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   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 Axle driven under slung alternator with V - belts 110V DC regulated at different speeds through RRU Battery back up during standing/slow movement of train   2X25KVA, 110 V DC/415 V inverters for AC load. 110 V DC supply for lights and fans

MOUNTING ARRANGEMENT OF AXLE DRIVEN ALTERNATOR

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

Batteries for TL & AC Alternator for TL & AC Non-AC Coaches 120 Ah- 110 V DC (nominal) , 18 Mono blocks of 6 volt each 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 kW AC (RMPU)- 25 kW, AC (US)- 18 kW

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

DISADVANTAGES OF SG SYSTEM   Load restricted to 2X25kw per coach Bulky 1100 Ah(AC)/ 120Ah (Non-AC) coach battery required during standby / slow movement   No standby alternator/battery  Extensive maintenance due to under-slung alternator, battery, axle-pulley  Poor system efficiency 54%  

END-ON-GENERATION SYSTEM Rajdhani, Shatabdi type fully AC trains with large power requirements. Two power cars each with 2X250 kW (new high Capacity ) Diesel alternator sets. Power fed by two feeders 750V 3- ph by I V couplers step down to 415V 3 ph for AC by 50/60 kVA transformers 110V AC lighting and fans by 415/110 AC transformer

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

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

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

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

TL & AC Maintenance

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

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

THANKS