north western railway training report

1. SUMMER TRAINING
ON
NORTH WESTERN RAILWAY JODHPUR
SUBMITTED BY:
ANUJ BOHRA
7 SEM (EE)
SUBMITTED TO:
Mr. Ravi Soni
Mr Ashwini Joshi
Electrical Department

2. CONTENTS
INTRODUCTION
 TRAIN LIGHTING
 ROOF MOUNTED A/C PACKAGE UNIT
 TRAIN LIGHT ACCESSORIES
 POWER SUPPLY

3. INTRODUCTION
 The Railway Workshop and Stores at Jodhpur were built in the year 1886 under the aegis of
Jodhpur Bikaner Railway (JBR) to cater for all sorts of engineering works.
 JU workshop was pioneer in Train Lighting when electric lighting was started on
experimental measure on Jodhpur Bikaner Railway in 1887.
 This workshop manufactured Arms and Defense spares during world wars I and II, Indo-
China and Indo-Pak wars.
 JU workshop introduced VISTODOM Roofing in Narrow Gauge Coaches for tourists.
 The coaches of the JOY RIDE TRAIN, being run in the Zoological Park at Delhi were
manufactured by this workshop.

4. TRAIN LIGHTING
1. SYSTEMS OF TRAIN LIGHTING
Following systems for train lighting are presently in use –
 Axle driven system working on 110 V DC supply.
 Mid on generation with 415 V, 3 Phase generation AC 110 V utilization.
 End on generation with 3 Phase 415 V generation and AC 110 V utilization.
 End on generation with 3 Phase 750 V generation and AC 110 V utilization.

5. 2. D.C. DYNAMOS / BRUSHLESS
ALTERNATORS & DRIVES
Regulators of 4.5 KW Alternator for any make will work for
any make of 4.5 kW brushless alternator, for same voltage
rating.
To achieve simplicity in maintenance, brushless alternators,
having no moving contacts or windings on rotors, have been
introduced on 110V.
The ratings in use are:
4.5 KW, 120V BG non-AC coaches
3.0 KW, 120 V for MG non-AC coaches
12.0 KW, 120 V for MG AC coaches / Jan Shatabdi Non AC
Coaches.
18.0 KW, 130 V for BG AC coaches (old)
25 KW,130V, alternator for BG AC coaches (new)

6. 2.1 CHARACTERISTICS OF 4.5 KW ALTERNATOR
& REGULATOR
 Output
 Voltage
 Current
 *Cut in speed
 **MFO
 Max speed
 Mounting
 Drive
4.5 KW
120V DC
37.5 A
350 RPM (Approx 19 KMPH)
600 RPM (Approx 31 KMPH)
2500 RPM (Approx 130 KMPH)
Transom
V belts (4)

7. 3. ELECTRONIC RECTIFIER CUM
REGULATOR (ERRU )
Features
 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.
 Monitoring real time value of alternator voltage,
load current, battery AH (IN), AH(OUT) etc.,
through interface fitted inside the coach.
ADVANTAGES
 Control circuit is Modular type design.
 Auto identification of alternator ratings and indications.
 Auto setting of parameter of voltage, load current, Battery current, over
voltage, over current and current limiting for all the regulator of 4.5 kW,
18 kW and 25 kW.
 Close regulation of voltage +/- 2 V over the entire range of load and
speed to have uniform charging of batteries.
 Less voltage and current ripple on Battery Charging current.
 Controlled Battery charging current to have longer life of batteries.
 This interface also has Emergency unit. In case of failure of one control
unit, the other control unit will take care of both regulators

8. THE MAIN RECTIFIER CONSISTS OF SIX SILICON DIODES
MOUNTED ON THE ALUMINIUM HEAT SINK EXPOSED TO
AIR AT THE REAR PORTION OF THE BOX.
RCR HAS THE FOLLOWING FUNCTIONS:
 RECTIFYING 3 PHASE AC OUTPUT OF THE
ALTERNATOR TO THE DC USING FULL
WAVE RECTIFIER BRIDGE.
 REGULATING THE VOLTAGE GENERATED
BY ALTERNATOR AT THE SET VALUE.
 REGULATE THE OUTPUT CURRENT AT
THE SET VALUE.

9. 3.1 DIFFERENT RATING & SETTING
25 KW Regulator
RATING
Voltage : 130 V
Full Load amps :193 A
1-Hour rating amps : 222 A
Speed Range : 800 rpm to 2500 rpm
SETTING
Normal : 127+/-0.5V at 97 A & at 1500 rpm
Over Load : 222 A at 120 V
Load Current : 230 A (Max.)
Battery charging current : 110 A (Max.)
18 KW Regulator
RATING
Voltage :130 V
Full Load amps: 138 A
Speed Range : 800 rpm to 2500 rpm
SETTING
Normal : 127V+/-0.5V at 70 A & at 1500
rpm
Over Load : 150 A at 120 V
Battery charging current : 110 A (Max.)
4.5 KW Regulator
RATING
Voltage : 124 V
Full Load amps : 38 A
Speed Range : 550 rpm to 2500 rpm
SETTING
Normal : 124+/-0.5 V at 19 A & at 1500 rpm
Load Current : 42 A (Max.)
Facility available for setting : 120V,122V &
124 V
Battery charging current : 24 A (Max.)

10. 4. BATTERY
An Electrical Battery consists
of number of chemical cells
connected in series or parallel.
Active materials of the lead
acid cell are:
1. Lead peroxide (+plate)
2. Sponge lead (-plate)
3. Dilute sulphuric acid as
electrolyte
Capacity of battery in AH Type of Coach where
at 27 Degree C at 10 Hr Rate generally used
120 110 V, BG coaches
450 MG AC Coach
525 Jan Shatabdi Non – AC coaches
800 II AC BG Coaches (Old) (Under-slung type)
1100 II AC BG Coaches (new)/AC 3 Tier Coach

11. 4.1 CHARGING SYSTEM
Two general methods are employed :
CONSTANT CURRENT SYSTEM- The charging current is kept constant
by varying the supply voltage to overcome the increase back emf of cell.
CONSTANT VOLTAGE SYSTEM- THE VOLTAGE KEPT CONSTANT
BUT IT RESULT IN VERY LARGE CHARGING CURRENT IN THE
BEGINNING WHEN THE BACK EMF OF THE CELLS IS LOW AND A
SMALL CURRENT WHEN THEIR BACK EMF INCREASES

13. ROOF MOUNTED A/C PACKAGE UNIT
Two high capacity packaged air-conditioning units of minimum of 7.0 TR of cooling
in 45°C ambient i.e. 14.0 TR for one coach, will replace the present underframe open
type AC system of capacity 5.2 TR each (Total 10.4 TR) for each coach.
Two packaged units are used in one coach each mounted above the toilets on both
ends supplying conditioned air into a tapered duct to serve the coach end to end.
The AC coaches running on Indian Railways can be broadly divided into two
categories.
• Self generating (S.G.) coaches.
• End-On-Generation (EOG) coaches

14. A/C EQUIPMENT IN RAILWAY COACHES
This consists of the following:
• Evaporator Unit.
• Compressor.
• Condenser Unit.
• Gauge panel.
• A/C control panel.
• Air Duct.
• Refrigerant piping & joints.
• Wiring.

16. TRAIN LIGHT ACCESSORIES
REGULATOR: THE REGULATOR WITH A SEPARATE RESISTANCE UNIT
ENCLOSED IN C.I. HOUSING IS PROVIDED FOR REGULATING FAN SPEED
IN UPPER CLASS COACHES.
FUSE PROTECTION: TINNED COPPER FUSE OF 35 SWG IS PROVIDED AS
PROTECTION FOR EACH FAN. THIS SAFE GUARDS THE FAN FROM SURGES
AND SHORT CIRCUIT AND ISOLATE THE CIRCUIT IN CASE OF FAULT
GIMBAL RING: THIS IS PROVIDED IN UPPER CLASS COACHES IN
SWIVELING TYPE FANS,SO THAT PASSANGERS CAN KEEP THE FAN ANGLE
TO ANY POSITION

17. POWER SUPPLY
 Power from the generating station, after being stepped up to extra high voltage (220KV) is carried
through transmission lines to a sub-station where the voltage is stepped down to 66 KV. This sub-station
is called the primary sub-station.
 From the primary sub-station, sub-transmission lines carry power to secondary sub-stations, where the
voltage is stepped down to 11 KV.
 From here, the power is carried through primary distribution lines (also called feeders) to distribution
sub-stations. At distribution sub-station, the power is further stepped down from 11 KV to 415/240Volts.
 The distribution sub-stations are situated at convenient locations as far as possible nearer to the load
centre.
 From the distribution sub-station, power is supplied to the consumers (domestic, commercial, industrial
etc.) through secondary distribution lines (also called distributors).

18. It must be noted that in the above
description and in figure 1, the
primary distribution line is considered
to be at 11KV.
This is generally true except at places
where load densities are very high.
In such places, the primary distribution
lines operate at 33 KV or even at 66
KV.
This is because very high voltages are
used to effect economy in transmission
of power.