage to the wheels.
The Sole Bar is throughout the whole body of the coach vertically. These are at the
bottommost position of the body.
The Cross Bar is the horizontally arranged bars across the body. They get their support
from the sole bar.
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(Body)
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SECONDARY SUSPENSION
SUSPENSION LINK
HANGER LINK
HANGER BLOCK
PRIMARY SPRING
JOURNAL
BEARING
AXLE
WHEEL
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10.PANTOGRAPH
A pantograph is a device that collects electric current from overhead lines for electric trains or
trams. It is spring loaded and pushes a contact shoe up against the contact wire to draw the
electricity needed to run the train. Pantographs are typically operated by compressed air from
the vehicle's braking system, either to raise the unit and hold it against the conductor.
Now a days all locos are running through Electricity with the help of OHE line Pantograph is
used to connect the loco with OHE line Loco contains 2 Bogies, each Bogie consist of 6 wheels.
So totally loco consists of 12 wheels. Pantograph draws 25 KV of electricity from OHE line,
which is very high AC voltage.
(PANTOGRAPH)
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Upper arm
Lower arm
Coupling rod
Lifting mechanism
Collector panel
Frame
When the pantograph slides in contact with the OHE line then it collects electricity and sends it
to a collecting device where it is stored and then it goes to the batteries and get stored there
.there is also a transformer which converts this dc into ac for the traction purpose.
10.b.PANTOGRAPH SPECIFICATIONS
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(dimension of pantograph)
10.c.METHOD OF PANTOGRAPH TESTING
(testing of pantograph)
It has completely addressed the major reliability problems of breakage of springs, servomotor
failures and jamming of plunger being faced in conventional Pantographs. The direct air
operated Pantograph uses state of art air spring and does away with more failure prone
components such as servo motor and the metallic
spring of the conventional Pantograph. There is provision of Auto dropping device to protect
pantograph from external hitting. Improved dynamic behavior of air operated Pantograph also
results in better current collection.
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(braking system)
Distributor valve
Indicators
Brake Discs
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(sliding controller)
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The driver lowers the BP pressure by engaging the A-9 valve in the engine.
Since CR pressure remains same, the main diaphragm (above the CR) moves up in
response to the pressure drop in DV.
Thus the AR pressure of 6 kg/cm^2 flows into the BC through pressure limiters which
reduces BC pressure to 3.8.
11.d.BRAKE RELEAS
BP pressure is again increased to 5 kg/cm2.
Consequently, main diaphragm move down and the three pressure valve closes the
Brake Cylinder
Brake Discs
Brake Shoes
Each axle is equipped with two grey cast iron brake discs. The brake energy is dissipated only
at the axle mounted brake discs, so the wheel set is only stressed by the weight of the coach.
The advantage of this arrangement is that the superposition of the thermal stresses and
mechanical stresses is avoided.
The braking force is generated for each disc by a brake caliper unit, which consists of a brake
cylinder and the brake caliper, amplifying braking cylinder force depending on the lever ratio.
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11.e.1.1.WORKING PRINCIPLE
Applying the service brake charges the brake cylinder and presses the brake pads against the
brake disc. Brake force is built up when the pads are applied. Venting the brake cylinder
releases the service brake. The return spring in the brake cylinder moves the caliper levers to
the release position.
The handbrake lever is moved mechanically. The piston is pushed forward, and the brake pads
are applied to the disc. When the parking brake is released, the caliper levers are drawn to the
release position by the return spring in the brake cylinder.
(brake caliper)
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11.e.3.BRAKE DISCS
The axle mounted brake disc consists of a gray cast iron friction ring and a cast steel hub,
connected by means of radially arranged elastic resilient sleeves which are secured in the hub
by means of hexagon screws. The friction ring is manufactured as a solid component or in a
split version. In the latter case, the two halves are held together by two tight fit screws.
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11.e.4.BRAKE SHOE
The brake shoe is provided with a brake pad holder carrying replaceable pads. The brake shoe
consists of the brake pad holder, the vertical pins and the brake pad. The brake pad holder is
provided with a dovetail guide into which the pad is slipped. The pad is held in place by a
captive gate, which is pivoted at the pad holder. To lock the gate a locking spring of spring steel
has been provided which is pre-tensioned such that in one position it secures the gate in the pad
holder and in the other (released) position it holds the gate open. For each brake disc a right and
a left hand brake shoe are required.
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12.Traction Motor
Direct-current motors with series field windings were the oldest type of traction motors. These
provided a speed-torque characteristic useful for propulsion, providing high torque at lower
speeds for acceleration of the vehicle, and declining torque as speed increased. By arranging the
field winding with multiple taps, the speed characteristic could be varied, allowing relatively
smooth operator control of acceleration. A further measure of control was provided by using
pairs of motors on a vehicle; for slow operation or heavy loads, two motors could be run in
series off the direct current supply. Where higher speed was desired, the motors could be
operated in parallel, making a higher voltage available at each and so allowing higher speeds.
Parts of a rail system might use different voltages, with higher voltages in long runs between
stations and lower voltage near stations where slower operation would be useful.
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12.1.WINDINGS
The DC motor was the mainstay of electric traction drives on both electric and diesel-electric
locomotives, street-cars/trams and diesel electric drilling rigs for many years. It consists of two
parts, a rotating armature and fixed field windings surrounding the rotating armature mounted
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13.CONCLUSION
I have complete my training from the ELECTRIC LOCO SHED, GHAZIABAD. I have
observed many shop in the workshop I mainly performed my training in the BOGIE
SECTION.
We have learned too much in the workshop. DIFFERENT TYPE OF WORKSHOP
TECHNOLOGY, TESTING OF THE PARTS OF THE LOCOMOTIVE AND THE
PROPER FUNCTIONING of the different locomotives parts as a TRACTION MOTOR.
In this way I have learnt a lot of things at loco shed Ghaziabad during my summer training
which would be very much useful in my future. There I have learnt the advantages of electric
locomotives such that they can save fossil fuels which are limited in amount and the pollution
induced due to them also reduced by using a neat and clean resource electricity as the power
source for locomotives.
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