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WAP4 successful locomotives of INDIAN RAILWAYS

WAP - 4 is a common electric locomotive used in India.

The locomotive was developed after a previous class WAP-1 was found inadequate to haul the longer, heavier express trains (24-26 coaches) that were becoming the mainstay of the Indian Railways network. It was introduced in 1994, with a similar bodyshell to the WAP-1 class, but with Hitachi traction motors developing 6,180 hp (4,610 kW) (5,400 hp or 4,000 kW Continuous.

Electricals are traditional DC loco type tap changers, driving 6 traction motors arranged in Co-Co fashion. This locomotive has proved to be highly successful, with over 750 units in service. Newer examples have been fitted with Microprocessor Controlled diagnostics, Static Converter units (instead of arnos) and roof mounted Dynamic (Rheostatic) Brakes.

The locomotive can be seen in service across the electrified network of Indian Railways and is homed at 14 sheds (depots).

The last locomotive produced by the Chittaranjan Locomotive Works (CLW) was numbered 25051 in December 2015 and production of this locomotive has been stopped.

Design

The loco has a streamlined twin cab carbody design, with top-mounted headlamps. The first 150 or so units had the headlamp mounted at waist level, with the lights being mounted in a protruding nacelle. Some earlier locos, especially from the Erode loco shed have the headlamps placed on the top. Later on the headlamps were placed in a recessed nacelle, and from road #22579 onward, the headlamps were moved to the top. Also they have digital notch repeaters.

Newer locos also feature larger windshields, more spacious driver cabin with bucket type seats and ergonomic controls. The control panel also features a mix of digital and analog displays in newer units (all analog display in older versions).

Original units were weighed 120 tonnes, which was brought down to 112 tonnes through the usage of lighter material.

Some of the WAP-1 and WAP-3 and all the WAP-6 units were rebuilt to WAP-4 specifications after replacing the bogies & electricals.

It has different underframe for handling larger buffing loads. Some units are fitted with speed recorders and some changes to control electronics. Some units also have data recorders for energy consumption. Some are even fitted with windshield washers. Few were provided with signalling lamps.

Technical variants include WAP-4E which are probably fitted with electronic sensor for sensing loss in pressure in pipes.

The Hitachi traction motors are the ones used on freight engines. It was a challenge to put these in a passenger engine due to weight constraints. So the transformer is aluminum foil-wound and aluminum chequered plates are used for reducing the weight.

415 volts, 3 phase, 50Hz power supply is used to drive various auxiliary motors like (i)Traction motor blowers (2) Transformer radiater blower (3) Transformer oil pump (4) Smoothing Reactor Blowers (5) Silicon Rectifier Blowers (6) Battery charger. The 3 phase, 415 volt supply is obtained from single phase supply by Arno converter or Static converter.

Indian railways has installed microprocessor based fault diagnostic system and Vigilance Control Device for the enhancement of safety and reliability of electric Locomotives. Some of the Newly manufactured WAP-4 locomotives also have air conditioning system for the comfort of loco pilot.

Performance

If the average weight of ICF coach is 55 tonnes then it can haul the following capacity in tonnes:

Grade\KPH	Start	20	40	60	70	80	90	100	110	120	130	140	150	160
Level	1500+	1500+	1500+	1500+	1500+	1500+	1500+	1500+	1500+	1500+	1500+	1155	805	570
1 in 500	1500+	1500+	1500+	1500+	1500+	1500+	1500+	1500+	1500+	1500+	1105	805	565	400
1 in 200	1500+	1500+	1500+	1500+	1500+	1500+	1500+	1320	1230	1035	730	535	375	260
1 in 150	1500+	1500+	1500+	1500+	1500+	1500+	1405	1090	1020	860	610	445	310	215
1 in 100	1500+	1570	1490	1405	1365	1195	1020	795	750	635	445	320	220	145
1 in 50	1160	770	750	720	710	625	530	410	390	325	220	150	90	45

With a LHB rake used on Rajdhani and Shatabdi Express trains, the following minimum acceleration times from 30-150 km/hr can be achieved :

15 coaches : 2.8 minutes 18 coaches : 3.6 minutes 21 coaches : 4.6 minutes

Technical specifications

Technical Specifications of WAP-4

Gear Ratio	23:58 (One loco, #22559, was said to have a 23:59)
Transformer	5400 kVA, 32 taps
Transformer cooling	Forced oil with Forced Air
Transformer Insulation	A
Pantographs	Two Stone India (Calcutta) AM-12.
Rectifiers	Two silicon rectifiers
Rectifier Cooling	Forced air
Current Ratings	1000 A for 10 min, 900 A continuous
Drive arrangement	Gear pinion
Number of sandboxes	4
2 headlights	90 W, 24 V
Lead acid battery	10 Batteries each of 11V, 75 Ah Capacity.
Arno Converter	1420 rpm
2 Elgi Compressors	1000 l/minute at 7.5 kg/cm2.
2 compressor motors	3 phase 12.5 hp and 380 V
2 SF India Ltd. Traction motor blowers	MLBR-42.5-144 type
2 Siemens Traction motor blower motors	22 kW, 415 V, 50 A and 2820 rpm
2 SF India Ltd. Smoothing Reactor Blower	PFTA-50, ARR6 type
Traction Motor Suspension	Axle-hung, nose suspended
Traction motor weight	3650 kg
Armature temperature rise	90 °C
Field temperature rise	70 °C
Commutator temperature rise	85 °C
Armature coil resistance at 110 °C	0.0126 ohms
Field coil resistance at 110 °C	0.0117 ohms
Commutator coil resistance at 110 °C	0.089 ohms
Traction motor continuous rating	900 hp, 750 V, 900 A and 895 rpm
Traction motor 1 hour rating	1030 hp, 750 V and 877 rpm
Traction Motor air gap main place	6.35 mm
Traction motor air gap inter-pole	10 mm
Traction motor	6 P
2 SF India Ltd. silicon rectifier blower	3100–3200 m/hr
2 Rectifier blower motor	22 kW, 415 V, 8 A, 2860 rpm and 60 kg(approx)
Oil cooler blower motor	30 hp, 380 V, 43 A and 1450 rpm
BEST and Co. Pvt. Ltd. Transformer Oil Pump	750 l/minute
Oil pump motor	3.3 kW, 415 V, 6.6 A and 2865 rpm
SL-30 type smoothing reactor	1250 V and 1350 A.
Smoothing reactor resistance at 110 °C	0.00718 ohms
Notches	32

Image Gallery

 12163 Dadar~Chennai Egmore SuperFast Express hauled by RPM WAP4 #22806

          12163 DR MS sf Express led by ED WAP4 #22730

       16381 CSTM~CAPE Express led bt ED WAP4 #22654

         11041 cstm~mas express led by ED WAP4 #22661





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