Power Factor of coaches

Load of EOG Coaches:

• 3AC/2AC:      40 KVA
• Pantry:           60 KVA
• Power Car:    80 KVA
•  
• IV Coupler rated for 750 V, 250 Amps
•  
• One enegine can take 7 coach load. ( 200 Amps)
•  
• Power factor:  0.6 lag
• Induction motors have poor power factor at light loads.
•  
• EOG coaches in IR: 1500

HOG Modification

Following modifications are planned:

100 VA Transformer: two nos. in each coach for control circuit supply.







RC Filter: to control harmonics in output filter.






Power car modification: Changeover Switch, UIC coupler, IV Coupler and power cabling

Charging R-22 in RMPU

System of tool talk started in maintenance depots

We have seen loudspeakers used by unions. We have given PA systems now to staff to utilise this energy to do "TOOL TALK" - a sfety cum work planning meeting just before staff and supervisors go to a rake for primary maintenenace.

Use of Thermal Gun

Thermal imaging gun is very useful toolto detect any hotspot after train arrival in electrical coaching.
This video created in Wadibunder depot is for education of electrical coaching staff.
Here we made a joint loose.
initial temp was 24 degrees . in two minutes it reached to 34 degress.
lesson:- loose joints can be detected by thermal gun

Underslung compressor schedule

Indian railway is still left with 1000 odd underslung AC coaches.
It is very important to maintain these compressors properly. Specially after R134 conversion

Types of HRC Fues : An inventry challenge

CESE Conference( 3rd Jan-2014) points

• For AC/Non ASC cocahes, Mobile cvhargers should be of 5 pin with 1 amp  glass fuse. RDSO to issue scheme.
• 3rd AC Coaches to have 10 Ton RMPU. RCF to do.
• RDSO to advise RMPU filter replacement peridicity.
• RDSO to advise OHP sensotr location in RMPU.
• RDSO to suggest SS conduits for LHB feeder cables instead of trays.
• Vane relay design to be made interchangeable.
• RDSO to advise making RBC underslung.

440 V 3 phase Rotary Changeover Switch

 Recenty we had a case of burning of rotary changeover switch.

 This coach was working on emergency mode.

 The box in which these two incoming and two outgoing cables are fixed is too cramped.

 Surprisingly this item is yet to be brought into primary maintenance schedule !

BLDC Fans

Two types of fans. Can you spot the difference? These are BLDC fans. In earlier design we had sensor magnets, now we have without sensor magnets. Latter are more reliable.

ELD of 25 KVA Bulk Inverter

 ON Board inverter ELD

 Current Sensing

Siemens

Safety settigs related to Heaters

LHB RMPU:-

Sensor setting:-       65 deg. cent.

ESTI setting:-         130 deg. cent.


Conventional RMPU:-

OHP Setting:-         85 deg cent.

DM Plant: An important M & P of electrical coach care

DM water stands for De Mineralized water. Theoretically it is water not containing any minerals or salts. Practically in most applications water from which all Ca and Mg salts are removed is termed as D M Water. Very high purity D M water is usually used for pharmaceutical preparations, High Purity Chemicals synthesis and boiler applications where scale formation is not desired at all. 
De-Mineralisation can be made by a number of processes. It includes Electro-De-ionisation. Ion-exchange, Reverse Osmosis and Distillation / Solar Distillation. Softening - removal of Ca and Mg ions is done in most cases by chemical method - as pre-treatment for efficiency improvement of most methods. 
Typical plant will consist of the following parts : (Considering Ground water or sea water as feed) ---> Chemical pretreatment with alum or other chemicals, Chlorination or Ozonation, Clarifier and Multi-media filters, Ion-Exchanger or Reverse osmosis membranes. Ultimate design will depend on end-use.

OPERATION AND MAINTENANCE OF DM PLANT

OBJECTIVE : Objective of this procedure is to provide operation and maintenance instruction of Dematerialization Plant  (DM Plant) as per safety and cGMP requirements.

SYSTEM REQUIREMENT: A number of minerals readily dissolve into raw water. DM Plant  removes mineral salt by an ion-exchange process from the raw water. After demineralization water passes through the fine filtration and UV sterilizer so that the water meet all the specification of pharmaceutical for purified water

SYSTEM DESCRIPTION:

The Indion Packaged Up flow DM Plant consists of water feed pumps (one working one stand by) with motor, activated carbon filter, strong acidic Cation unit, strong alkaline anion unit, Mixed bed unit, 5 micron filter, UV sterilizer, inter connected pipe work with valves & ejectors, pressure gauges, flow meter, conductivity meter etc.,

In Activated carbon filter (ACF), Activated carbon used is in granular form which is filled in mild steel pressure vessel. ACF eliminates suspended solids and absorbs most pollutants dissolve in water like detergents, phenols, obnoxious gases like chlorine & sulphur dioxide. It also helps to reduce the impurities like colour, taste etc.

Cation Exchange column of MSRL material contains strongly acidic Cation Exchanger resin. The Cation Exchange material, which exchanges Cations such as Calcium, Magnesium and Sodium for hydrogen ions to form the corresponding acids. This process is reversed when the resin is regenerated by hydrochloric acid through column.

Anion Exchange column of MSRL material contains a strongly basic Anion resin.  The strongly basic Anion Exchanger will remove the acid formed by the cation exchange material and producing water, which is free from dissolved solids. This process is reversed when the resin is regenerated by Caustic Soda solution Mix bed Exchange column of MSRL material contains Cation and Anion resins and thoroughly mixed with compressed air.  When the water passes through Mixed Bed Column the traces of dissolved salt leaked out will be retained in the Mixed Bed Column.

Conductivity meter is used to show the purity of dematerialized water. The conductivity is proportional to be the residual ionized solids in the water. Low conductivity indicates water of high purity.

5 micron filters with SS housing removes the particular impurities from the water.

UV as disinfections is used for removing microbial reduction.

The unit is fitted with all necessary piping, valves & ejectors from the raw water inlet and to DM water outlet.

Berth Reading Lights

We could have avoided inventory by using either of pin or screw type lamps.

Stopper Failures

WE should respect T and P

It has been observed that:-

• ·        LED Torch supplied by railways have been kept at home by staff.
• ·        Hygrometeers for measuring specific gravity is not being used by staff.
•      Two lamp test box supplied for earth leakage testing not being used by staff.
• ·       Hardness tester not being used by staff. 

  There are many more tools and plants like multimeters, torque wrenches, tong-testers etc which were purchased and distributed to staff. Many such tools got failed in warranty but rake supervisors never reported and we could not claim warranty.

That’s why tool talk is important. You can check fro tool distribution register what tools have been given to staff and can question them why they have not brought the tools. 

SMI and MS book relaased by CEE

Division published two booklets of compilation of all SMIs and MSs related to electrical coach care.

Doing away with power cars / generator vans?

First ACCI Lobby in Indian Railways

Before

After 

Indian Railways first ACCI lobby was made functional at CSTM in Central Railway in 2014. Earlier we had lobbies only for Crew, poor ACCIs were left out.

Inside Engine Room of Power Car

Alternator manual with how many cells?

alternator spec:  http://www.rdso.indianrailways.gov.in/works/uploads/File/SPEC_AC_0013(Rev%202).pdf

We are in habit of using 6 cells ( 12 V) for doing field supply manual of 25 KW alternator in AC coaches in case of RRU/ERRU failure.

Henceforth this activity should be done using tap from across 8 Cells ( thus giving 16 Volts approx). This is needed since most of the time batteries are already drained and we don’t get even 12 V from  6 Cells.

Table below relates train speed with RPM:-

Speed for Alternator output	RPM	KMPH
Cut in speed (below which no gen)	400	22
	500	30
Minimum speed for full output	930	51
	1500	82
	2500	136
	2800	156

LHB RMPU Pictures

Condensor fans on top.

Inside RMPU

Canvas Duct of LHB coach

 Canvas duct of LHB coach ducts are exposed to atmosphere. They get torn . How to overcome this problem?

Battery Charger

The non LHB AC Coach battery charger in the coaches is used for external charging of the batteries.

AC Coach Rotary Switch