Indian locomotive class WAG-9

The Indian locomotive class WAG-9 is a class of 25 kV AC electric locomotives that was developed in the 1995 by ABB Group (ABB) for Indian Railways. The model name stands for broad gauge (W), AC Current (A), Goods traffic (G), 9th generation (9) locomotive. They entered service in 1996. A total of 1996 WAG-9 have been built at Chittaranjan Locomotive Works (CLW), with more units being built at Diesel Locomotive Works (DLW) and Bharat Heavy Electricals Limited (BHEL). It was the most powerful freight locomotive of its fleet until the formal induction of the WAG-12.

WAG-9/9H
Lallaguda WAG-9 at Agra Fort railway station
Type and origin
Power typeElectric
DesignerABB Group
BuilderChittaranjan Locomotive Works,
Electric Locomotive Works (Bhusawal), Bharat Heavy Electricals Limited, Diesel Locomotive Works
Build date1996 - present
Total produced1876 as of August 2020
Specifications
Configuration:
​
 • UICCo′Co′
Gauge5 ft 6 in (1,676 mm)
BogiesAdtranz Fabricated Flexicoil IV
Wheel diameterNew:1,092 mm (3 ft 7 in),
Half worn:1,054 mm (3 ft 5 1⁄2 in)
Full worn:1,016 mm (3 ft 4 in)
Wheelbase15.7 m (51 ft 6 in)
Length20.562 m (67 ft 5 1⁄2 in)
Width3.152 m (10 ft 4 1⁄8 in)
Height4.525 m (14 ft 10 1⁄8 in)
Axle loadWAG-9 : 20.5 tonnes (20.2 long tons; 22.6 short tons) WAG-9H/Hi/9i : 22.0 tonnes (21.7 long tons; 24.3 short tons)
Loco weightWAG-9 : 123 tonnes (121 long tons; 136 short tons) WAG-9H/9Hi/9i : 132 tonnes (130 long tons; 146 short tons)
Electric system/s25 kV 50 Hz AC Overhead
Current pickup(s)dual pantographs
Traction motorsWAG-9/9H/9i : Adtranz 6FRA6068
MU working2
Loco brakeAir and Regenerative
Train brakesAir
Safety systemsSlip/slide control, Main overload relay, Over voltage relay, No volt protection, Vigilance Control Device, Fire Detection Equipment, Fire Extinguishers and Earth fault relay
Performance figures
Maximum speed120 km/h (75 mph)
Power output6,122 hp (4,565 kW) continuous
Tractive effortStarting : 475 kN (107,000 lbf)
(WAG-9), 510 kN (110,000 lbf)
(WAG-9H/i/Hi) Continuous : 325 kN (73,000 lbf) at 50 km/h
Career
OperatorsIndian Railways
NumbersStarting from 31000-31999, 32000+ & 90001+ CLW

34001+ BHEL

41000+ DLW
NicknamesNAVYUG, NAVJYOTI, NAVDISHA, NAVSHAKTI, NAVODAY, NAVASHA, NAVGHANSHAKTI, Dr. SILVER, NAVSHATAK, NAVPRAGATI, NAVSHAKTI NAVEEN, ASHOK & KAVIGURU
LocaleAll Over India
Dispositionactive

The WAG-9 is one of the most successful locomotives of Indian Railways serving freight trains for over 25 years. A passenger variant of the WAG-9 was developed namely the WAP-7 locomotive by modifying the gear ratio to pull lighter loads at higher speeds.

Introduction

The WAG-9 locomotive is referred to as the "Heavy Haul" freight locomotive of the Indian Railways (IR). It was conceived in response to the extreme growth in the rail freight transportation sector, which is considered to be of great importance to the growth of the economy of India. The need for more electrification and electric locomotives in India had increased. Around 60-65% of the freight haulage of the IR takes place on the electrified section of the Golden Quadrilateral (Indian Railways) and diagonals (which account for 25% of the route). These are very busy routes, so clearance is a necessity. Electrical powers give it a great sectional clearance ability. Thus, these locomotives are important for the Indian Railways.

These locomotives have entered the Western Railway zone of Mumbai. The first 22 units were imported from ABB. Of these, the first six were fully assembled and rest were in kit form. CLW started producing of WAG-9 traction motors on 1 November 1999. The units built by ABB have pantographs with two end horns while the CLW built units have pantographs with single end horns which are common in India. This class had a capacity to MU several units, but IR restricts them to two, because of dynamic loading restriction on most bridges. Regenerative brakes provide about 260 kN of braking effort.

The WAG-9H also has different application software than the WAG-9. The first WAG-9H was commissioned on 30 June 2000. The #30130 prototype was housed at Gomoh (GMO). This was then converted back to standard WAG-9 in 2002. This unit has a livery of twin white stripes on green, instead of yellow stripe on green, seen on the other WAG-9(x)s.

The WAG-9i was introduced in 2010, and was #31215. It was homed at the GMO shed. With IGBT, even if one traction motor failed, other traction motors can function with a total output of 5500 hp.

Newer WAG-9 units have "CLW Glorious 50 years" marked on their sides. Some WAG-9(x)s are fitted with a solid cowcatcher while others are fitted with grilled cowcatchers. Some have American style flasher lamps while others have Indian style flasher lamps. http://elocos.railnet.gov.in/Study_Material/TSD_3Ph.pdf.

Newer versions of the WAG-9 feature full Insulated-gate bipolar transistor (IGBT) traction control; the debut model was the WAG-9 31248. The class as a whole is denoted by the WAG-9i prefix in its model number, although there is a technical variant of this class named WAG-9H, with the "H" meaning "Heavy".

The WAG-9H/9Hi locomotives are the second heaviest in regular service in India, the only freight-dedicated three-phase AC locomotives in the country, and the only electric locomotives in India fitted with IGBT. They are also the freight locomotives with the highest operational speed in India.

It is similar to the WAP-7 class locomotive but features a different gear ratio, which makes it suitable for heavy freight operations. In November 1998, the Chittaranjan Locomotive Works (CLW) started producing these with indigenous components. The first of which, named Navyug (New Era), was produced on 14 November 1998. Like the WAP-5 units, the WAG-9 has GTO thyristor converters and three-phase asynchronous motors.

Operations

WAG-9 has quickly become one of the important locos in the Indian railways. With its higher power, this locomotive has replaced WAG-7 which was the main electric loco before WAG-9's arrival. Applications where twin WAG-7s were required are now handled by a single WAG-9. This includes both leading a long consist and for banking operations. The regenerative braking capabilities of WAG-9 has also helped reduce the electricity consumption. The original WAG-9 had some wheel slippage incidents while hauling heavy load. This was rectified through the introduction of WAG-9H and subsequently using WAG-9i. This has significantly reduced the issue that were associated with the original version.


Chittaranjan Locomotive Works (CLW) turned out its first 9,000 hp WAG-9 freight locomotive on 31 March 2019, the last day of the financial year. This 9,000 hp version of the WAG-9H has been classified by IR as WAG-9 HH. The first H stands for higher axle load and the second H stands for the higher power rating. The class has been allocated a block of serial numbers starting with 90001, the number of the first unit. The decision to upgrade the power output of the WAG-9 was taken to partly meet the demands of the upcoming electrified Western Dedicated Freight Corridor (WDFC). The upgraded locomotive class will also augment hauling capacity on the existing network of the Indian Railways.[1]

Future Developments

WAG-9s are modified to have high-reach pantographs. This is to enable them carry double-stack containers in electrified sections. In such sections, the Overhead wires are placed in a higher position.
WAG-9HH: Chittaranjan Locomotive Works (CLW) turned out its first 9,000 hp WAG-9 freight locomotive on 31st March 2019, the last day of the financial year.This 9,000 hp version of the WAG-9H has been classified by IR as WAG-9 HH. The first H stands for higher axle load and the second H stands for the higher power rating. The class has been allocated a block of serial numbers starting with 90001, the number of the first unit.[2][3]

Locomotive sheds
Zone Name Shade Code Quantity Introduction
WAG9 WAG9H
Central Railway Bhusaval BSL 29 10 October 2013
Ajni AJNI 36 124 14 January 2000
Kalyan KYN 2 30 23 January 2013
Eastern RailwayBardhamanBWN(D) 251 March 2020
East Central Railway Pt. DD Upadhyaya Junction DDU 16 1 July 2020
Gomoh GMO 75 166 9 March 1997
Barauni Junction BJU 52 20 June 2012
East Coast Railway Visakhapatnam VSKP 160 22 July 2014
Northern Railway Ludhiana LDH 132 21 December 2015
Khanalampura KJGY 22 1 September 2019
North Central Railway Kanpur CNB 93 27 January 2016
South Central Railway Lallaguda LGD 70 59 1 May 2007
Kazipet KZJ 2 82 29 August 2013
Gooty GY (D) 20 31 August 2019
South Eastern Railway Tatanagar TATA 2 151 21 March 2010
Bondamunda BNDM 47 20 August 2016
Bokaro Steel City BKSC 41 31 March 2019
Rourkela ROU 82 31 January 2019
South East Central Railway Bhilai BIA 159 14 January 2009
South Western Railway Krishnarajapuram KJM(D) 3 1 June 2020
Western RailwayValsadBL191 July 2020
West Central Railway Tughlakabad TKD 30 95 1 September 2008
New Katni Jn. NKJ 63 26 September 2017
NKJ(D) 4 1 June 2020
Total 216 1660
Total Locomotives Active as of 01-08-2020[4] 1876

Named Locos
  • WAG-9 31022 Navyug
  • WAG-9 31023 Navjyoti
  • WAG-9 31024 Navdisha
  • WAG-9 31030 Navshakti
  • WAG-9 31033 Navoday
  • WAG-9 31058 Nav Ghanshakti
  • WAG-9 31086 Dr Silver
  • WAG-9 31100 Navshatak
  • WAG-9 31112 Navpragati
  • WAG-9 31121 Navpragati
  • WAG-9 31162 Nav Shakti
  • WAG-9 31215,31255 Naveen
  • WAG-9 31475 Ashok
  • WAG-9 31619 Kaviguru

Performance

Two WAG-9 class units can haul a load of 4,500 tonnes (4,400 long tons; 5,000 short tons) on grades of 1 in 60 (1.67%). The WAG-9H was expected to haul 58 BOXN wagons, i.e.,4,700 tonnes (4,600 long tons; 5,200 short tons), without multiple units on grades of 1 in 150 (0.67%). The locomotive can run even in 100% humidity, or in deserts, where there is high saturation of conductive particles. For shunting up to 15 km/h (9.3 mph), it can haul 7,500 tonnes (7,400 long tons; 8,300 short tons) on grades of 1 in 1000 (0.1%) or less. The atmosphere may be humid and salty. Regenerative braking will provide braking force of no less than 260 kN (58,000 lbf) at 10–62 km/h (6.2–38.5 mph) and closer to 260 kN (58,000 lbf) at higher speeds. Below is the capacity of the WAG-9 while hauling BOX wagons (in tonnes}):[5]

Grade\km/hStart2030405060708090100
Level6000+6000+6000+6000+6000+6000+6000+6000+6000+6000+
1 in 5006000+6000+6000+6000+6000+6000+6000+498541503500
1 in 2005060506050605060506040453325278023652040
1 in 1504250425041654080398532002640222018951640
1 in 1003205291028702825277522401855156513451165
1 in 50182014551445143514201440945795680590
  • TKD WAG9H 31483 at Toranagallu Jn
  • Bhilai based WAG9H standing at Katihar goods yard
  • Tri Colour CNB WAG9 32433 standing at Katihar
  • Ludhiana based WAG9HC with BCNA entering Katihar
  • Gomoh based WAG-9 loco with freight rake
  • Indian Railways WAG-9 class AC electric locomotive no. 31179 pauses at Agra Fort railway station
  • WAG 9 - Navshatak
  • WAG 9 at Vasai Road
  • Lallaguda WAG 9 twins at Ghatkesar

Technical specifications

The WAG-9 technical specifications are:[6]

Traction Motors ABB's 6FRA 6068 (850 kW, 2180V, 1283/2484 rpm, 270/310A. Weight 2100 kg) Axle-hung, nose-suspended, Class 200 Insulation, Forced Air Ventilation
Gear Ratio 77:15 / 64:18 / 107:21
Transformer[7] ABB's LOT 6500, Class A Insulation, OFAF cooling, Primary (25 kV, 6531 kVA), Secondary rating(4x1269 V, 4x1450 kVA, 4x1142 A), Auxiliary (1000 V, 334 kVA, 334 A), Filter (1154 V, 400 kVA, 347 A), 9,450 kg (20,830 lb)
2 Power Drives WAG-9/9H : Power converter from ABB, type UW-2423-2810 with SG 3000G X H24 GTO thyristors (D 921S45 T diodes), 14 thyristors per unit (two units), OFAF cooling. Line converter rated at 2 x 1269V @ 50 Hz (more or less 3%), with DC link voltage of 2800V(nominal). Motor/drive converter rated at 2180 V phase to phase, 971 A output current per phase, motor frequency from 0 to 132 Hz.

WAG-9i : IGBT based alternatives from Bombardier and Crompton Greaves-CAF Power

Bogies (Design later used for IORE and China Railways HXD3B; bogie wheelbase 1,850 mm (72 7⁄8 in) + 1,850 mm (72 7⁄8 in)
Unsprung mass per axle 3.984 t (3.921 long tons; 4.392 short tons)
Loco Weight 123 t (121 long tons; 136 short tons) wag9 / 135 t (133 long tons; 149 short tons) wag 9HH
Length over head-stocks 19,280 mm (63 ft 3 in)
Distance between axles of bogie 1,850 mm (72 7⁄8 in)
Cab length 2,434 mm (95 7⁄8 in)
Pantographs Two Secheron ES10 1Q3-2500, 186 kg (410 lb) (without insulators).
Drive Arrangement Gear Pinion
2 HCBO-605-115 type Traction Motor Blowers by Flakt and ABB 4.05 m3/s (143 cu ft/s) and 416 kg (917 lb)
Traction Motor Blower Motors of 200L55-RFXH2A-D1 type by Landert 3 phase, 415 V, 50 Hz, 2930 rpm, 25 kW (34 hp) and Class F insulation
2 Oil Cooler Blowers by Behr 4.05 m3/s (143 cu ft/s).
Oil Cooler Blower Motors of 200L55-RH2A type by Landert 3 phase, 415 V, 50 Hz, 2930 rpm, 25 kW (34 hp) and Class F insulation
2 TAO8-2174/15 type Transformer Oil Pumps by Fumettaz 1,000 L/min (220 imp gal/min; 260 US gal/min)
Transformer Oil Pump Motors by Landert of 112M-2B type 3 phase, 415 V, 50 Hz, 2930 rpm, 4.7 kW (6.3 hp) and Class F insulation
2 TC10-2185/29 type Converter Oil Pumps by Plumettaz 960 L/min (210 imp gal/min; 250 US gal/min)
112M-2F type Converter Oil Pump Motors by Landert 3 phase, 415 V, 50 Hz, 2860 rpm, 11 kW (15 hp)., 95 kg (209 lb) and Class F insulation
2 2A3200 C13-T32 type Main Compressors by D&M 1,745 L/min (384 imp gal/min; 461 US gal/min), 10 kg/cm (2,000 lb/yd), 600 kg (1,300 lb), and 15 kW (20 hp),
Main Compressor Motors of 200l55-RPAH8B type by Landert 3 phase, 415 V, 50 Hz, 730 rpm, 15 kW (20 hp), and Class H insulation
2 HCBO-415-60 type Machine Room Blowers by Flakt and ABB 1 m3/s (35 cu ft/s), 140 kg (310 lb), 415 VAC and maximum temperature rise of 80 degrees Celsius (176 degrees Fahrenheit)
132M-RFXHE2C type Machine Room Blower Motors by Landert 1 phase, 415 V, 50 Hz, 2830 rpm, 28 kW (38 hp) and Class F insulation
FF 3145 type Auxiliary Compressor by D&M and Bristol 7.03 kg/cm2 (100.0 psi) and 50 kg (110 lb)
Auxiliary Compressor Motor by D&M 110 V DC, 50 Hz, 1450 rpm and 0.75 kW (1.01 hp) (Air Dryer provided)
Ni-Cd(SAF-39 SBL 199) type Battery by Saft Groupe S.A. and Nife 110 V DC + 20% / -30%, 5 hrs discharging and 78 cells
BUR 10 A 100 LVPS type Auxiliary Converter by ABB 3 phase, 415 V and 100 kVA
Nominal supply voltage 22.5 kV
Normal variation in supply voltage 19-27.5 kV
Occasional maximum voltage 31 kV (15 min)
Occasional minimum voltage 16.5 kV (15 min)
Variation in supply frequency More or less 8% (46–54 Hz)
Distance between neutral section 25–50 km (16–31 mi)
Types of neutral section 41 m (135 ft), insulated overlap on both ends and neutral wire which is not earthed OR

4.61–9.6 m (15.1–31.5 ft), insulated portion of Polytetrafluoroethylene on both sides and middle portion of neutral section which is solidly earthed

Pantograph bounce <45 m (148 ft)
Devices on the track Tracks should have DC track circuits. Devices such as axle counters, block instruments and point machines may be employed
Communication network Control circuits, teleprinter circuits, VHF/UHF and micro-wave circuits may be employed
Temperature of atmosphere −10 to 50 degrees Celsius (14 to 122 degrees Fahrenheit)
Temperature of atmosphere in direct sunlight 75 degrees Celsius (167 degrees Fahrenheit)
Temperature of atmosphere in shade 55 degrees Celsius (131 degrees Fahrenheit)
Temperature inside dead locomotive while exposed to direct sunlight 70 degrees Celsius (158 degrees Fahrenheit)
Dust concentration in terrain Up to 0.0016 mg/L (5.8×10−11 lb/cu in)
Operation in flood At 10 km/h (6.2 mph) with water of 102 mm (4 in) above rail level
pH value in atmosphere 8.5
Sulphate in atmosphere 7 mg/L (2.5×10−7 lb/cu in)
Chlorine in atmosphere 6 mg/L (2.2×10−7 lb/cu in)
Conductivity in atmosphere 130 micro Siemens/cm
Altitude of operation Between 160 m (520 ft) above sea level and sea level
Vibration in traction motors 300 g (worn gear-pinion)
Starting resistance of BOXN wagons excluding locomotive on level track 4 kg/ton
Starting resistance of locomotive on level track 6 kg/ton
Rate of change of tractive effort 20 kN/sec
Rate of change of braking effort 100 kN/sec
Efficiency of line converter at continuous speed for full load 97%
Buffing load 400 tonnes (390 long tons; 440 short tons)
Ground clearance above rail with full load and full worn wheels 102 mm (4.016 in)
Traveling distance annually 200,000 km (120,000 mi)
Life 35 years
Sandboxes 50 kg (110 lb) each
Max difference in diameter of wheels on the same axle 0.5 mm (0.020 in)
Max difference in wheels of the same bogie 4 mm (0.157 in)
Overall max difference of diameter of wheels 20 mm (0.787 in)
Train brakes 242 kN (54,000 lbf), 35% adhesion
Parking brake force 37 kN (8,300 lbf)
Auxiliary reservoir 135 kg (298 lb)
Scavenge blower to traction motor blower 42 kg (93 lb)
Oil cooling unit 930 kg (2,050 lb)
Scavenge blower to machine room blower 37 kg (82 lb) and 415 V AC
Cubicle auxiliary circuits 1 220 kg (490 lb)
Cubicle control circuits 1 160 kg (350 lb)
Central electronics 1 32.34 kg (71.3 lb)
Main reservoir 330 kg (730 lb)
Central Electronics 2 31.34 kg (69.1 lb)
Cubicle control circuits 2 170 kg (370 lb)
Cubicle auxiliary circuits 2 105 kg (231 lb)
Filter cubicle 400 kg (880 lb)
Cab heater and crew fans 110 VAC
Fire alarm 1170 Hz
Dials illumination level 10-90%
Heater capacity 2.2 kW (3.0 hp)

See also

References
  1. "New 9,000 hp WAG-9 HH Locomotive Rolls Out of CLW". RailPost.in - Indian Railways News & Analysis. 2 April 2019. Retrieved 5 April 2019.
  2. New 9,000 hp WAG-9 HH Locomotive Rolls Out of CLW
  3. WAG-9HH 9000 HP loco fit to run at 100 kmph
  4. "e-Locos".
  5. "Trainweb".
  6. Indian AC electric loco information
  7. "Driver's Manual" (PDF).
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