Coaching stock Manufacturing of coaching stock Sanction Pink

Coaching stock

Manufacturing of coaching stock • Sanction (Pink book, RSP) (Nodal directorate-PU) • Issue of Particular specification including Electrical part and layout plan by RDSO – General layout – Type of shell and Bogie – Type of key materials and systems (brakes, electrics etc) • Preparation of detailed drawings by Mechanical design of PU

Manufacturing of coaching stock • Preparation of detailed drawings by Electrical design of PU • Issue of material schedule for procurement of materials • Setting up jigs and fixtures • Manufacturing of prototype • Tests and trials in coordination with RDSO • Issue of speed certificate by RDSO • CRS sanction

Head On Generation (HOG) Coaches

SELF GENERATION (SG) SYSTEM • Generation is AC which after AC-DC rectification becomes 110 Volt DC (with battery back up) for lights & fans. For AC (RMPU) , it gets converted into 415 V, 3 ph through Inverters. END-ON-GENERATION (EOG) SYSTEM • 750 Volt Generation from DG sets placed in power cars at the ends. HEAD-ON-GENERATION (HOG) SYSTEM • Power Supply from OHE through LOCO Transformer

SELF GENERATION SYSTEMS Ø Axle driven under slung alternator with V - belts Ø 110 V DC regulated at different speeds through RRU Ø Battery back up during standing/slow movement of train Ø 2 X 25 KVA, 110 V DC/415 V inverters for AC load. Ø 110 V DC supply for lights and fans

MOUNTING ARRANGEMENT OF AXLE DRIVEN ALTERNATOR

SGAC LAYOUT Belt Pulle y Pulley mounted on Wheel 3 Phase AC Alternator Rectifier cum Regulator Unit Self Generation System Battery 25 k. VA AC Coach Inverter AC Control Panel AC Package Unit Light & fans

Batteries for TL & AC v Non-AC Coaches 120 Ah- 110 V DC (nominal) , 18 Mono blocks of 6 volt each v Air Conditioned coaches 1100/800 Ah (VRLA/low maintenance)- 110 V DC: 56 cells of 2 Volt each. Alternator for TL & AC • Non AC- 4. 5 k. W • AC (RMPU)- 25 k. W, AC (US)- 18 k. W

ADVANTAGES OF SG SYSTEM Ø Flexibility in rake formation Ø Independent of mode of traction Ø No separate power car required Ø Failure in one coach do not affect other coach Ø Feed extension is possible in emergency from adjacent coach

DISADVANTAGES OF SG SYSTEM Ø Load restricted to 2 X 25 kw per coach Ø Bulky 1100 Ah(AC)/ 120 Ah (Non-AC) coach battery required during standby / slow movement Ø No standby alternator/battery Ø Extensive maintenance due to under-slung alternator, battery, axle-pulley Ø Poor system efficiency 54%

END-ON-GENERATION SYSTEM ØRajdhani, Shatabdi type fully AC trains with large power requirements. ØTwo power cars each with 2 X 250 k. W (new high Capacity ) Diesel alternator sets. ØPower fed by two feeders 750 V 3 - ph by I V couplers step down to 415 V 3 ph for AC by 50/60 k. VA transformers Ø 110 V AC lighting and fans by 415/110 AC transformer

Advantages of EOG system Ø No restriction of Load due to high capacity power cars Ø Does not require bulky batteries, alternators Ø Standby DA sets Ø Independent of mode of traction Ø Less maintenance required due to elimination of under slung alternator, battery, axle pulley etc. Ø Higher system efficiency

Disadvantages of EOG system Ø Flexibility in rake formation not possible Ø High cost of energy due to high fuel cost Ø Noise and smoke pollution from power car Ø Passenger capacity reduced due to provision of power car

HEAD-ON GENERATION SYSTEM (HOG) Ø Power supply received from loco or tapped from OHE in power car Ø Cost effective, reliable and energy efficient Ø Elimination of heavy under slung alternator in SG coaches and DA sets in EOG power car avoiding noise and smoke pollution

HOG SYSTEM Ø Single phase power from OHE through Loco/ separate Pantograph in power car. Ø Inverter (single phase to 3 phase) can be bulk mounted on/under power car or individual coach.

TL & AC Maintenance

Maintenance schedules Ø Trip maintenance, under gear and safety checking Ø Monthly maintenance : Schedule ‘A’ Ø Quarterly maintenance : Schedule ‘B’ Ø IOH after 9(conventional)/18 Months (LHB) : Schedule ‘C’ Ø Periodical Overhauling (POH) : once in 18 (conventional)/36 Months (LHB)

Maintenance philosophy Ø At present all TL items like alternators, regulators, fans, lights, battery are maintained departmentally. Ø Under- slung type AC Coaches all equipment like compressors, condenser, evaporator, panel are maintained departmentally. Ø Contract with OEM for 4 -monthly schedule of inverters. Ø Comprehensive service contract for RMPU for Trip, monthly, 3 monthly & Periodic overhaul with RDSO approved sources. Ø Selective outsourcing of ACCA.

THANKS