Golden Rock Railway Workshop

Inplant training report

Report submitted
by
Name
PASUPATHI.V

College
ALAGAPPA CHETTIAR COLLEGE
OF ENGINEERIN AND
TECHNOLOGY, KARAIKUDI
ALAGAPPA CHETTIAR COLLEGE
OF ENGINEERIN AND
TECHNOLOGY, KARAIKUDI

PRADEEP.R

VINOTH KUMAR.M

ALAGAPPA CHETTIAR COLLEGE

OF ENGINEERIN AND
TECHNOLOGY, KARAIKUDI
ALAGAPPA CHETTIAR COLLEGE
OF ENGINEERIN AND
TECHNOLOGY, KARAIKUDI
ALAGAPPA CHETTIAR COLLEGE
OF ENGINEERIN AND
TECHNOLOGY, KARAIKUDI
KARUNYA UNIVERSITY,
COIMBATORE

MARIAPPAN.S

VELMURUGAN.V

SAM EBENEZER RAJ.A

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.

Index
S.No
Content
.
1 Ponmalai GOC a brief history
2

Electrical Maintanence /
Safety Cell /
Basic Training Centre
Electrical Millwright Shop
i. Induction Motor
ii. DC Motor
iii. Standard Wire Gauge
iv. Slip Ring Induction
Motor
v. Crane Section
vi. Control Gear

Page No.
5
6

7
9
10
11
12
13

PowerHouse Substation
Oil Circuit Breaker

14
15

16

Electrical & Electronics Lab

Wagon Bogie Section
(Computerised Numerical
Control)
Traction Generator

Traction Motor

18

17

Ponmalai GOC a brief history

The Golden Rock Railway Workshop is situated in Ponmalai (Golden

Rock), Tiruchirapalli in the Indian state of Tamil Nadu, is one of the three mechanical railway
workshops serving the southern zone of the Indian 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 (0.81 km2), out of which 26 acres
(110,000 m2) 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,
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Railway colony, Golden Rock was one of the first places to be lit by electrical lights in
Tiruchirappalli city those days.

Electrical plant maintenance

There 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 cell
Safety 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 centre

Shop 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 Millwright
Induction motor

Synchronous speed
An AC motor's synchronous speed,

, is the rotation rate of the stator's magnetic field, which is

expressed in revolutions per minute as

(RPM),

where

is the motor supply's frequency in hertz and

is the number of magnetic

poles. That is, for a six-pole three-phase motor with three pole-pairs set 120 apart,
equals 6 and

equals 1,000 RPM and 1,200 RPM respectively for 50 Hz and 60 Hz

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 Motor

The 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 torque

DC MACHINE

10

A DC motor is 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 directcurrent 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. The universal motor can
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

11

British Standard Wire Gauge is a set of wire sizes given by BS 3737:1964 (now
withdrawn), and is generally abbreviated to SWG. It is also known as: Imperial Wire
Gauge or British 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 by Order of Council August 23, 1883. It was constructed by improving
the Birmingham Wire Gauge. It was made legal standard March 1, 1884 by the British Board.
The basis of the system is the mil, or 0.001 in. No. 7/0, the largest size, is 0.50 in. (500 mils or 12.7
mm) in diameter, and the smallest, No. 50, is 0.001 in. (1 mil or about 25 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

12

A slip ring is an electromechanical device 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 called rotary electrical interfaces, rotating electrical
connectors, collectors, swivels, or electrical rotary joints, these rings are commonly found
in slip ring motors, electrical generators for alternating (AC) systems and alternators and in
packaging machinery, cable reels, and wind 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
on aerodrome beacons,rotating tanks, power shovels, radio telescopes or heliostats.
A slip ring is a method of making an electrical connection 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.

13

CRANE SECTION

An overhead crane, commonly called a bridge crane, is a type of crane found in

industrial environments. An overhead crane consists of parallel runways with a traveling bridge
spanning the gap. A hoist, 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 a gantry crane (USA, ASME B30 series) or a goliath 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.

Configurations
EOT (Electric Overhead Traveling) Crane
This 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.

14

Rotary overhead crane

This 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 a jib crane by 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 motor contactor. 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
magnetic contactors. Very large motors running on medium voltage power supplies (thousands
of volts) may use power circuit breakers as switching elements.
A direct on line (DOL) or across the line starter 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

15

operated; larger sizes use an electromechanical contactor (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 10 kW.

POWERHOUSE
A substation is a part of an electrical generation, transmission, and distribution system.
Substations transform voltage from 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
on SCADA for remote supervision and control.
A substation may include transformers to change voltage levels between high
transmission voltages and lower distribution voltages, or at the interconnection of two different
transmission voltages. The wordsubstation comes 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 one power station,
where the generators were housed, and were subsidiaries of that power station.

16

OIL CIRCUIT BREAKERS

Oil 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 axially
or 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 any
steel tank.Minimum oil circuit breaker needs only 1/10 oil of bulk oil circuit breaker

17

Electrical and Electronics Laboratory

CNC MACHINES

18

Numerical control (NC) is the automation of machine tools that 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
is computer (or computerized) numerical control (CNC), in which computers play an integral
part of the control.
In modern CNC systems, end-to-end component design is highly automated using
computer (CAD) and computer-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

19

An alternator is an electrical generator that converts mechanical energy to electrical

energy in the form of alternating current.[1] For reasons of cost and simplicity, most alternators
use a rotating magnetic with a stationary armature. Occasionally, a linear alternator or a rotating
armature with a stationary magnetic field is used. In principle, any AC electrical generator can
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 a permanent
magnet for its magnetic field is called a magneto. Alternators in power stations driven by steam
turbines are called turbo-alternators. Large 50 or 60 Hz phase alternators in power plants
generate most of the world's electric power, which is distributed by electric power grids.

TRACTION MOTOR
20

A traction motor is an electric motor used for propulsion of a vehicle, such as

an electric locomotive or electric roadway vehicle.

Traction motors are used in electrically powered rail vehicles such as electric multiple
units and other electric vehicles such as electric milk floats, elevators, conveyors,
and trolleybuses, as well as vehicles with electrical transmission systems such as dieselelectric, electric hybrid vehicles and battery electric vehicles.

Swiss Rhaetian Railway Ge 6/6 IKrokodil locomotive, with a single large traction motor
above each bogie, with drive by coupling rods.
Traditionally, these were series-wound brushed DC motors, usually running on approximately
600 volts. The availability of high-powered semiconductors (such as thyristors and the IGBT)
has now made practical the use of much simpler, higher-reliability AC induction motors known
as asynchronous traction motors. Synchronous AC motors are also occasionally used, as in the
French TGV.

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