Transcript Slide 1

Challenges Before CLW to Manufacture New Generation Electric
Locomotives to Meet the XI Plan Requirements
R.K. Bansal
Chief Electrical Engineer
Providing Motive Power to a Resurgent Nation
Meeting the Motive Power Requirements of
a Resurgent Nation
Providing Motive Power to a Resurgent Nation
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
• > 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 II
Present 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 Nation
Providing
Motive Power
to a Resurgent
WAG-9
WAP-5
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NEW VARIANT WAG9H
NEW VARIANT WAP7
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Assimilation of 3-Phase Drive TechnologyPresent 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.)
25
22
21.5
20
12.4312.81
15
13.6
13 12.77
11.87 11.85
10
5
97-98
98-99
99-00
00-01
01-02
02-03
04-05
05-06
06-07
0
97-98
98-99
99-00
00-01
01-02
02-03
04-05
05-06
06-07
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Evolution of Power
HP
WAG9
6000
WAG7
6000
5000
5000
4000
WAG5
WAG4
WAG1
2900
3150
WAM4
4000
3400
3000
2000
1000
0
1963
1967
1970
1983
1991
1996 Year
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Evolution of Speed
Can be
upgraded to
200 kmph
WAP5
WAP4
160
WAP1
130
140
160
140
WAM4
100
120
WAG1
100
80
WAG4
80
80
60
40
20
0
1963
1967
1970
1984
1986
1995
Year
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Section-III
Why 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
•
IR’s 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
@ 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
1800
1700
1650
1550
1600
1400
1200
1000
1000
1000
Requirement
CLW Production
1000
800
700
650
Shortfall
550
600
400
200
0
2007-12
2012-17
2017-22
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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
• Imported
• Indigenous
– No Regular Approved Source
:104
: 64
: 40
: 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
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