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Saturday, April 5, 2014

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.
              
                      


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.



       
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.

    
 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.


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.

        
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.

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:

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.

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

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

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

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 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.

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.

DISCRIPTION OF DIFFERENT TYPE OF MOTOR

CONDENSER MOTOR:
This motor is used in coaches for driving fans. The specifications of the motor are as follows:

Voltage                           :                    110 Volts
Power                             :                     1.25 HP or 1KW
Current                           :                     9.1 Amp
No of slots                      :                     25
Conductor gauge            :                     17
Winding type                  :                     Wave (triplex)
Stator Winding                :                    Compound


BOLWER MOTOR:
It is a DC series motor used in AC coaches. Its specifications are follows:

Voltage                            :                      110 V, DC
Power                              :                       0.67 HP
Rotor Winding                :                       Wave (triplex)
Commutator Segments   :                       25
Coil Pitch                        :                       75
Coil Span                        :                       1-7
Stator Winging               :                       Series Winding




SERIES MOTOR:
It is also used for driving fans. Its specifications are follows:

Supply Voltage                     :                           110 V DC
Power                                    :                           36 W
Current                                  :                           0.33 Amp
Wire gauge                            :                           32
No of Slots                             :                          12
Commutator segments           :                          24
No of Poles                            :                          2
No of Coils                             :                         12 each, 80turn, 2 layer


3-Ф SLIP RING INDUCTION MOTOR:
Its specifications are as follows:
Wattage                                  :                         4.5 KW
Speed                                     :                          940 rpm
Power                                     :                         6 HP
Slots in stator                         :                         45
Slots in rotor                          :                         36
Wire Gauge                           :                          18 SWG

No of Poles                            :                          6

GENERAL ELECTRICAL REPAIR SHOP


Different type of electric motors, electric generators, welding transformers are repaired overhauled in general Electrical Repairing Shop.
Ø  Electrical motors such as Compressor motors , Blower motors, Single phase series motors,
Three phase induction motors.
Ø  Electric generator such as Alternator (4.5 KW, 18 KW, 25KW) and D.G. set.
Ø  Welding plant transformers are repaired and overhauled.
There are separate section in this shop to perform different tasks:
1.      Alternator overhauling and rewinding section.
2.      Alternator testing section.
3.      Electric POH and testing lab section.
4.      Electric motor and rewinding section.
5.      Vacuum impregnation plant and furnace section.
6.      Welding plant over hauling section.
7.      DG set repair section.
8.      Electro planting section.

4.5 KV ALTERNATOR:
Technical Description
Voltage                              :                  120 V DC
Current                               :                 37.5 Amp
Cut in speed                       :                 358 rpm (211.5 km/hour)
Min speed for full output   :                 550 to 600 rpm
Maximum speed                 :                 2500 rpm (30km/hour)
Setting on regulator            :                 Voltage setting 124 V DC
                                                              Current setting 37.5 Amp
Principal of operation:
                                 The alternator consist of two sets of winding namely AC winding and field winding, both accommodated in the stator. The AC windings are distributed in small slots and field windings are concentrated in two slots. Each field coil spans half the total no. of slots. AC coils are connected in star and field coils are connected ion series.

The rotator consisting of stacked stamping reassembles a cogged wheel having eight sets of teeth and slots, uniformly distributed on the rotor surface skewing the rotor axis.

The core the stator which is completely embraced by the field coil will retain a residual magnetism if excited by a battery once. The fluxed produced by field coils find its path through the rotor. When the rotor is rotated the passage of the rotor teeth and slots alternatively under the field offers a varying reluctance path for the flux produced by the field coils. This flux which varies periodically links with the AC coil and induced alternating voltage in the AC coil. The frequency of the induction voltage depends on the speed of the rotor. The magnitude depends on the speed of rotor and level of excitation. The field is strengthened by a positive feedback system in the regulator to attain the desired output voltage.


The regulator/rectifier unit has following main function:
Ø  Rectifying the 3 phase AC output of the alternator to DC using full wave Rectifier Bridge.
Ø  Regulating the voltage generated by the alternator at se value.
Ø  Regulating the output current at set value.
The regulator rectifier unit consists of following basic parts.
Ø  Power Rectifier
Ø  Voltage Regulator
Ø  Excitation Transformer
Ø  Voltage Detector
Ø  Magnetic Amplifier
Ø  Field Rectifier Unit
Ø  Free- Wheeling Diode
Ø  Rectifier Bridge
Ø  Current Regulation Circuit
Ø  Over Voltage protection Circuit

Testing of Alternator:
The alternator is testing by direct loading. The shaft of the alternator is rotated through a prime mover (Synchronous Motor) and following specifications which are given at half load are tested:

Specification
          ALT-1
        ALT-2
         ALT-3
Rating
         4.5KW
      1800 KW
        25 KW
Speed (rpm)
         1500
        1500
        1500
Current (Amp)
           19
         70
          97
Voltage (volts)
         127
        127
        127



Data for 4.5 KW Alternator at full load:
Current                         :                      37.5 Amp
Voltage                         :                     122Volts

Speed                            :                     600 to 700 rpm