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INDUSTRIAL TRAINING ATNORTHERN RAILWAYS(COACH CARE CENTRE,NZM)

ASHWANI KUMAR (04413304912) ANAND PRAKASH GAUTAM

(00313304912) BHARAT GAUTAM (04913304912) NIKHIL KUMAR RATHI (0501304912) RAHUL RANJAN (04713304912)

History

Organizational Structure

Linke-Hofman & Busch (LHB) Coaches

CONTENTS

• Railways were first introduced to India in 1853 from Bombay to Thane. • In 1951 the systems were nationalized as one unit• Indian state-owned enterprise, owned and operated by the Government of India through the Ministry of Railways.

HISTORY

It is one of the world's largest railway networks comprising 115,000 km (71,000 mi) of track over a route of 65,000 km (40,000 mi) and 7,500 stations.

As of December 2012, it transported over 25 million passengers daily (over 9 billion on an annual basis).

2011, IR carried over 8,900 million passengers annually or more than 24 million passengers daily (roughly half of which were suburban passengers) and 2.8 million tons of freight daily.

2011–2012 Indian Railways had revenues of 

Total revenue 1119848.9 million (Us$17 billion)

Freight 696759.7 million (US$11 billion)

Passengers tickets 286455.2 million (US$4.4 billion)

Top •Ministry of railway •Railway board

Middle •16 zones headed by general manager•68 divisions headed by division railway manager

Bottom •Station masters who control individual station

ORGANIZATIONAL STRUCTURE

LHB COACHES

IV COUPLER

EXT.SUPPLY SOCKET

BATTERIES BATTERY FUSE BOX

AC PACKAGE UNIT FRESH AIR INTAKE EXHAUST

FANS

GENERAL FEATURES OF LHB COACH MICRO-PROCESSOR BASED AC PACKAGE INTEGRATED SWITCH BOARD CABINET

INTERVEHICULAR COUPLER (IVC) PANTRY EQUIPMENTS IGBT BASED BATTERY CHARGER EPOXY COATED TRANSFORMER VARIOUS LIGHT FITTINGS MICRO-PROCESSOR BASED PUMP UNIT WHEEL SET EARTHING DEVICE SMF BATTERIES FEEDER JUNCTION BOX DC-DC CONVERTERS

ALTERNATOR

Connection StarGenerated voltage 97V ACRating 4.5kWNo. Of V grooves 4

The alternator is mounted between two wheels. The V belts are attached in the V grooves on the pulley attached to the shaft and the axis of the wheel.

RECTIFIER CUM REGULATOR UNIT (RRU)

Speed Range 550 RPM to 2500 RPMVoltage 124VRating 4.5kWFull Load Current 38A

RRU is connected just beside the alternator to rectify the output of the generator.

The RRU has following functions:

1. To rectify the 3-phase AC output of the alternator through DC full wave bridge rectifier.

2. Regulator the voltage generated by the alternator at the set value.

3. Regulating the output current.

The output of the RRU is given to battery box to charge the battery .

In a non AC coaches a battery box consist of 18 cells(6V/120Ah each) ,In AC coaches 2 battery box 56 cells(2V/1100Ah each) used.

BCT is provided for external charging of the batteries at stations or maintenance lines.

Used Battery in train is VRLA (Valve Regulated Lead Acid) types advantages -

1. Topping up with water is not required.2. Periodical checking of specific gravity is not

required.3. Regular maintenance to avoid sulphation of

terminals and connections not required.

Battery and Battery Charging Terminals: -

110 V , 70 Ah , VRLA BATTERY MAIN FEATURES CONSTRUCTIONAL FEATURES • PURE LEAD -TIN PLATE ( THIN ) • 12 VOLTS BATTERY MODULE • UL 94 V-O NORYL PLASTIC CONTAINER WITH METAL JACKET• M6 (F) NO MAINTENANCE TERMINALS • CAN BE MOUNTED IN ANY ORIENTATION PERFORMANCE FEATURES• WIDE TEMPERATURE RANGE : -40 Deg.C to +55 Degree C• 400 + FULL DEPTH OF DISCHARGE CYCLES • 8+ YEARS FLOAT LIFE @ 25 Degree C• 2 YEARS SHELF LIFE • HIGH DISCHARGE RATE @ 25Degree C• RAPID RECHARGE • DEEP DISCHARGE RECOVERY

110V,70AH VRLA LIGHT WEIGHT BATTERIES

9 MODULES OF 12 VOLTS EACHTOTAL WEIGHT 235 Kgs

Rotary Junction Box is provided inside the coaches.

It is used to arrange and control the power supply to various circuit of the

coaches (e.g. light, fan) with the help of rotary switches and HRC fuses.

4 Rotary switches are connected in Rotary Junction Box:

1. The first switch is used to supply 70% light load in coach.

2. The second switch is used to supply 30% light load in coach.

3. . The third switch is used to supply fan load in coach.

4. The fourth switch is known as EFT switch.

ROTARY JUNCTION BOX

It is provided at the both end of the coach to feed the

additional supply to the adjacent coach in case of emergency.

Supply from the healthy coach may be extended to him/dark

coach by connecting wire(1.5x2 meter) for supply to the

positive and negative terminals of the EFT.

Emergency Feed Terminals (EFT)

ROOF MOUNTED AC PACKAGE UNITCAPACITY

COOLING - 22.5KW ( 6.4 TON ) HEATING - 6.1KW

•POWER INPUT - 17KVA•OPERATING VOLTAGE - 3 PHASE,415V,50HZ•WEIGHT - 630KG•DIMENSIONS - 2330X2000X500•COMPRESSOR - BRISTOL MAKE TYPE H23A 563 DBE

SALIENT FEATURES•NTC TYPE TEMP. SENSORS•SERVO MOTOR CONTROLLED FRESH AIR DAMPERS• MICRO-PROCESSOR CONTROL ( WITH RS232 PORT )•HARTING CONNNECTORS •HUMIDITY CONTROL•CAPACITY CONTROL THROUGH BYPASS SOLENOID VALVE •MOTORS ARE PROTECTED WITH THERMAL SWITCHES•ANALOGUE LP/HP DATA DISPLAY

ROOF MOUNTED AC PACKAGE UNIT

CONDENSOR FANS AIR INTAKE FOR THE CONDENSOR FANS

MCB’S

ANTI-SKID DEVICE

DISCONNECTING AND EARTHING DEVICE

BATTERY CAHRGER

SPACE FOR THE MAIN CONTACTORS

DC DC CONVERTERS

SWITCH BOARD CABINET

SALIENT FEATURES

• CAPABLE OF SWITCHNING , CONTROLLING , ADJUSTING AND MONITORING OF AIR CONDITIONING , PANTRY , LIGHTING , PUMP , SANITARY & ANTI-SKID PROTECTION .

• DIMENSIONS : 1850 ( H ) x 1280 ( W ) x 1040 ( D )

• EASY FRONT ACCESS FOR MAINTENANCE WITH SEPARATE HOUSING FOR BATTERY CHARGER , DISCONNECTING AND EARTHING DEVICES

• SEGREGATION FOR DIFFERENT VOLTAGE LEVELS

• EXTERNALLY VENTILATED

SWITCH BOARD CABINET

400 AMPS INTERVEHICLE COUPLER

IVC PLUG

IVC PLUGHOUSING ( AL. DIE CAST )

MAIN CONTACTS( 400 AMPS ) CONTROL PINS

( 25 AMPS )

TERMINALS

MAIN CABLES

FEEDER JUNCTION BOX

CARBON BRUSH( 20 x 42 x 52 )

COPPERBRAIDED CABLE

BRUSH HOLDER

DETAILED VIEW OF THE CARBON BRUSH

60 KVA TRANSFORMER WITH EPOXY ENCAPSULATION

TERMINAL BOARD

PERFORATED SS HOUSING

MOUNTING ARRGT. WITH AVM’S

• TYPE - EPOXY COATED ENCAPSULATED , WATER PROOF

WINDING

• RATING- 3ø , 50Hz , 60KVA, 750/415V

• INSULATION - CLASS H

• NATURAL AIR COOLED

• WEIGHT - 335KG ( Max.)

• DIMENSIONS - 600X530X626

• DEGREE OF PROTECTION -

IP-21 HOUSING

IP-65 TERMINAL BOX & WINDING

60 KVA TRANSFORMER

WATER PUMP WITH CONTROLLER

WATER LEVEL SENSOR PUMP BOX

• SELF PRIMING MONO BLOCK TYPE MICR-CONTROLLER BASED WITH INFRA-RED SENSOR FOR DRY RUN PROTECTION PUMP• OPERATING VOLTAGE : 3 PHASE,415V+/-5%,50HZ• POWER RATING : 200W (MAX.)• RPM : 2700• DISCHARGE CAPACITY : 10 LPM• WEIGHT : 6.5 KG• PROTECTION : IP-54MICRO-CONTROLLER• INPUT SUPPLY : 24V DC +/-10% WATER LEVEL SENSOR

TYPE OPTICAL LEVEL SENSOR WITH UNMODULATED INFRA-RED TYPE, 24V DC 20 mA HOUSED IN POLYSULPHANE ENCUMBENT

OTHER DETAILS OPERATING AT 0-100 LUX AT 30HZ WITH PRESSURE WITHSTANDING AT 10 BAR AT 60ºC ,INTERFACE PIPE THREADING 3/8”

WATER PUMP WITH MICRO-CONTROLLER AND SENSOR

AIR CONDITIONING SYSTEM

Principle of Operation of the AC System:

LATENT PRINCIPLE

EXPANSION PRINCIPLE

THE REFRIGERATION CYCLE

TYPES

• FLOURESCENT TUBES 18 WATTS

• INCANDESCENT LAMPS 10 WATTS ( FOR NIGHT LIGHT AND PANTRY)

• HALOGEN LAMPS 10 WATTS ( READING LIGHTS )

FLOURESCENT TUBES USED AS GENERAL LIGHTING , VESTIBULE , TOILET , PANTRY

AND EMERGENCY WORKING AT 110 VOLTS AC/DC WITH INVERTER

AND WITH POLYCARBONATE DIFFUSERS

TECHNICAL DATA OF THE INVERTER FOR FL. LAMP ( SIZE - 48x36x252 )

NOMINAL INPUT VOLTAGE 110 V AC/ 50 Hz ( 88 -138 V RANGE )

TECHNICAL DATA OF THE INVERTER FOR READING LIGHTS ( SIZE - 36x31x296 )

NOMINAL INPUT /OUTPUT VOLTAGE 110 V DC / 12 V DC

POWER 0 - 60 W / 12 V

COACH LIGHTING