Power cars provide power to End-On Generation coaches in Indian Railways. Earlier models had single engines but now have twin engines rated at higher power outputs. The power supply arrangement includes alternators, transformers, and air circuit breakers to control output. Engine accessories include items like oil coolers, pumps, governors and injectors. Modifications have improved safety, such as adding a neutral current reactor to reduce harmonics and interlocking the fire alarm with generator circuit breakers. Maintenance includes cleaning radiators, thermo imaging, and modifying control circuits.

1. POWER CAR
INTEGRATED
MODULAR
EQUIPMENT

2. Histories
 Power car are needed to proved power supply to End
On Generation type coaches in Indian railway.
 There was Single Engine power car of Rolls Royce
make diesel Engine with Lancashire make
Alternator.320BHP/300KVA
 Before 1992 There was twin Engine Power car of
Kirloskar Cummins Make Engine Rated for 235 BHP at
415Volt.
 After 1992 High capacity power car were introdused in
IR of Caterpillar and Cummins make rated 425 BHP at
750 volts.

3. FEEDER EARTH FAULT PROTECTED BY FEL
EXISTING SUPPLY ARRANGEMENT OF POWER CAR

4. Power supply arrangement
Two 500KVA Alternator feed power supply to EOG
coaches at 750 Volt independently.
200VA Instrument transformer are provided to supply
instrument like frequency meter , AEL , KW meter ect.
Alternator Earth leakage relay are provided to shut down
Engine in case of fault.
The ACB are provided to control Alternator out put supply.
Separate 60 KVA Transformer are provided to step down
750 volt to 415 volt for Radiator motor / Ventilation motor
operation .
Feeder contactor are provided to control out put from
power car, which is protected with Feeder Earth leakage
relay.

5. 21.6 LTR,640BHP, RAIL USE 490BHP
GREAVES
ENGINE

6. CUMMINS ENGINE
19 LTR,600BHP, RAIL USE 490BHP

7. ENGINE
ACCESSORIES
AND
PARTS

8. OIL COOLER
GREAVES ENGINE CUMMINS ENGINE

9. COOLENT PUMP
GREAVES ENGINE CUMMINS ENGINE

10. TURBO CHARGER
GREAVES ENGINE CUMMINS ENGINE

11. AFTER COOLER
CUMMINS ENGINE
GREAVES ENGINE

12. FUEL PUMP
CUMMINS ENGINE
Greaves Engine Injector Pump

13. SPEED G0VERNOR
GREAVES ENGINE CUMMINS ENGINE

14. INJECTOR
CUMMINS ENGINE
GREAVES ENGINE
(Cracking of welding Pipe
line)

15. ECPG GEVERNOR
CUMMINS ENGINE

16. ELECTRONIC GEVERNER
SYSTEM

17. CYLINDER HEAD
CUMMINS ENGINE
GREAVES ENGINE

18. PISTON LINER

19. BY PASS FILTER
CUMMINS ENGINE
GREAVES ENGINE

20. SAFETY CUT OUTS

21. OVER SPEED CUT OUT
(CUNMMINS ENGINE)
SELECT MAKE MMR WITH
FEQUECY TRIPPING

22. LOP CUT OUT LOW COOLENT
LEVEL
1.5 BAR TRIPPING

23. ACB / UVR / ELR
1. Short circuit
2. IDMT and Overload
3. Earth Fault
400/380 VOIL 1.5 TO 2.5AMP

24. ALT ACB
CBCT
200 mA TRIPPING
CURRENT
ALTERNATER EARTH LEAKAGE RELAY

25. Earth leakage relay
S. No. Name of firms Settings
Secondary
Setting
Primary
1 M/s Design &
Prototype
600 µA 300mA
2 M/s Navago 20mA 1Amp

26. ALT ACB
CBCT
200mA TRIPPING
CURRENT
FEEDER EARTH LEAKAGE RELAY
FEEDER
CBCT
BUS COUPLER

27. SAFETY LOOP
Relay used for safety loop instead of
Darlington pair as used in conventional
Coaches (Micro switch problem)

28. SMOKE DETECTOR
PROVIDED OVER GREAVES ENGINE WITH FIRE BALL

31. Diesel oil consumption
Load Kw Lt /min Lt/ Hr
50 0.33 19.8
100 0.51 30.6
150 0.77 46.2
213 0.901 54.06
270 1.182 70.92
301 1.264 75.84
358 1.48 88.8
384 1.62 97.2

32. Lub oil Consumption
 Cummins Engine ,1 lt /72 Hrs working of Engine
 Greaves Engine , 1 lt /48 Hrs working of Engine

33. Problem to concentrate
 Ventilation Fan centre bolt, replacement of vent fan motor
Assy. WR modified end cover motor to give more strength.
 Greaves Radiator Base Frame.
 Greaves Engine monitoring gauges. Engine Monitoring
System(EMS).
 Exhaust Flexible bellow for greaves Engine.
 Over heating of Cables terminal.
 Lub oil consumption Greaves Engine.
 Fire prevention in Greaves Engine Compartment.
 Breakage of Crank shaft of Greaves Engine.
 Breakage of coupling of Greaves Engine.

34. Ventilation Fan assembly
Replaced End cover with flange

35. Alternator Crompton Greaves
Replacement of Greaves Coupling
with Cummins

36. Thermograph of Electrical system

37. Alternator supply incoming current
transformer terminal lug normal temperature is 30.80
˚ C ,Y phase temperature was 62.90 ˚ C of Y phase
,lug was loose –tighten the lug. (delta t=32.10 ˚ C)

38. NEUTRAL CURRENT
REACTOR
Block 3rd harmonic component

39. 17.Excessive neutral current in power car
Trials were conducted and it was observed that about
100 Amp full load current was flowing in the neutral
feeder.
This was attributed to third harmonics generated by the
alternators as the loads are fully balanced.
A reactor was designed by KEL and placed in the
alternator circuit. The neutral current was reduced to 1.4
Amps only.
With this it was now possible to make the earth leakage
protection system fully functional. Earth faults were
created and the protection scheme was found to be fully
functional.
M/s KEL will supply these reactors to W Rly to be
provided on all power cars.

40. LIVE INSULATION MONITOR

41. INSULATION MONITORING DEVICE
•Insulation Monitoring Device is being provided in the Imported LHB Coaches, which
gives indication in case the insulation of the system is less than the preset value of the
device.
•Insulation measuring device monitors the insulation resistance of unearthed AC three
phase four wire AC .
•A measuring Special Hi frequency-low voltage is created in the device. One pole of
measuring device connected to the Star point and the other pole is connected to earth
through an electronic measuring circuit.
•These terminals are permanently monitored and in case of failure (when ohmic
insulation between mains and earth falls below the set value and closes the measuring
circuits) a signal LED flashes and a luminous display on the switch cabinet door is
activated.

42. Ensure Thermo Imaging of Power Panel on
Load
Check and ensure proper
cleaning of
radiators. Clean by water jet
machine 4.9-5.6
kg/cm2 (70-80 psi) with OGR
and ID-27 or
any other suitable cleaning agent
MAINTENANCE
SCHEDULE

47. Modifications :
Problem The Engine was not stopping when radiator motor
gets failed.
Solution The control Circuit was suitably modified to ensure
the engine tripping in the event of radiator motor
failure.

48. 15.Isolation valve for diesel tank in power car
Diesel tank consists of two halves connected through a
pipe.
There has been a case were entire diesel has been
wasted due to damage to tank due to cattle run over.
Now a isolation valve has been provided in between the
two halves to avoid this waste of diesel in cases of
exigencies.
Now a days RCF providing Metal flexible pipe line in
place of rigid steel pipe line, which get chocked within
year as it is meant for water.

50. 3 Interlocking of fire alarm with the trip circuit of
the breaker of DG sets
Two smoke detectors have been provided in the
power car. One in the engine portion and other in the
switch board cabinet. At present, on detection of
smoke, an alarm gets activated. It has not been
interlocked with the trip circuit of the breakers to shut
down the DG set.