VOCATIONALTRAINING REPORT EASTERN RAILWAY SEALDAH DIVISION Submitted by : Souptik Mukhopadhyay 5th Semester Dept. of Electrical Engineering I.I.E.S.T,Shibpur ACKNOWLEDGEMENTS I, the undersigned student of Electrical Engineering department of I.I.E.S.T,Shibpur(formerly known as Bengal Engineering and Science University, Shibpur) have completed two weeks training at Eastern Railway (Sealdah Division). I am very much grateful to the authority of the organization for taking initiative for the vocational training to upgrade my knowledge by placing me at Eastern Railway (Sealdah Division). I owe many thanks to several people who helped and supported me during this training. I wish to express my gratitude to the officials and other members of Eastern Railway who rendered their help during the period of my training. I am extremely grateful to the H.R. Department and Electrical Department of Eastern Railway (Sealdah Division). I express my sincere gratitude to: Mr. Asit Das of Power House/ Substation. Mr. Yadav Roy, Mr. Paltu Ghosh, of AC Coaching and Rajdhani Express Department. Mr. Tiwari Yadav, Mr. Mondal of TL Coaching. Last but not the least I wish to avail myself of this opportunity to express a sense of gratitude and love to my friends and my beloved parents for their heartiest support, guidance and for everything. With due regards and thanks to everyone involved in this project I conclude this project. Yours sincerely Souptik Mukhopadhyay 1. TRAIN LIGHTING TRAINING PERIOD: 23/06/2014 TO 26/06/2014 INTRODUCTION Train lighting of a self-generated coach is being discussed here. The generation is done by the under gear equipment i.e. a 3 phase brushless alternator with a Rectifier cum Regulator Unit(RRU) ALTERNATOR S P E C I F I C AT I O N O F A LT E R N AT O R : Connection Generated voltage Rating No. Of V grooves Star 97V AC 4.5kW 4 The alternator is mounted between two wheels. The V belts are attached in the V grooves on the pulley attached to the shaft and the axis of the wheel. External Components: Bogie bracket Suspension pin Cutter pin Split pin Bogie nylon bush Tension rod Bogie bush Alternator power supply 1. The alternator starts producing voltage when rotor achieves a minimum speed of 350rpm.The alternator does not generate until the train achieves a minimum speed of 22kmph. 2. The output of alternator is provided to RRU at an optimum speed of 38kmph 3. 110 V DC from RRU feeds the whole lighting system of the coach and simultaneously charges the cells used underneath each coach .When the train is at standstill the charged cells provide the lighting.. RECTIFIER CUM REGULATOR UNIT(RRU) Main features of ERRU with UVC: Fast and reliable switching devices. Alternator identifying facilities and Auto setting of parameters such as output DC voltage, battery current, load current which in turn increase the life of battery and the alternator itself. Battery current. Less voltage and current ripple on Battery Charging current. load current.5 kW. over voltage.5 kW Regulator: Ratings : . over current and current limiting for all the regulator of 4. Close regulation of voltage +/. UVC is interchangeable with all types of Electronic Regulators from 4. Monitoring real time value of alternator voltage. Auto identification of alternator ratings and indications. 18 kW and 25 kW. Auto setting of parameter of voltage. battery AH (IN). Main Components of ERRU : The main components of the ERRU are as follows Terminal Box Power Unit Universal Voltage Controller (UVC) Static Over Voltage Protection (OVP) Emergency Field Extension with interface High Reliable Components Hall Effect Sensor. Main advantages of ERRU: Control circuit is Modular type design. Controlled Battery charging current to have longer life of batteries. AH(OUT) etc. load current.5 kW to 25 kW. Rating and Settings : 4.. ISOPACK Power Diodes. through interface fitted inside the coach.2 V over the entire range of load and speed to have uniform charging of batteries. Hall Effect Senor. – A.C. HALL EFFECT SENSOR : The Hall sensor is a transformer operating with a balanced magnetic flux principle to measure D. The primary current produces a magnetic field. via an electronic amplifier.C – pulsating current with galvanic insulation between primary and secondary circuits. Settings : Normal : 124V +/.Voltage : 124 V Full Load amps : 38 A Speed Range : 550 RPM to 2500 RPM. This closed loop current sensing is fed into the main circuit to limit the output current and protect the equipment from over current. And at 1500 RPM Facility available for setting: 120V. ISOPACK POWER DIODES : . The secondary current thus injected is the exact replica of the primary current times the turns ratio. which is detected by a Hall Effect device and. The working principle of these components are ad mentioned below are explained here under.0. Isopack Power Diodes.) HIGHLY RELIABLE COMPONENTS : High reliable components are added to minimize the failure in the Electronic Regulator.5 V at 19 Amp. is immediately balanced by injecting a current into the secondary winding.122V & 124V Load Current : 42 Amp (Maximum) Battery charging current: 24 Amp (Max. 3. They can be mounted directly on the heat sinks needing no insulation in between. If any disconnection is found. I (avg) : 350 Amps. 4. . This results in effective heat transfer to the heat sink and thereby reducing temperature of the device.These diode modules contain two diodes in a single pack and have a base plate. The ratings of devices are as follows – VRRP : 1800 Volts peak to peak. Check all the connections are tight. tighten the connection. The reverse connection may cause severe damage in regulator. connect the connectors in original position. Open door may give chance to enter the dust and metallic things inside and this may cause any short circuit in the regulator. Do not disconnect the connectors from UVC and terminals. Care must be taken for connecting the terminals in correct polarity. which is ceramic isolated from the power circuit. These modules are tested for more than 1. If found any loose connection. PERIODICAL MAINTENANCE INSTRUCTION FOR ERRU 1. 2.5 kV isolation between live terminals and base place. Do not keep open the UVC door as well as regulator box and terminal covers. Do not connect any wrong side and wrong connection will cause damage in regulator. Type of cells in use for train lighting and coach air-conditioning are :Capacity of battery in AH Type of coach at 27 Degree C at 10 Hr Rate where generally used 120 110 V. OVP and fuse. is suggested to use proper HRC fuse. BG coaches 450 MG AC Coach 525 Jan Shatabdi Non . 6.5. the lead peroxide on the positive plates as well as the spongy lead on the negative plates are converted into lead .AC coaches 800 II AC BG Coaches (Old) (Under-slung type) 1100 II AC BG Coaches (new)/AC 3 Tier Coach PRINCIPLE OF OPERATION : In a charged lead acid cell positive terminal consists of lead peroxide (PbO2) and the negative terminal of spongy lead (Pb). so do not bypass the protecting systems lie. Protections are safety for our systems. In case of fuse blown. BATTERIES Description of different types of cells: Lead acid cells demand less maintainence and are less costly. Dilute sulphuric acid (H2SO4 + H2O) serves as electrolyte. Do not tie with wire and this wire-fuse will cause any damage in the regulator. The overall reactions inside the cell during discharge and charge are represented most -conveniently by a reversible equation as follows :- PbO2 + Pb + 2H2SO4 <=> 2PbSO4 + 2H2O During discharge. 245 to 1. the specific gravity of the electrolyte falls. Sulphuric acid is formed and the water consumed. and then a faster voltage drop. From 2. The specific gravity of the electrolyte rises. sulphuric acid (H2SO4) is consumed and water (H2O) is formed. later a faster rise of cell voltage. GENERAL . The specific gravity is the relative weight or density of the electrolyte as compared with a similar volume of pure water. The amount of ampere-hours (constant current x time) taken out is called the capacity of the cell at this rate. MAINTENANCE : Hydrometer is used to ascertain the specific gravity of electrolyte in a lead acid cell. the extent of fall being proportional to the ampere-hours taken out. In this process. The process at first causes a slow.210 and 1. This voltmeter shall preferably be of a dry cell operated digital type with a range of D.4 volts onwards gassing sets in due to a strong decomposition of water into hydrogen and oxygen. The lead-sulphate on the positive plates is reconverted into lead peroxide and the lead sulphate in the negative plates into spongy lead. This value for fully charged cells at 27 degree C shall be between 1. from 0 to 200 V.C. which depends on the rate of discharge current. until a permissible lower limit (final discharge voltage) is reached. Voltmeter is used for taking the individual voltage of cells and the battery as a whole. There is at first a slow. Violent gassing is injurious to the plate material. The specific gravity of a cell should be maintained at the value given by the manufacturer in the fully charged condition. The chemical process during charge is the reverse of that during discharge.sulphate (PbSO4). Consequently.255 for cells over 525 Ah capacity as per IS:6848. So after reaching this gassing voltage the rate of the charging current must be limited to within safe permissible values.220 for cells up to 525 Ah capacity and between 1. . replenish with pure battery grade water. Intermediate overhaul. Running maintenance of storage batteries falls under four categories :1. 2. prompt remedial measures of defects/replacement of cells and quality POH work in Shops to achieve the expected life without any loss of efficiency below 80 %.The rating assigned to the cell or battery is the capacity expressed in ampere-hours(after correction to 27 degrees C) stated by the manufacturer to be obtainable when the cell or battery is discharged at the 10 Hr. "SWITCH ON" lights and fans in each coach and take the voltage readings across the set of 56 cells. Replace vent plugs after taking specific gravity and ensure that they are tight. watch for crack in the cells and also check the voltage on load which should not be less than 1. Replace missing/defective floats. They are often left to idle for long duration or charged at higher rates. SKEL 611 for topping up battery grade water. rate to the end voltage of 1. Such strenuous service of these cells therefore calls for systematic and thorough examination while in service. Quarterly examination. Fortnightly examination.Train lighting batteries of coaches by the very nature of service conditions cannot be expected to have steady rate of charge/discharge. 3. 4. remove the cell and replace by a spare one preferably of the same make and lug date or a lug date as close to the one already in the coach. Check tightness of packing and use additional packing if required. Use special containers provided with automatic siphoning device to RDSO drawing No. If any cell needs too much water for replenishing. In case of low level.80 V per cell. In case of any defect. Trip examination. "SWITCH OFF" all lights and fans. Tap the floats of each cell and check for correct electrolyte level as indicated in the float stem.80 V. and EOG coaches where the system voltage could be DC 110 V or AC 110 V. Use the battery charging terminals provided in coaches for charging purposes. SPECIFICATION . MOG. Secure battery box cover finally after all works are completed.210 and 1. Use a clip-on d.220 for the cell up to 525 Ah or as recommended by the manufacturers and which is stenciled on the battery box. Check up correct polarity and connect the charging cables. Keep vent plug tight. The person in charge of battery maintenance should record all the readings mentioned above in his diary and this information should be transferred to the register maintained for various trains. Replace if found missing. Check the specific gravity of Pilot cells and the total voltage of battery on load at the end of charge and record. As a passenger amenity item. 300 mm and 200 mm sweep carriage fans are used on Indian Railways in SG.Coaches with discharged batteries which show less than 22 V on load should be put on charge at double the normal rate of charges and continued as long as possible till gassing starts or till the specific gravity rises to the fully charged value which should be between 1. CARRIAGE FAN GENERAL 400 mm. c. Never skin the insulation of cables near end cell connections for this purpose. Check anti-theft rods and provision of nuts both inside and outside the battery box on either side. ammeter of 0-100 A range to check up the battery charging current. Ensure that washer is available for vent plugs. Note down the rate of charging and the number of hours of charge. carriage fans have to be maintained in such working condition as to obtain good air flow and trouble free service for ensuring maximum passenger satisfaction. .G system. 110 V system.C. Performance requirements of these fans are as follows: Requirement A. Fan sizes 400 mm 300 mm 200 mm 400 mm 300 mm 200 mm Minimum Air in m3/min 50 37 20 65 30 14 Maximum Electrical Power 35 29 18 60 40 28 input in Watts Maximum Weight in kg. 15 14.O.5 10 CARRIAGE LIGHTING GENERAL Carriage lighting is provided from :a.5 10 15 14. 110 V in MOG system.C. Fan sizes PERFORMANCE DATA D.C. b..110V in E. Diesel generator sets with step down transformers on A. Axle driven generators in conjunction with storage batteries on D. c.Railway carriage fans are either of the fixed or swiveling type and conform to specification IS: 6680.C. Diesel generator sets with step down transformers on A.C. : 18 W.Ceiling light fittings in I. long fluorescent lamps with inverters . postal vans and dining cars on DC 110 V sys. II Sleeper. 2 ft. II&III AC. OVERALL SCHEMATIC DIAGRAM OF POWER DISTRIBUTION FROM . ALTERNATOR 2. POWER HOUSE TRAINING PERIOD: 26/06/2014 TO 30/06/2014 . Electric power may flow through several substations between generating plant and consumer.while a step down transformer decrease the voltage while increasing the current for domestic and commercial distribution . The word substation comes from the days before the distribution system became a grid.INTRODUCTION o A substation is a part of an electrical generation. where the generators were housed and were subsidiaries of that Power station. Substations transform voltage from high to low or reverse or any of several other important functions. The first substation were connected to only one power station. 1 THE LOW TENSION SECTION 2 THE HIGH TENSION SECTION . transmission and distribution system. IN SEALDAH POWER HOUSE the control is divided into two sections. o A substation has a step up transformer increase the voltage while decreasing the current . and its voltage may change in several steps. This varying magnetic field induces a varying electromotive force (EMF) or voltage in the secondary winding. This effect is called mutual induction. an electric current will flow in the secondary winding and electrical energy will be transferred from the primary circuit through the transformer to the load.the induced voltage (Vs) in the secondary winding is proportion to primary voltage (Vp) and is given by the ratio of the number of turns in the secondary(Ns) to the number of turns in primary(Np) as follows----Vs/Vp=Ns/Np .T section } Relays { Earth Fault Relay & Over Current Relay } Bus Coupler Hooter / Alarm Isolator {P.F :1 Sub Station } The components are described in brief from the power house below:- STEP-DOWN TRANSFORMER A transformer is a device that transfers electric energy from one circuit to another circuit through inductively coupled conductors--the transformers coil---a varying current in the first or primary winding creates a varying magnetic flux in the transformer core and thus a varying magnetic field through the secondary winding.T side & vacuum circuit breakers on H. If a load is connected to the secondary. The main components of the power house are Transformers{300 KVA &500 KVA} Circuit breakers { Air circuit breakers on L. In an ideal transformer . one 300KVA and another 500KVA. Transformer ratings:- . IN SEALDAH POWER HOUSE two transformers are used. By appropriate selection of the ratio of turns. A spare 300KVA transformer is kept for backup. the winding are coils wound around a ferromagnetic core. air-core transformers being a notable exception. In the vast majority of transformers. a transformer thus allows an alternating current voltage to be “stepped up” by making Ns greater than Np or “steped down” by making Ns less than Np. V: 695.C SERIAL NO: MAKER KVA VOLTS AT NO LOAD AMPERES PHASES TYPE OF COOLING FREQUENCY IMPEDENCE VOLTS VECTOR GROUP REF CORE & WEDGES WEIGHT OF OIL TOTAL WEIGHT OIL AMOUNT MAX.V: 6000V L.62A H.V: 48.V: 415V H. TEMP RISE IN OIL 1581/D7-08 AUTOMATIC ELECTRIC GROUP 500KVA H.11A L.V: 3 OIL NATURAL COOLING 50C/S 4.37% DY11 1140KG 451KG 2105KG 530LITRES 45 DEGREE .V: 3 L. 500KVA transformer ALARM/HOOTER SYSTEM(BUCCHOLZ RELAY) The alarm is employed to the system to indicate the faulty condition. DIAGRAM {BUS COUPLER AND BUZZER(ALARM/HOOTER) AT SEALDAH POWER HOUSE H. If any fault occurs in the system components the alarm sounds to notify.T.PANEL}:: . but other operating principles are also used. bus coupler is used to join the buses of different voltage level. PROTECTIVE RELAYS A relay is fault sensing device. Such switches are often found in electrical distribution and industrial applications where machinery must have its source of driving power removed for adjustment or repair. Relays are used . an isolator switch is used to make sure that an electrical circuit can be completely de-energised for service or maintenance. BUS COUPLER Bus coupler provides electrical isolation bus by employing coupling transformers and fault isolation resistors. High voltage isolation switches are used in electrical substations to allow isolation of apparatus such as circuit breakers transformer and transmission lines for maintenance. The buses of two different voltage levels cannot be connected in series. So. The Bus couplers contain two isolation resistors {one per wire} and an isolation transformer {with a ratio one to the square root of two}.ISOLATOR In electrical engineering. The purpose of bus coupler is to prevent a short on a single stub from shorting the main data bus. Many relay use an electromagnet to operate a switching mechanism mechanically. The Relays used in Sealdah Power House are of mainly two types: OVER CURRENT RELAY EARTH FAULT RELAY THE RELAY SPECIFICATION::{SPECIFICATION BASED ON ONE SAMPLE ON H. in modern electric power systems these functions are performed by digital instruments still called “protective relays”.T.2. The first relays were used in long distance telegraph circuits. Signal. Solidstate relays control power circuits with no moving parts. SEC: 5 AMPS. CDG31EG001SBCH SERIAL NO. CDG31EG001SBCH SERIAL NO. PANEL OVER CURRENT RELAY Model No. A type of relay that can handle the high power required to directly control an electric motor is called a conductor. 130954160621011 C. SEC: 5 AMPS.1-4 AMPS FREQUENCY:50HZ .T. Relays with calibrated operating characteristics and sometimes multiple operating coils are used to protect electrical circuits from overload or faults. Relays were extensively used in telephone exchanges and early computers to perform logical operations.5-10 AMPS FREQUENCY:50HZ EARTH FAULT RELAY Model No.T. instead using a semiconductor device to perform switching. 130954160621011 C.where it is necessary to control a circuit by a low-power signal (with complete electrical isolation between control and controlled circuit) or where several circuits must be controlled by one. repeating the signal coming in form one circuit and retransmitting it to another. and it provides the medium for the extinguishing of arc.C. THE OIL CIRCUIT BREAKER SPECIFICATION :: {BASED ON ONE SAMPLE ON L. It insulates between the phases and the ground.NO TYPE NORMAL CURRENT SERVICE VOLTAGE DESIGN FREQUENCY BREAKING CAPACITY TRIP COIL RATING 2K2132 HN2T 400A 415V 50HZ 25MVA 5A . The decomposition of oil into gas requires energy that comes from the heat generated by the arc. the arc vaporises the oil and creates a large bubble that surrounds the arc.PANEL ON 1. Main disadvantage of the Oil Circuit Breaker is the flammability of the oil and the maintenance necessary to keep the oil in good condition. The gas inside the bubble is around 80%hydrogen.B}:: The oil in OCB’s serves two purposes. When electric arc is drawn under oil. which impairs ionisation. OIL CIRCUIT BREAKER{O.NO PF SUB STATION} SL. The oil surrounding the bubble conducts the heat away from the arc and thus also contributes to deionisation of the arc.T. industrial. in prefabricated substations. transformers. motors. THE AIR CIRCUIT BREAKER SPECIFICATION:: {SPECIFICATION BASED ON ONE SAMPLE ON L.PANEL} MAKER FRAME SL. RATIO 100/200% 800/5 Protection circuit breakers of electrical machines {generators.NO. They are used in all type of plants {civil.T. CALIBRATION C. IEC-947-2 UTILIZATION CATEGORY PULSER LH800 DM 1T3P Y606183 IS:13947{PART-2} 8 RATED CHARACTERISTICS .T. in mines. and in the service selector} as well as in the equipment on-board ships. capacitors}. and for primary and secondary distribution in general. 25 FREQUENCY: 50/60HZ 40 AC DIAGRAM {AIR CIRCUIT BREAKERS} . IN ITH@40 DEGREE C ICS & ICU ICW POWER FACTOR Ui=1000VUe=415V U/V 400A 800A 50Ka 50Ka.1sec 0. o THE SCHEMATIC DIAGRAM OF AIR CIRCUIT BREAKER DISTRIBUTION SYSTEM . o A DISTRIBUTION SYSTEM FROM 11KV SUBSTATION . o SCHEMATIC DIAGRAM OF 6KV DISTRIBUTION ARRANGEMENT IN SEALDAH . o SF6 CIRCUIT BREAKER . THE RAJDHANI EXPRESS TRAINING PERIOD: 01/07/2014 TO 04/07/2014 .3. lunch. Passengers are served complimentary meals during the journey. However power required for lighting. high tea. and dinner.445 km in 17 hours 20 mins. breakfast. Presently the technology used in these trains has been obtained from Germany.G sets). implementing EOG(End on Generation) with two power cars at the two ends of the train. operating between New Delhi and other important destinations. heating. these could include Morning Tea. with each individual coach built and exported by LINKE-HOFMAN & BUSCH(known as the LHB coaches). INTRODUCTION Rajdhani Express is a passenger train service. Rajdhani Express was introduced in 1969. They are fully air-conditioned. air conditioning purposes is generated using Diesel Generator sets(known as D. for providing fast connections (up to 140 km/h or 87 mph. This superfast train service runs on electric locomotives drawing power from overhead 25 kV lines with the help of Pantographs. especially state capitals. speed variation depending upon the particular track section) from New Delhi to the capital cities of various states in India. The first Rajdhani Express left New Delhi station for Howrah station to cover a distance of 1. offered by the Indian Railways. This superfast train service get highest priority on the Indian railway network.or 4-berth lockable bedrooms.The newest coaches are said to be manufactured by a German company ALHSTORM. AC 2-tier with open berths (bays of 4 berths + 2 . Depending on the duration and timings of the journey. All Rajdhani Express trains offer three classes of accommodation: AC First Class with 2. 385 ampere current . D.Generally the efficiency is around 80% so about 300 amperes can be used . Reactor Inter Vehicular coupling(known as Z-S coupler) between coaches. fans.The engine provides the mechanical energy required to rotate .etc. Transformers Disconnecting and Earthing Device Battery Box Fuses Air conditioning system Water Heater Lights.berths on the other side of the corridor) with curtains for privacy. pantry. Diesel Engine : The Diesel engines are manufactured by Cotton-Greaves . Each alternator produce 750 V ac supply .with a capacity to provide approx.G SET : Each Power car has two diesel engines coupled with alternators for power generation. and AC 3-tier (bays of 6 berths + 2 berths on the side) with curtains for privacy(according to recent directive the curtains in all 3 tier accommodations have been removed).Each coach requires about 40 ampere current . POWER SCHEME IN RAJDHANI EXPRESS The components used in the power supply system consists of the following components : Diesel Generator(DG ) set(2 in each power car ) comprising diesel generator and an alternator coupled together. FREQUENCY PHASE P. Each engine produces 496 BHP of mechanical energy. The alternator specifications are as follows:- Alternator Specifications:- MAKER KIRLOSKER ELECTRIC CO.Each power car has two alternators. R.C 1500 750V 385A 280V 1.8 Y 55 DEEGREE C EXTR. Alternator :The alternator is coupled with the diesel engine . EXTN.M VOLTS AMPS EXTN.P.F CONNECTION COOLING TEMPERATURE The voltage required for usage for the appliances in the coaches is 415 V. LTD FRAME KVA 4AB355/7 500 KVA A.5A 50 Hz 3 0.the alternator shaft for electrical power generation. But the alternator generates more voltage because there are . D.transmission losses from the power car to the coaches.G SET INSIDE POWER CAR INDUCTIVE REACTOR: . At the time of coach removal. Because if any of the coaches is needed to be removed for maintenance or some other purpose then the transmission line is to be cut. Among them the odd order harmonics specially the 3rd order harmonics can damage the electrical equipment severely . At the time of .Only the primary harmonics present in the signal.The power generated in an ideal alternator is totally sinusoidal without any unwanted surges and other harmonics .The reactor is used to remove these unwanted signals and provide pure sinusoidal signal. REACTOR SPECIFICATION MAKER KERALA ELECTRICAL AND ALLIED ENGG. which is not a good operation. coupling is opened and the coach is disconnected from the supply. The fixed transmission lines are not used in the supply system. RISE CORE AND WINDING TOTAL WEIGHT INTER-VEHICULAR COUPLING : The power generated at the power car alternator is supplied to the coaches via inter – vehicular coupling or ZS coupling. LTD. 125V 50A 150 Hz 1 CLASS H AC3 AN 115 DEEGREE C 60KG 110 KG VOLTS AMPS FREQUENCY PHASE INSULATION CLASS INSULATION LEVEL TYPE OF COOLING MAX TEMP. CO. . While starting the maintenance the device disconnects all supplies and after the job completion the device connects the coach to the supply. I-V COUPLING DISCONNECTING AND EARTHING DEVICE : While maintenance all the live supplies are to be removed and switched off.maintenance the coupling is connected to the dummy connector at the coaches. 3 phase 50 Hz AC to 130V DC and step down chopper i. After next 8 minutes of turning of the water pump system the contact no. 13. When EBC also fails we can observe the backup time for other components from MVR (Minimum voltage relay) card. When both the battery chargers fail to operate then the contact no. Each box contains 9 batteries and each battery supplies 12. In float mode the battery set of LHB EOG coach gets charged with a voltage of 121.e. 8 gets opened instantly.e. BATTERY BOX: Under each coach there is a battery box.5V i. 10 gets opened resulting turning off the lighting circuit. Rectifier unit converts 415V.2 V DC. . 9 gets opened resulting in turning off the water pump system. resulting in turning off the PA system and the Music system. the DC to DC converter converts 110V to 24V.5V – 129V. If somehow this unit fails to charge the battery the Emergency Battery Charger (EBC) charges the battery. Each box supplies 110V DC.5V per mono block and in boost mode it gets charged with 128. RBC consists of a rectifier and a step down chopper circuit. Thereby it chooses the charging voltage. When RBC fails to operate Emergency Battery Charger starts to operate giving a constant supply of 115V – 118V to the batteries. After next 30 minutes of the failure the contact no. The batteries are charged by regulated battery chargers (RBC) in side of each coach. Operation of RBC and EBC: Regulated battery charger can sense the battery condition whether it is to be charged in the float mode (fully charged) or in boost mode (discharged below a certain level). This is used for back up supply to the coaches. The Transformers are used to step down the voltage level to 415V AC.Battery box under the coach TRANSFORMER: The power generated in the alternator is 750V. . The transformers are located under the coaches. This is much higher than the required value. Under each coach there is one transformer to supply power (excluding pantry cars which have two transformers for each coach). .O Primary :Star :Delta Secondary WATER PUMPS: The 750V AC coming from the alternators is stepped down to 3 phase 415V AC by the 60 KVA transformer. OUTPUT WEIGHT VECTOR CONNECTION VECTOR TYPE Vimal Transformer Corporation 750V AC 415 V AC 60 KVA 50Hz <4% 46.Transmormer Specifications: MAKER INPUT OUTPUT CAPACITY FREQUENCY IMPEDANCE LINE AMP. This 415V AC drives two centrifugal pumps located in a stainless steel casing at the under frame supply the water to the tanks.Y.2A <440KG Y.2A 83. After 4 hours a microcontroller switches the operation to the other pump. These supply water in the coaches. THE COACH CONFIGURATION OF SEALDAH– NEW-DELHI RAJDHANI EXPRESS Almost every Rajdhani Express offers three classes of accommodation: First class AC with 2 or 4 berth lockable bedrooms AC 2 tier with open berth with curtains for privacy AC 3 tier with curtains for privacy The Rajdhani Express contains 20 coaches in total. The coaches are as below:: First class AC: 1 coach AC 2 tier: 3 coaches AC 3 tier: 10 coaches Pantry car: 2 coaches Power car: 2 coaches :H1 : A1-A3 :B1-B12 :PC :EOG . while the other is kept on standby for 4 hours maximum.One of the 415 V pumps is always kept running. Each coach also has an "advanced pneumatic disc brake system" for efficient braking at higher speeds. The improved suspension system of LHB coaches ensures more riding comfort for the passengers compared to conventional rakes. However. India.24m means a higher passenger capacity. They are relatively quieter as each coach can produce a maximum noise level of 60 . Their length of 23. "modular interiors" that integrate lighting into ceiling and luggage racks with wider windows.The coach configuration is as follows: Rake/Coach Composition LOCO-EOG-H1-PC-A3-A2-A1-B12-B11-B10-B9-B8-B7-B6-B5-B4-B3B2-B1-PC-EOG LINKE-HOFMANN-BUSCH COACHES Linke Hofmann Busch (LHB) coaches are the passenger compartments of Indian Railways that have been developed by Linke-Hofmann-Busch of Germany (renamed Alstom LHB GmbH in 1998 after the takeover by Alstom) and produced by Rail Coach Factory in Kapurthala. The tare weight of the AC chair car was weighed as 39. The air conditioning system of the LHB coaches is of higher capacity compared to the older rakes and is controlled by a microprocessor which is said to give passengers better comfort than the older coaches during summer and winter seasons. The coaches are designed for an operating speed up to 160 km/h and could go up to 200 km/h. These coaches are made of stainless steel and the interiors are made of aluminium which make them lighter as compared to conventional rakes. which means they do not get turned over or flip in case of a collision (chiefly head-on). They are considered to be "anti-telescopic". they have been tested up to 180 km/h.5 Tons. compared to conventional rakes.54m and a width of 3. LHB coaches of the Rajdhani Express Here’s a list of the Circuit diagrams to be included in these pages that were xeroxed by us:1. wiring diagram of lighting circuit power and control .layout inside and underframe 2.decibels while conventional coaches can produce 100 decibels. Each LHB coach costs between Rs 15 million to 20 million. whereas the power car which houses a generator costs about 30 million.layout roof 3.wiring diagram of microproccesor wiring diagram of ebc and rbc 6.inside viw of lhb coach panel s-1 4.single line diagram of power circuit of lhb coaches 5. The 3 tier (6+2 berth) and the 2 tier (4+2 berth) coaches have their own controlling and safety units at the ends of the coaches. Each coach is provided with music system and announcement system which is controlled from the panels at the end. Each coach gets its own power supply from the transformer below them. For this purpose 2 deep freezers. 2 bottle coolers and 2 hot .AC 2 TIER & AC 3 TIER COACHES: The train has 3 AC 2 tier and 10 AC 3 tier coaches. Each coach has its own storage selection for food and water. This may contain 2 berths or 3 berths system.cases are provided. FIRST CLASS AC COACH: The train has only one first class AC coach. 230ltr Bottle cooler 90ltr Hot case 140 meals Insect killers Oven toaster Grill LOAD (WATT) QUANTITY 400 1 TOTAL LOAD(WATT ) 400 200 1 200 1600 1 1600 20 1200 2 1 40 1200 . The announcement and the music volume can be regulated in the first class compartment. The coach has controllable music system.There are two pantry cars at the two ends of the train after the power cars. This unit is operated by the compressors and the blower motors of its own mounted below this unit. THE PANTRY CAR: The pantry car is the coach to supply food to the passengers and the staff members. The different components of the pantry car are as follows: EQUIPMENT DESCRIPTION Deep Freezer. The first class coach does not have any bottle cooler or freezer. 310 ltr Electric chimney 1 Electric chimney 2 Electric chimney 3 Total load (watt) 2000/3000 2000/3000 2000/3000 2000 1 1 1 2 2000/3000 2000/3000 2000/3000 4000 2000 1 2000 2000 1 2000 2000 1 2000 300 1 300 300 1 300 300 1 300 300 1 300 with 2000 Watt water boiler 28540 Total load (watt) with 3000 Watt water 31540 boiler Due to all these high rating equipments are housed in the pantry car.Water boiler1 Water boiler2 Water boiler1 Electric burner 1 Electric burner 2 Electric burner 3 Electric burner 4 Refrigerator. water boiler and other high loading elements there are much more risk for fire hazards. Due to the operation of the heater. To deal with this problem the Smoke Detector is kept mounted in the ceiling of the car connected with alarm system. The smoke detector has a simple thermostat switch that automatically switches on the alarm under critical conditions. . it requires more electric supply than other coaches. An inside view of the pantry car . AIR CONDITIONING SYSTEM Principle of Operation of the AC System The air-conditioning process maintains a constant climatic condition by controlling temperature. Motor-driven compressor. The air-conditioning system adopted in air-conditioned coaches work on mechanical compression system and consists of the following: Evaporator unit consisting of cooling coil(heat exchanger). heater and motor-driven blower unit. Air cooled condenser (with cooling fan driven by motor) Liquid receiver and dehydrator. Thermostatic expansion valve. Refrigerant piping for conveying the refrigerant(R-134A). humidity. (i) Latent principle Any substance in passing from the liquid to gaseous state absorbs at constant temperature s specific quantum of heat known as the latent heat of evaporation and gives up latent heat on passing from gaseous to liquid state. . The refrigerating system depends for its action of the following principles. Application: Evaporator and Condenser (ii) Expansion principle When a gas expands without external heat exchange it temperature falls and when it is compressed without external heat exchange its temperature decreases. cleanliness. The air-conditioning system includes both refrigeration and heating. noise and air motion. Apart from cooling. The compression process elevates the pressure from 37 psi(maximum 46 psi) to 150 psi(maximum 180 psi). The compression of the gas also heats up the gas to a superheat condition. The line A-B represents the expansion that takes place in the expansion valve while the line B-C represents the refrigeration effect that is obtained in evaporator.The cooling and heating will nave be . the refrigerant reaching the point A at the end of this part of the cycle. The refrigerant gas at low pressure (represented by point C) is compressed to point D. the air conditioning equipment is also required to provide heating when the outside temperature varies from 400 C to 200 C . The gas at the compressor outlet is superheat and latent heat are removed at constant pressure .The Refrigeration Cycle A typical refrigeration cycle in an air-conditioned coach can be represented also in a pressure enthalpy diagram as in figure. the heater is switched on according to the setting of thermostat.7 meter cube per minute per passenger in the case of compartments where smoking is permitted. RDSO specification also lays down that the equipment shall admit fresh air at the rate of 0. the return air filters so that the dust contained air in the return air is extracted. The expanded refrigerant passes through a heat exchanger. Evaporator unit The evaporator unit consists of a thermostatic expansion valve. a heat exchanger.necessarily automatic by means of thermostatic controls incorporated in the unit. The function of the thermostatic expansion valve is to allow the compressed refrigerant liquid to expand to a lower pressure corresponding to the load demand. Expansion valve . When the outside ambient is very low and when the refrigeration is not required.heating unit and a centrifugal blower driven by a motor. a resistance. Fresh air is drawn through filters to eliminate dust and is mixed with the return air in the plenum on the inlet side of the evaporator. Similarly. Description of various components of Air-conditioning System.35 metro cube per minute per passenger in the non-smoking area and 0. The cooled air is led through the ducting to the various compartments and diffused by means of air diffusers. the heat in the air is transferred to the refrigerant causing the cooling of the air and the evaporation of the refrigerant inside the tubes. The liquid receiver is a cylindrical container which contains a reserve of the refrigerant liquid. The expansion valve admits more refrigerant when the air conditioning load is high.. The refrigerant liquid leaving the condenser is led into the liquid receiver from where it proceeds to the expansion valve on the evaporator.The primary function of the expansion value is to control the quantity of liquid refrigerant admitted into the cooling coils of the evaporator. Condenser The condenser serves the function of extracting the heat absorbed by the refrigerant vapour in the evaporator and the heat absorbed during the compression process.If the airconditioning load varies greatly the superheat may be set between 101 O F to 150O F. . and reduces it to the minimum when the load is low. which is force-cooled by means of two or three axial flow blower fans. Compressor The refrigerants vapour drawn from the evaporator is compressed by means of a multi cylinder reciprocating compressor. The refrigerant vapour is cooled at constant pressure by means of the air blown over the finned tubes and liquefied. The work done due to compression raises the temperature of the refrigerant vapour. A dehydrator and filter are also provided to ensure that the refrigerant is free from moisture and dust particles. The condenser consists of a heat exchanger. It should be provided atleast temperature when the installation is brought into operation to remove any moisture in the piping system. also cause corrosion in working parts. Connections to the gauge panel from the . and liquid line(from the liquid receiver to the inlet side of the expansion valve). Refrigeration piping The refrigerant piping consist of the suction line(from the evaporator outlet to the compressor inlet) and the discharge line(from the compressor outlet to the condenser inlet). The dehydrator is another drying device containing silicalgel or other similar drying agent inserted in the refrigerant load for removing moisture from the refrigerant while in operation. This is best achieved by subjecting the system of vacuum for 2 or 3 days. I t is a pressure operative switch which switches off the compressor drive motor when the pressure exceeds a preset valve. Low Pressure cut-out This is also a pressure operated switch similar to the high pressure cut-out switch. Dehydrator and Filter Water vapor or moisture will cause trouble in any refrigeration system. It protects the system against unduly low evaporator temperatures and formation of frost on the evaporator. and. but is shuts down the compressor if the suction pressure drops down below 10 psi gauge. The moisture may freeze and block the expansion valve orifice. High Pressure Cot-out The high pressure cut-out is essentially a safety device against build up of excessive delivery pressure and protects the compressor and piping system from damage. This relay works in conjunction with a “Vone Switch” provided in trio air circuit.C.compressor delivery side(high pressure side).The prevents energisation of the compressor motor and condenser motor or Heater till trio evaporator motor (16) comes ’ON’ and blows air into the duct through the evaporator coil. If the evaporator blower motor supply fails or the motor does not run. A. Cooling Pilot Relay – Acts as an electrical link between the cooling thermostats and the control circuit of the compressor and condenser.This will trip to stop the compressor motor and condenser motors/heater. to avoid nuisance – tripping. the lubricating oil connections. and prevent them from starting by cutting off the supply to their control circuit if the voltage of the battery is below 100 and reset when battery voltage rises to 102 V. This is energized by electronic triggering set off by heat thermostat. Control functions Panel Components and their Evaporator Fan Motor Contactor. Low Voltage Relay. Evaporator Fan Motor Proving Relay. the compressor motor and the condenser motors/Heater will get switched ‘OFF’ by this relay.Controls the supply of the evaporator motor. are also part of the piping system. low pressure side and from the compressor crankcase. The relay is provides with a build-in time delay f 5 seconds. only copper pipes are used for refrigerant piping. . AC Control Panel:The control of the airconditiong system is achieved by means of Airconditioning Control Panel. Low pressure cut out. non-poisonous. heater and normal voltage. Main Control Switch. This is energized by electronic triggering set off by thermostats.A pressure switch to shut down the compressor when compressor discharge pressure is too high. High pressure cut-out. compressor motor.A pressure switch to protect against working of compressor with low suction pressure due to loss of Freon gas or other reasons. Desirable properties of the refrigerant: It should be non-irritating. and acts in conjuction with thermal cut-out to shut down the compressor only if the low oil pressure persists. Single thermostat .i. The switch has been connected to the compressor discharge header by means of copper piping. Pilot lights. This has got provision to select blower only.MEDIUM and HIGH temperature setting.This is the control switch for starting or shutting down the plant. Indications are now by LEDs. blower fan motor. Oil pressure Cut-out Switch. LOW.Acts as an electrical link between the heating thermostats and the control circuit of heater.These lights indicate respectively normalcy oh the mains .Heating Pilot Relay.This protect the compressor against lubrication failure either due to lesser oil oil pump failure or blocking of oil piping.e Electronic thermostat is used for heating & cooling purpose. . This switch has been connected by means of copper piping to the suction header of the compressor. noninflammable and have no faning effect on food stuffs if it escapes. It has excellent refrigerating properties and is the first choice for most air conditioning plant. non-toxic. It should not have any corrosive action on any working part of the compressor . Refrigerant 4.Weight 2.C Nil Nil Heavy Nil Heavy Excellent Deteriorates quickly due to dust collection under coach Old and obsolete Passengers at end Takes from toilet 50-100% Latest Nil From roof 25%-100% .Water drop on 13.C system with conventional under frame Hung 1. The volume of vapor for given weight should be low to reduce the size of the compressor. condenser and evaporator.Cpacity control 900 Kg 4 Hrs R-22 Monochlorodia fluoro methane Less than 3. Power Supply 8. Performance 11.Roof leak potential 7. Comparison of roof mounted A. charge 5. system design 6. It is safe. Leak detection should be easy and simple.Fresh air 14.0 kg Hermetically sealed Nil 2700Kg 4 days R-134a Tetra flouro ethane 15-20 kg Open Enormous A.Installation Time 3.Damage due to Cattle run 9. Latent heat of vaporization should be large to minimize the quantity of refrigerant used. noninflammable. It should not have any disagreeable order.Technology 12. Damage due to flash floods 10. R-134a(Tetra fluro ethane) is used as refrigerant as it is environment friendly replacing R-134a . 15.Down time for repairs 4 hrs Very long repair require .