Professional Documents
Culture Documents
Indian Railways: North-Western Railway Workshop
Indian Railways: North-Western Railway Workshop
NORTH-WESTERN RAILWAY
WORKSHOP
PROJECT REPORT
1.ACKNOWLEDGEMENT
2.INTRODUCTION
3.ADMINISTRATIVE HIERACHY
4.POWER SHOP
5.TRAIN LIGHTNING SHOP
ALTERNATOR AND RCR SECTION
FAN SECTION
TRAIN WIRING SECTION
BATTERY SECTION
6.ELECTRICAL PCO SHOP
7.AC SHOP
CONVENTIONAL COACH
ROOF MOUNTED COACH
ACKNOWLEDGEMENT
Theoretical knowledge of every student of Engineering College takes
training according to his own branch in a well-established factory or an
organization in which work is being done practically and how practical work
is managed in normal condition. I am grateful to Prof. Sanjay Bhandari, the
Head of Training and Placement Department, and Prof. Ashwani Joshi, the
Departmental Head of Training and Placement Department at JIET Group of
Institutions for giving me the permission for training.
DURATION:-
From 8th jun, 2018 to 15th july, 2018.
GUIDED BY:- Nitin sir
The electricity is supplied by RSEB (Rajasthan State Electricity Board)
and is also generated by generator sets in case of supply failure. The
requirement of electricity in workshop is as follows:
Railway Workshop has its own 11/0.4 KV substation, the incoming feeder of
11 KV is coming from 66 KV Mohanpura Pulia Jodhpur. The main equipment
of the substation are as follows:
1. Insulators
2. Metering and Indicating Instruments
3. Instrument Transformer
4. Capacitor banks
TRANSFORMER:
CIRCUIT BREAKER:
Make or break the circuit either manually or by remote control under normal
conditions.
1. Break a circuit automatically under fault conditions.
2. It makes and breaks the normal operating current.
DETAIL OF SUB-STATIONS:
SPECIFICATION OF MEGGER:
MEGGER: It is equipment for checking the insulation level of any
equipment. It is available in different ratings in a wide range. It is based on
the bridge balance method. Its scale is non-uniform. The rating of the megger
is:
Variable Voltage 250 volts
Calibration In terms of Mega ohms.
Scale Nonlinear
Range 0Ω to infinite Ohms (≥50Ω)
Rotation 160 RPM for producing full
250 volts.
In the previous brush paint hand method, the varnish layer was improper and
problem of wet varnish inside winding, which may cause problem at the time
of working, this was because there was not any system by which we can dry
the inside varnish, also varnish layer was not properly established on the inside
winding. That’s why need of VACUUM PRESSURE INSULATING PLANT
(VPI) is considered.
Its cost is very much nearly 25 lacks, which was beyond the limits of
workshop. Then some innovative minded people made this plant of their own
in the workshop, with just at the rate of nearly 2.1 lakhs. Also it is worth to
note that the scrap material or we can say already available material in the
workshop is used in the manufacturing of this plant, like compressor,
compressor motor, heating element and its box.
OPERATION:
Step1: Open valve 1, 3, 6
Close valve 2, 4, 5
Start vacuum pump
Step3: Open valve 4, varnish will start flowing into the VPI Tank Close valve
4 when the electric component is completely submerged in the varnish.
Step5: Close valve 3 and 6. Start the compressor build pressure in air tank 3
and 6. Stop air compressor when pressure gauge shows 3 to 4 kilogram
pressure.
Step6: Open varnish to storage tank. Open valve 1, 2, 4 and keep these valves
open till the VPI tank empties.
Step7: Close valve 1, 2, 4 in series wait for 15 minutes. Open the top lower
take out the component. Put the component in the oven for curing.
Step8: Cure the oven for 8 hours at 1200C and for 4 hours at 1500C.S
ELECTRIC SAFETY:-
Electricity has become as important as air, water & food in human life. Life
without electricity is not imaginable for its use in different form has so deeply
entrenched into our lives.
Unlike food & water but like air it is life supporting if in control but
devastating when out of control. Hence, the saying “Electricity is a good
slave but bad Master”. PUBLIC SAFETY IN PUBLIC utilities is globally
achieved through three tier structure.
Personal Protection:-
2. Always wear safety glasses with side shields when working with shop
equipment
3. Wear approved hard hats whenever there is a chance of objects falling from
above. In addition, wear suitable gloves for the job at hand when working
with the following:
Sharp-edged stock
Unfinished lumber
Safety Guidelines:-
Follow these guidelines for general shop safety:-
1. Know the hazards associated with your work. Be sure you are fully educated
on the proper use and operation of any tool before beginning a job.
2. Always wear appropriate safety gear and protective clothing.
3. Wear nitrile gloves when cleaning with degreasers or ferric chloride.
4. Maintain good housekeeping standards.
5. Keep the work area free from slipping/tripping hazards (oil, cords, debris,
etc.).
6. Remove sawdust, wood chips, and metal chips regularly.
7. All containers must be labeled with its contents.
8. Leave in place and utilize all shielding on tools and equipment.
9. Know where fire extinguishers are located and how to use them.
TRAINTRAING &
LIGHTNING SHOP
DURATION:-
From 16th Jun, 2018 to 26th Jun, 2018.
Some diodes make up the positive and negative half of the main three-phase
bridge rectifier, which receives the three-phase AC input from the alternator
and gives a DC output to DC positive and DC negative.
The current transformer senses in all three phase. The secondary of which has
a burden resistance to divert the secondary current into voltage. This AC
voltage is rectified by diodes and fed to the voltage divider chain. The voltage
output is rectified and fed separately to another voltage divider chain. These
two sensed voltage are compared with the reference voltage of the Zener diode
and subsequently fed to the control winding of the magnetic amplifier. This
enables the magnetic to act as an ON/ OFF switch for controlling the alternator
field current in turn the alternator output voltage.
SOME APPLICATIONS OF THE RECTIFIER CUM
REGULATOR:
The bridge connected by silicon diode rectifies the three-phase output from
the alternator. The DC excitation to the field is obtained by full wave
rectification of AC current provided the field transformer and the load winding
of the magnetic amplifier.
The voltage induced in the alternator winding is dependent on the speed of the
revolution of the rotor and on the excitation current. In the absence of the
voltage detector and the magnetic amplifier, the voltage of the alternator will
rise indefinably due to the positive feedback limits only by the saturation on
saturation. But as soon as the preset voltage is reached, the Zener diode
indicator DT1 is conducted and sends a “control current” through the magnetic
amplifier winding. The flux produced by the control is in such a way that it
opposes the flux produced by the load winding, thereby increasing the
impedance of the field circuit. This increase in the field impedance reduces
the field current and brings back the output voltage to the normal value
required.
The current limiting is also achieved in the similar manner, when the
predetermined load current is delivered by the alternator, the secondary
voltage of the CT after rectification by the bridge will provide the necessary
“error signal” for the magnetic amplifier. In this case also the voltage across
the resistance will be sufficient to cause the Zener diode in voltage detector
DT2 to conduct the control current from this also passes through the same
control winding.
The effect of the control current is to retain the current at the limited value and
to the reduce voltage, for a sustained overload. The generator voltage will fall
to the battery voltage and relieve the alternator immediately, thereby reducing
the chances of damage due to the load.
The aim in maintenance is to reduce or compensate for the wear and tear in
operation so that the installation continues to function well and give good
service. Preventive maintenance covers the following basic four aspects:
One of the basic causes of passenger complaint is excessive noise of fans and
steps should be taken to minimize the noise level. The acceptable level of
noise shall be less than 80 db.
RUNNING MAINTENANCE:
The nature of defect in carriage fans mainly comes under the following
categories:
FIRE IN COACHES:
CONSTRUCTION:
POSITIVE PLATES: The Tubular Positive plates are made up of number
tubes which contain the active material.
The tubes having large numbers of minute pores allow the electrolyte to
pass through, quite freely while preventing effectively any loss of the active
material. The active material in the positive plates of the battery expands on
discharging, but the tubes are strong enough to resist this expansion, thus
eliminating shedding.
The frame and spines of the Positive Plate forming the grid are cast from a
corrosion-resistant lead alloy. A bar of acid-resistant plastic seals the bulbs at
the bottom and locates the spines of the grid.
NEGATIVE PLATES: The plates consist of a lead grid into which the active
material is pressed. The grids are designed to retain the active material in
position. Number of negative plates is one more than positive plates.
SEPERATORS: The life of any battery depends very much on the quantity of
separators used between the positive and negative plates. The separators used
in CG cells are made of micro porous synthetic material. They are strong,
flexible and resistant to damage by heat and acid.
The electrical resistance of the separators is extremely low and electrolyte
diffusion is excellent.
CELL CONTAINERS: The containers are made of Hard Rubber with high
isolating strength and resistance to acids. The containers hold a large enough
electrolyte reserve so that maintenance intervals foe the batteries are long.
CELL COVER: These are made of Hard Rubber, resistant to acid having vent
and level indicator holes.
CELL PLUGS: The plugs called vent filler plugs, are easy to remove. They
have correctly dimensioned holes for venting gases given off during charging.
The electrolyte level is checked by plugs fitted with the level indicator.
ACTIVE MATERIALS OF LEAD-ACID CELLS:
Those substances of the cell which take active part in chemical combination
and hence absorb or produce electricity during charging or discharging, are
known as active materials of the cell.
The active materials of the lead-acid cell are:
1. Lead Peroxide (PbO2) for positive plate.
2. Sponge Lead (Pb) for negative plate.
3. Dilute Sulphuric Acid as electrolyte.
1. LEAD PEROXIDE:
It is the combination of lead and oxygen. It is dark chocolate in color
and is quite hard and but brittle substance. It is made up of one atom of
lead and two atoms of oxygen and its chemical formula is PbO 2. As said
earlier, it forms the positive active material.
Hence, the lead-acid cell depends for its action on the presence of two
plates covered with PbO2 and Pb in a solution of dilute H2SO4 of specific
gravity 1.21 or near about.
CHARGING SYSTEMS:
CLEANLINESS:
It is essential that the battery and battery box be always maintained dry
and clean. Water or electrolyte spilled over the top of the cells should be wiped
off at once. Any corrosion occur anywhere in the metal work, neutralize the
acid over the area with a 5% weight by volume solution of soda or freshly
diluted 1:5 Ammonia in water. Wash with clean water. After that wipe dry the
parts and protect from further corrosion by applying a thin layer of petroleum
jelly. The battery box may also be protected by painting it with a good acid
resistant paint.
EQUALISING CHARGE:
During actual operation of the battery a few or all the cells in the assembly
may get under changed as indicated by the values of sp. gr. of the electrolyte.
Reasons can be many e.g. initial difference between individual cells causing
difference in charge acceptance of abnormal working conditions causing the
battery as a whole to become under changed.
If the lead-acid cells remain under changed over long periods, the
resulting sulfation in the cells may become so heavy that the cells may go
beyond salvage.
Equalizing charge is an extended charge, given in order to bring all the
cells in the battery bank back to healthy state.
Give equalizing charge to the cells, regularly at intervals of 10 to 12
weeks. First, fully charge the battery in the same way as done with bench
charging. Reduce the current to the equalizing rate given in table IV, and
continue with the charging till the sp. gr. of electrolyte in the individual cells
remains unchanged over a period of three hours and is within the specified
range.
CHARGING:
Discharged batteries should be charged back at the earliest opportunity,
i.e. not later than 12 hours after unloading the battery from the coach.
FACILITIES REQUIRED IN BATTERY SECTION:
1. REQUIREMENT OF MORE SPACE:- The work load is increasing
regularly in the battery section. But charging along with discharging
could not be possible at a given time due to the scarcity of space
therefore there is requirement of more space.
2.NUMBER OFF STAFF:
In battery section the staff is not available according to work load
therefore work is being late. To increase the rate of work there should be
requirement of more staff.
3.TOOLS:
In battery section required tools are not available. Due to lack of tools
the workers have to face inconvenience.
4.SAFETY ITEMS:
At the time of charging and discharging, battery releases harmful gases
and at the time of dispose the acid is diffuse from these gases and acid
is very harmful for human body. For safety of human body safety items
are required. For example: Gloves, Goggles, Mask and Long size shoes
etc. there is scarcity of these items.
2. The new comer batteries of HBL Company are less costly but these
are not successful. In these batteries reclamation is not possible and
the report of these batteries is not so good. In comparison Exide
batteries are better than HBL batteries.
PRODUCTION AND
CONTROL ORGANISATION
DURATION:-
From 27th June, 2018 to 2nd July, 2018
GUIDED BY:-
Naveen Verma
INSULATING TESTING:
It is really a very important test which must be done in all out going
coaches. By this we check earth fault, short circuiting between the
connections, insulation breakdown and leaking of the battery. It is done
by 500 volts MEGGER. This process is called “MEGGERING”. It is
necessary because, if earth fault will occur than: checking can also be
done using “TWO LAMP METHOD”.
1. Possibility of shock to the passengers.
2. Short circuit may occur
3. Whole battery will collapse, because there will be continuous losses
in the metal part of the coach.
4. PROBLEM OF COMMUNICATION EQUIPMENTS (mobile,
pager, etc.) may occur because as current flow in the metal frame of
coach, some type of magnetic field may generate and it will affect
severally the communication wave.
5. Fire hazard may occur.
MEGGER:
DURATION:-
From 3rd July, 2018 to 19th July, 2018
GUIDED BY:-
R. K. Sharma
INTRODUCTION:
Air conditioning means to make air fit to promote comfort and effecting or to
ensure proper operation of delicate equipment or to help manufacturing
operation more often it involves following operation:
To supply duty clean fresh air to keep low order concentration of carbon
dioxide and smoke with in low limits.
To cool the air in summer and to heat in winter in order to maintain
proper temperature inside the premises of air conditions.
To control the humidity of the air conditioned premises.
To obtain air movement without producing annoying draught.
BASIC CYCLE:
The compressor draw low temperature refrigerant vapor from the
evaporator and compress the Freon gas such that high temperature gas
via the hot gas line to the condenser where heat is given up to the ambient
the air loss of heat cause the high temperature gas to condense the high
pressure receiver from the liquid receiver is passed via a line shut off
value filter drive moisture indicator, solenoid value and thermostatic
expansion valve to the evaporator.
As the refrigerant is fed into the evaporator coil via the thermostatic
expansion valve it expand to become a low temperature/pressure liquid
this liquid than absorbs heat from the air passing over the evaporator coil
via fined surface causing it to vaporize and is then drawn back to the
compressor through its suction line to be recompressed.
REFRIGERANT CONTROL:
As the valve throttle the suction line, the evaporator pressure will tend
to the pressure corresponding to the air temperature passing above the,
reducing the temperature differential between the evaporating
refrigerant & air the evaporator capacity will balance the load represents
than the proper throttling of the suction line is achieved further this
throttling action will reduce the flow of the suction gas to the compressor
resulting in a lower suction pressure at the compressor inlet, and the
corresponding reduction of the compressor capacity to match load
requirements.
On arrival at shop, first they note down the defects and deficiencies in
all equipment like compressor & its motors, condenser including liquid
receiver cum dehydrator, and condenser monitors, evaporator units & its
motor, battery charger cum pre cooling transformer, battery, battery box,
etc.
Test the insulation resistance of the armature and field with the 500
VMEGGER. It should be more than 1M ohms.
Use voltage drop method for open & short circuit method.
If the armature or field is burned, overhead or short circuit. Rewind it
if it is in good condition than apply a coat of air during insulation
BECTOL on the winding.
Checking the commutator surface if the surface is found improper
(grooving, pitting marks, ovality, blackness etc.) skim or polish the
commutator surface.
Checking of field winding by resistance method for the open circuit or
short circuit.
Blow out the carbon dust because it is of conducting nature, and in the
worst condition it may cause the short circuit.
Checking that THE BRUSH SHOULD BE IN THE NEUTRAL AXIS.
In this condition the speed of rotor in both the direction will be same
measuring of insulation of each relay, contractor and fan motor, it should
be less than 2 M ohms.
Each & every equipment should be provided with “Anti-theft
mechanism”.
Surface of copper socket and Bus shall be cleaned to remove the
oxide film from the joints also loose joints should be avoided.
After POH do the COOLING TEST on the coach:
COOLING TEST:
Cooling capacity test should be carried out by providing electrical
compensating load for worst ambient condition and full occupancy of
the coach the duration for pre cooling the coach would be between 3
to 4 Hrs. after the stabilization of the temperature each berth (20mm
from window and back rest panel and 100 mm above the birth should
be recorded the variation in temperature on the different berths should
not exceed 1 degree centigrade.
TECHNICAL SPECIFICATIONS:
10 Horse Power Compressor Motor:
OUTPUT 10/11.01 HP
VOLTAGE 110/130 volts
CURRENT 80/76 Amps
SPEED 1140 RPM
DIRECTION OF ROTATION ANTI CLOCKWISE FROM
COMMUTATOR END
TYPE OF COOLING FAN COOLING
CONNECTION COMMULATIVE
COMPOUND, SELF EXCITED
INSULATION CLASS I
OUTPUT 1 KW
VOLTAGE 130 Volts
CURRENT 9.5 Amps
SPEED 1500 RPM
DIRECTION OF ROTATION CLOCKWISE FROM
COMMUTATOR END
TYPE OF COOLING NATURAL COOLING
CONNECTION COMMULATIVE COMPOUND,
SELF EXCITED
INSULATION CLASS F
GENERAL: The equipment is designed to supply 135V /200 ADC output for
feeding the following loads in AC rail coaches:
To charge 110V, 800 to 950 AH lead acid batteries
To feed the AC motor load.
SPECIFICATION:
INPUT VOLTAGE 415 +0%/-10%, THREE PHASE
FREQUENCY 50 Hz +/-3%
OUTPUT 200 A at 135 V DC
RATING(CONTINOUS)
CONTROL BY MEANS OF TWO COARSE
FINE 4 POLE ROTARY
SWITCHES
The Ac input terminals and interconnecting terminals are fixed on the terminal
board in front of the transformer box and the rectifier box for power
connection as well as control circuit connections.
The rectifier box comprises of the 3 phases bridge rectifier, surge suppressor,
shunt, o/p fuses two terminal board also for interconnecting and DC output
terminals. The diodes are mounted on the heart sink.
SPECIAL FEATURES:
OUTPUT VOLTAGE CONTROL: The Dc o/p voltage of the
equipment can be manually varied between 104 V(no load) at 415 V AC
input and 136 V(at 370 V AC I/p) this is achieved by the use of two 4
position coarse fine adjustment rotary switches the tap changing is done
on the primary winding of the transformer
OVER CURRENT PROTECTION: Back up protection is provided by a
thermal overload relay on the input side of the equipment HRC fuses are
also provided on the AC and Dc sides of the equipment.
TRSIENT VOLTAGE PROTECTION: An R-C surge suppressor is
provided on the secondary side of the transformer to suppress transient
over voltage that may arise in the system R-C surge suppression circuits
are provided across each semi semiconductor device for whole storage
protection.
POWERPOWER CIRCUIT OPERATION:
The AC input to the transformer passes through the input fuses and contractor
the tape on the primary can be changed by the two rotary switch for coarse
and fine control of the DC o/p voltage from 104 to 138 VA 3 phase diode
bridge rectifier rectified the AC secondary voltage of the transformer into DC
which is supplied to the load and the battery the input power supply to the
transformer can be switched ON only when the rotary switch are in the
minimum o/p voltage position.
In Vent selection of RSW-3 heating or cooling, are disabled and only the
blower is on:
In “low”, “medium”, or “high”, selection if temperature is below the
temperature selected for heating the heaters will get switched “ON” the heater
“ ON” green indication will come “ON” they will remain “ON” until the
desired
In the temperature is above the selected temperature the condenser fans
will start and their indications (green color leads) will come on and so the
green cool indication come ON after a delay varying between 2 to sequentially
and their green indication will come ON. This mode will continue till the
desired temperature will reached. Then the compressors and the condenser
fans will get switched OFF.
The unit will keep cycling in either mode to maintain the
selected temperature .To disable the operation of either her of the compressor
use RSWP(located inside the control panel) in the bottom left portion of
control panel above RSW1.
INTERLOCKS:
When following interlocks have been provided in the control panel:
a) If blower motor is not ON no other equipment can get switched
ON.
b) If Vane Relay is not ON Red “AIRLOSS”LED will glow and no
other equipment except the Blower can get switched ON.
c) Only if at least of one condenser FAN is ON the compressor can
get switched ON.
d) However if either condenser fan is defective one of the compressor
operation should be disable by using RSWS.
e) If heater is ON neither compressor can get switch ON heater can
get switched ON only both condenser fans are OFF.
POWER CIRCUIT
The three phase 415 VAC 50 HZ power supply is used to operate two
hermetically sealed compressor. One double shaft blower motor is shown in
power diagram. The equipment are protected by using MCBS and Overload
relays.
(All motors and compressor are designed to operate on 415 VAC 3 phase, 50
HZ).
CONTROL CIRCUIT:
A step down transformer of 415 V/110 V is used to provide 110v AC signal
phase to circuit. The thermostat PCB, Hp, LP and other interlocking device
operate on control voltage for protection of various equipment. However, the
crank case heater of both compressor are operator on 415 VAC and are kept
is switched OFF. This is also ensure that the crank case lubricating oil of the
compressor is kept ware during OFF cycle and machine shout down so that
refrigerant does not migrate into the compressor crank case. This will ensure
that during compressor start up, no liquid refrigerant is present in the
compressor damage due to absence of lubricant.
Three stage thermostat e are provide for cooling and heating to
maintain 24, 24, 26 deg. C during summer (for cooling and 19, 19, 21 ºC
during winter (for heating) at low medium and high position of rotary switch
RSW4 respectively.