Golden Rock Railway WorkshopInplant training report

Report submittedbyNameCollege

PASUPATHI.VALAGAPPA CHETTIAR COLLEGE OF ENGINEERIN AND TECHNOLOGY, KARAIKUDI

PRADEEP.RALAGAPPA CHETTIAR COLLEGE OF ENGINEERIN AND TECHNOLOGY, KARAIKUDI

VINOTH KUMAR.MALAGAPPA CHETTIAR COLLEGE OF ENGINEERIN AND TECHNOLOGY, KARAIKUDI

MARIAPPAN.SALAGAPPA CHETTIAR COLLEGE OF ENGINEERIN AND TECHNOLOGY, KARAIKUDI

VELMURUGAN.VALAGAPPA CHETTIAR COLLEGE OF ENGINEERIN AND TECHNOLOGY, KARAIKUDI

SAM EBENEZER RAJ.AKARUNYA UNIVERSITY, COIMBATORE

Acknowledgement

I Sincerely thank Shri.SELVAM.V ,IRSME,CWM/GOC for providing this opportunity to under goinplant training in central workshops ,Sothern Railway,Golden Rock.

I extend my heartful thanks to Shri.RAJA MOHAMED IQBAL.K Principal /BTC And Shri.RAVEENDRAN.G,CI/BTC for guiding in each step.I also like to thank the officers,staff of the GOC Shops and BTC for guiding and helping me to get the best training.

IndexS.No.ContentPage No.

1Ponmalai GOC a brief history5

2Electrical Maintanence /Safety Cell /Basic Training Centre6

3Electrical Millwright Shopi. Induction Motorii. DC Motoriii. Standard Wire Gaugeiv. Slip Ring Induction Motorv. Crane Sectionvi. Control Gear7910

111213

4PowerHouse Substation Oil Circuit Breaker1415

5Electrical & Electronics Lab Wagon Bogie Section (Computerised Numerical Control)

16

6Traction Generator17

7Traction Motor18

Ponmalai GOC a brief history

TheGolden Rock Railway Workshop is situated in Ponmalai (Golden Rock),Tiruchirapalliin the IndianstateofTamil Nadu, is one of the three mechanical railway workshops serving the southern zone of theIndian Railways.This repair workshop is basically a "Mechanical Workshop" which comes under the control of the Mechanical Department of the Indian Railways. The other two mechanical workshops of Southern Railway are located in Perambur, Chennai. They are "Carriage Works, Perambur" and "Loco Works, Perambur"The total area of this workshop is around 200 acres (0.81km2), out of which 26 acres (110,000m2) is covered under roof. At present 6,091 employees are working in this workshop. This workshop is primarily engaged in the activities of DSL Loco POH, heritage steam locomotive POH, coaching stock maintenance and wagon manufacturing and other sundry activities.This workshop when built had state-of-the-art facilities rarely seen in those days. It had its own powerhouse which generated electricity for the workshop and the colony. In fact, Railway colony, Golden Rock was one of the first places to be lit by electrical lights in Tiruchirappalli city those days.

Electrical plant maintenanceThere is a dedicated team to maintain the electrical equipments and machineries available in GOC Shop. Apart from maintaining the Electrical machineries, the team is also looking after electrical power distribution system and conservation measures, with close monitoring of electrical energy utilization, the shop had reduced the electrical energy from 81.12 Lakhs unit in 200708 to 75.58 Lakhs in the year 200809. it had resulted in a financial savings of Rs.29.04 Lakhs in 200809.

Safety cellSafety Department at GOC Shop is functioning for the last 30 years for the goal of reducing accidents, injuries and hardship of the labours by improving the work methods and their knowledge in creating awareness in safe working methods. This approach was focused through systemic training, mock drills, shop floor counseling, data updating and scientific elimination of work related hazards, through display of posters, issue of safety magazines incorporating various safety procedures and catching an emotional rapport with audience through tailor made safety modules.The Safety Department has bagged three State-level Awards from Government of Tamil Nadu in three different fields for the year 2005.

Basic training centreShop is attached with a training centre mainly to cater to the requirement of Act Apprentice courses under Apprenticeship act 1961. This is a statutory in nature. The duration of the training varies from one year to four years depending on the entry level qualification and trade in which the apprentice is to be trained.Apart from act apprenticeship the Training Centre also takes care of the need based training for the Artisans, Special supervisory skill training for supervisors.

Electrical MillwrightInduction motor

Synchronous speedAn AC motor's synchronous speed,, is the rotation rate of the stator's magnetic field, which is expressed in revolutions per minute as(RPM),whereis the motor supply's frequency in hertz andis the number of magnetic poles.That is, for a six-pole three-phase motor with three pole-pairs set 120 apart,equals 6 andequals 1,000 RPM and 1,200 RPM respectively for 50Hz and 60Hz supply systems.

Slip

Typical torque curve as a function of slip, represented as 'g' here.Slip,, is defined as the difference between synchronous speed and operating speed, at the same frequency, expressed in rpm or in percent or ratio of synchronous speed. Thus

Standard torque

Speed-torque curves for four induction motor types: A) Single-phase, B) Polyphase cage, C) Poly-phase cage deep bar, D) Poly-phase double cage

Typical speed-torque curve for NEMA Design B MotorThe typical speed-torque relationship of a standard NEMA Design B polyphase induction motor is as shown in the curve at right. Suitable for most low performance loads such as centrifugal pumps and fans, Design B motors are constrained by the following typical torque ranges: Breakdown torque, 175-300 percent of rated torque Locked-rotor torque, 75-275 percent of rated torqueDC MACHINE

ADC motoris any of a class of electrical machines that converts direct current electrical power into mechanical power. The most common types rely on the forces produced by magnetic fields. Nearly all types of DC motors have some internal mechanism, either electromechanical or electronic, to periodically change the direction of current flow in part of the motor. Most types produce rotary motion; a linear motor directly produces force and motion in a straight line.DC motors were the first type widely used, since they could be powered from existing direct-current lighting power distribution systems. A DC motor's speed can be controlled over a wide range, using either a variable supply voltage or by changing the strength of current in its field windings. Small DC motors are used in tools, toys, and appliances. Theuniversal motorcan operate on direct current but is a lightweight motor used for portable power tools and appliances. Larger DC motors are used in propulsion of electric vehicles, elevator and hoists, or in drives for steel rolling mills. The advent of power electronics has made replacement of DC motors with AC motors possible in many applications.

STANDARD WIRE GAUGE

British Standard Wire Gaugeis a set of wire sizes given byBS3737:1964 (now withdrawn), and is generally abbreviated to SWG. It is also known as:Imperial Wire GaugeorBritish Standard Gauge. Use of SWG sizes has fallen greatly in popularity, but is still used as a measure of thickness in guitar strings and some electrical wire. Cross sectional area in square millimetres is now a more popular size measurement. The current British Standard for metallic materials such as wire and sheet is BS 6722:1986, which is a solely metric standard.SWG was fixed byOrder of CouncilAugust 23, 1883. It was constructed by improving theBirmingham Wire Gauge. It was made legal standard March 1, 1884 by the British Board.The basis of the system is themil, or0.001in. No. 7/0, the largest size, is0.50 in. (500 mils or12.7 mm) in diameter, and the smallest, No. 50, is0.001 in. (1 milor about25 m) in diameter. Between each gauge, the weight diminishes by approximately 20%. Because the weight per unit length is related to the area, and therefore the square of the diameter, the diameter diminishes by approximately 10.6%:

SLIP RING INDUCTION MOTOR

Aslip ringis anelectromechanicaldevice that allows the transmission of power and electrical signals from a stationary to a rotating structure. A slip ring can be used in any electromechanical system that requires rotation while transmitting power or signals. It can improve mechanical performance, simplify system operation and eliminate damage-prone wires dangling from movable joints. Also calledrotary electrical interfaces,rotating electrical connectors,collectors,swivels, orelectrical rotary joints, these rings are commonly found inslip ring motors,electrical generatorsfor alternating(AC) systems andalternatorsand in packaging machinery, cable reels, andwind turbines. They can be used on any rotating object to transfer power, control circuits, or analog or digital signals including data such as those found onaerodrome beacons,rotating tanks,power shovels,radio telescopesorheliostats.A slip ring is a method of making an electricalconnection through a rotating assembly. Formally, it is an electric transmission device that allows energy flow between two electrical rotating parts, such as in a motor.

CRANE SECTION

Anoverhead crane, commonly called abridge crane, is a type ofcranefound in industrial environments. An overhead crane consists of parallel runways with a traveling bridge spanning the gap. Ahoist, the lifting component of a crane, travels along the bridge. If the bridge is rigidly supported on two or more legs running on a fixed rail at ground level, the crane is called agantry crane(USA, ASME B30 series) or agoliath crane(UK, BS 466).Unlike mobile or construction cranes, overhead cranes are typically used for either manufacturing or maintenance applications, where efficiency or downtime are critical factors.ConfigurationsEOT (Electric Overhead Traveling) CraneThis is most common type of overhead crane, found in most factories. As obvious from name, these cranes are electrically operated by a control pendant, radio/IR remote pendant or from an operator cabin attached with the crane itself.Rotary overhead craneThis type of overhead crane has one end of the bridge mounted on a fixed pivot and the other end carried on an annular track; the bridge traverses the circular area beneath. This offers improvement over ajib craneby making possible a longer reach and eliminating lateral strains on the building walls.CONTROL GEAR A small motor can be started by simply plugging it into an electrical receptacle or by using a switch or circuit breaker. A larger motor requires a specialized switching unit called a motor starter or motorcontactor. When energized, a direct on line (DOL) starter immediately connects the motor terminals directly to the power supply. Reduced-voltage, star-delta or soft starters connect the motor to the power supply through a voltage reduction device and increases the applied voltage gradually or in steps.In smaller sizes a motor starter is a manually operated switch; larger motors, or those requiring remote or automatic control, use magneticcontactors. Very large motors running on medium voltage power supplies (thousands of volts) may use powercircuit breakersas switching elements.Adirect on line(DOL) oracross the linestarter applies the full line voltage to the motor terminals, the starters or cubicle locations, can usually be found on an ELO drawing. This is the simplest type of motor starter. A DOL motor starter also contains protection devices, and in some cases, condition monitoring. Smaller sizes of direct on-line starters are manually operated; larger sizes use an electromechanicalcontactor(relay) to switch the motor circuit. Solid-state direct on line starters also exist.A direct on line starter can be used if the high inrush current of the motor does not cause excessive voltage drop in the supply circuit. The maximum size of a motor allowed on a direct on line starter may be limited by the supply utility for this reason. For example, a utility may require rural customers to use reduced-voltage starters for motors larger than 10kW.

POWERHOUSEAsubstationis a part of an electricalgeneration,transmission, and distributionsystem. Substations transformvoltagefrom high to low, or the reverse, or perform any of several other important functions. Between the generating station and consumer, electric power may flow through several substations at different voltage levels.Substations may be owned and operated by an electrical utility, or may be owned by a large industrial or commercial customer. Generally substations are unattended, relying onSCADAfor remote supervision and control.A substation may includetransformersto change voltage levels between high transmission voltages and lower distribution voltages, or at the interconnection of two different transmission voltages. The wordsubstationcomes from the days before the distribution system became a grid. As central generation stations became larger, smaller generating plants were converted to distribution stations, receiving their energy supply from a larger plant instead of using their own generators. The first substations were connected to only onepower station, where the generators were housed, and were subsidiaries of that power station.

OIL CIRCUIT BREAKERSOil circuit breakers are used for ratings up to 72.5KV.There is an tank is located,which contains the huge amount of oil.Such breakers are used for indoor metal clad draw out type switchgear.Oil is used as arc extinction medium as well as insulation medium.It is also known as transformer oil.The electrodes are separated in the oil filled tank.Arc controlling device is fitted to assist the arc extinction process. The construction of breaker is such that arc control devices makes the flow of gases produced during arc quenching is axiallyor radially with respect to arc. Disadvantages of bulk oil circuit breaker: a)Large quantity of oil is necessary for arc quenching and insulation purposes. b)After certain numbers of operation the oil should be replaced. c)Above the rating of 36KV the size of tank is too large. This disadvantages are led toward the invention of minimum oil circuit breaker.Minimum oil circuit breaker not needs anysteel tank.Minimum oil circuit breaker needs only 1/10 oil of bulk oil circuit breaker

Electrical and Electronics LaboratoryCNC MACHINES Numerical control(NC) is theautomationofmachine toolsthat are operated by precisely programmed commands encoded on a storage medium, as opposed to controlled manually via hand wheels or levers, or mechanically automated via cams alone. Most NC today iscomputer (or computerized) numerical control(CNC), in whichcomputersplay an integral part of thecontrol.In modern CNC systems, end-to-end component design is highly automated using computer(CAD) andcomputer-aided manufacturing(CAM) programs. The programs produce a computer file that is interpreted to extract the commands needed to operate a particular machine via a post processor, and then loaded into the CNC machines for production. Since any particular component might require the use of a number of different tools drills, saws, etc., modern machines often combine multiple tools into a single "cell". In other installations, a number of different machines are used with an external controller and human or robotic operators that move the component from machine to machine. In either case, the series of steps needed to produce any part is highly automated and produces a part that closely matches the original CAD design.

TRACTION GENERATOR SECTION

Analternatoris anelectrical generatorthat converts mechanical energy to electrical energy in the form ofalternating current.[1]For reasons of cost and simplicity, most alternators use a rotating magneticwith a stationaryarmature. Occasionally, alinear alternatoror a rotating armature with a stationary magnetic field is used. In principle, anyACelectrical generatorcan be called an alternator, but usually the term refers to small rotating machines driven by automotive and other internal combustion engines. An alternator that uses apermanent magnetfor itsmagnetic fieldis called amagneto. Alternators inpower stationsdriven bysteam turbinesare called turbo-alternators. Large 50 or 60 Hzphase alternators in power plants generate most of the world's electric power, which is distributed byelectric power grids.

TRACTION MOTORAtraction motoris anelectric motorused for propulsion of a vehicle, such as anelectric locomotiveor electric roadway vehicle.

Traction motors are used in electrically powered rail vehicles such aselectric multiple unitsand otherelectric vehiclessuch aselectric milk floats,elevators,conveyors, andtrolleybuses, as well as vehicles with electrical transmission systems such as diesel-electric, electrichybrid vehiclesandbattery electric vehicles.

SwissRhaetian Railway Ge 6/6 IKrokodillocomotive, with a single large traction motor above each bogie, with drive by coupling rods.Traditionally, these wereseries-wound brushed DC motors, usually running on approximately 600 volts. The availability of high-powered semiconductors (such as thyristorsand theIGBT) has now made practical the use of much simpler, higher-reliabilityACinduction motorsknown as asynchronous traction motors.Synchronous AC motorsare also occasionally used, as in the FrenchTGV.4