Part – A 1 mark each

Expand the following abbreviations:

(1) MCB (11) FL (21) DCP (31) MS Sheet

(2) PCB (12) OT (22) ERRU (32) OP Cutout
(3) ICF (13) IOH (23) RMPU (33) LP Cutout
(4) POH (14) VRLA (24) OVP (34) HP Cutout
(5) EFT(TL system) (15) OBC (25) RRU (35) DC
(6) SMF (Battery) (16) CCA (26) IC Lamp (36) AC
(7) LAP (17) NDA (27) HRC (37) ISO
(8) CL (18) SCL (28) PF (38) PNM
(9) LHAP (19) DAR (29) PRS (39) PWM
(10) CFL (20) WCA (30) GI (40) WRA

(41) RCF (51) BTU (61) AXEE

(42) RPM (52) DB (62) IDN
(43) RITES (53) AHU (63) EIW
(44) SWG (54) PVC (64) PL No.
(45) DE (55) SG AC coach
(46) NDE (56) OHP
(47) DLW (57) CWM
(48) CLW (58) CEE
(49) MACP (59) CESE
(50) SMI (60) Dy.CEE

Answers:

(1) MCB - Miniature Circuit Breaker

(2) PCB - Printed Circuit Breaker
(3) ICF - Integral Coach Factory
(4) POH - Periodical Overhauling
(5) EFT(TL system) - Emergency Feed Terminal
(6) SMF (Battery) - Sealed Maintenance Free
(7) LAP - Leave on Average Pay
(8) CL - Casual Leave
(9) LHAP - Leave on Half Average Pay
(10) CFL - Compact Fluorescent Lamp
(11) FL - Fluorescent Lamp
(12) OT - Over Time
(13) IOH - Intermediate Overhauling
(14) VRLA - Valve Regulated Lead Acid
(15) OBC - Other Backward Class
(16) CCA - City Compensatory Allowance
(17) NDA - Night Duty Allowance
(18) SCL - Special Casual Leave
(19) DAR - Discipline and Appeal Rules
 -2-

(20) WCA - Workmen Compensation Act

(21) DCP - Duty Card Pass/Dry Chemical Powder
(22) ERRU - Electronic Rectifier cum Regulator Unit
(23) RMPU - Roof Mounted Package Unit.
(24) OVP - Over Voltage Protection
(25) RRU - Rectifier cum Regulator Unit
(26) IC Lamp - Incandescent Lamp
(27) HRC - High Rupturing Capacity
(28) PF - Power Factor/Provident Fund
(29) PRS - Passenger Reservation System
(30) GI - Galvanized Iron
(31) MS Sheet - Mild Steel
(32) OP Cutout - Oil Pressure
(33) LP Cutout - Low Pressure
(34) HP Cutout - High Pressure
(35) DC - Direct Current
(36) AC - Alternating Current
(37) ISO - International Organisation for Standardisation.
(38) PNM - Permanent Negotiating Machinery
(39) PWM - Pulse Width Modulation.
(40) WRA - Water Raising Apparatus.
(41) RCF - Rail Coach Factory
(42) RPM - Revolutions per Minute.
(43) RITES - Rail India Technical and Economic Services
(44) SWG - Standard Wire Gauge.
(45) DE - Driving End
(46) NDE - Non Driving End
(47) DLW - Diesel Locomotive Works
(48) CLW - Chitaranjan Locomotive Works
(49) MACP - Modified Assured Career Progression
(50) SMI - Special Maintenance Instructions
(51) BTU - British Thermal Units
(52) DB - Dry Bulb
(53) AHU - Air Handling Unit
(54) PVC - Polyvinyl Chloride
(55) SG AC coach - Self Generation AC coach
(56) OHP - Overheat Protection.
(57) CWM - Chief Workshop Manager
(58) CEE - Chief Electrical Engineer
(59) CESE - Chief Electrical Services Engineer
(60) Dy.CEE - Deputy Chief Electrical Engineer
(61) AXEE - Assistant Executive Electrical Engineer
(62) IDN - Inspection Demand Note
(63) EIW - Essentially Indirect Worker
(64) PL No. - Price List Number
 -3-

Part – B 1 mark each

Fill up the blanks:

(1) The unit of resistance is ______________

(2) Power drawn in a DC circuit is the product of _________ and ____________
(3) OD and ID of the pipe are given. The thickness of pipe is _________________
(4) The instrument used for measuring insulation value is________________
(5) The unit of current is __________________
(6) The refrigerant used in RMPU AC coach is _____________
(7) The two terminals of diode are _____________ and ______________
(8) Instrument used for non-contact temperature measurement is _______________
(9) Anemometer is used for measurement of ____________________
(10) LHAP can be accumulated by a Railway employee to ___________ number of
days maximum.
(11) S1539 form is used for ________________________
(12) Number of ‘V’ belts for each alternator in an AC coach is_____________
(13) The condenser motor failure in an AC coach will result in the operation of
_______
(14) Specific Gravity of electrolyte is measured by _________________
(15) CFL is more __________________ than IC.
(16) Eco friendly refrigerant introduced in AC system is_________________
(17) A Railway employee is eligible for LAP for _________ days per year.
(18) Direct reading Ammeter is connected in _________ with load to measure load
current.
(19) The number of divisions in Southern Railway are __________
(20) Form used for Non-stock indent is ________________
(21) Battery capacity used in BG AC 3 Tier RMPU coach is _____________
(22) The type of battery used in BG RMPU AC 3 Tier coach is ____________
(23) The unit of capacitance is ______________
(24) Illumination level is measured by ____________
(25) When two resistors R1 and R2 are connected in series, the effective resistance is
___________
(26) When two resistors R1 and R2 are connected in parallel, the effective resistance is
_____________.
(27) Voltmeter is connected _________________ with the supply to measure supply
voltage.
(28) The normal domestic voltage is ___________ AC single phase.
(29) An insulator should have high _____________ between live part and earth.
(30) Instrument used for measuring the thickness of sheet/strip is ___________
(31) BG AC coach alternator winding is with __________ class insulation.
(32) Diameter of a pipe is measured with _____________
(33) The specific gravity of distilled water is ___________
(34) FL fitting to work on 110V DC in BG TL coaches are provided with __________
(35) Field wire cut will result in ______________ of alternator.
(36) Electrolyte of LMLA battery is _____________
(37) The rating of HRC fuse of BG RMPU AC coach with 1100 AH battery is ______
 -4-

(38) The total alternator capacity used in BG RMPU 3 tier AC coach is

______________
(39) RCF is located at ______________
(40) Cross section area of conductor required will _________ when current passing
increases.
(41) One meter is equal to __________mm.
(42) Feeler gauge is used to measure the ___________
(43) Type of ‘V’ belts used in 110V BG AC coach is ___________
(44) The capacity of AC plants is given in terms of ________
(45) The rating of condenser fan motor in conventional under-slung BG AC coach is
________
(46) Privilege pass is valid for _________
(47) No.of privilege pass a Railway employee is eligible up to 5 years of service is
_____
(48) The capacity of RMPU AC plant on one side of AC coach is ___________
(49) The current rating of MCB for light circuit in 110V BG Non-AC coaches is
________ Amps.
(50) Diameter of tension rod spring for 18 KW alternator is __________
(51) Diameter of tension rod spring for 25 KW alternator is ________
(52) Length of indicator plate in tension rod assembly for 18 KW alternator is _______
(53) Clearance of Axle pulley from wheel flange for 18 KW alternator is __________
(54) Clearance of Axle pulley from wheel flange for 25 KW alternator is _________
(55) Power consumption for one RMPU AC compressor is ____________

Answers:

(1) Ohms.
(2) Voltage and current.
(3) (OD – ID)/2
(4) Megger
(5) Amperes
(6) R22
(7) Anode and Cathode.
(8) Infrared Thermometer
(9) Air Velocity
(10) Unlimited
(11) Returning materials to Stores Department.
(12) 12
(13) HP cutout
(14) Hydrometer
(15) Energy efficient
(16) R134a
(17) 30 days
(18) Series
(19) Six
(20) S1302
(21) 1100Ah
(22) VRLA
 -5-

(23) Farads
(24) Lux meter
(25) R1 + R2
(26) R1.R2/(R1 + R2)
(27) Across/parallel
(28) 230V
(29) Resistance
(30) Micrometer
(31) H Class
(32) Vernier Calipers
(33) 1.
(34) electronic ballast
(35) non-generation
(36) Sulphuric acid
(37) 400A
(38) 2 Nos., 25KW
(39) Kapurthala
(40) increase
(41) 1000 mm
(42) clearance
(43) C122
(44) Tons
(45) 1.0 KW
(46) Four months
(47) One set
(48) 7 tons
(49) 10 Amps.
(50) 14mm
(51) 16 mm
(52) 290 mm
(53) 247mm
(54) 228 mm
(55) 5250 watts

Part – C 1 mark each

Choose the correct answer:

(1) Which of the following motor is used in domestic refrigerators

(a) DC shunt motor (b) Reluctance motor
(c) Single phase induction motor (d) Synchronous motor

(2) The brushes of electrical motors are made of

(a) carbon (b) copper
(c) cast iron (d) steel

(3) Which of the following is the best conductor of electricity

(a) Copper (b) Aluminium
(c) Iron (d) PVC
 -6-

(4) The capacity of a battery is measured in

(a) ampere (b) volts
(c) ampere hour (d) watts

(5) Positive terminal of a diode is called

(a) polarity (b) gate
(c) anode (d) cathode

(6) Frequency of Domestic Electric Supply in India is

(a) 60 Hz (b) 100 Hz
(c) 0 Hz (d) 50 Hz

(7) Voltage of Domestic Electric Supply in India is

(a) 230V DC (b) 110V AC
(c) 230V AC (d) 110 V DC

(8) Equipment used to convert AC into DC

(a) capacitor (b) rectifier
(c) inverter (d) battery
(e) amplifier

(9) Equipment used to convert DC into AC

(a) capacitor (b) rectifier
(c) inverter (d) battery
(e) dynamo

(10) Unit of inductance is

(a) Ohms (b) Megohms
(c) Henry (d) Charles

(11) Reading of a megger when the equipment is open circuited

(a) infinity (b) 500 ohms
(c) zero (d) 10 meg ohms

(12) A 2 ohms resistor when 1 ampere current is passed will dissipate a power of
(a) 2 watts (b) 4 watts
(c) 0.5 watts (d) 0.25 watts

(13) A closed switch has a resistance of

(a) infinity (b) zero
(c) about 500 ohms (d) about 50 ohms

(14) Tong tester is used for measuring

(a) Resistance (b) Energy
(c) Current (d) Pressure
 -7-

(15) The capacity of an AC plant is indicated in

(a) Liters (b) Tons
(c) Amps. (d) Temperature °C

(16) The capacity of water cooler is indicated in

(a) Liters (b) Tons
(c) Amps. (d) Temperature °C

(17) 0°C is equivalent to

(a) 0°F (b) 32°F
(c) 100°F (d) 212°F

(18) When 2 Nos. of 5 ohms resistors are connected in series, the effective resistance is
(a) 5 ohms (b) 7 ohms
(c) 2.5 ohms (d) 10 ohms

(19) Battery used in BG RMPU 3 tier AC coach is

(a) 800 AH (b) 1100 AH
(c) 120 AH (d) 450 AH

(20) Refrigerant used in RMPU AC coach in S.Rly is

(a) R12 (b) R22
(c) Ammonia (d) R134a

(21) Type of fire extinguisher used in electrical fire

(a) Soda acid (b) Foam type
(c) DCP type (d) none of the above.

(22) S1302 form is used for

(a) stock item (b) non-stock item
(c) T&P item (d) none of the above

(23) 3 phase full wave rectifier has

(a) 6 diodes (b) 4 diodes
(c) 3 diodes (d) 7 diodes

(24) Single phase full wave rectifier has

(a) 2 diodes (b) 6 diodes
(c) 4 diodes (d) 1 diode

(25) The capacity of storage battery is expressed as

(a) No.of charger it can take (b) Ampere hour it can deliver
(c) Time for which it can be used (d) discharging current

(26) The cut in speed of 25KW alternator in an AC coach is

(a) 400 rpm (b) 600 rpm
(c) 1000 rpm (d) 300 rpm
 -8-

(27) Electrolyte used in Lead Acid battery is

(a) Hydrochloric acid (b) Distilled water
(c) Sulphuric acid (d) Nickel Cadmium

(28) Ammeter is connected with load in

(a) parallel (b) one end connected to earth
(c) before the load (d) in series.

(29) Rating of BG TL coach alternator is

(a) 4.5 KW (b) 3 KW
(c) 18 KW (d) 25 KW

(30) Rating of RMPU 3 tier AC coach alternator is

(a) 4.5 KW (b) 12 KW
(c) 18 KW (d) 25 KW

(31) Instrument used to measure temperature

(a) Temperature meter (b) Heat meter
(c) Lux meter (d) Thermometer

(32) LAP can be accumulated to a maximum

(a) 180 days (b) 30 days
(c) 240 days (d) 300 days

(33) SF 11 is used to frame

(a) Warning (b) Minor penalty
(c) Suspension (d) Major penalty

(34) Inverter is used to

(a) convert AC into DC (b) regulate voltage
(c) drop voltage (d) convert DC into AC

(35) The capacity of the battery used in 110V BG TL coach

(a) 210 AH (b) 120 AH
(c) 800 AH (d) 1100 AH

(36) One Ton of Refrigeration means

(a) 400 BTU/Hr. (b) 12000 BTU/Hr.
(c) 12000 BTU/day (d) 3000 BTU/Hr.

(37) The rating of alternator used in under-slung BG AC coach is

(a) 12 KW (b) 12.5 KW
(c) 18 KW (d) 4.5 KW

(38) Illumination level is measured with

(a) Lux meter (b) Multi meter
(c) Light meter (d) Tachometer
 -9-

(39) Rotational speed is measured by

(a) Lux meter (b) Multi meter
(c) Anemometer (d) Tachometer

(40) The minimum speed for full output of 25KW KEL alternator is
(a) 100 rpm (b) 400 rpm
(c) 2500 rpm (d) 800 rpm

(41) The rated full load voltage of 25 KW KEL alternator is

(a) 130 V (b) 193 V
(c) 140 V (d) 110 V

(42) 500 watts lamp working for 20 hours consume energy of

(a) 20 Units (b) 50 Units
(c) 10 Units (d) 1000 Units

(43) The alternator of TL coaches generate power at

(a) Single phase AC (b) 3 phase AC
(c) Two phase AC (d) DC

(44) The gap between the two parts of axle pulley after tightening should not be less
than
(a) 1 mm (b) 2 mm
(c) 3 mm (d) 4 mm

(45) Total No.of compressors in a RMPU BG AC coach is

(a) 2 (b) 4
(c) 1 (d) 6

(46) RMPU AC plants in an AC coach works on

(a) 110 V DC (b) 440 V AC 3 phase
(c) 440 V AC Single phase (d) 24 V DC

(47) Compulsory Retirement is a

(a) Major penalty (b) Minor penalty
(c) Equal to Voluntary Retirement (d) none of the above

(48) As per Ohm’s Law

(a) V = IR (b) V = I / R
(c) R = V x I (d) I = V x R

(49) Unit of resistance is

(a) Ampere (b) Volts
(c) Ohms (d) Henry

(50) In a 4 sq.mm PVC cable, 4 sq.mm stands for

(a) Thickness of wire (b) Length of wire
(c) Cross section area of conductor (d) Cross section area of cable
 - 10 -

(51) In house wiring, the black wire indicates

(a) Phase (b) Neutral
(c) Earth wire (d) Dead wire

(52) In a wiring circuit fuse will be placed on

(a) Phase (b) Neutral
(c) earth (d) any one of the above.

(53) Which are the following test to be conducted before connecting a wiring to main
line
(a) IR test (b) Continuity test
(c) Polarity test (d) all above.

(54) A generator converts

(a) Mechanical energy into light
(b) Mechanical energy into Electrical energy
(c) Electrical energy into Mechanical energy
(d) Heat energy into Electrical energy

(55) Solar Energy is used for

(a) lighting (b) cooking
(c) battery charging (d) all above.

(56) When resistances are connected in parallel, the equivalent resistance

(a) decreases (b) increases
(c) no change (d) may decrease or increase

(57) When resistances are connected in series, the equivalent resistance

(a) decreases (b) increases
(c) no change (d) may increase or decrease

(58) A step up transformer increases

(a) power (b) current
(c) voltage (d) frequency

(59) The Electrical Inspector for Zonal Railway is

(a) CEE (b) Dy.CEE
(c) DRM(Elec.) (d) CESE

(60) Under worst weather conditions, the insulation resistance value with 500V
megger between winding and earth for 110V BG AC coach alternator should not
be less than
(a) 0.5 megohms (b) 1.0 megohms
(c) 2.0 megohms (d) 20 megohms

(61) Under worst weather conditions, the insulation resistance of cables to earth with
500V megger in BG AC coach in megohms should not be less than
(a) 0.5 megohms (b) 1.0 megohms
(c) 2.0 megohms (d) 10 megohms
 - 11 -

(62) The safest value of current the human body can carry more than 3 seconds is
(a) 15 mA (b) 25 mA
(c) 35 mA (d) 9 mA

(63) Which of the following precaution after switching off power supply is to be taken
if a man suffers from electric shock and unconscious
(a) call a doctor
(b) make him to lie on the ground
(c) provide him glucose
(d) lie him down on the ground and start artificial respiration till a doctor comes.

(64) Workshop comes under

(a) Continuous duty (b) Factory Act
(c) Intensive (d) HOER

(65) The value of insulation resistance is expressed in

(a) Ohms (b) Volt
(c) Megohms (d) Milliohms

(66) The capacity of BG TL alternator is

(a) 3 KW (b) 4.5 KW
(c) 12 KW (d) 18 KW

(67) The voltage setting of AC coach Regulator at 50% of full load current in the test
bench is
(a) 127 V (b) 124 V
(c) 130 V (d) 120 V

(68) The workshop staff can avail maximum CL per year.

(a) 12 days (b) 9 days
(c) 8 days (d) 10 days

(69) The water in the tank of WRA is lifted by

(a) Air pressure (b) Vacuum
(c) Suction (d) None of the above.

(70) Insulation resistance value of AC coach measured with 500V megger in fair
weather condition should be minimum
(a) 10 megohms (b) 100 megohms
(c) 0.5 megohms (d) 2 megohms

(71) The compressor used in RMPU AC coach is of type

(a) semi sealed (b) open type
(c) hermetically sealed (d) none of the above.

(72) During replacement of RMPU AC compressors, for leak test pressure charge the
system is done with
(a) R22 (b) R134 a
(c) Hydrogen (d) Nitrogen
 - 12 -

(73) Terminal Box side of AC coach alternator is provided with

(a) NU 311 roller bearing (b) NU 312 roller bearing
(c) 6312 ball bearing (d) 6311 ball bearing

(74) Non terminal box side of AC coach alternator is provided with

(a) Single ball bearing 7312 (b) Pair of ball bearings 7312
(c) Roller Bearings NU 312 single (d)Roller Bearing NU312 pair

(75) Class of insulation for 25 KW AC coach alternator winding is

(a) F class (b) E class
(c) H class (d) B class

(76) Tripping of HP cutout may be due to

(a) Condenser fan motor failure (b) Gas leakage
(c) Thermostat not operating properly (d) Compressor motor failing to stop

(77) The heat removed by a 5 Ton AC plant

(a) 60,000 BTU/Hr. (b) 6000 BTU/Hr.
(c) 50,000 BTU/r. (d) 60,000 BTU/day

(78) Standard Form No. _______ is issued for imposing minor penalties to a Railway
Servant
(a) 5 (b) 7
(c) 11 (d) 10

(79) Standard Form No. ______ is issued for imposing major penalties to a Railway
Servant
(a) 5 (b) 7
(c) 11 (d) 10

(80) Length of indicator plate for 25 KW alternator tension rod with 16 mm spring
(a) 290 mm (b) 295 mm
(c) 270 mm (d) 310 mm

Answers :

(1) (c) single phase induction motor

(2) (a) carbon
(3) (a) copper
(4) (c) ampere-hour
(5) (c) anode
(6) (d) 50 Hz
(7) (c) 230 V AC
(8) (b) Rectifier
(9) (c) Inverter
(10) (c) Henry
(11) (a) infinity
 - 13 -

(12) (a) 2 watts

(13) (b) zero
(14) (c) current
(15) (b) Tons
(16) (a) Liters
(17) (b) 32°F
(18) (d) 10 ohms
(19) (b) 1100 AH
(20) (b) R22
(21) (c) DCP type
(22) (b) non-stock item
(23) (a) 6 diodes
(24) (c) 4 diodes
(25) (b) ampere-hour it can deliver
(26) (a) 400 rpm
(27) (c) Sulphuric acid
(28) (d) in series
(29) (a) 4.5 KW
(30) (d) 25 KW
(31) (d) Thermometer
(32) (d) 300 days
(33) (b) minor penalty
(34) (d) convert DC into AC
(35) (b) 120 AH
(36) (b) 12000 BTU/Hr.
(37) (c) 18 KW
(38) (a) Lux meter
(39) (d) Tachometer
(40) (d) 800 rpm
(41) (a) 130 V
(42) (c) 10 units
(43) (b) three phase AC
(44) (c) 3 mm
(45) (b) 4
(46) (b) 440V AC 3 Phase
(47) (a) Major Penalty
(48) (a) V = IR
(49) (c) ohms
(50) (c) Cross section area of conductor
(51) (b) Neutral
(52) (a) phase
(53) (d) all above
(54) (b) Mechanical energy into Electrical energy
(55) (d) all above
(56) (a) decreases
(57) (b) increases
(58) (c) voltage
(59) (a) CEE
 - 14 -

(60) (d) 20 megohms

(61) (b) 1.0 megohms
(62) (d) 9 mA
(63) (d) lie him down on the ground and start artificial respiration till a doctor comes
(64) (b) Factory Act
(65) (c) Meg ohms
(66) (b) 4.5 KW
(67) (a) 127 V
(68) (c) 8 days
(69) (a) Air pressure
(70) (d) 2 megohms
(71) (c) hermetically sealed
(72) (d) Nitrogen
(73) (b) NU312 roller bearing
(74) (b) pair of ball bearings 7312
(75) (c) H class
(76) (a) Condenser fan motor failure
(77) (a) 60,000 BTU/Hr.
(78) (c) 11
(79) (a) 5
(80) (b) 295 mm

Part –D 5 mark each

Answer the following questions :

(1) What is the testing procedure for OHP cutout, HP cutout and LP cutout in
an AC coach?

TESTING OF OHP cutout :

Switch “ON” the heaters with blower off (take out blower fuses and short the
vane relay terminals). Keep the package in manual heating mode. The heaters should
trip.

TESTING OF HP cutout:

Switch “ON’ the compressor with condenser fan OFF. Take out the condenser
fan motor fuses. Keep the package in manual cool mode. Compressor should trip in 3
minutes. HP cut-outs should be reset after each trip.

TESTING OF LP cutout:

Switch “ON” the compressor and condenser with blower OFF. Take out
the blower motor fuses and short the vane terminals (44-45). Keep the package in
manual cool mode. Compressor should trip in 3 minutes.
 - 15 -

(2) What are the main parts (units) of an ERRU?

Electronic Rectifier cum Regulator Unit (ERRU) Parts:

The Electronic Rectifier cum Regulator Unit (ERRU) employs IGBT with
driver circuit for control of field excitation. The ERRU consists of the following
units.
1 Field Rectifier Unit
2 ISO pack power diodes
3 Static OVP
4 Hall effect sensor
5 Universal Voltage controller (UVC)

(3) What is the lubrication procedure of AC coach alternator bearings during

POH?

Lubrication of AC coach alternator bearings during POH

Greasing of bearings have to be done only during the POH.

For re-lubrication of 7312 BECBJ bearing, remove fan cover, end shield
and bearing covers. Now the bearings are accessible. Remove the old grease
completely thoroughly washing the bearings with white spirit and fill with new
grease. For re lubrication of NU 312 Roller bearings, remove the bearing cover
and take out the outer race along with the housing from inner race fitted on the
shaft. Now the bearing is accessible. Remove the old grease completely by
thoroughly washing the bearing with white spirit and apply new grease. The type
and quantity of grease to be used is given in the table.

Bearing type Qty. of Grease in gms Type Grease

Ball Bearing 7312 BECBJ 140 Servogem RR3
Roller Bearing NU 312 ECJ 60 Servogem RR3

(4) What is the necessity and importance of Crank Case heaters in a RMPU AC
coach?

Crank Case Heaters and its importance:

The Crank case heaters of both compressors are operated on 415 V AC

and are kept energized all the time till the main supply is switched off. This is to
ensure that the crank case lubricating oil of the compressor is kept warm during
OFF cycle and machine shut 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 crank case to cause foaming of the oil and
consequent compressor damage due to absence of lubricant.
 - 16 -

(5) What are the functions of rotary switches provided in RMPU AC coach
panel?

Functions of Rotary Switches in RMPU AC coach panels:

1. To switch ON/OFF main supply.

2. To switch ON Blower.
3. To select auto/manual heat/manual cool/vent mode as per requirement
of inside condition.
4. To select the working of compressors i.e comp.1 & 2 ON/Comp.1
bypass/Comp.2 bypass.

(6) What are functions of RRU in an AC coach?

The Regulator/Rectifier unit has mainly following function.

 Rectifying the three phase AC output to DC using full wave rectifier bridge.
 Regulating the voltage generated by the alternator at set value.
 Regulating the output current at the set value.
 Feeding 110V DC supply for coach load and battery charging in running.

(7) What is the POH attention given for Alternator Terminal Box?

Periodical overhaul of alternator terminal box:

 Loosen captive screw of cover and open the cover. Check if the terminal
block is modified one if old type, replace with modified type.
 Check for any damage of terminal board, replace if necessary
 Check the condition of incoming/outgoing leads if damage, replace the same
or repair the damage leads.
 Ensure proper tightness of the terminals.
 Clean the terminal box thoroughly.
 Check that no hardware has worked loose, replace the damage rusted
fasteners.

(8) How to test a diode?

A diode conducts in only one direction and offer a very high resistance to
the current in the reverse direction. This phenomenon is used in the testing of
diodes.

Use a multimeter in resistance range. The leads of the multimeter are

connected to the diode after disconnecting the diode from the associated circuit.
One lead goes to the anode and second to the cathode. Observe the deflection to
the multimeter.

Now reverse the connection to the diodes. Observe the deflection.

 - 17 -

If the diode is good it shows infinite resistance (no deflection) on the

multimeter in one direction and 500 Ohms to 1000 Ohms in the other direction.
An open diode will show infinite resistance in both directions, and a short
diode will show full deflection in both directions.

(9) How to test insulation resistance of AC coach alternator and RRU. Give
required insulation values.
Insulation resistance test for ac coaches alternator & regulator:
Alternator :

Between stator Above 20 M. Ω

Winding and earth
Between field Above 20 M. Ω
Winding and earth
Between field Above 20 M. Ω
Winding and stator
Regulator:

Short all terminal Above 10 M Ω

(live parts) together and
check the insulation
resistance between the
live parts and earth

The insulation resistance of all the above should be measured by 500V

megger.

(10) What are the states under Region A, B & C under OL Act?

Region A – Bihar, Jharkand, Haryana, Himachal Pradesh, Madhya Pradesh,

Rajasthan, Uttar Pradesh and Union Territories of Delhi and
Andaman Nicobar Islands.

Region B – Gujarat, Maharashtra and Punjab and the Union Territory of

Chandigarh.

Region C – States and Union Territories not referred in Region A & B ( i.e
Tamilnadu, Kerala, Karnataka, Andhra Pradesh, Orissa, West
Bengal, Sikkim, Assam, Nagaland, Meghalaya, Arunachal
Pradesh, Goa etc.)

(11) (a) What are the cases where regional language, Hindi, English should be
used?
i. All boards exhibited for the general public.
ii. Forms used by the public
iii. Station announcements.
 - 18 -

(b) What are the places where Hindi and English should be used?

1. Rubber stamps.
2. Heading on all file covers and registers.
3. Name badges and photo identity cards etc.

(12) Explain the principle of operation of AC coach alternator.

Principle of operation of AC coach alternator

The core of the stator which is completely embraced by the field coils will
retain a residual magnetism if excited by a battery once. The flux produced by the
field coils find its path through the rotor. When the rotor is rotated when driven
by axle on train running through V belts and pulleys, the passage of rotor teeth
and slots alternatively, under the field, offers a varying reluctance path for the
flux produced by the field coils. The flux which vary periodically links with AC
coils and induces an alternating voltage in AC coils. Once starting generation, the
3 phase output voltage from alternator is connected to RRU/ERRU, rectified and
fed back to the field to achieve required level excitation.

The frequency of the induced voltage depends on the speed of rotor,

whereas the magnitude depends on the speed of the rotor and the level of
excitation. The field is controlled through regulator to attain desired output
voltage by means of positive feedback system.

The 110V DC output voltage from RRU feeds the coach load and battery
charging.

(13) Explain the basic construction of AC coach alternator.

Basic construction of AC coach alternator

The alternator is totally enclosed, hetropolar induction type machine

having no winding on the rotor. It has no sliding contacts like brushes, slip rings,
commutators etc; offering robust construction suitable for severe shocks and
vibrations encountered in Railway services.

The alternator consists of two sets of windings viz. AC winding and field
winding both accommodated on the stator. The AC windings are distributed in
the small slots and field windings are concentrated in two slots. Each field coil
span is half of the total number of stator slots.

The rotor consist of stacked stamping, resembles a clogged wheel and is

screened. The field winding produces a steady magnetic flux.
 - 19 -

(14) Explain RMPU AC unit arrangement in an AC coach.

It has two hermetically sealed three phase compressors, two vertical flow
condenser fans and one blower unit as evaporator fan. Condenser fan motor is of
water proof three phase.

There are two independent refrigerant circuits in each PAC unit having a
compressor, condenser coil and evaporator (cooling) coil. The condenser fans
and evaporator blower are common. Each circuit has its own fresh air and return
air filters. Each evaporator (cooling coil) fits in its own drain pan. Each drain
pan has its own drain outlet.

(15) What is the importance of earthing in an Electrical power system?

The frame of every metal-cased electrical equipment should be efficiently

connected to earth, to drain away any leakage of current due to poor insulation, so
that it may always be safe to work upon.

Any leakage to the metal casing of the equipment due to failure will result
in short circuiting of phase supply with neutral through earth and the large current
makes the fuse to blow off or MCB to trip.

(16) What is the function of 25KVA inverter in a RMPU AC coach?

RMPU AC plant in RMPU AC coach has all its equipments like

compressors, condenser fan motor, evaporator blower motors, heaters which are
rated for 415 V AC 3 phase 50Hz. The battery provided in RMPU AC coach is
110V, 1100 Ah charged by RRU/ERRU connected with 25 KW axle driven
alternator. While running, power is to be drawn from alternator and regulator and
on stabling from battery at 110V DC. Hence 110V DC supply is to be inverted
into 3 phase 415V AC 50 Hz and waveform is to be nearer to sine wave
(simulated). 25 KVA inverter does this work in a RMPU AC coach.

(17) What is the function of 2.5 KVA inverter in a pantry car?

Pantry has electrical equipments like refrigerator and deep freezer/bottle

cooler which are rated for 230V AC single phase 50 Hz. The battery provided in
a pantry car is 110V 120Ah charged by RRU/ERRU connected with 4.5 KW axle
driven alternator. While running, power is to be drawn from alternator and
regulator and on stabling from battery at 110V DC. Hence, 110V DC supply is to
be inverted into 230V AC single phase, 50Hz. and waveform is to be nearer to
sine wave (simulated). 2.5 KVA inverter provided in the pantry car does this
work.

(18) What is the difference between Dry bulb and wet bulb temperature?

Dry bulb temperature is the temperature reading taken by a thermometer

with its sensing bulb open to atmosphere.
 - 20 -

Wet bulb temperature is the temperature reading taken by a thermometer

with its sensing bulb covered well by a wet cloth.

Wet bulb temperature is less than the Dry bulb temperature since the water
in the wet cloth while evaporating will take away the latent heat of evaporation
from the sensing bulb.

(19) What are the fundamental units of an electric circuit?

The important units are:

a) Voltage also called potential difference or e.m.f. (electromotive force)

expressed in volts.
b) Current expressed in amperes.
c) Resistance expressed in ohms.
d) Power expressed in watts, or horsepower
e) Energy expressed in watt-hours or kilowatt-hours or units.

(20) What is Ohm’s Law?

Ohm’s Law shows the relationship between voltage, current and

resistance. The law states that current is directly proportional to voltage and
inversely proportional to resistance. This can be expressed by the following
equation,

I = E/R, R = E/I and E = IR

Where I is the current in amp., E is the potential difference in volts, and R

is the resistance in ohms.

(21) What are the electrical equipments available in a pantry car? Give with
rating.
1. 2.5 KVA inverter 110V DC/230V AC single phase.
2. Refrigerators about 300 liter capacity
3. Deep freezer 100-120 liter capacity
4. Exhaust fans.
5. Flame Proof Light fittings in gas cylinder room.

(22) How the earth leakage test is conducted in a coach?

Earth leakage test is conducted by double test lamp each with 110V same
wattage bulb. The connection diagram is given in the annexure.

When there is no earth both bulbs will glow to the same brightness. When
there is –ve earth, bulb-A will only glow with full brightness and when there is
+ve earth, bulb-B will only glow with full brightness. Bulbs are marked suitably
 - 21 -

with “+ve earthed” and “–ve earthed”. The respective lamp will alone glow with
full brightness if there is earth fault.

(23) What are the parts of a conventional DC fan in a 110V TL Coach?

Parts of a conventional DC fan :

a. Armature with coil and commutator

b. Static cored with poles with field coils inserted
c. Bearings
d. Fan blade
e. Fan guard
f. Carbon brush holders, carbon brushes, springs
g. Body

(24) What is the function of OVP in a regulator for alternator? When it will
function?

Function of OVP:

OVP will stop the field current of the alternator and stop generation when
overvoltage is generated due to any reason i.e defect/malfunctioning of alternator
or RRU. OVP is connected with RRU to sense the output voltage.

OVP will function only when output voltage exceeds the set voltage of
RRU/ERRU to protect lights, fans and other electrical equipments from damage
to overvoltage. The situation generally occurs when voltage regulation circuit in
ERRU/RRU fails. The trip voltage set for OVP is 145 V. Once tripped, OVP has
to be reset manually.

(25) Explain proficiency in Hindi and working knowledge in Hindi.

Proficiency in Hindi :
An employee shall be deemed to possess proficiency in Hindi if he has
passed the matriculation or any equivalent or higher examination with Hindi as
medium of examination.

Working knowledge in Hindi :

An employee shall be deemed to possess working knowledge in Hindi if
he has passed the matriculation or any equivalent or higher examination with
Hindi as one of the subjects.

(26) What are the MINOR penalties?

1. CENSURE
2. Withholding of promotion for a specified period.
 - 22 -

3. Recovery from his pay of the whole or part of any pecuniary loss caused
by him to the Government or Railway Administration by negligence or
breach of order.
4. (a) Withholding of Privilege Passes or Privilege Ticket Orders or both.
(b) Reduction to a lower stage in the time scale of pay for a period not
exceeding three years without cumulative effect and not adversely
affecting his pension.
5. Withholding of increments of pay for a specified period with further
directions as to whether on the expiry of such period this will or will not
have the effect of postponing the future increments of pay.

(27) What are the MAJOR penalties?

a. Reduction to a lower time scale pay, grade, post or service with or without
further directions regarding conditions of restoration to the grade or post of
service from which the Railway Servant was reduced and his seniority and
pay in such restoration to the grade or post or service.
b. Compulsory retirement.
c. Removal from Service which shall not be disqualification for future
employment under the Government or Railway Administration.
d. Dismissal from service, which shall ordinarily be disqualification for future
employment under the Government or Railway Administration.

(28) Define ISO 9001, ISO 14001 system.

ISO 9001 system is for monitoring and maintaining the quality of the
products conforming to the defined level at each and every stage, through various
documents, inspection, checklists.

ISO 14001 is Environmental Management system. It is a method of

monitoring and maintaining the working environment to the defined level through
various process and system for reducing the generation of wastages and its
disposal as per the norms.

(29) Find out the total for (1/8) + (3/4) + (1/2) – (1/4)

Solution:
(1/8) + (3/4) + (1/2) – (1/4) = (1 + 6 + 4 -2)/8
= 9/8 = 1 ⅛

(30) Convert 45° C into ° F

Solution:

°F = [° C x (9/5)] + 32
= [45 x (9/5)] + 32
= 81 + 32
= 113° F
 - 23 -

(31) Convert 104° F into ° C.

Solution:

°C = (° F – 32) x (5/9)
= (104 – 32) x (5/9)
= 40° C

(32) (a) Convert the fraction 7/20 into percentage

Solution:

(7/20) x 100 = 35%

(b) Convert 5.03 mts. into mm

Solution:
1 meter = 1000mm
5.03 meter = 5.03 x 1000
= 5030 mm

(33) What are the POH activities for pre-cooling rectifier unit and 25KVA
inverter unit of RMPU AC coach?

Pre-Cooling Transformer Rectifier Unit

Open the cover and clean externally with compressed air.
Dismantle the unit as per manufacturer’s instructions.

Remove and clean the contacts by means of a clean rag soaked in petrol.
Contacts, which are burnt, should be replaced and covered with Vaseline.
Clean the transformer, rectifier and rotary switch. Check for operation; if
defective, change it.
Inverter Unit

Open the front panel door and clean with compressed dry air. In case the
compressed air pressure is too high, cover the nozzle with thin cloth to reduce the
pressure.

Clean the semi-conductor device’s heat sink with compressed air. In case the dust
is not removed completely from fins use hard hairbrush and again blow with
compressed air for cleaning the heat sink.

Check that all connections to PCB are tight and no insulation on cables, boards
and insulator is damaged.

Check for normal routine performance test as per manufacturer’s instructions.

 - 24 -

Part – E 10 marks each

Answer the following :

I. (a) Write a letter to your immediate officer regarding warranty failure of an

electrical equipment requesting to advise the firm.

No.WS/Elec/WF Ponmalai
Dt: 09.07.10
AXEE/TL/GOC

Sub: Warranty failure of 25KW RRU – KEL make.

====

One number 25KW KEL make alternator received in coach

No.ACCW 05122 was found defective and it is under warranty up to
14.02.2011. The details are given below:

Sl. No. : 09121538

Loaded at : MDU Division
Date of loading : 15.02.2010
Date received for POH : 02.07.2010
Nature of defect : No Generation and field winding is
open circuited .

The firm M/s KEL may be advised to attend the defect or replace the
above 25KW alternator failed under warranty and lying at Train lighting Shop,
Ponmalai.
Sd/-
(M.Muthukumar)
JE/AC/GOC
For SSE/AC/GOC

(b) Write a letter to your immediate supervisor regarding IOD of an

employee working under your control.

No.WS/Elec/IOD Ponmalai
Dt: 09.07.10
SSE/AC/GOC

Sub: IOD to Sri K.Vijayakumar, Technician/AC/Gr.II

====

Sri K.Vijayakumar, Technician, ACM/Gr.II, T.No.AC 16022 while on

duty at 09.40 hrs. on 09.07.10 and carrying out POH of condenser fan motor
and assembling for coach No. ACCW 87058 had a deep cut on his left middle
 - 25 -

finger due to piercing by a screw driver and bleeding severely. He was given
first aid and he has to be sent to Railway Hospital, GOC for treatment.
Necessary IOD form may be issued and two staff working nearby have been
sent for witness signature.

Sd/-
(K.Ramanathan)
JE/AC/GOC
II. Write short notes on any two

(a) Non-conventional Energy

Energy sources not used conventionally and in large scale are called
non-conventional energy sources. Conventional energy sources because of
continuous usage are getting depleted for example petroleum products, coal,
natural gas etc.

Non-conventional energy is available in abundant since the sources are

generally of renewable type i.e inexhaustible. The cost of method and
equipments tapping them is costlier at present. When conventional energy
sources are depleting, non-conventional energy sources usage have to increase
and cost may come down on large scale utilization. Example for non-
conventional energy sources,
1. Solar energy
2. Wind energy
3. Geo thermal energy
4. Tidal energy

(b) Payment of Wages Act

As per the Payment of Wages Act, the wages of every person

employed upon or in any railway, factory or industrial or other establishment
shall be paid before the expiry of the seventh day after the last day of the wage
period in respect of which the wages are payable. The wage period shall not
exceed 30 days.

(c) Procedure for processing NS items

1. Preparation of indent.
2. Getting signatures of competent authorities.
3. Non-stock certification from stores officers
4. Vetting from finance and approval from CWM/CEE/AGM as per the
schedule of power.
5. Submitting indent to stores
6. Purchase action.
7. Receiving the material.
8. Inspection.
9. Bill certification.
 - 26 -

(d) Ton of refrigeration

This is the unit for the capacity of Air Conditioners. 1 Ton of
refrigeration is the heat removed by melting 1 American Ton of 2000 lbs of
ice into water at 0°C in 24 hours. Latent heat diffusion for 1 lb of ice is
144 BTU and for 2000 lbs of ice in 24 hours,

2000 lbs x 144 BTU/lb = 288000 BTUs in 24 hours.

1 Ton of refrigeration = 12000 BTUs/Hr.

(e) Function of Expansion valve and capillary tube in AC system

The primary function of the expansion valve is to control the quantity of

liquid refrigerant admitted into the cooling coils of the evaporator. The heat
load on the evaporator varies depending upon the heat gain. The expansion
valve admits more refrigerant when air conditioning load is high and reduces
it when the load is low. All this is done automatically.

In smaller AC plants, refrigerators etc., expansion valve is not provided to

achieve simplicity and replaced by one or more capillary tubes to regulate the
gas into the evaporator to match with the heat load where the pressure is
lowered by the suction of the compressor.

(f) Dry and wet type thermometer:

The dry bulb temperature is that indicated by an ordinary thermometer,

provided its bulb is perfectly dry. The wet bulb thermometer is with its bulb
covered by a thin cotton sleeve soaked in water. The water in the wet cloth
around the bulb takes away its latent heat of vaporization from the bulb to get
it cooler and hence wet bulb thermometer shows a lower temperature than dry
bulb temperature. The drop in temperature depends upon the relative
humidity of the surrounding air.

(g) Modified Assured Career Progression(MACP):

Financial upgradation will be available in the next higher grade pay when
a Railway employee has completed 10 years of continuous service in the same
grade. There shall be three financial upgradations under the MACPs counted
from the direct entry grade on the completion of 10, 20, 30 years of service
respectively.

MACPs envisages merely placement in the next higher grade pay in the
recommended revised pay bands and grade pay. Hence the revised pay under
MACPs may be different to that what is available in next promotion. During
financial upgradation the pay shall be raised by one increment i.e. 3%. After
financial upgradation, if regular promotion is given, there shall be no further
fixation of pay at the time of regular promotion if it is in the same grade pay.
If it is in a post carrying higher grade pay the difference in grade pay is
admissible and no pay fixation is allowed.
 - 27 -

III. Draw the power circuit diagram of a RMPU AC coach and explain.
It feeds supply to 2 hermetically sealed R-22 compressors, one double
shaft blower motor and two water proof condenser fan motors designed. Power
supply to these motors as well as two heaters is conveyed at 415 Volts through the
contacts of seven contactors shown in the power circuit diagram. (The magnetic
coils of all contactors are operated at 110 volts AC in the control circuit). The
motors are protected by MCB/fuses and overload relays.
Two crank case heaters receive direct supply from the bus bars through
main supply rotary. In case phase is missing or is reversed in the Incoming
Power, the Negative Sequence Voltage Sensing Single Phasing Preventors
installed in the control circuit will not allow the AC unit to start until abnormality of
such supply is corrected.

IV. What are the salient features of RMPU AC plant and advantages over
conventional under-slung AC plant?
High savings Light in weight, saves fuel for hauling. Weighs 1400 Kg. (as
compared to 2700 Kg. for conventional AC)
Ease in The unit is factory made, assembled & gas charged and tested
Installation for performance prior to delivery. Installation requires simply
lowering the unit in the false ceiling above the toilet are on both
ends of the coach and connecting it to wire harness, drain pipe
and flexible duct. It taken slightly more than 6 hours to air-
condition a coach.
Low down Replacement of the PAC unit can be done in less than four
time hours.
Better The PAC unit remains outside the comfort zone and therefore,
passenger there are no chances of water drip on passengers.
Hygienic Free Fresh air is taken from the roof which air supplies cleaner, fresh,
free of the toilet smell as prevalent in conventional system.
Refrigerant Hermetically sealed system has no fittings or shaft seals, thus
Leak this presents little potential of gas leaks and avoids major break
downs.
Low The unit is almost maintenance free since it uses 3 phase AC
Maintenance motors-no commutators or brushes to wear out.
Rapid Heat Mounted on the roof, thus no dust dissipation collected in
Dissipation condensers, therefore, requires no maintenance or water spraying
on condenser coils, giving rapid and better hear dissipation.
Safe No chance of damage to flash floods, cattle runs or flying
Operation ballast.
Energy Compact and modular with short Refrigerant Efficient pipes,
Efficient thus loss of capacity through longer connecting pipes is
eliminated.
Capacity Use of 4 compressors per coach offer 25% to control 100%
control capacity and standby facility, saving electricity. Compressors
are started through time delay relays to reduce peak current
draw.
 - 28 -

V. What are the safety protections provided in RMPU AC coach and give the
function of each.
Safety protections in the control panel of RMPU AC coaches.
Temperature protective Thermostats (OHP) set at 200Deg. C. are
provided on each heating element to switch OFF power to the Heater element in
case the surface temperature of the heater reaches 200 Deg. C.
Electro-Pneumatic Time Delay Relay are provided on each compressor to
ensue delay in starting of each compressor when power is switched “ON” and to
prevent both compressors starting at once.
TWO VANE RELAYS are provided to ensure operation of condenser
fans. Compressors or Heaters only when the air flow is present across the cooling
coils and the heating elements.
High Pressure Safety Cut-out (HP) and Low Pressure Safety Cut-out (LP)
are provided to switch OFF compressor when the High pressure exceeds 420
PSIG or Suction pressure drops below 35 PSIG. The LP cutout is auto reset
where as HP cutout is manual reset type.
Over load Relays with built in single phasing protection are provided to
protect compressor, condenser Fan and Blower motors against single Phasing and
overload.
VI. What are the final testing to be carried out on RMPU AC coach after POH?
Final testing of AC coach after POH

 Visual inspection of coach for proper fitment of equipment.

 Ensure that refrigerant pipes are properly clamped.
 Suction pipe for proper lagging.
 Check safety chain and tension rod of BL alternators for proper fitness.
 Under frame cables leading to alternator are properly cleated.
 Check earth leakage by two lamp method.
 Check central panel and ensure that proper MCB fuses are provided.
 Check contactors, relay and switches for correct sequential operation.
 Check heaters for correct operation.
 Check hooter for proper operation.
 Start the plant and check condenser motor, compressor, blower motor for
any abnormality.
 Check leakage air from doors.
 Ensure that batteries are in fully charged condition.
 Run the plants with dynodrive motors for 8 hrs. At different speed.
 Ensure that both the alternators are sharing load equally during run. If not
set both the alternator panels.
 - 29 -

VII. What are the fire prevention measures to be carried out in 110V DC self-
generating coach?
a) The following checks shall be carried out and ensured on wiring of the coaches.
a. There should not be loose cable terminations.
b. All cables should be of right size as per standard designs with fire retardant
properties.
c. All the terminations should be properly terminated with lugs.
d. Materials and equipments used should be of fire retardant quality.
e. The number of joints and junction boxes should be reduced to minimum.
f. Positive and negative cables should be run in separate conduits.
g. The cables should be secured to the coach structure by using cleats at an
interval not exceeding 500mm.
h. The cleats should have non-inflammable property. PVC/FRP cleats only to
be used.
i. Wherever cables traverse through holes and orifices, such openings shall be
provided with PVC/FRP grommets/bushes with non-inflammable property.
j. Damages to cables insulation shall be prevented and attended to
immediately, if any.
k. All the cable terminals and cable lugs should always be provided with heat
shrinkable sleeves. The effort should be made that the stripped portion of
the cable is fully inserted inside the lug gland and is not exposed outside.
This will avoid shorting of the cables at the terminations where the
clearances are critical.
l. The insulating FRLT tape should be as per ICF specification No.
ICF/Elec/921 and RCF specification No. EDTS 174.
m. Provision of fuses both on positive and negative side for all lights and fans
n. Earth checking
o. Coach insulation test
p. Rewiring at the end of codal life.
b) The following checks shall be carried out on protective devices.
a. No protective system shall be in isolated/bypassed condition.
b. It has to be ensured that the correct size and capacity of the fuses and
MCBs are provided for the different loads.
c. The protective devices such as fuses, MCBs etc, must conform to their
relevant specification and shall be of procured from approved sources.
d. Contactless infrared thermometers should be used for detecting the
overheated joints in the terminal boards. This check should be done
during monthly maintenance.
e. FRP trays shall be provided at the bottom of the battery boxes for LMLA
battery.
f. There should be clear warning indication that the laptop/mobile charging
points are meant for charging purpose only and shall not be used for any
other purpose.
 - 30 -

c) The following modifications to wiring in luggage portion of SLRs to be done to

avoid damage during luggage loading and possibility of causing electrical fires.
(i) No switches to be provided inside the luggage portion. Switches
shall only be in the guard’s compartment.
(ii) No wiring shall be exposed in the luggage portion. The wiring
shall be kept to the minimum level and taken through conduits
inside the paneling.
(iii) Lamps in the luggage portion shall be mounted in a recessed
manner with protective grills.
VIII. Write an official language policy including OL Act
Part XVII of the Indian Constitution was passed on 14.09.1949 and it
contains provisions on Official Language. It has four chapters and contains
articles 343 to 351. It first chapter deals with Official Language of the Union and
contains articles numbers 343 & 344. Its second chapter which deals with
regional languages contain provisions on languages to be used in the Supreme
Court and in the High Court and for Acts, Bills etc. Fourth chapter contains
articles No. 350 & 351.
Article 350 contains provisions for language to be used in representation
for redress of any grievance to any officer or authority of the Union or State.
Further it also provides for facilities for instruction in Mother-Tongue at primary
stage.
Article no. 351 contains directive for development of the Hindi Language.
The Official Language Commission constituted under 344 (1) had inter-alia
recommended that provisions should be made to allow the use of English
Language for the Official purposes of the Union beyond 26th January 1965. The
Parliamentary Committee also endorsed this recommendation of the Language
Commission. In accordance with the provisions made in article 343(3) of the
constitution, Parliament enacted in Official Language Act – 1963 for continued
use of English.

IX. What are the documents under OL Act which are to be issued in Hindi,
English bilingual form?

There are 14 documents under Section 3 (3) and they are to be invariably
issued in Hindi – English bilingual form
1. General Orders (Memorandum, Circulars etc.)
2. Rules
3. Notices
4. Notifications
5. Resolutions
6. Administrative and other reports
7. Press communiqués
8. Contracts
9. Agreements
10. Licenses
11. Permits
 - 31 -

12. Tender Notices and Tender Forms

13. Papers to be laid before a House or both the Houses of Parliament.
14. Reservation Charts.
X. Explain the working principle of a transformer with sketch.
A Transformer is a static (or stationary) piece of apparatus by means of
which electric power in one circuit is transformed to electric power of a same
frequency in another circuit. It can raise or lower the voltage in a circuit but with
a corresponding decrease or increase in current. The physical basis of a
transformer is mutual induction between two circuits linked by a common
magnetic flux. In its simplest form, it consists of two inductive coils which are
electrically separated but magnetically linked. If one coil is connected to a source
of alternating voltage, an alternating flux is set up in the laminated core, most of
which is linked with the other coil in which it produces mutually-induced e.m.f.
If the second coil circuit is closed, a current flows in it and so electric energy is
transferred from the first coil to the second coil. The first coil, in which electric
energy is fed from the a.c. supply mains, is called primary winding and the other,
from which energy is drawn out, is called secondary winding.
XI. Explain the salient features of Factory Act and Workmen Compensation Act.
Factory Act: As per the Factory Act, Factory means any premises where 10 or
more workers are working or were working on any day of the preceding 12
months and in any part of which a manufacturing process is being carried out.
Factory Manager means a person who has ultimate control over the affairs
of the factory.
As per the Factory Act, overtime to the staff should be calculated on a
daily basis or weekly basis whichever is more favourable to the employee.
Hours of working: 48 hrs./week. Not more than 9 hours/day. Not more than 5
hours at a stretch and then half an hour break. Working hour including intervals
not more than 10½ hrs./day.
Sunday and holiday work CR within 3 days. Not more than 10 days
without a rest day. Period of work is notified on notice board. For more than 9
hrs./day and 48 hrs/week, OT is to be paid at twice ordinary wages. Total hours
including OT should not be more than 13 hrs./day and 60 hrs./week. Maximum
allowed is 7 days continuous OT and 75 hours OT in a quarter.
Health : Regular cleaning, disinfection, painting, ventilation, no overcrowding,
lighting, drinking water, cooler, toilets.
Safety : Protection guards, blow off fuses, chain ropes, hoists, load testing,
explosives and inflammable protected.
Welfare : Washing facility, cupboards, first aid box, ambulance, canteen.
Workmen Compensation Act: This Act is for declaring compensation to
workmen under disabled or died on duty. This Act defines the activities to be
 - 32 -

treated as on duty of workmen and also defines the disablement into different
types with periods for the purpose of paying compensation by the employer i.e
permanent/temporary and partial/total disablement.
The employer shall not be liable for paying compensation under WCA in
respect of any injury which does not result in the total or partial disablement of
workmen for a period not exceeding 3 days. The amount of compensation under
WCA where death results from an injury is an amount equal to 50% if the
monthly wages of the deceased workman multiplied by the relevant factor or an
amount of Rs.90,000/- whichever is more.
The minimum compensation under WCA for permanent total disablement
is Rs.90,000/-.
XII. Draw Air Conditioning System cycle diagram and explain.
The refrigerant gas is compressed by the compressor. This compressing of
gas increases its temperature higher than the outside ambient temperature due to
heat of compression. This hot compressed refrigerant vapour is injected inside
the tubes of the Condenser Coil. Air is blown across the condenser Coil by
condenser fan causing refrigerant to cool down and therefore, condense from
vapour to liquid refrigerant inside the condenser Tubes.
The high pressure condensed liquid refrigerant now flows through an
expansion device and connected with the Evaporator coil.
The other end of the Evaporator coil connected to the suction part of the
Compressor which sucks the refrigerant and drops the pressure inside the
Evaporator coil. Drop in pressure causes evaporation of the liquid refrigerant to
gas which makes the Evaporator coil extremely cold due to heat of vaporization.
Air to be cooled or conditioned is blown across the Evaporator coil by
evaporator blower. The heat from this air is absorbed by the evaporating
refrigerant causing the air to cool down.
The refrigerant gas sucked by the compressor is again compressed to high
pressure and pushed into the condenser coil completing the refrigerant cycle.
XIII. Explain the working principle of any one make of rectifier cum regulator
unit used in AC coaches with circuit diagram
Principle of working principle of 25KW KEL RRU : -
The 3 phase AC output from the alternator is fed to the 3 phase bridge
rectifier (PR) of the RRU and converted it into DC.

Alternator field supply is derived directly from two phases of alternator

rectified by rectifier D1 to D4 and connected in series with alternator field
winding and main windings of two magnetic amplifiers MA1 and MA2 each of
which has 4 control windings. Out of four, two are used in each. Control winding
10-11 of both magnetic Amplifiers are for regulating voltage and current of the
alternator. The other control winding 20-40 is for field feedback/protection.
 - 33 -

The main winding impedance varies when the current in the control
winding varies due to change in magnetic flux towards saturation or otherwise.
The impedance variation of main magnetic windings varies the field current to
achieve desired voltage and current regulation.

Voltage control /regulation circuit consists of 3 phase bridge rectifier RT1

and voltage detector DT1. Three phase alternator voltage is rectified to DC and
applied to DT1. Voltage setting is through Rheostat setting Rh1. When set
voltage reaches, zener diode D6 conducts and current passes through the gate
windings 10-11, increasing the impedance of the main winding, causing reduction
in field current and the 3 phase output voltage of alternator. Zener stops
conduction. Current stops through gate winding 10-11 decreasing the impedance
of main windings, causing increase in field current and increase in 3 phase output
voltage of alternator till zener starts conduction. Voltage is thus maintained at set
voltage.

Current control/regulation is through CT1, CT2, CT3 in each phase and 3

phase bridge rectifier RT2 and current detector DT2. Current setting is done by
Rheostat setting Rh2. Zener D9 conducts and stops to regulate output voltage in
the same manner and maintains the current at set value.

XIV. What are POH schedule for Brushless Alternator, RRU, Pulleys, Tension
gear of AC coach?

VISUAL INSPECTION
Carry out visual inspection of the machine and record the following:-
Serial number and name plate particulars of the machine.
Check that rotor rotates freely.
Check alternator tension rod.
ELECTRICAL CHECKS
Carry out the following electrical checks and record the following:-
Open the cover of the terminal box and check whether the internal
termination and terminal board are intact.
Tighten all the connections on the terminal board.
Using a multimeter, check continuity between
Field terminal F+&F-
Stator terminals U&V, V to W and W to U
Check the insulation resistance by 500V megger between
Stator terminals and frame of machine.
Field terminals and frame.
 - 34 -

OVERHAULING

The machine received for overhauling should be externally cleaned with wire
brush and wiped before dismantling.

Clean and re-grease the bearing after removing the bearing from the bearing
housing. Only Servo Gem (RR-3) grease shall be used.

Clean the mating surface of the end shield.

While removing and placing the rotor, care should be taken that the rotor does not
rub over the field coils.

If any grease has crept into the stator surface, clean it before assembling.

If stator and rotor parts are found rusty, clean. Apply the insulating varnish (air
drying) of recommended grade. Impregnation of the varnish shall be done in an
air circulated oven.

Change the alternator suspension nylon bushes 100% and change the suspension
pin on condition basis.

Apply the insulating varnish (air drying) of recommended grade. Impregnation of

the varnish shall be done in an air circulated oven.

After complete fitment and greasing, the bearing noise shall be recorded using
shock pulse meter during running on test bench.

Only bearing of SKF/FAG shall be provided as per recommendation of RDSO.

The pulley condition such as wear on V group, pulley key way, shaft way, groove
angle etc. shall b e monitored during POH. Proper gauges shall be used for
checking “V” groove of the pulley and replacing.

TESTING OF ALTERNATORS

INSULATION RESISTANCE TEST

Check the insulation resistance

Alternator

Between stator winding and earth - above 20 megohms

Between field . winding and earth - above 20 megohms

Between field . winding and stator - above 20 megohms

 - 35 -

Regulator

Short all terminal (live parts) together and check the insulation resistance
between the live parts and earth. It should be above 10 megohms.

Note: The insulation resistance of all the above should be measured by 500V
megger.

RECTIFIER REGULATOR UNIT

The procedure to be followed shall be as per guidelines given below.

Check the terminals and inside wires for heating signs and looseness. Blow out
the dust.

Replace the damaged wiring/terminals. The wiring of the regulator shall be done
systematically.

Check the PCB circuit with PCB testing kit or multimeter to identify defective
components. Replace defective components.

Check field transformer for correct voltage. Replace, if found defective.

V-BELTS/TENSIONING GEAR

The existing V belts shall be replaced with the new V belts 12 Nos. having same
grade/make. The old V belts removed from service are to be destroyed.

Tensioning gear shall be removed and its spring shall be checked for proper
functioning. If required moving parts of tensioning device including spring shall
be replaced.

V GROOVED AXLE PULLEY AND ALTERNATOR PULLEY

The procedure to be followed shall be as per guidelines given below:

Check the pulley for slippage, tightness and physical damage to grooves. Ensure
availability of locking nuts and split pins in position. Check the alignment of axle
pulley with the alternator pulley and adjust. Change the rubber packing in axle
pulley.

Replacing the pulley if any groove is damaged/broken/worn-out.

The pulley shall be replaced after four years period or earlier on condition basis.
 - 36 -

XV. What are the final testing to be carried out on under-slung AC coach after
POH.

Visual inspection of each equipment for their proper fitment.

Ensure that refrigerant pipes are properly clamped.

Ensure all the modifications are complied with.

Check safety chain and tension rod of alternator for proper fitness.

Under frame cab les leading to alternator should be properly cleaned.

Check earth leakage by two lamp method.

Check refrigeration system for any leakage before charging the gas.

Conduct vacuum test. (For 12 hrs.)

Conduct pressure test.

Vacuum test for 15 minutes for dehydration of refrigeration system.

Check control panel and ensure that proper fuses are provided.

Check contactors, relay and switches for correct sequential operation.

Ensure that time delay in operation of contactor.

Check heaters for correct operation.

Check hooter for proper operation.

Check hooter for proper operation.

Start the plant and check condenser motor, compressor motor, blower motor for
any abnormality.

Check leakage air from doors.

Check oil level in compressor, the level when operating should be ½ bull’s eye.

Check the proper working of capacity control solenoid valve.

Run the plant for four hours. An equivalent heat load (convector heater) should
be kept for performance test of plant.
 - 37 -

If new expansion valve is provided during POH, it should be set properly.

Ensure that batteries are in fully charged condition.

Run the plants with dynodrive motors for 8 hrs. at different speeds.

Ensure that both the alternators are sharing load equally during run. If not set
both the alternator panels.

General Checks

Suction pressure gauge reading should be 37-40 PSI (2.6-2.8 Kg/sq.cm.)

Delivery pressure gauge reading should be 150-170 PSI 10.6-12Kg/sq.cm.)

Oil pressure should be minimum 3 Kg/sq. cm. above suction pressure.

Feel temperature. Suction should be cold and sweaty. Delivery should be very
hot and liquid line should be warm.

The coach shall be jointly inspected with division’s staff and the performance of
electrical and refrigeration equipment shall be recorded. Any attention to the
given equipment shall be given before dispatch of the coach from workshop.

XVI. What are POH schedule activities for RMPU AC plants in RMPU AC coach?

Pre-Inspection

On arrival to shop, place the coach on the pit line and inspect the electrical and
air-conditioning equipment. Conduct the cooling test. If the cooling time is less
than the specified values, any further attention to refrigeration circuit is not
necessary, except cleaning. Check operation of all protections and note down the
defects and deficiencies.

Lift the roof-mounted unit with the help of 1 ton lifting arrangement as per
procedure and place it on the wheeled trolley to take it to the shop for
overhauling.

With the help of compressed air, remove the dust of the conditioned air duct.

Check for corrosion in trough

It is necessary to check steel trough, which is provided below AC package unit

during every POH of AC coach. If any corrosion is observed, then it should be
patched up with 2mm. thick sheet of stainless steel.
 - 38 -

Check for corrosion of welded joints of AC package unit structure

The welded joints of AC package unit structure should be examined carefully for
presence of corrosion and such corroded members shall be replaced/rectified.

Check for accumulation of water in condensed drain pipe and trough outlet

Clean the condensed drain pipe and trough outlet pipe with help of compressed
air. It is also desirable to blow compressed air into the pipe from below, every
two months to avoid any choking of pipe due to accumulation of dust, etc.

Deterioration of rubber lining

If there is any deterioration or cracks in rubber lining provided on AC package

unit, it should be replaced

OVERHAULING ACTIVITIES

Compressor

There is no need to open the refrigeration system of the AC package units, since it
is completely sealed at factory. Conduct the cooling test. If the time required to
cool the coach is more than the recommended value and it does not decrease even
after cleaning of condenser and evaporator, the compressor will have to be
changed.

Condenser and Evaporator

Clean the condenser coil and cooling coil with steam of 10 kg/sq.cm. to clean
thoroughly and to remove all dirt and mud thoroughly. This can be done without
removing the coils from their places.

Motor for Condenser and Evaporator

Check for abnormal noise, vibrations, burning smell.

Check foundation bolts for looseness and tight, if necessary.

Check the terminals after opening terminal box cover and see for tightness.

Check the condition of terminal lugs.

Check the earth connection of the motor body.

Clean the motor by blowing compressed air.

Lubricate the motor bearing by approved lubricant use lubricating gun for
greasing.
 - 39 -

Check the alignment and re-align the driving and driven shafts.

Check the coupling for looseness and tighten if necessary.

Check the duct for crack and for loose/missing fixing bolts.

Measure the insulation resistance of winding with a 500V megger. If the

insulation resistance is less than 10 M ohm, run the motor for half an hour for
drying. If insulation level does not improve re-varnish.

A/C Control Panel And Power Panel

Completely isolate the panel from the power supply and its loads. Contacts of the
contactors shall be removed and cleaned by means of clean rag socked in petrol.
Contacts, which are burnt, should be replaced, after which they should be lightly
covered with silican gel/petroleum jelly.

Similarly, dismantle the contacts of the relays and clean them by means of clean
rage soaked in petrol. Contacts which are burnt should be replaced.

Check whether all connections are tight. If found loose, tighten the same.

Replace all the fuse links.

Check rotary switch for proper working by ensuring following:

Ensure that all the poles are functioning.

Check that knob shaft is not having any play.

Check, clean and tighten all connections.

Check for defective ammeters and voltmeters, and replace the defective ones.

Check for continuity and sequence list of AC equipment.

Check that all mounting screws are intact and tight.

Check all terminals, terminal marking and ensure that legend plates are intact.

Check all indicating LEDs are functioning.

Cutouts

Clean the cover with Petrol and test for correct operation of settings.

Calibrate with the standard gauges.

 - 40 -

XVII. What are the POH activities for fans, lights and wiring in an AC coach?

Fans and lights

Dismantle the lower guard, upper guard, blade and fan motor.

Check the guard assembly, repair/replace if necessary.

Check the blade angle with a measuring gauge. Correct the same if
necessary.

Check the insulation resistance of the fan motor. The IR value should not
be less than 2 mega ohms.

Check the fan leads and change it if necessary.

Check the armature winding and field coils, repair/replace, if necessary.

Check the commutator for grooving, pitting marks, ovule, blackness etc.
Skim or polish the commutator as required.

Check the carbon brush and brush spring. Replace by correct grade of
carbon brush as recommended by RDSO. The fan spring should be with
proper tension. Replace the same if necessary.

Apply air drying insulating varnish if IR value of the armature and field
coils is low, give impregnation treatment in an air circulating oven.

Clean the ball bearing, check for noise, replace if necessary or grease it
with recommended grade.

Check the rubber packing at fan base. Replace if found cut/damaged.

WIRING

Light fittings

The light fittings, reflectors, clear acrylic sheet cover, glass globe, holders,
etc., shall be checked and cleaned. All defective parts shall be replaced.
Anti-theft arrangement for fluorescent light fittings shall be checked.

Coach Insulation

Insulation resistance of the coach shall be measured with 500V megger.

The same should be more than 2 mega ohms in fair weather conditions but
it should not be less than 1 mega ohm under highly humid/wet weather.
 - 41 -

Cable Joints

It shall be checked. Loose joints and cables having damaged insulation

shall be replaced/repaired. All cable ends shall be properly socketed with
crimping type copper sockets.

Surface of copper sockets and bus bars shall be cleaned to remove the
oxide film from the jointing surface before making a bolted joint and shall
be coated with corrosion resistant conducting grease of approved make to
prevent reformation of oxide film.

Fire retardant PVC grommets are to be ensured for all cable entries.
Tighten connections as needed.

*****