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Electric Loco Shed-11145124

Industrial Training
On
Electric Loco Shed

Submitted by:
Arshad Alam
11145124
th

5 Sem A1 (ME)
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MMEC, MULLANA

Electric Loco Shed-11145124

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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Electric Loco Shed-11145124

INDEX

1. INTRODUCTION

2. HISTORY

3. OVERVIEW OF TRAINING

4. TYPES OF LOCOS HOLDING

5. SYNTAX USED IN LOCOS

6. TYPES OF INSPECTION AND THEIR PLACES

7. WHEEL AND AXLE ASSEMBLY

8. BOGIE

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9. BODY

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10. PANTOGRAPH

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11. BRAKING SYSTEM

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12. TRACTION MOTOR

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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

DEE 1 (Mr. K.K. Rastogi )

ADEE - 2

SHED STORES DEPOT


SMM 1

SUPERVISORS, ANCILLARY AND OTHER STAFF


ELS/GZB:- SS-992, OR-871

RSO:- SS-166, OR-172

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Electric Loco Shed-11145124

Overview Of Traction Offerings

[1] Traction transformer


[2] Traction converter
[3] Traction control
[4] Train Control and Monitoring System
[5] Traction motor
[6] Diesel engine generator
[7] Auxiliary converter
[8] Battery charger
[9] Energy storage

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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locos which have been converted back to a WAP-1. Also homes WAP-4, WAP-5 and WAP-7
and one WAM-4 for departmental duties. Has largest fleet of 3 phase passenger locos Or, in
"WAP 5".
The initial cost of the establishment was 1.5 crore and in starting it was serving for the total
number of 34 locos but at present it has ability of maintenance 184 locos.

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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Electric Loco Shed-11145124

4.TYPES OF LOCOS HOLDING

WAP1 (Traction motors:3900hp,18 coaches)

WAP4 (Traction motors:5350hp,750V,26 coaches)

WAP5(Traction motor: 3 phase squirrel cage induction motors) 5450hp,2180V

WAP7(Traction motor: 3 phase squirrel cage induction motors) 6250hp,2180V

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.

5.SYNTAX USED IN LOCOS


The first letter (gauge)

W Indian broad gauge (the "W" Stands for Wide Gauge - 5 ft 6 in)

Y metre gauge (the "Y" stands for Yard Gauge - 3 ft or 1000mm)

Z narrow gauge(2 ft 6 in)

N narrow gauge (toy gauge) (2 ft)

The second letter (motive power)

D diesel

C DC electric (can run under DC overhead line only)

A AC electric (can run under AC overhead line only)

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)

The third letter (job type)

G goods

P passenger

M mixed; both goods and passenger

S shunting (also known as switching engines or switchers in the USA and some other
countries)

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U electric multiple unit (used to carry commuters in city suburbs)

R Railcars

For example, in "WDM 3A":

"W" means broad gauge

"D" means diesel motive power

"M" means suitable for both goods and passenger service

"3A" means the locomotive's power is 3,100 hp ('3' stands for 3000 hp, 'A' denotes
100 hp more)

Or, in "WAP 5":

"W" means broad gauge

"A" mean AC electric traction motive power

"P" means suitable for Passenger service

"5" denotes that this locomotive is chronologically the fifth electric locomotive model
used by the railways for passenger service.

6.TYPES OF INSPECTION AND THEIR PLACES


Inspection name
Trip Inspection

Place
Outstation shed or homing loco shed as
convenient

Monthly Inspection

Homing or nominated Electric Loco Shed

Two-monthly Inspection

Homing Electric Loco Shed

Four monthly Inspection

Homing Electric Loco Shed

Annual overhaul

Homing Electric Loco Shed

Intermediate overhaul

Homing Electric Loco Shed or Nominated


Workshop.

Periodical overhaul

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Workshop nominated for the purpose

Electric Loco Shed-11145124

7.WHEEL AND AXLE ASSEMBLY


Wheel and axle assembly is the main part of an loco it is the wheel which takes the complete
load of the loco and also makes a loco to run. In this way we can say that this is also the main
supporting part of the traction system.
It basically consists of four main parts.

Wheel

Axle

Bearing and Housing

(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.

(axle wheel with attached to Bogie)


7.c.COMPONENTS OF WHEEL AND AXLE
ASSEMBLY
The components of wheel and axle assembly are given
below

Two brake disks (4), diameter 640 mm and


width 110 mm.

In built slack adjusting brake cylinder fitted

Two wheel discs

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7.d.AXLE BEARING
A taper roller cartridge type bearing is used and it makes up a preassembled unit. The axle
bearings on the bogie are fitted with sensors for detecting speed (whose signal is elaborated by
the ant slipping system) and a current return device.
The ends of the control arms are fitted with centering devices for the primary suspension spring
assembly. The bearing lubricating plug is fitted in the lower part.

(axle bearing with direction)


7.e.SOME SPECIFICATIONS OF WHEEL AND AXLE

Width of wheel

Flange thickness

32-29.5mm and for WAP729

Distance between two wheels

1596 approx.

Flat thickness

6.5mm

Root wear

4.0 -6.0m

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65-27mm

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8.BOGIE
Solid welded Bogie Frame

made up of two longitudinal components connected by

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

consists of two spring packs which sustain the bolster beam

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

1.Bogie frame longitudinal component


2. Cross-beam

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COMPONENT OF BOGIE

(component of bogie section)

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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

(body rotational parts)

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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.

9.a.CENTER PIVOT ASSEMBLY


Center Pivot is welded to the upper bolster plank and passes through the supporting frame
which is rectangular in shape. This is a pivoting system used in transportation of force through a
mechanically advantageous system of pivot. At the bottom of the center pivot there is a traction
lever. A traction rod is also connected at the end of traction lever having its other end connected
with the cross bar.

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9.b.BOGIE BODY CONNECTION


In coaches, there are a special kind of bolts called swing bolts, which are four numbered in
each trolley. These connect the body to the bogie to the body. Each bolt is fastened with a pin
which can swing in the direction of the motion.

(Body)

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9.c.LOAD DISTRIBUTION
SIDE BEARING
UPPER SPRING BEAM

SECONDARY SUSPENSION

SUSPENSION LINK

HANGER LINK

HANGER BLOCK

PRIMARY SPRING

AXLE BOX WING

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)

10.a.HOW DOES PANTOGRAPH WORK


A pantograph is operated by the compressed air of compessor which is located nearby the
compressed air cylinder of braking system. when brakes are applied there is no need of the
electricity for running of the loco so the pantograph get down and after release of break when
need of tractive power arises then once again the pantrograph get raised and collects the
electricity .Pantograph has some parts such as

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Upper arm

Lower arm

Coupling rod

Carbon strips (initially made up of mild steel)

Lifting mechanism

Collector panel

Frame

Guiding rod etc.

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.

(pantograph attach with engine)

10.b.PANTOGRAPH SPECIFICATIONS

Maximum height = 2440-2460mm

Panto pan length= 1800mm

Width of panto pan= 240 mm

Length of carbon strip=1039-1038mm

Width of carbon strip= 24mm

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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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(air raised pantograph)

11.PNUEMATICS OR AIR BRAKE SYSTEM


In Air Brake system compressed air is used for operating the brake system. The locomotive
compressor charges the feed pipe and the brake pipes throughout the length of the train. The
feed pipe is connected to the auxiliary reservoirs and the brake pipe is connected to the brake
cylinders through the distributor valve. Brake application takes place by dropping the pressure
in the brake pipe. The schematic arrangement of the brake equipment is shown as in figure.

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(braking system)

11.a.COMPONENTS OF AIR BRAKE SYSTEM

Brake Container (Brake Equipment Panel)

Distributor valve

Pressure Tanks (125 litres, 75 litres, 6 litres)

Indicators

B.P./F.P. Couplings and Hoses

Emergency Brake Pull Box

Emergency Brake valve

Bogie Brake Equipment, consisting of

Brake Discs

Brake Caliper Units (consisting of Brake Cylinder, Brake Calipers, Brake


Pads)

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Wheel Slide Control System, consisting of

Microprocessor Control Unit

Speed Sensor/Pulse Generator

(sliding controller)

11.b.BRAKE CONTAINER PANEL


The Brake Container (Brake equipment panel) consists of a Manifold on which various devices
like the Distributor Valve, Cocks, Test fittings etc. are mounted. It also consists of the
reservoirs required for the Brake system. The container is mounted under the car body and
different lines (Feed pipe, Brake pipe, etc.) are connected to it.

(brake equipment panela)

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11.c.BRAKE APPLICATION

The driver lowers the BP pressure by engaging the A-9 valve in the engine.

This loss in pressure is transmitted from one bogey to the next.

Since CR pressure remains same, the main diaphragm (above the CR) moves up in
response to the pressure drop in DV.

As a result the three pressure valve opens the AR-BC port

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

AR-BC port and opens the BC-atm port.

BC pressure is released and the brake caliper is disengaged.

11.e.BOGIE BRAKE EQUIPMENT


The Bogie Brake equipment consists of:

Brake Caliper Units

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.BRAKE CALIPER UNITS
The brake caliper units are readyto-use combinations of a brake caliper and brakecylinder,
providing automatic slack adjustment for wear (abrasion) on brake pads and brake discs.
Consequently, the clearance required between the disc and pads for smooth running remains
practically constant while the brakes are released. Brake Caliper units consist essentially of the
brake cylinder, the brake caliper, and the brake shoes d1 and d2 with snap lock gates. The brake
caliper units are held in the vehicle bogies by a three point-mounting arrangement.

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.2.BRAKE CYLINDERS
U-series brake cylinders with automatic slack adjustment are used to operate the friction brakes
in rail vehicles. U-series brake cylinders are essentially distinguished by their integral, force
controlled slack adjustment mechanism which is designed as a single acting clearance adjuster.
The working of this mechanism is not influenced in any way by the elastic brake rigging
deflection, which varies according to the brake force. In the course of braking, the slack adjuster
quickly and automatically corrects the increasing brake pad or brake block clearance due to
wear.

(brake system and caliper)

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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Axle Mounted Brake Discs

Wheel Mounted Brake Discs

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.

(electric traction moter)


A variant of the DC system was the AC operated series motor, which is essentially the same
device but operated on alternating current. Since both the armature and field current reverse at
the same time, the behavior of the motor is similar to that when energized with direct current.
To achieve better operating conditions, AC railways were often supplied with current at a
lower frequency than the commercial supply used for general lighting and power;
special traction current power stations were used, or rotary converters used to convert 50 or 60
Hz commercial power to the 16 2/3 Hz frequency used for AC traction motors. The AC system

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allowed efficient distribution of power down the length of a rail line, and also permitted speed
control with switchgear on the vehicle

(combination of traction motor & axle)

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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around a shaft. The fixed field windings consist of tightly wound coils of wire fitted inside the
motor case. The armature is another set of coils wound round a central shaft and is connected to
the field windings through "brushes" which are spring-loaded contacts pressing against an
extension of the armature called the commutator. The commutator collects all the terminations
of the armature coils and distributes them in a circular pattern to allow the correct sequence of
current flow. When the armature and the field windings are connected in series, the whole
motor is referred to as "series-wound". A series-wound DC motor has a low resistance field and
armature circuit. Because of this, when voltage is applied to it, the current is high due to Ohm's
law. The advantage of high current is that the magnetic fields inside the motor are strong,
producing high torque (turning force), so it is ideal for starting a train. The disadvantage is that
the current flowing into the motor has to be limited, otherwise the

12.2.Advantages of Electric Loco


 High power-to weight ratio.
 High torque motor are used in electric traction.
 Fewer Locomotive
 Fast Acceleration
 Higher limit of speed
 Higher hauling capability
 No carbon emission
 Less noise pollution
 Maintenance cost is 50% of that for steam engine.
 Steam engine requires two hours for heat up whereas electric engine start within
moment.

12.3.Disadvantages of Electric Loco


 Maintenance cost is high.
 Significant capital cost of electrification.
 Overhead wires further limit the clearance in tunnel.
 Railway traction need immune power, with no cuts.

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(layout of wap-5 loco)

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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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14..Refrences & Bibliography


1. google.co.in
2. Wikipedia.en
3. Indian Railway website
4. Scribd.in

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