Challenges Before CLW to Manufacture New Generation Electric Locomotives to Meet the XI Plan Requirements

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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
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CHITTARANJAN LOCOMOTIVE WORKS

• Meeting the Motive Power Requirements of a
  Resurgent Nation

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Road Map

• 1. History of CLW
• 2. Present Status
• 3. Why full switchover to new generation 3-phase
  completely
• 4. Challenges

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History of CLW
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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

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CLW has Manufactured

• 2351 Steam Locomotives 1950-1974
• 842 Diesel Locomotives 1968-1994
• gt 3000 Electric Locomotives since 1961
• CLW has manufactured all three types of
  locomotives together between 1968 1974

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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

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DC LOCO WCM5
DC LOCO WCG2
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WAG1
WAM4
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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)

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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

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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)

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WAG7
WAP4
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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
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3-Phase Propulsion in IR

• Contract with ABB in 1993
• For WAG-9 WAP-5 class
• Technology transferred to CLW

Chittaranjan Locomotive Works
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WAG-9
WAP-5
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NEW VARIANT WAG9H
NEW VARIANT WAP7
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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

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Cost Reduction - 3-phase Locos (WAG9)(In Rs Cr.)
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Evolution of Power
HP
WAG9
WAG7
WAG5
WAM4
WAG4
WAG1
Year
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Evolution of Speed
Can be upgraded to 200 kmph
WAP5
WAP4
WAP1
WAM4
WAG1
WAG4
Year
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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

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3-Phase Drive-Self Debt Paying Platform
Pays Back by Generating Electricity
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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

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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

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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.

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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)
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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.

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A New Perspective

• IRs 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 _at_ 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.

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Section-IV Challenges

• Increased demand of locos
• Vendor Development
• Paradigm shift in technology
• Infrastructure
• Obsolescence
• Handling heavier load at higher speeds
• Human Resource Development

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Momentous Decision

• Complete Switch-over
• to
• Three-Phase Propulsion by 2011-12

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Challenges- Requirement of New Electric Locos
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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.

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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

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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

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Challenge-Obsolescence

• We can repair run a 150 year old steam
  locomotive
• But repairing a 10 year old television is a
  challenge

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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

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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

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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

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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

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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

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Thank You