Indian locomotive class WAP-5

The Indian locomotive class WAP-5 is the name of a class of "High Speed" electric locomotives produced and used by Indian Railways. The first 10 locomotives were imported from ABB in Switzerland in 1995. These locomotives are a hybrid design mixing SBB-CFF-FFS Re 460 design and German DB Class 120 mechanics and chassis.

WAP-5
Ghaziabad based WAP-5 rest at Bhopal.
Type and origin
Power typeElectric
BuilderCLW, (India)
ABB, (Switzerland)
ModelLok 2000
Build date1995–present
Total produced239 as of October 2023
Specifications
Configuration:
​
 • UICBo'Bo'
Gauge5 ft 6 in (1,676 mm)
BogiesHenschel Flexifloat
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)
Wheelbase13,000 mm (42 ft 8 in)
Length18,162 mm (59 ft 7 in)
Width3,142 mm (10 ft 3+3⁄4 in)
Height4,237 mm (13 ft 11 in)
Axle load19.5 tonnes (19.2 long tons; 21.5 short tons)
Loco weight78 tonnes (77 long tons; 86 short tons)
Electric system/s25 kV 50 Hz AC Overhead
Current pickup(s)pantograph
Traction motors4 ABB Group 6FXA 7059
Gear ratio67:35:17 (160 km/h)
59:35:19 (180 km/h)
MU working2
Loco brakeAir and Regenerative
Train brakesAir
Safety systemsTPWS (Train Protection and Warning System), Vigilance Control, Slip/Slide Control, Main Overload Relay, No Volt Relay, Over Voltage Protection and Earth Fault Relay
Performance figures
Maximum speedOperational : 160 km/h (99 mph)
Trials: 184 km/h (114 mph)
Special version(WAP5A): 200 km/h (124 mph) [1]
Potential: 225 km/h (140 mph)[2]
Modified Gear Ratio:200 km/h (124 mph)
Power outputWAP-5
Continuous : 6,000 hp (4,474 kW)
Tractive effortStarting : 258 kN (58,000 lbf)
Career
OperatorsIndian Railways
Numbers30000-30200 & 35001+
NicknamesVijay Utkarsh, Nav Jagran, Nav Kirti, Gaurav and Navodit
Delivered1995-1996
First run1997
DispositionActive

One of the notable features of WAP-5 is regenerative braking. Other notable features of this loco are the provision of taps from the main loco transformer for hotel load, pantry loads, flexible gear coupling, wheel-mounted disc brakes, and a potential for speed enhancement to 200 km/h (120 mph). Braking systems include 160 kN (36,000 lbf) regenerative brakes, loco disc brakes, automatic train air brakes, and a charged spring parking brake.

On 3 July 2014, a WAP-5 set an Indian speed record by hauling a train from Delhi to Agra within 90 minutes at a speed of 160 km/h (99 mph).[3]

The Gatimaan Express and Bhopal Shatabdi trains hauled by WAP-5 locomotives travel at 160 km/h (99 mph) and 150 km/h (93 mph) respectively in the New Delhi - Agra Cantt section.

Locomotive sheds
Zone Shed Code Name Quantity Introduction
HOG Non HOG
Eastern RailwayHWHHowrah 30 6 2019
Northern RailwayGZBGhaziabad 66 71 1997
Western RailwayBRCVadodara 23 43 2011
Total 119 120
Total Locomotives Active as of October 2023[4] 239

Aerodynamic WAP-5

In October 2015, Chittaranjan Locomotive Works rolled out a WAP-5 locomotive (no. 30086) with a gear ratio of 59:35:19 for speed operations up to 200 km/h (120 mph). The control software was also modified accordingly. Another locomotive (no. 30164) was rolled out with aerodynamic cab profile. This is just a trial and not intended for passenger use as the tracks are not supported in major routes. Also the coaches used on Indian Railway is not yet upgraded to match the aforesaid speed

Head-On Generation (HOG)
HOG equipped Howrah based WAP-5 at New Delhi

A main feature of Some locomotives of this class is that they eliminate the need to have separate End on Generation (EOG) sets or DG (Diesel Generator) sets for supplying power to the train resulting in significant savings on maintenance and running costs. This technology, called HOG or "Head On Generation", transfers electric power from the loco's pantograph to the coaches instead of EOG where a power car equipped with diesel generator capable of generating adequate power of 3-phase 50 Hz 415 V / 750 V AC (called 'head-end power') is provided at either end of the train rake to supply power.[5][6][7]

A WAP-5 locomotive (no. 30140) with Head-on Generation (HOG) was rolled by CLW in June 2018. In this locomotive, the hotel load converter has been accommodated in the same cubicle of traction converter. More locomotives of this type will be rolled out in future.

Power upgrade to 6000 HP

In March 2018, CLW rolled out a WAP-5 locomotive (no. 30136) with an enhanced power output of about 4,500 kilowatts (6,000 hp). Modifications were carried out in the control software. Based on successful trials, the Indian Railways decided to proliferate the modification on all WAP-5 locomotives.

Tejas Express push-pull version
Tejas livery WAP-5 numbered 35012 & 35013 at CLW

Two WAP-5 locomotives (no. 35012 and 35013) were given an asymmetric body design with an aerodynamic profile for one cab and a blunt profile for another cab at the opposite end, which is intended to be semi-permanently coupled with a train in normal operation (a similar design was previously used on the British Rail Class 91 locomotives). One locomotive will be placed on each end of the train to utilize a push-pull configuration for future Tejas Express services. The two locomotives have a power output of 6,000 horsepower (4,500 kW) and will have a maximum speed of 160 kilometres per hour (99 mph). These locomotives were inaugurated in October 2020.[8][9]

Liveries
  • The most common livery for WAP-5 locomotives is white, black and a twin red band.
  • In 2014, Amul Milk made a contract with Vadodara Shed to apply wrap advertising on 20 Vadodara-based WAP-5 locomotives.
  • WAP-5 locomotives based at Electric Loco Shed, Ghaziabad have large P-5 decals on the sides.
  • Another wrap advertising for Fortune Edible Oils was released by Vadodara (BRC) Electric Loco Shed with locomotive no. 30081.
  • One wrap advertising for Fortune Edible Oils was transferred from Vadodara (BRC) Electric Loco Shed to Howrah (HWH) Electric Loco Shed with locomotive no. 30115.
  • Another two wrap advertising for Fortune Biryani Special Basmati Rice were transferred from Vadodara (BRC) Electric Loco Shed to Howrah (HWH) Electric Loco Shed with locomotive no. 30106 and 30112 respectively.
  • The Tejas WAP-5 with the same livery as the Tejas Express.
  • GZB WAP 5 with Sampark Kranti Express
    GZB WAP 5 with Sampark Kranti Express
  • Ghaziabad based WAP 5 getting ready to haul the Garib Rath Express
    Ghaziabad based WAP 5 getting ready to haul the Garib Rath Express
  • BRC based Amul Milk advertised WAP-5 locomotive
    BRC based Amul Milk advertised WAP-5 locomotive
  • Habibganj - New Delhi Shatabdi Express arriving Habibganj with GZB WAP-5
    Habibganj - New Delhi Shatabdi Express arriving Habibganj with GZB WAP-5
  • A WAP-5 hauling the Bhopal Shatabdi Express
    A WAP-5 hauling the Bhopal Shatabdi Express
  • Ghaziabad based WAP-5 #30032
    Ghaziabad based WAP-5 #30032
  • A Ghaziabad-based WAP-5 at Anand Vihar Terminal
    A Ghaziabad-based WAP-5 at Anand Vihar Terminal
  • WAP-5 30010 hauling Hazrat Nizamuddin bound train number 12779 Goa Express arriving at Itarsi.
    WAP-5 30010 hauling Hazrat Nizamuddin bound train number 12779 Goa Express arriving at Itarsi.
  • WAP-5 from Ghaziabad Depot pulling Swarn Shatabdi Express train No. 12004 from New Delhi to Lucknow.
    WAP-5 from Ghaziabad Depot pulling Swarn Shatabdi Express train No. 12004 from New Delhi to Lucknow.
  • WAP-5 30022 rests at Bhopal.
    WAP-5 30022 rests at Bhopal.

Technical specifications

Specifications are as follows:[10]

Technical specifications
General Information
Gauge Broad gauge 1,676 mm (5 ft 6 in)
Line voltage 25000 V
Type of current Alternating Current (AC)
Axle load 19.5 tonnes (19.2 long tons; 21.5 short tons)
UIC classification Bo-Bo
Length over head-stocks 16,880 mm (55 ft 4+5⁄8 in)
Length over buffers 18,162 mm (59 ft 7 in)
Bogie wheel base 2,800 mm (9 ft 2+1⁄4 in)
Wheel base 13,000 mm (42 ft 7+3⁄4 in)
Body width 3,142 mm (10 ft 3+3⁄4 in)
Cab length 2,434 mm (7 ft 11+7⁄8 in)
Pantograph locked down height 4,237 mm (13 ft 10+3⁄4 in)
Bogie center distance 10,200 mm (33 ft 5+5⁄8 in)
Height over pantograph 4,237 mm (13 ft 10+3⁄4 in)
Body width 3,142 mm (10 ft 3+3⁄4 in)
Coupling Central Buffer Couplers (CBC)
Surface corrugated or plain
Traction motors
Type 6FXA 7059 3-phase asynchronous motors, 1,166 kW (1,563 hp), 2180 V, 370 A continuous, 396 A for 1 hr, 540 A max, 1585 rpm continuous, 3174 rpm max, Weight 1990 kg. Forced-air ventilation, partly suspended. Torque 6930/10000 N-m. 96% efficiency.
Make ABB
Traction motors insulation Class 200
Traction Motor's Short Time Overload Rating 1150 kW, 1540 V, 540 A, 1107 rpm
Traction Motor's 1 hour rating 1150 kW, 2044 V, 396 A, 1485 rpm
Traction Motor's Continuous Rating 1150 kW, 2180 V, 370 A, 1585 rpm
Number of Traction Motors 4
Gear Ratio 67:35:17 (160 km/h or 99 mph)
59:35:19 (200 km/h or 120 mph)
Transformer
Type ABB LOT-7500/LOT-7775: {7475 kVA/7775 kVA, 25 kV, 299A-primary/311A}-primary, {4x1269 V, 4x1450 kVA, 4x1142 A}-secondary, {1000 V, 334 kVA, 334 A}-Auxiliary, {960 V, 2x622.5 kVA, 2x648 A}- Hotel Load and {1154 V, 400 kVA, 347 A}-Filter
Transformer Insulation Class A
Make ABB, HI VOLT, BHEL
Weight 10000 +/-3% kg
Power Converter
Number of converters 2
Semiconductors GTO thyristors / IGBT
GTO

Type : UW-2423-2810
SG 3000G X H24 GTO thyristors (D 921S45 T diodes), 14 thyristors per unit (two units). Line converter rated at 2 x 1269 V @ 50 Hz, with DC link voltage of 2800 V. Drive converter rated at 2180 V phase to phase, 953 A output current *per phase, motor frequency from 0 to 160.3 Hz.

IGBT IGBT type 5SNA 1200G450300

2105 kW, individual axle control configuration, MITRAC software, water cooled. Newer locomotives have IGBT based propulsion system.

Hotel Load Converter
Make BHEL / ABB
Rating 2x500 kVA
Voltage 750 V +/- 5%, 3 phase
Bogie
Type Bo-Bo Henschel Flexifloat bogies with quill drive.

Bogie center distance 10,200 mm (33.5 ft); bogie wheelbase 2,800 mm (9.2 ft)

  • Unsprung mass per axle: 2.691 t
  • This Locomotive has a Fully Suspended Drive.
Drive Arrangement Gear coupling and 3-stage gears
Design 2-axle fabricated
Primary suspensioncoil
Secondary suspensioncoil
Pantograph
Type Two Stone India (Calcutta) AM-92, Two WBL-85, Two Schunk for the imported locomotives.
Pantograph Weight 231 kg
Other information
2 FLAKT ABB Traction Motor Blowers 3.6 cubic meter per sec
Landert Traction Motor Blower Motor 3 phase, 415 V, 50 Hz, 2930 rpm, 25 kW
200L55-RFXH2A-01 Traction Motor Blower Motor Insulation Class F
2 Oil Cooler Blowers 8.8 cubic meter per sec
Landert Oil Cooler Blower Motor 3 phase, 415 V, 50 Hz,2930 rpm, 25 kW
200L55-RH2A Oil Cooler Blower Motor Insulation Class F
2 Howden Safanco Scavenge Blowers for Traction Motors and Oil Cooler Blower 0.664 cubic meter per sec
Landert Scavenge Blower Motor for Traction Motors and Oil Cooler 3 phase, 415 V, 50 Hz, 2850 rpm, 3 kW
100L28-R2C Scavenge Motor Blower Motor Insulation Class H
2 Transformer Oil Pumps by Plumeliaz 1000 liters per minute
Landert Transformer Oil Pump Motor 3-phase, 415 V, 50 Hz, 2850 rpm, 4.7 kW
112M-2B type Transformer Oil Pump Motor Insulation Class F
2 Converter Oil Pumps by Plumeliaz 960 liters per minute
Converter Oil Pump Motor by Landert 3-phase, 415 V, 50 Hz, 2860 rpm, 11 kW
112M-2F type Converter Oil Pump Motor Insulation Class F
2 Main Compressors by D&M 1 kg/cm2
Main Compressor Motor by Landert 3-phase, 415 V, 50 Hz, 730 rpm, 15 kW
200155-RPAH8B Main Compressor Motor Insulation Class H
2 Machine Room Blower by Flakt and ABB 1 cubic meter per sec.
Machine Room Blower Motor by Landert 1-phase, 415 V, 50 Hz, 2830 rpm, 2.6 kW
132M-RFXHE2C type Machine Room Blower Motor Insulation Class F
Scavenge Blower for Machine Room Blower by Howden Safanco 0.1 cubic meter per sec.
Scavenge Blower Motor for Machine Room Blower by Landert 1-phase, 415 V, 50 Hz, 2910 rpm, 0.75 kW
9DL24-RE2C type Scavenge Blower Motor for Machine Room Blower Insulation Class F
Auxiliary Compressor by D&M and Bristol 141.6 ft per min., 7.03 kg per cm2.
Auxiliary Compressor Motor by D&M 110 VDC, 1450 rpm, 75 kW
Battery by Saft Nife 110 V, 199 AH, NiCd (SAF-39 SBL199)

Performance

WAP-5 (5440 HP) has the following capacity for ICF coaches in tonnes:

GradientStart20 km/h30 km/h40 km/h50 km/h60 km/h70 km/h80 km/h90 km/h100 km/h110 km/h120 km/h130 km/h140 km/h150 km/h160 km/h
Level1500+1500+1500+1500+1500+1500+1500+1500+1500+1500+1500+1500+1500+1500+14701230
1 in 5001500+1500+1500+1500+1500+1500+1500+1500+1500+1500+1500+1500+147012501065910
1 in 2001500+1500+1500+1500+1500+1500+1500+1500+1500+1500+13501160995860745645
1 in 1501500+1500+1500+1500+1500+1500+1500+1500+1500+13101125970840730635550
1 in 1001500+1500+1500+1500+1500+1500+146013251125970840730635555480420
1 in 501010980965955940865780710610525455400345305265230

Average weight of an ICF coach is 55 tonnes.

Acceleration

A 24 coach (1430t) passenger rake can be accelerated to 110 km/h in 312.1 seconds (over 6 Km), to 120 km/h in 402sec (6.9km); and to 130km/h in 556 sec (14.2km) by a WAP5.[11][12]

See also

References
  1. "'Make in India' speed boost for Indian Railways! Gets first 200 kmph capable aerodynamic electric locomotive". Retrieved 6 November 2018.
  2. "[IRFCA] Indian Railways Locomotive Roster List". Archived from the original on 5 February 2018. Retrieved 4 February 2018.
  3. "200 km in 90 mins: Delhi-Agra high speed train sets new speed record". The Economic Times. 3 July 2014. Retrieved 10 July 2014.
  4. "e-Locos".
  5. "Train had WAP-7 engine, 'black box' may reveal cause". Zee News. 9 August 2010. Retrieved 25 August 2012.
  6. "Recent Developments". Chittaranjan Loco works. Retrieved 25 August 2012.
  7. "Development of Electric locomotive with Head On Generation (HOG) facility" (PDF). Indian Railways.
  8. "New Aerodynamic 160 kmph WAP-5 Locomotives Flagged Off At CLW". www.railpost.in. 2 October 2020. Retrieved 27 December 2020.
  9. Chittaranjan Locomotive Works unveils New Tejas Locomotive for Push Pull Premium Train on YouTube
  10. "Indian railway fan club".
  11. "Monograph on Bo-Bo Flexi Coil Fabricated Bogie" (PDF). Indian Railways Institute of Civil Engineering. June 2017. Retrieved 20 March 2023.
  12. "Simulation of mix-traffic railway networks" (PDF). Indian Railways Institute of Civil Engineering. 2017. Retrieved 20 March 2023.
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