General

Services
Electrical
 Functional Setup: General Services

Power supply arrangement

Power wing

Energy conservations and Green Initiatives

Coaching wing Non- AC COACH Maintenance

AC Coach Maintenance
General Services – Coach Maintenance

Duties:

Maintenance of Electrical equipment

in a coach.
History of Train lighting system

• Initially lighting in trains was done using candles, lamps,

oil and later on by gas.

• Train lighting by electricity was introduced to prevent

fire accidents.

• Introduced on Indian Railways in 1897.

• Started with 24 V DC system.
• Now, switched over to 110 V DC system.

…
 Generation Systems for a coach

HOG MOG EOG

SG SG SG SG

● Self Generating(SG): 110V DC

● Mid-on-Generation(MOG) : 415/110V AC (30 KVA DG SET 2 nos.)- Passenger trains
● End-on-Generation (EOG) (Power cars): 750 V, 3-phase, 4 wire system (High capacity
Power car) - Rajdhani / Shatabdi trains

● Head on Generation(HOG): Hotel load winding on Electric locomotive

 Self Generation (SG) Systems for a coach

● Alternator / Generator : It is suspended from the under frame of

the coach and driven by flat belt Axle Pulley

TRAINLIGHTING:
4.5 KW, 110 VOLTS,
V-belts
4 V-Belts on 1 pulley

AIR-CONDITIONING:
18/ 22.5 / 25 25 K W, Axle Pulley
110 Volts,
6+6 V-Belts on 2 pulleys
Rectifier Cum Regulator Unit (RRU)

• Mounted on under-frame of the coach

• It rectifies AC to DC and regulates the output voltage level.

Battery:

• The power is supplied to the load from the battery when the train is stationary.

• It gets charged during the run.

Capacity of Non AC coach Battery : 120 Ah

 Types of Batteries

VRLA : Valve Regulated Lead Acid Battery SMF : Sealed Maintenance Free Battery

Container -Hard rubber Advantages

Electrode plates -Two (Positive & Negative)
Positive plate - PbO2 • It is compact and can be oriented in vertical,
Negative plate - Spongy lead horizontal position.
Medium - Sulphuric Acid • There is no fume or smell from the battery
since the acid is in gel form.
• The battery can be installed in the equipment
prior to transportation since there is no
leakage or water spill during transportation.
• More economical than any other forms of
battery.

Issues: Frequent topping up and leakage of electrolyte

 Self Generating System in a Coach
+ve
Alternator
Pulley
Battery
Fan
Rectifier
Rectifier- Light
cum
cum-
Regulator

V Belts
Axle pulley
Alternator
-ve

• The load of the train at rest is fed by the battery. After attainment of Minimum Speed for Full Output i.e. (MFO – RPM-600 for Non-AC Coaches
& 800 for AC Coaches) and Output-128.5V, :
Generation Voltage will exceed battery voltage and load will be fed by Alternator &

The battery will be in charging mode.

The regulation of voltage at 128 V is being done by RRU Unit by Zener Diode Arrangement and Over voltage
Protection (OVP) set at 145 V in case of RRU Panel failure for safeguard of equipments.
Working of Train Lighting and Fan Circuit

FDB- Fuse Distribution Board

FDB

Negative
Fuse box

Batteries
Different Levels of Protection in TL coach

FDB: Fuse Distribution Board

FDB

Main
Fuse box
Train Lighting Major Components

● Alternator
● Axle pulley & V-Belts
● Rectifier cum regulator unit
● Battery
● Junction box, Rotary Switch, MCBs
● Lights & Fans
● Mobile Charging points
 Limitations of Self Generation System

• External hitting of under-slung equipment

• Maintenance of batteries
• Maintenance of pulley-belt system as they are subjected to continuous vibration
• Limited generating capacity as size of generator can not be increased to safety
consideration and space constraints.
• Unsuitable for electrical load (hotel load) of trains such as Rajdhani and Shatabdi Exp.
Advantage Of 110 V DC Train Lighting System over 24 V DC

• Lesser weight per KW output

• Additional load is possible
• Current will be less, hence cable connections will be smaller in size
• Less maintenance as compared to 24 V DC system.
 Mid On Generation (MOG) System

MOG

Used for trains having frequent stops.

Suitable for slow moving passenger trains.
Supply is obtained at 110V through one power car in the center
having two 230 kVA DG sets.

ADVANTAGES DISADVANTAGES

• Centralized control in all coaches. • Space constraint since one coach has to
• Absence of bulky batteries. be dedicated for power generation
(Power Car).
• Reduced maintenance.
 End On Generation System

• Rajdhani/ Shatabadi works on OG configuration.

• Two Generator Cars (Power cars) at both ends of

the train to cater to Hotel load requirement i.e.
lighting, fan, AC and Pantry equipment.
• Each power car is equipped with two generating
sets of 500 KVA capacity each

• .Electrical power to the train is supplied through

two sets of feeder at 750 V, 3 phase 50 Hz.

POWER CAR Block Diagram

 End On Generation System

Advantages Disadvantages

Elimination of bulk batteries Higher fuel cost

No External hitting of under-slung equipment Noise & smoke pollution
Lesser Maintenance Reduction in commercial space
Lesser Downtime Need for staff to operate & maintain.
Improved Reliability
High Power requirement is met

EOG EOG
 Head on Generation (HOG) System

• Power is provided from the locomotive at

the head of the train.

• 2 X 500 kVA hotel load convertors are fitted in

Locomotives to convert single phase into
three phase supply electricity for train
lighting, air-conditioning and for pantry cars..

HOG
 POWER CAR Block Diagram

Locomotive Coaches

HOG Power Car Coach

 Advantages of HOG System

•
• No noise and air pollution.
• Cost of power production per unit is cheaper than EOG & SG
• Less maintenance vis-à-vis Power car
• Higher reliability
• More commercial space available due to elimination of one power car.
• Reduction in Carbon footprint by 31, 88,900 Ton per annum.
• Saving of Rs. 2,300 Cr in fuel cost due to elimination of power cars.

EOG rakes are being converted to HOG. 1,120 trains have been converted so far.
General
Services
Electrical

Air Conditioning
 History of Air conditioning in Coaches

1906 : the term "Air Conditioning“ was used for the first time.

1910- 1920 : Air-conditioning in its primitive stage was started on Railways

Initially, khas-khas mats were provided which were kept moist by reservoirs
specially provided for the purpose.

Use of ice blocks:

• Ice blocks were kept in containers.
• These were replenished at several halts along the
line.
• A battery operated blower constantly blew air into these blocks
and the cold air entered the coaches through vents.
History of AC coaches in India

• Air-conditioning in coaches was first introduced

in India in 1936.
• The coach was constructed in Matunga workshop,
Mumbai.
• Electro-mechanical air-conditioning system was
used.

1955: AC Chair Car stock was introduced

1956: The first fully air-conditioned train with Ist AC was

introduced in between Howrah and Delhi. Popularly
known as the AC Express.

1979: two-tier AC coaches introduced.

1993: 3-tier AC coaches were introduced by RCF.

2005: 3-tier economy (Garib Rath) AC coaches introduced.

Design parameters for RAIL AIRCONDITIONING

Supplying clean fresh air at a controlled uniform temperature.

Catering to the continuously changing number of passengers.
Providing for heating as well as cooling on a train that travels through
areas of widely differing climate during its journey.
Operation of the equipment from power generated, stored and controlled
on the train.

The requirement of fresh air inside the compartment :

A/C First Class : 0.70 m³/min/person
A/c Sleeper & A/C Chair car : 0.35 m³/min/person
Factors to decide comfort level in Air-conditioned Passenger Coach

• Temperature
• Relative Humidity
• Draft (Velocity of Air)
• Purity of air and
• Noise
Temperature settings in AC Coach

single temperature settings

For Summer : 230 C - 250 C

For Winter : 190 C - 210 C

Temperature setting is displayed in AC coaches to keep the passengers

informed about temperature setting and to reduce passenger
complaints.
 Air-conditioning – comfort factors: Humidity
Absolute humidity

• It is the mass of water vapor divided by the mass of dry air in a volume
of air at a given temperature.
• Absolute humidity is expressed as grams of moisture per cubic meter
of air (g/m3).
• The hotter the air is, the more water it can contain.

Relative humidity

• It is the ratio of the current absolute humidity to the highest possible

absolute humidity (which depends on the current air temperature).

• 100 percent “relative humidity” means that the air is totally

saturated with water vapor and cannot hold any more.
 Importance of Relative humidity

If the relative humidity is low, we feel much cooler than the actual temperature
because our sweat evaporates easily, cooling us off.

If the air temperature is 24 degree Celsius and the relative humidity is zero percent,
the air temperature feels like 21 degree Celsius to our bodies.

If the air temperature is 24 degree C and the relative humidity is 100 percent, we feel
like it's 27 C.
 Unit of Refrigeration
● Unit of Refrigeration – Ton (TR)

● It refers to the latent heat required to melt a ton of ice at 32 degree F in 24 hours
1 Ton (TR) = 12000 BTU/Hr
= 3000 k Cal/Hr
1 Ton(TR) Can Cater to Approx. 10 X 10 X 10 Cubic feet (Space)

Refrigerant

• Earlier Freon 12 or Freon 22 (di-Chloro-di-fluoro-methane) gases used.

• Replaced by R-134 a (Tetra-fluro-ethane) Halogen free gas to reduce Ozone

layer depletion in SG underslung coaches.

• R-407C (mixture of R -32, R-125 and R-134a ) is being used in LHB AC coaches
 Refrigeration Cycle

Condenser – it cools the hot gas

and liquidifies it under pressure.

Compressor –
compresses & delivers
gas into condensers at a
high pressure & high
Expansion Valve – It controls temperature
and regulates the rate of flow Evaporator
of liquid refrigerant under
high pressure
Evaporator –the cooling unit in
which liquid refrigerant under low
pressure evaporates & in-doing so
takes away the latent heat thereby
cooling the medium surrounding
the cooling coil.
Method to control Relative Humidity

Let us assume that outside ambient air is at 26 deg. C

with 95% RH.

When it is sent over the evaporator at 4 deg. C, moisture

is condensed as capacity to hold water depends on
temperature.

When this air is sent inside the AC compartment after

raising the temperature to 21 deg. C, the RH becomes
Evaporator
50% inside as there is now less moisture.
New development in Air conditioning system for a coach
RDSO has finalized technical specification for AC coaches which have and reverse cycle features.

Inverter based compressor

• works on a principle of Variable Frequency Drive (VFD) to cause the speed of the compressor to vary
as a result of varying load conditions.

Advantages:
• Inverter compressor technology is highly responsive, efficient and compact.
• The inverter units are quieter, with lower operating cost and more reliability.
• The inverter air conditioning units have increased efficiency when compared to traditional air
conditioners.
• Sharp fluctuations in the load are eliminated.

Reverse cycle features

• In reverse cycle feature, a reversing Valve changes/reverses- the direction of the flow of refrigerant,
which changes the direction of Heat Transfer.

• The system uses heat absorbed from the Air of the surroundings, whereas electric heaters generate
heat by consuming electricity.
Issues in Railway Coach Air-conditioning

• Requirement of very high reliability standard.

• Equipment should be light in weight.
• Equipment should take minimum space.
• Available power has to be utilized.
• people move in and out of coach at all hours of the day
• Rapidly changing ambient conditions as the train moves from one part of the
country to another.
• Excessive vibrations.
• Dusty atmosphere.
• Safety of passengers

...
 Systems of Generation for AC coaches

1. Self generating Coach :

• 22.5 /25 kW, 110V, 3 phase alternators driven by axle pulleys are used to generate power.
• The supply is given to RRU (Rectifier cum Regulator unit).
• The output is used to charge batteries and to invertors.
• Invertors gives 415 V 3 phase AC to AC plants.
Supply System in End-on-Generation (EOG) Coaches

● AC coaches draw power from the DG sets in Power cars.

● Power is generated at 750 V, 3 phase, 50 hz .
● Power supply is obtained by tapping one of the two feeders running end to end of the
train.

Power supply to AC plants

● 50 KVA transformer is provided in each coach which steps down voltage to

415 V, 3 phase, 50 Hz AC supply for AC equipment.

Power supply to lights and fans

• a step down transformer of capacity 3 KVA is provided in each coach which steps down the voltage
from 415 V, 3 phase to 190 V, 3 phase.
• 110 V AC supply is provided for lamps and fans by connecting them between line and neutral of the
secondary side of transformer.

Emergency lighting System in EOG Coaches

• One battery is provided on the under frame to supply emergency lights provided in the Coach
• Capacity of battery is 24 V, 90 AH
Battery Charging at the Terminal Stations

• one 200A capacity battery charger is provide in AC Coach.

• The battery charger takes 440 V, 3 phase supply through

special battery charging sockets mounted diagonally on each
end wall of a coach.
Mounting arrangement of AC system in AC coaches

Roof mounted package unit (RMPU)

(RMPU)

Under Slung (US) arrangement AC Coach

(US)
 Disadvantages of Under slung AC system

• Refrigerant gas leakage from pipes and joints

• Heavy weight - coach tare weight increases

• Large space occupation by the equipment

• Maintenance problems for underslung equipment

• Energy efficiency is low

• Under-slung equipment get hit by ballast, CRO
• Accumulated dust affects heat transfer…..

Solution : Roof mounted packaged unit (RMPU)

Roof mounted packaged unit (RMPU)

• RMPU is a package Units for Rolling Stock applications

• RMPU of 5.2 TR introduced in the year 1992

• Mounted above the toilets on both ends of a coach.

• This unit can work on H.O.G./E.O.G./ SG coaches.

Top view • RMPU Body is made of Stainless Steel Grade- 304 – ideal for extreme and
non-uniform weather conitions.
 ROOF MOUNTED AC PACKAGE UNIT

Sealed Compressors

CONDENSOR FANS
AIR INTAKE FOR
THE CONDENSOR FANS

HEATING
THERMOSTAT
ELEMENTS
• Each RMPU has two circuits i.e.
two sealed/scroll compressors,
two condensers &
two cooling coils cum heaters.

• The RMPU is capable to work even with one circuit.

• Reliable static Inverters (for conversion of 110 volt DC into 3-phase AC) used in AC
Coach
• 3- phase brushless compact motors are used
CAPACITIES OF AC PLANTS IN COACHES

Sr. Type of Coach No. of A.C. Calculated A.C. load Capacity of A.C.
No. Plants of coach Plants provided

01 A.C. 1st class 01 5.30 TR 7.0 TR x 1

02 AC 2 tier 02 7.48 TR 7.0 TR x 2

03 AC composite coach 02 7.97 TR 7.0 TR x 2

04 AC chair car/ AC 3 Tier 02 11.10 TR 7.0 TR x 2

 Air Flow in AC coaches

RMPU

Coach main duct

RMPU

Fresh air
Conditioned air
Return air
●43
Comparison of RMPU with Conventional under-frame AC system

RMPU Conventional AC
Weight 900 Kgs 2700 kgs
(2 units)
Installation time 4 hrs 4 days
Refrigerant R – 134a R – 12
Refrigerant charge 2.85 Kgs 15 Kgs

Danger due to cattle run Nil Heavy

over / flood
Down time for repairs 4 hrs. Very long time
 Capacity of battery in AC Coach

Type of AC No. of sets & capacity of Relevant BIS

Coach battery specification
AC 2T Sleeper 1 set of 800 AH (56 cells) IS : 6848
AC Chair Car - - do - - do -
AC composite - do - - do -
AC 1st class. 1 set of 525 AH - do -

Lithium Ion Phosphate batteries are being provided in 2 coaches on experimental basis.
These batteries are lighter in weight and size with longer codal life.
A view at Coaching depot
General
Services
Electrical

Power Supply
Arrangement
 General Services -Power

Responsibility #1

Operation and maintenance (O&M) of lighting arrangement of service buildings,

railway colonies, railway stations and platforms.

To ensure adequate, efficient and reliable lighting arrangement as per laid down
norms of Railway Board.
Adequate Lighting arrangement
Illuminance (E)

▪ This is the measure of Quantity of light (lumens) incident on a surface per unit area (m2). The unit is
‘lux’ (lumen/m2).

Illumination levels (in lux)

Area Airport Standard A1/A station B station C/D/E stations

Concourse 200 100 100 100

Circulating area 150 50 30 20

Waiting Hall 200 100 100 100
Covered Platform 200 50 30 20
Reservation office 200 200 200 200
Outdoor car 50 20 20 20
parking
Stairs/FOB/Subway 150 50 30 20

A1/A - Zonal Railway HQ and State Capital

B - Railway Divl. HQ and State Distt. HQ
C/D/E - Other stations
Yard Lighting

Factors to be considered while designing the lighting:

▪ Wide area coverage

▪ Ease of maintenance
▪ Free of obstruction for vehicle movement
▪ No infringement for OHE, or loco movement
▪ All weather protection

Use of high mast for

yard lighting
Workshop / Shed Lighting
Factors to be considered while designing the lighting
• Protection and safety
• Uniform Illumination
• Environmental factor
• Obstructions and infringements

Types of Fittings used

High Bay fitting Low Bay fitting

• Ceiling height > 20 ft.

• 150 W or above
• Beam angle 90 degree or narrower LED Based Roof Lights
in Workshops
Office Building Lighting

Factors to be considered while designing the lighting

• Uniformity of Illumination
• Day light availability
• Desired/recommended illumination for task
• Glare level
• Office Aesthetics

Types of Fittings used

18 W LED Tube Light Down lighter Mirror optic

 General Services -Power

Responsibility #2 Air conditioning of services buildings

Operation and Maintenance of Air conditioning Equipment in Passenger Reservation System, Control
Office, Hospital operation theatres, Auditoriums, Conference halls, Meeting rooms, officers chambers etc.
as per Railway Board Norms.
Types of Air-conditioning Equipment

• Centralized AC plant
• Individual Rooms
• Window type
• Split Type

Use only 3 stars or above rated ACs

for energy efficiency
The temperature settings is to be maintained
between 24-26 degree Celsius.
 General Services -Power

Responsibility #3 Passenger amenities : Lifts, Escalators at Railway Stations

Lifts at other locations on need basis.

Sanctioned for major stations

Capacity- 100 passengers per minute

Speed – 0.5 m/Sec (nominal)

Angle of inclination - 30 degree

VVVF Control – smooth & energy efficient

 General Services -Power

Responsibility #4

Maintenance of sub-stations (other than TRD) & electric distribution network

Incoming Voltage: 33/11 kV

Output Voltage: 440 volts
 General Services -Power
Responsibility #5 Pumping installations

To install, operate and maintain adequate size pumps for water supply to stations,
colonies, office buildings, washing lines, coach watering systems etc.
 General Services -Power

Responsibility #6

Electrical contractor to all the Departments

Electrical Shocks

A person feels an electric shock when electricity passes through his body.

Strength of current and Effects

Between 1 mA to 8 mA just bearable

Between 8 mA and 15 mA
Between 20 mA and 50mA passing
through the chest
The currents above 200 mA
a painful shock and contract the muscles
may stop breathing
punctures the outer skin of the body
and causes burns and/ or death

Safety Measure

A well designed Earthing arrangement.

Earthing

• Earthing is used for protection from an electric shock.

• It provides a path for the fault current to flow to earth.
• It also causes the protective device (either a circuit-breaker or fuse) to switch off
the circuit that has the fault.

● Earth Values : L.V. – Less than 10 ohms

H.V. – Less than 0.5 ohms

Precautions to be taken

• Design earthing system as per requirement

• Carry out regular inspections to check value and conditions
 Electrical Fires

Causes Preventive measures

• Overloading of Equipment • Avoid overloading of Equipment

• Poor Maintenance • Proper Maintenance
• Wrong electrical connections • Quality workmanship
• Ensure protection devices are in circuit
• Testing and calibration of protective devices
• Ensure proper earthing
• Select material of approved quality
 General Services -Power

Important Acts and Codal Provisions: Difference between Act and Rule

▪ Indian Electricity Act 2003 An Act is primary legislation. It is the ‘law’ which has been passed by
both of the Houses of Parliament and approved by the President.
▪ The Electricity Rules 2005

▪ Track Crossing Regulation 1987

Rules are framed to frame methods and procedures to make the Act
operational.
The rules are enacted into operation by the government or
ministries rather than the legislature.
General
Services
Electrical

Energy
conservations and
Green Initiatives
 Some Energy Conservation initiatives

• All fittings replaced by LED fittings

• All ACs to be at least 3 star rating

• Bulk Compressors being replaced by smaller compressors in repair shops and workshops.

• Water coolers replaced by water dispensers.

• 70/30 platform lighting circuit

• Energy Audit of Work Centres

.....
Energy Management Systems (EnMS) ISO 50001:2018

• Enables an organization to follow a systematic approach in

achieving continual improvement of energy performance

Use data to
Develop a better
Fix targets and Review how Continually
policy for understand Measure the
objectives to well the policy improve
more efficient and make results
meet the works energy
use of energy decisions
policy management
about energy
use
Solar Energy : a game changer for IR

• IR has about 51,000 Hectare of vacant land.

• The land has 20 GW potential capacity.

• Railways requirement about 4 GW over 5-8 years with 100% electrification &
operationalization of DFC routes.
• Thus Railways entire power requirement can be met through green power by
deployment of solar plant in vacant Railway land.
• Actions have been initiated to make IR first Railways to Transform itself as ‘Net Zero’
Carbon Emission Mass Transportation Network by 2030
 PLANNING AND PROGRESS OF RENEWABLE ENERGY IN IR

RENEWABLE ENERGY

SOLAR ENERGY WIND ENERGY – LAND BASED

ROOFTOOP (for Non traction) &
LAND BASED (for Traction)
PROGRESS
PLANNING – 103 MW already wind based power
– 200 MW plants with 26 MW in Rajasthan, 21
PLANNING PROGRESS MW in Tamil Nadu & 56.4 MW in
- 500 MW ROOFTOP Maharashtra.
– 114 MW Rooftop Solar Plants
- 500 MW LAND BASED installed in 900+ stations - 200 MW wind energy plants are
planned to set up in Gujarat,
- Tenders awarded for 245 MW with DOC
Rajasthan and Karnataka.
Dec’2022 & Balance tendering is under
progress by REMCL. - tendering is under progress by
REMCL.
-4500 Ha land has been identified to
install 1 GW solar plants for traction.

Indian Railways’ Solar Mission is part of National Solar Mission Target

Q&A