2016 SINGLE LINE DIAGRAM OF POWER CIRCUIT OF LHB COACH
Guided By: Mr.KESHAV KUMAR Sr.instrutor TL/AC
CETI, Thakurli
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PROJECT REPORT ON NEUTRAL SECTION
:PRINCIPAL: MR. YASHWANT URHEKAR CETI , Thakurli
:Guided By:
Mr. VED PRAKASH SAHU Sr.instrutor OHE
:COURCE CO-ORDINATOR: CO-ORDINATOR:
Mr. KESHAV KUMAR
Mr. J.L.GENDLE
Sr.instructor
Sr.instructor
TL/AC
TRS(EMU)
2
TABLE OF CONTENTS
Sr. No.
Topic
Page No.
01
Acknowledgement
04
02
Project team
05
03
Certificate
06
04
Introduction of LHB
07
05
Advantages of LHB Coaches
08
06
Power Supply Arrangement
10
07
Single Line Diagram of Power Circuit of LHB Coaches
12
08
Equipment use in LHB Coaches
13
09
LHB AC Coaches Contactors & Relay
27
10
LHB AC Coaches Fuses
29
11
Power Car(LHB)
30
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ACKNOWLEDGEMENT
It is indeed a matter of great pleasure and proud to present this project of “ . we are highly indebted to Mr. Ved Prakash Sahu(OHE) Sr. instructor of CETI Thakurli for his invaluable guidance and wish to record our deep sense of gratitude and appreciation for his support. We would like to render our sincere thanks to Mr.Yaswant Urhekar, principal CETI Thakurli, Mr.Ved Prakash Sahu Sr. instructor (OHE) of CETI Thakurli, Mr.J.S.Gendle Sr. Instructor (EMU),course coordinator of CETI Thakurli and Mr.Keshav Kumar Sr. instructor (TL/AC), course coordinator of CETI, Thakurli for their continuous support, guidance and inspiration in all the phases of our project work and encouragement that we have received.
Project Team
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Project Team Sr. No.
Name
Designation
Div/Rly.
1
Mr. DALIP SINGH MEENA
Tr. SSE
LJN/ NER
2
Mr.KRISHNA NAND YADAV
Tr. SSE
ALD/NCR
3
Mr. SANDEEP KUMAR MAURYA
Tr. JE
LJN/NER
4
Mr.DEVENDRA SINGH
Tr. JE
LJN/NER
5
Mr.SANDEEP KUMAR JAREDA
Tr. JE
LJN/NER
6
Mr.RAJU KUMAR GOND
Tr. JE
LJN/NER
7
Mr. RAJU
Tr.JE
8
Mr.ROHIT PATIL
Tr.JE
9
Mr. PREMCHANDRA PRAJAPTI
Tr. JE
10
Mr. JITENDRA PRASAD
Tr.JE
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This is certify that project work entiteld is a bona-fide work carried out by…………………………………….………………......an induction trainee of CETI batch from 03 OCTOBER 2016 to 18 MARCH 2017 under my guidance and direction.
Signature of guide:
Signature of course coordinator:
Mr.VED PRAKASH SAHU
Sr.instructor OHE
Mr.KESHAV KUMAR Sr.instrutor TL/AC
Mr.J.L GENDLE Sr.instructor TRS(EMU)
Signature of principal:
Mr. YASHWANT URHEKAR Principal CETI Thakurli
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LHB TYPE COACH
(M/s LINKE HAFFMAN BUSH, GERMANY)
In order to make quantum jump in passenger coach technology and to bring it to contemporary world standards, Indian Railway entered into supply and technology Transfer contact with ALSTOM-LHB, Germany, As part of supply contract M/s ALSTOM-LHB , Germany supplied 24 coach consisting of 19 second AC Chair cars and 3 Generator cum brake Vans.
Rail coach factory, Kapurthala has been entrusted with the task of developing and manufacture of modern, high speed state of art coaches under transfer of contract.RCF took the challenge, achieved the target and rolled out first rake of LHB coaches on 13-12-2003 for Rajdhani Express between New Delhi to Mumbai Central.
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Advantages of LHB Coaches Passenger Related Areas
Improved ride comfort –ride index of 2.5/2.75 at 160 Kmph As compared to 3.25/3.5 for ICF coaches at 130 Kmph. Higher speed potential of 160 kmph. Windows of big size allowing good visibility with functional roller blinds. Luggage rakes of modern designs with integrated lamps for all seats.
Mechanical Advantages
Modern designs of vestibule for inter car connection. Anti –climbing feature to prevent climbing off during collision. Four emergency window are provided per coach. Coach length is increase by about 1.7 m to provide extra carrying capacity. Length of ICF coach is 21337 mm (21.3 meter)where as LHB coach is 23040 mm (23.04 meter) . This extra length means two additional rows of chairs in chair cars or one additional bay in sleeper coaches. 1 AC 2 AC 3 AC
18 to 24 46 to 54 64 to 72
Electrical Advantages
Low noise, microprocessor controlled AC unit. Light weight epoxy molded 60 KVA Transformer. Integrated modular single switchboard with controls of AC lighting. Provision of FRLS cables. Uniformity of illumination. IGBT based battery charger used. Humidity control sensor provided. Temp control in seven step. Disconnecting and earthing device provided. Exhaust fan provided in toilet Flap motor to adjust volume of fresh air automatically. NTC type sensor provided.
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POWER SUPPLY ARRANGEMENT The power system for the coach has been designed to feed the various electrical loads in the system operating at different voltage. There will be following voltage system for feeding the various electrical loads.
750 V 3 Phase AC supply system 415 V 3 Phase AC supply system 240 V AC single Phase 110 V AC single Phase 110 V DC
The coach will select the input supply from either of the two feeders available on the coach at 750 V Three phase supply through disconnecting and earthing device provided in which board cabinet.
The 750 V 3 phase supply is stepped down to 415 V ,3- phase supply with the help of one 60 KVA epoxy cast and encapsulated transformer, which is provided on the under-frame of the coach.
The electrical equipment of roof mounted package units, exhaust fans and pump equipment are supplied with 415 V, 3-phase supply received from 60 KVA transformer.
Loads of electrical appliances provided in sub pantry such as hot case, bottle cooler, and refrigerator shall be fed with single phase at 240 V, 50 Hz by using one out of three phases and neutral connection of 3-phase 415V AC supply.
The lights, electric razors socket etc. shall be supplied at 110 V, single phase AC received from regulated battery charger.
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The 110 V DC is used for supplying control for roof mounted package unit , anti-skid device, light control, emergency lights, telephone, night lights, berth reading lights, power contactors control etc.
A DC-DC converter shall be used to obtain 24 V DC for control systems for pump, sanitary and public address system, return air flap unit i.e. servo motor of air conditioning system etc.
The power and control supply arrangement to various electrical loads in the coaches shall generally be similar to originally imported LHB AC coaches. The 415/240 V AC network is designed as unearthed IT-4 conductor system.
Roof coach wiring shall be routed in PVC rigid conduit/trenches conduits. Under frame wiring shall be with IP68 protection and shall be covered with perforated cable trays as a primary safe guard against ballasts hitting.
All the equipment above 250 V shall be earthed at two places and below 250 V at one place. Voltage segregation shall be ensured during wiring.
As per rule 64-A of IE rules, over current protection shall be provided to disconnect the supply automatically, if the rated current of the equipment, cable or supply line is not designed to with stand.
The system will have earth fault/earth leakage protection to disconnect the supply automatically, if the earth fault current exceeds the limit of current for keeping the contact potential within reasonable limits.
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FEEDER JUNCTION BOX
3 phases,750 volts AC supply.
A Feeder is a conductor which coonects the local generating station to to the area where the power is distributed.
The main consideration in the design of a feeder is the current carrying capacity.
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Disconnecting and Earthing Device Disconnecting and earthing device is provided in switch board cabinet and is fed 750 V from power car through ZS couplings. It has two positions “ON” & “EARTH”. It
disconnects coach feed at 750V in case of emergency like contactor jamming and earths the coach for maintenance even during running of coaches.
Capacity
: 120Amp.
Purpose maintenance.
: It is an off load switch to ensure earthing before
Locations
: In bottom right side of switch Gear rack.
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Summary of technical specification of LHB Coaches Electrical Equipments INTER VEHICULAR COUPLER ASSEMBLY
Rated Current Capacity
: Phase & Neutral wires-400Amp : Earth wire-260 amp : control wires-25Amp
Cable Size
: Phase wire-120/150Sq mm : Neutral wires-95 Sq mm : Earth wires-70 Sq mm
Insulation Resistance Value
: More than 500 mega ohms
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MAIN FEEDER FUSE Fuses
: HRC 750V,63 Amp, 25KA : Total 3 number in each feeder
MEASURING & MONITORING RELAY (MMR)
Purpose
: To check for phase sequence matching between iv coupler wires & coach 3-phase wires. : Additionally it gives over voltage & under voltage protection also.
Setting
: +/- 10% of 750 V for O.V & U.V
MINIMAL VOLTAGE RELAY Purpose : To protect battery from over discharging : It works in three steps. At 106 V it arrange to switch off reading light. : At 104 V it arrange to switch off DC to DC converter load : At 96 V it arrange to switch off emergency lights also. Setting
: As above
LIGHTING TRANSFORMER Rating (KVA/Volt/Amp) : 3KVA 230/110 Volt AC
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COACH LIGHTING
Type
Fluorescent tubes
:18 watts
Incandescent lamps :10 watts(for night light & pantry)
Halogen lamps
:10 watts (reading lights)
Fluorescent tubes are used as general lighting, vestibule, toilet, Pantry and emergency working at 110 volts AC/DC with inverter And with polycarbonate diffusers.
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The inverter for fluorescent lamp Normal input voltage
:110v AC/50Hz (88-138 v Range )
The inverter for Reading Lights
Normal input/output voltage
: 110v DC/12 v DC : 0-60 w/12v
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60 KVA TRANSMORMER
Rating (KVA/Volt/Amp)
: 60KVA,750/415Volt : 3 Phase (46.2/83.4 Amp)
Type of Transformer
: Cast Resin Dry type
Type of Mounting
: Underslung,4bolt
Location
: Underframe
Cooling
: Natural air cooled
Class of Insulation
: H
Connections
: Star-Star
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PUMP
Rated speed
: 2800 RPM
Rating (HP?KW/AMP)
: 0.5 H.P/0.37KW/1.2 Amp
Motor insulation Class
: F
Total head
: 8Metre
Discharge
: 38 LPM
Power supply of controller
:
24 volt
MAIN BATTERY CHARGER Purpose
: To give battery the regulated voltage
Rated output voltage (float)
: 121 v at 4 amp
Boost Charging setting
: 127 V at maximum 6 amp.
Boost current limit
: Above 6 amp
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BATTERY
Type
pure lead tin VRLA monoblock battries
Operating temp. range
-40 to +50 deg. C
Terminals
high conductivity copper alloy terminals
Separator
high quality absorbent glass mat separator
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Pressure valve
self releasing pressure regulating valve
Container
impact resistant ABS container &lid
Plates
plates with superior grids and active materials
Charging for pure float
float – 13.5 v for 12 v battery
Application
boost- 13.8 v for 12 v battery
Charging for semicyclic
float -13.7 v for 12 v battery
Application
Boost – 14.0 v for 12 v battery
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EXHAUST FAN Purpose to exhaust the coach air to atmosphere in order to dilute the carbon dioxide concentration & to make toilet & corridor portion indirectly air conditioned. Location for exhaust toilet, control panel & mini pantry equipment area.
RMPU UNIT Nos. of RMPU unit in each coach 2 units (2 X 5 Ton ) capacity each in power car only one unit.
BLOWER MOTOR
Rated speed
1420 RPM
Rating (HP/KW/Amp.) 1.0 HP/.75 KW/1.85 Amp. Fan blade material
Plastic
Motor insulation class
H class
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CONDENSER MOTOR Rated speed 1380 RPM Rating(HP/KW/Amp.) 1.0 HP/.75 KW/1.85 Amp
COMPRESSOR Type of compressor hermetically sealed Rating 415 v 3ph AC 50 Hz LP cut out (for scroll) 20.0 BARS (max.) HP cut out (for scroll) 27.5 BARS (max.)
FILTERS Fresh air size 48 cm x 26 cm Return air size 83 cm x 43 cm
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MINI PANTRY EQUIPMENT HOT CASE
Heater rating Blower rating Air flow qty
500 W for one unit 45 W 230/250 cubic meter per hour
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BOTTLE COOLER
Capacity
2nd AC 280 LTR 3rd AC 170 LTR
Comp Rating Refrigerant used Cond. Motor Rating Capacitor size
KCE 444 R-134 1/36 HP 10 micro farad
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DEEP FREEZER Capacity 2nd AC 37 LTR 3rd AC 22 LTR Comp. rating KCE 345LAG
LHB AC COACHES CONTACTORS & RELAY
K01,K02
Main contactor feeders
K03,K04
MMR(measuring monitoring relay) 750 v
K05
Anti stand drive
K06
brake application
K07
brake release
K08
MVR(minimal voltage relay step 1)
K09
MVR (minimal voltage relay step 2)
K10
MVR (minimal voltage relay step 3)
K11
Light control relay (AC light)
K12
Light control relay (Reading light)
K13
Light control relay (night light)
K14
Light control relay (AC light)
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K15
Light control relay (DC light)
K16
Light control relay (DC light)
K17, K18
Light control relay
K19, K20
UIC light remote control relay
K21, K22
Aux cont. return air flap motor
K23
415 v OK relay
K24, K25
Contactor pump control
K26, K28
Blower motor cont.
K27
Controller OK
K29
Exhaust fan cont.
K31,K32,K36,K37 Condensor motor cont. K33,K34,K38,K39 comp. motor cont. K35,K40
Air heater cont.
K41,K42
Local main supply cont.
K43
common cont. for LMS
K44
main cont. transformer output
K45
MMR 415 v for LMS
K48
Emergency light relay
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LHB AC COACHES FUSES
F42/43=25 Amp Main 110V DC F10/11/12=100 Amp Main transformer output 440 V F47/48/49=80 Amp LMS incoming 440V F50/51/52=63 Amp Net 1 feeder incoming 750 V for coach F53/54/55=63 Amp Net 2 feeder incoming 750V for coach F56/57=2 Amp UIC light remote control 24V DC F58/59/60/61/62=2 Amp insulation control 110V AC/440V AC F67=1 Amp LMS 230V (K41) F68=1 Amp LMS 230V (K42) F69/70/71=1 Amp MMR-LMS (K43) F72=1 Amp main contractor transformer output (K44) F73=1 Amp 415V Ok (K23) F74/75=10 Amp 1 Amp MMR net 1-750V F90/91/92=1 Amp MMR net 1-750V
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F94/95/96=1 Amp MMR net 2-750V
POWER CAR (LHB)
ALTERNATOR
KVA-500/400KW 750Volts , 3 Phase,1500RPM Amps-385 Extitation=45V
ALTERNATOR PROTECTION
1) 2) 3) 4)
Over loading-280 Amp Under voltage Earth leakage Short circuit
ENGINE
BHP-490
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SAFETY DEVICE FOR ENGINE 1) 2) 3) 4)
Over speed cut out=1800 RPM CFR On High water temp.=70F-90C cut supply to FSS & FSRD Low lubrication oil pressure 3 to 7 Kg
STATRER MOTOR
Volts-24 DC series motor Compound motor-4 pole Starting current-260 Amp Rotation-clockwise
STARTER BATTERIES 24 Volts 390 AH for starting engine Starting current-260 Amp
THROTTLE MOTOR Use to very speed of engine=24V DC
OVR RELAY Input-750
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RADIATOR MOTOR 415 Volts 40 H.P 54 Amps Radiator Starter-Star/Delta VENTILATION FAN 415 Volts 5 KW Duty-51 ACB
3 Pole circuit breaker Making capacity=25KA Breaking capacity=50KA Provided with UVR & ELR UVR-Coli activated by 415V & pick up voltage is 380V
TRANSFORMER (Delta)
Input-750V Output-415V Current Primary-42.2A
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Secoundary-83.4A POWER CAR GENRAL INSTRUCTION
Take a round in every 60 minutes in the engine room to check whether all equipments are working normally & enter the reading in the log book in every one hour.
Record the quantity of fuel while taking/handing over the charge.
Inform your in charge before energizing the feeder.
Record tripping. If any in the log book.
Always keep your tool box ready with you. Check expiry date of fire extinguisher.
As & when you get a chance e.g at halt station. Check the under frame.
Keep the power car clean & tidy. Do not keep inflammable articles & ensure that there is no oil spilled in power car. Always use tin containers for storing oil etc.
Maximum load permissible on a CUMMINS engine is 360 amp. (feeder load should no exceed 300 amp.)
Do record the reason in the log book if standby engine has to be started enroute.
Ensure that all the HRC fuses are of proper rating and all the indicator lamps are in working condition.
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Equipments Details •
ZS Coupling (Male)
– 02 Nos.
•
ZS Coupling (Female)
– 02 Nos.
•
Switch Board Cabinet
– 01 No
•
Disconnecting & Earthing Device (DED)
– 01 No.
•
MMR
•
Feeder Contactors(750V)
•
60 kVA Transformer
•
Contactor for Transformer Output (415 V) – 02 Nos.
•
Blower Motors
– 02 Nos.
•
Compressors
– 04 Nos.
•
Condenser Motors
– 04 Nos.
•
Microprocessor
– 01 No.
•
Filters in RMPU
– 04 Nos.
•
Mono Block Pumps
– 02 Nos.
•
Pump Controller
– 01 No.
•
RBC (6.5 KW)
– 01 No
•
EBC (2.5 KW)
– 01 No.
•
Set of Batteries(12Vx09 Nos) 70 AH VRLA – 01 Set.
•
1 KVA Transformer
•
Wheel Skid Protection (WSP)
– 03 Nos – 02 Nos. – 02 Nos.
-- 01 No. -- 01 No.
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