TRAIN LIGHTNING SHOP

The shop deals with the periodical over haul of the fans, batteries and the rotary switches used in the train. The basic details of the equipments over hauled in this shop are as follows:

Fans:                 

The fans used in the train are mainly of two types:

1.                  DC fans

2.                  AC Fans

DC Fans:

This type of fan is mainly used in the general and sleeper compartments of the train. DC series motor is used in this type of fan. It works on 110 volts dc supply. The ratings of this type of fan are 110 volts 2 amp.

It has lap winding on the armature circuit at an angle of 90 degree. The stator consists of field coil and two poles. These poles are magnetic poles. It has two ball bearings one at the top and other at the bottom. It has two carbon brushes, carbon cap and carbon holder for ball bearing. The winding is made up of copper wire. The insulation between windings is done through glimmer paper of 5mm thickness.

AC Fans:

This type of fan is used in the AC compartments of the train. It is singles phase capacitor run type fan. The motor used in the fan is an induction motor. The ratings of this type of fan are as follows:

Voltage: 230 volts

Current: 0.5 amps

Speed: 350 rpm

The stator winding is divided in two parts; auxiliary winding and main winding. These windings are in parallel with each other. A capacitor is joined in series permanently with the auxiliary winding both in starting and running condition.

These fans are quiet, self starting, efficient, smaller and need less maintenance. These fans can be fixed on moving type. The moving type fan has a grumble ring on which the fan rotates.

Fan testing board:

The fans who are POH have been done are tested through fan testing board for proper working and efficiency. It has ammeter, voltmeter, and wattmeter. The voltage setting for dc fans is 110 volts and for ac fans is 230 volts. The load current should be in between 0.28-0.40 amp. The IR value (insulation Resistance) should be 20 Mega ohms minimum.

Batteries:

Batteries are one of the most important requirements of the train. When the train stops and the alternator stop working battery takes the full responsibility of train lightning. These cells are designed for rugged service. This shop deals with the periodical overhauling and maintenance of these batteries. New cells are initially charged and old cells are periodically overhauled in this shop.

Initial Charging:

The filling plugs are removed and the cells are filled with pure Sulphuric acid previously diluted to specified specific gravity to the maximum indicating mark.

Specific Gravity for filling in new cells	1.190
Specific Gravity of electrolyte at the end of charge	1.21. to 1.215
Maximum permissible temperature of electrolyte during charge	50 degree.

These batteries are allowed to stand for 12 hours. The electrolyte is stored to original level. The battery should be charged at first charge current of 3.5 amp per set for 80 hours. After 18 hours specific gravity and voltage of the cell should be measured. Specific gravity should be in between 1.210 to 1.220 and voltage should be in between 6.3 to 6.4 volts per mono block or per cell. These batteries are given rest for 12 hours.

These batteries are then discharge through discharge plant at rate of 12 amps per set. After discharge specific gravity should not be less than 1.110 and voltage should be 4.5 volts.

Normal Charging:

The normal charging is done at rate of 12 amps per set up to a min of 12 hours. The specific gravity should be in between 1.210 to 1.220. Specific gravity is rated so because the internal resistance of the electrolyte is min in between.

These cells are then given rest for 8 hours and then they are ready for use.

Trickle charging:

Trickle charging is also known as slow rate charging. If the cells are not used they are charged as slow rate i.e. 3.5 to 4.5 Amps per set.

Slow rate charging is also used as a treatment for POH. During this process the electrolyte is taken out and the cell is filled with distilled water. Then they are charged at rate of 3.5 amps per set for 80 hours. After 80 hours all cells are opened and distilled water is poured out. An electrolyte of specific gravity 1.250 is filled and cells are normally charged at rate of 12 amps per set for 12 hours. Then they are discharged at a rate of 12 amps per set. Then they are again charged at rate of 12 amps per set.

POH of old batteries:

Periodical overhauling of old batteries is done to check whether they are in condition for further use or not. In this process old cells are charged for 16 hours at rate of 12 amp per set. Then their specific gravity is and voltage is measured. If they are more than 80 % of the standard values, then they are discharged at rate of 1 amp per set for 8 hours. These batteries are then again charged for 8 hours at rate of 12 amps per set.

Rotary switch board:

Rotary switch board is also known as upper frame junction box. This junction box has two main junctions positive and negative. The positive and negative terminal from the upper frame terminal and the four positive and three negative distributions wires of SPM meet at this junction box. All positive terminals meet at the main positive and the negative terminals meet at man negative.

The main negative has a HRC fuse (High rupturing Capacity) in series of 32 amps. The main positive has 4 points. All 4 points have a HRC fuse of 16 amps each in series. Three rotary switches are connected in series with three of the points. The fourth point work as an emergency terminal. In case the light system of the coach fails it provides emergency light to the coach through EFT from other coaches.

Rotary switch 1 is for light 1 which provides 70% of the light in the coach. Rotary switch 2 is for light 2 which provides 30% of the light in the coach. It is responsible for the light in the galleries and the night light. Rotary switch 3 is for fans. In the entire junction is responsible for the lightning system in the coach.

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POWRE HOUSE

Power is supplied to the entire workshop with the help of two feeders north and south. If any fault occurs in any one of the two feeders, then total supply is given by the other feeders. The feeders take supply from HYDEL comes into HT panels of the power house. In the HT panel there are OCB’s and MCCB’s which trip down to off position in case of any fault. These OCB and MCCB work as protective devices. The power is step down as required by transformers of different ratings. The specification of the transformers are as follows:

Transformer no.                                                   Details of transformer

1                                                                                                                                           For 3.3KV incoming 11/3.3 KV, 750 KVA  installed on Oct 1969

2                                                                                                                                           For 3.3 KV incoming , 750 KVA installed on Oct 1961

3                                                                                                                                            For 500 KVA DG set 11/3.3KV , 1000 KVA installed on Oct 1961 , Reinstalled in 1997                                   

4                                                                                                                                           Disconnected from 11 KV supply 11/3.3KV ,1000 KVA

5                                                                                                                                           For auxiliary and office 3.3/.44KV , 500 KVA installed on Jan 1958

With the help of these transformers supply is converted into required voltage and is fed to the substation 1, 2, 3, 4, 5&6, hospital feeder, GM office , loco shed and colony feeder.

In cases of power break down there is a voluntary arrangement for power generation through a D.G set (diesel generator) of 2250 KW. One of its units is of 1750 KW and other is of 500 KW.

The specification of its two unit is as follows:

1750 KW D.G. SET

Type                         :          AK132M53                                                                                                     Engine Maker          :          DLW,Varanasi,16Cylinders                                                                                Power                       :           1750                                                                                                           Speed                       :            1000 rpm                                                                                                  Power factor             :            0.8                                                                                                     Phase                       :             3-Φ                                                                                                           KVA                       :            114.8                                                                                           Poles                       :                   6                                                                                                               Frequency                :               50 Hz    

Excitation Voltage   :               65 Volts                                                                                          Excitation Amp        :              1100 Volts or 11KV                                                                     Connection                :                     Star (Y)   

Generator unit maker:            BHEL, Hyderabad, India

500 KVA D.G. set:

Type                       :       AC                                                                                                                      KVA                      :            500                                                                                                                  Speed                     :            1500 rpm                                                                                                        Voltage                   :                 415 Volts                                                                                           Current                    :              696 Amp                                                                                                      Frequency                :               50 Hz                                                                                                      Excitation Voltage   :               73 Volts                                                                                                 Excitation Current   :           2.1 Amp                                                                                              Connection              :                     Star (Y)                                                                                       

Power factor            :               0.8                                                                                                 Phase                       :    3-Φ                                                                                                         Frequency               :     50 Hz                                                                                                           Makers                    :   Kirloskar Electrical Ltd.

Preferred units of 1750 KW D.G. set:

Ø  Air compressor unit, Air tank.

Ø  Fuel oil tank.

Ø  Lube oil cooler and filters.

Ø  Air filters.

Ø  Pre lubes assembling.

Ø  Water pump.

Ø  Turbo super charger.

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DISEL ELECTRIC POWER PLANT

It is a poniard in which a diesel engine is used as a prime mover for the generation of electrical energy. The diesel engine obtains energy from a liquid fuel usually called diesel oil and converts it into mechanical energy.An alternator or a DC generator mechanically coupled to the diesel engine to convert the mechanical energy into electrical energy.

                                             A diesel electric power plant is also included in this workshop to supply the electric power in absence of both north feeder and south feeder. It works to generate the required electrical power for the workshop.

              

                      

 ELEMENTS OF DIESELELECTRIC POWER PLANT:

Diesel Engine:

This is the main component of the power plant which develops power. This may be horizontal or vertical type. The horizontal type diesel engine is used in this workshop. These engines are available in low, medium and high range. Speeds commonly used are in the range of 5000 to 1000 rpm. The rating of an engine which should be specified correctly is the net output in KW developed continuously at the crank shaft coupling by the engine in good operating condition, at a height of less than 450 m at a temperature of 32 Deg C and barometric pressure 717.5mm Hg.

ENGINE AIRINTAKE INCLUDING AIR FILTERS, DUCTS AND CHARGER:

       

The air filter are provided to remove dust and other suspended impurities from air to be supplied to the engine. The super charger is usually employed to increase the pressure of intake air above atmospheric Ozone in order to develop an increased power output. The air is drawn from outside the engine room and delivered to the Intel manifold through ducts or pipes and filters. In cold season the intake air is heated by the heat from exhaust gases.

ENGINE FUELSYSTEM INCLUDING FUEL TRANSFER PUMPS, STRAINERS, HEATERS AND CONNECTING PIPEWORKS:

    

 Fuel transfer pumps are required to transfer fuel from delivery point to storage tanks and form storage tanks to day tanks and then to engine. Strainers are provided to remove suspended impurities and thus ensure clean fuel supply to the engine. Heater are required to clean the oil especially during winter season.

Engine exhaustsystem including silencer and ducts:

This system is provided to discharge the engine exhaust to the atmosphere outside the building. The temperature of exhaust gas is high so its heat is utilized in heating oil or air supplied to the engine in winter season.

Engine coolingsystem including pumps, tower or spray ponds, water treatment or filtrationplant and connecting pipe:

        

In engine the heat is generated due to burning of and it uses partially gets converted into useful work. The remainder is wasted as heat in the outgoing exhaust gases and in heating the engine, and if not removed may disintegrate the lubricating oil film on the cylinder walls and damage the cylinder liners, head, walls piston and rings.

         So small engines may be air cooled but large engines mostly make use of forced water cooling cooled cold water is send through the cylinder jacket with the help of a pump. The hot water is cooled in spray pond and is circulated. The water used for cooling engine cylinder is softened by water filtration plant in order to avoid formation of scales etc. in it. Hot well is provided in surge tank to make a provision for expansion of jacket water.

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MANUFACTURING SHOP

In manufacturing shop different type filtering and items used in coaches are manufactured. The different type of items are manufactured in this shop are listed below:

1)       M.S. Battery Box Standard.

2)       M.S. Battery Box Door Standard.

3)       M.S. Battery Box Door Modified.

4)       M.S. Anti Theft Rod

5)       Tube Light Wire Guard

6)       E.F.T Cover Styling Square

7)       Flux Type Square Light Filtering for SLR Coach

8)       M.S. Sheet Packing ‘U` Type

9)       Panel Hanger for Alternator

10)   Light Bracket

11)   Fan Bracket

12)   TPIC Switch Junction Box for AC

13)   Bus Bar Box for AC Coach

14)   Liquid Receiver Guard for AC

15)   Compressor Front Cover for AC

16)   M.S. Battery Box for AC Coach(1800AH)

17)   L Clamp for AC Coach

18)   U Clamp for AC Coach

19)   M.S. Plate 20x10 cm for AC Coach

20)   Tension Rod Pin for Alternator

21)   Base Plate for (Tangle Switch Housing/Tube Light Filtering)

22)   Rubber Cleat with M.S. base

23)   Wooden Cleat with M.S. base

24)   Compressed Ply Packing

25)   Bakelite Terminal Base for Welding Plant

Different Types of machines used in manufacturing shop are:

TURNER:

This machine is used to cut and turn the wood in different shapes and sizes .The specification of this machine is as follows:

Type           :    3-phase induction motor

Current       :     8 Amp

Speed          :    720 rpm

Voltage       :    420 Volts

Power          :     3.7 K.W.

SHEARING   MACHINE

This is a multipurpose machine .Different types of rods, angles and M.S. sheet are cut and punched with the help of this machine.

DRILLING MACHINE:

This machine is used for drilling holes in different types of sheets and rods .The specification of the drilling machine installed in this shop is as follows:

Type           :               3-phase induction motor

Voltage       :              420 volts

Speed          :              1455 rpm

Connection   :             star connected

WELDING TRANSFORMER:

The welding transformer is used for welding the joints in different items manufactured by this shop. The specification is as follows:

Type                            :                 ac/dc 3-phase

Input Voltage              :                 440 volts

Output Voltage           :                 62 volts

Input Current              :                 16 amp

Output Current           :                 440 amp

Automatic welding     :                 300 amp

Welding Current        :           50 -450 Amp

CENTRE LATHE MACHINE

This machine is used to cut and finish the job of different shapes and sizes. The specification of this machine is as follows:

Type      :    3-phase 16 LG/6 8” Centre F.T. gap Bed, Vee Belt drive

Power    :      3 H.P.

Voltage    :    400/440 volts

GRINDING MACHINE:

This machine does the work of grinding the job. The given job is finished smoothly by this machine. The specification is as follows:

Voltage     :     400 volts

Speed       :       2850 rpm

Power     :         63 H.P.

With the help of these machines the different types of jobs are cut, punched ,drilled, welded and finished .These manufactured items are now used in different parts of train for different purpose.

Working of different fittings:

Working of different fittings in a particular coach is following:-

Alternator suspension pin is mainly manufactured to hang alternator below the coaches so that it can produce electricity without falling.Square light fittings are manufactured for light guards of bulb.Tube light fittings are manufactured for light guard of tube light .These fittings are made by knitting of thin wires which protect the tube lights from external damages and prevent it from falling.

EFT (emergency feeding terminal) is manufactured for emergency purposes which is clear from its name. When any coach is unable to provide supply to its electrical equipments then it takes supply from adjacent coach and adjacent coach provides supply through the terminal that is emergency feeding terminal. Generally four EFTs are fitted in a coach, two for each side of coach.

EFT covers are manufactured to protect EFT from environment factor and to protect insulated steel body of the coaches through which electricity do not flow otherwise it may lead to an accident.

Battery boxes are manufactured to keep the batteries below the coaches, which is made of wood or steel.

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WELDING OF TRANSFORMER

The over hauling of welding plant transformer is also done her. It is a 440/80 Volt transformer. It has a junction circuit breaker. It has three controllers: one for on/off function, one for slow working and one for fast working.

ELECTRONIC BLAST:

The electronic blast is used in tube lights for its proper working. The electronic blast consists of following parts of specified ratings:

Name of Equipment	Remark	Ratings
Choke	1	11W, 110V   18W, 110V   20W, 110V
Electrolytic Condenser	5	10 µFarad, 450V   11 µFarad, 60V   100 µFarad, 50V   10 µFarad, 50V
Capacitor	5	0.22 µFarad, 400V
Resistor	10	2.2Ω, ¼ W   47Ω, ¼ W   470, ¼ W
Biasing Coil	1	_________________________
Transistor	1	1 MJE,1300S, NPN,   100N, 1NPN
HRC	3	6565
Diode	4	IN4007
Diode	4	IN4148
Resistance	2	16kΩ

PRE COOLING TRANSFORMER:

         

The pre cooling transformer is used in AC coaches. When the train stops at any station for more than 10 mins and is loaded with passengers, then the pre cooling transformer is attached to the main supply of the coach. This is done to maintain the comfort temperature of the coach because the batteries are not designed to bear so much load for such a long time. The pre cooling transformer is a 200 Amp, 440/220volts transformer. A rectifier is attached to this transformer which changes AC to DC. The 3-Ω supply is given to HRC fuse. ML4 contactor is connected to these fuses. The rating of this contactor is 70Amp, 415Volts. The supply is given to the rotary switch which is a 4 pole, 4 way, 63 Amp switch. The primary coil of transformer consists of two type of winding – fine and coarse.

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