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3 Final INTERNSHIP REPORT
3 Final INTERNSHIP REPORT
SUMMER INTERNSHIP
Internship Report
submitted by
200430109002
BACHELOR OF ENGINEERING
in
Electrical Engineering
CERTIFICATE
This is to certify that the internship report submitted along with the internship entitled
Industrial training has been carried out by Jadeja Luckyrajsinh Yuvrajsinh under my
guidance in partial fulfilment for the degree of Bachelor of Engineering in Electrical
engineering of Gujarat Technological University, Ahmadabad during the academic year
2023-24
Date: 10/08/2023
DECLARATION
We hereby declare that the Internship report submitted along with the internship
entitled Industrial training submitted in partial fulfilment for the degree of
Bachelor of Engineering in Electrical engineering to Gujarat Technological
University, Ahmedabad, is a bonafide record of original internship work carried
out by me INDIAN RAILWAY WORKSHOP BVP under the supervision of
Prof. M.U. Ghanchi and that no part of this report has been directly copied from
other student.
List of Figures
7 Zs coupler 12
8 Transformer 13
9 REBC 14
10 LHB battery 15
Abbreviations
List of Contents
1 Overview of Company 1
2 Structure of Workshop 3
3 Departments in an workshop 4
5
3.2. Electrical Department
4 Types Of coaches 6
7 Interconnection of components 14
8 Meggering 15
9 Conclusion 16
ABSTRACT
This intership focuses on the key aspects of the work associated with
coaches of the workshop, regarding roles, facilities and functions of the
workshop but also other key components such as electrical and electronic
system which modern trains rely heavily on.
Acknowledgement
And also, thanks to my industrial guide Mr. Mayur Jani who accepted me
to do an internship in Electrical department Of railway Workshop
and give an opportunity to work with them and provide with information
About their work and about coaches.
Got a very good experience going out and working in the field. Thank you
so much GTU for taking this step for the students.
The workshop of Indian railways refers to various facilities and services where various maintenance,
repair and manufacturing activities related to rolling stock(trains and locomotives and other
equipments are carried out. Indian Railways, being one of the largest and busiest railway networks
in the world, operates numerous workshops across the country to ensure the smooth functioning
of its operations. These workshops play a crucial role in maintaining and improving the railway
system’s efficiency, safety and reliability.
Railway workshops play a crucial role in the maintenance, repair, and manufacturing of various components
and rolling stock used in the railway industry. The roles and objectives of a railway workshop can vary
depending on the specific type of workshop and its focus. Here are some common roles and objectives
associated with railway workshops:
1. Maintenance and Repair:
Railway workshops are responsible for the maintenance, repair, and overhaul of locomotives, passenger cars,
freight wagons, and other rolling stock.
Regular maintenance ensures that the rolling stock remains safe, reliable, and efficient for operation.
2. Component Manufacturing and Fabrication:
Workshops often produce various components and parts needed for the construction and repair of rolling stock.
This includes manufacturing metal parts, fabricating interiors, and producing electrical components.
3. Upgrades and Modernization:
Workshops may be tasked with upgrading older rolling stock to incorporate modern technologies, improve
energy efficiency, and enhance passenger comfort and safety.
4. Research and Development:
Some workshops engage in research and development activities to innovate new technologies, materials, and
designs for railway equipment. This can lead to advancements in safety, efficiency, and performance.
5. Training and Skill Development:
Workshops provide training and skill development for railway technicians, engineers, and other staff members.
This ensures that personnel have the necessary expertise to maintain and repair rolling stock effectively.
6. Quality Control:
Workshops enforce rigorous quality control measures to ensure that all maintenance and manufacturing
activities meet strict safety and performance standards.
7. Inventory Management:
Workshops manage inventories of spare parts and components required for maintenance and repair, ensuring
that the necessary parts are readily available when needed.
8. Safety Enhancements:
Workshops may develop and implement safety enhancements, such as improved braking systems, fire
suppression mechanisms, and collision avoidance technologies.
9. Environmental Sustainability:
Some workshops focus on developing environmentally friendly technologies, such as reducing emissions and
improving energy efficiency in rolling stock.
10. Collaboration with Rail Operators:
Workshops collaborate closely with rail operators to understand their needs and priorities, ensuring that
SHOPS
The maintenance of coaches is done using various shops at different stages this is explained as below.
Most of the workshops mainly undertake the POH of coaches, wagons and other rolling stocks over
Indian Railways. Objective of workshops include production and maintenance of rolling stock and
ensure its availability to cater transportation needs of Indian Railways.Major Activities carried out in a
Mechanical Workshop involve the following :
(i) Repair and reconditioning of rolling stock and of Plants & Machinery
(ii) Assembly and overhauling of :
a) Coaching Stock
b) Goods Stock
c) Locomotives
d) Cranes of different capacities
(iii) Implementation of all the instructions/upgradations for rolling stock enforced by Railway Board
Another major aspect of this department is performing brake related Servicing and overhauling . It
Maintains and repair braking systems to ensure the proper functioning of brakes, which are crucial for
the safe operation of trains. Brakes are a consumable item but are still properly documented andthen
replaced and other systems relating to it repaired.
The body work is conducted and are responsible authority to Inspect, repair, and overhaul bogies
(undercarriages) that support the rolling stock, ensuring they are in good working condition.all of the
replacemets items are issued and certified for proper fitting but after finishong repairs proper
performance can be guaranteed only after Conducting performance tests on mechanical components and
systems to ensure they meet required standards and perform efficiently. Currently Older ICF coaches are
Retrofited with modern technologies and upgrades to enhance performance, energy efficiency, and
safety.
2. Electrical Department
The Electrical Department in a railway workshop is responsible for the maintenance, repair, and overall
functioning of electrical systems and components associated with railway rolling stock and infrastructure.
Thisdepartment ensures that various electrical systems, ranging from traction and control systems to
lighting and communication systems, are operating efficiently and safely. some of the key tasks and
responsibilities of the Electrical Department in a railway workshop are explained and described below:
The electrical departments indirectly Oversee the maintenance and repair of control systems that govern
the operation of rolling stock, including acceleration, deceleration, speed regulation, and braking. The
Management of the distribution of electrical power within rolling stock, ensuring proper functioning of
systemssuch as lighting, air conditioning, heating, and passenger amenities.
Its the primary obejective of the electrical department They Oversee signaling systems that guide trains
safely along tracks and through junctions, ensuring proper functioning of signals like pull chain light that
makes it easier for guard to understand where a emergency has taken place,working of emergency lights
in the rare caseof full blackout of coach,working and safety of passenger and controlling switches.
The necessary maintenance of electrical systems related to passenger comfort and amenities, including
lighting,air conditioning, heating, power outlets, and entertainment systems ensuring uninterrupted power
supply from overhead wires.
Another major area where electrical department works is in Managing battery systems used for
emergencybackup power and energy storage, ensuring their readiness and functionality.
At last Conduct testing, diagnostics, and performance evaluations of electrical systems to identify issues
andensure compliance with safety and regulatory standards.
Currently older ICF coaches are being upgraded to LHB this work also needs upgrading electrical
componentsso Upgrade and retrofit older rolling stock with modern electrical technologies to improve
energy efficiency, safety features, and passenger amenities is also done.
The Electrical Department's work is essential for maintaining the reliability, safety, and efficiency of
electricalsystems within the railway network. By ensuring that electrical systems function properly, this
department contributes to the overall operational excellence of the railway system.
TYPES OF COACHES
There are 2 types of coaches (i) ICF coaches (ii) LHB
The first attempt at standardization of manufacture of passenger coaches on Indian Railways led
to thedevelopment of IRS design of steel bodied coaches. An integral all metal coach design
was taken from M/s Schlieren, Switzerland in 1954 for manufacture at Integral Coach
Factory.These coaches aregenerally found in yellow or green color scheme .ICF is an Indian
Railways manufacturing unit located in Chennai, Tamil Nadu. It was established in 1952 andhas
been producing coaches for the Indian Railways network.ICF coaches were the standard for
many years, but they have been gradually replaced by LHB coaches due totheir improved safety
and comfort features.They are Heavier in weight and complex.The ICF coaches are broad gauge
self generating coaches, Meaning they are not supplied withelectrical power from the overhead
lines of other Power car connected with the train.In order to accomplish this the ICF coaches are
equipped with Alternators attached to the wheel which charge the batteries when rolling. the
charged batteries supply the electricals needs of a singlecoach.
GUJARAT TECHNOLOGICAL UNIVERSITY 8 SSEC,BHAVNAGAR
341289
1. Alternator.
Figure 3. Alternator \
Alternators are commonly used to generate electrical power on board trains. They are usually
driven by the train's diesel engine or other prime movers, such as electric motors in the case of
electric trains. The alternators convert mechanical energy into electrical energy, which is then used
to power the coach's electrical systems. The alternators used here are of DC brushless type.
These are axles driven with a belt drive to transfer the mechanical motion of the axle.
To rectify the 3 phase AC output of the alternator through DC full wave bridge rectifier. In Self-Generating
Train Lighting and Air Conditioned (SG TL & AC) coaches, requirement of electricity for operating lights,
fans and air conditioning is fulfilled by generating by alternators driven by the axle of the coaches. Battery
of sufficient AmpereHour capacity is also connected parallel to feed the power to the coach during low
voltageconditions. In these SG coaches, magnetic amplifier controlledRectifier cum Regulator Units
(RRUs)are used initially to convert AC output of alternator into DC and regulate/ control the DC voltage
generated through the regulation of the field current of the alternator. This also prevents the reverse flow of
current from battery to alternator during periods of nongeneration. This rectified and regulated DC power is
used to operate the various electrical equipment and accessories inside the coach and to charge the batteries.
3. Batteries
2. LHB COACH
LHB coaches are a newer type of passenger coaches that offer improved safety, comfort, and aesthetics.
Thesecoaches are named after the German company Linke-Hofmann-Busch, which designed the
technology used intheir construction. They are made out of stainless steel and aluminium to decrease
weight which decreases the chance of the coach tipping over .
The LHB Coach is further divide in two categories NON AC LHB and AC LHB coach
The Indian Railways has been gradually phasing out ICF coaches and replacing them with LHB coaches.
LHBcoaches are considered superior in terms of passenger safety and comfort, which aligns with modern
railway standards. However, the transition from ICF to LHB coaches is a gradual process due to the large
number of coaches in the Indian Railways flee
GUJARAT TECHNOLOGICAL UNIVERSITY 12 SSEC,BHAVNAGAR
341289
NON AC LHB
There are three main electrical systems in LHB non AC coach the first one is the power supply
, Train lighting and water supply arrangement.
Tapas supply system in the non AC coach consists of 10 major items listed below. The interconnection
of these items is designed to feed various electrical loads in the system operating atdifferent voltages.
1. Zs Coupling (500 Amp) 750 V
The Zs coupling are the under frame mounted inter vehicular coupler which are used for the transmission
of 750 Volt 50 Hertz supply from power cars located on ends of the rake . Each end of the coach
comprises of 2 couplers one female and one male each unit comprises of a 5 wire system.Hence total
there are 4 coupler on each coach. The coupler is held on with stainless steel ratchet assembly
This is a 3 phase dry type distribution transformer designed for LHB type NONAC
EOG coaches for providing power to coaches from 750 V supply of power cars. There
are two types of transformer i.e. type I- 9 kVA for general IInd classand 3 tier sleeper
coaches (train lighting load 6.5 kVA-415V + 2.5 kVA -190V AC) and Type II- 15 kVA
for chair cars (pantry load and train lighting load 12.5
kVA- 415V+ 2.5 kVA 190V AC). The input line current is 6.92 ampere at 7:50 Volt the nominal output
current is 6.26 ampere for 4.5 kva at 415 Volt and 13.67 ampere for 190 Volt . The insulation class of
insulation material is classified as class H. The rated efficiency is greater than 96%. The Transformer is
enclosed and protected in a stainless steel box which has a water and dust protection rating Of IP-67. The
Transformer is connected in Star—star-star(Yyy) configurationthe winding is Super enamelled copper
winding able to withstand a rise in temperature to aboiut 115 degree Celsius . the total weight of the
transformer is 200kg. The transformer is fitted with 4 aniti vibration mountings and is protected via fuses d
over all dimensions, construction and mounting of the transformer is same as in 60 kVA transformer of
LHB AC coaches Following fusesare used in protection.
For 9kVA transformer.
HT HRC fuse 3.3 kVA 20 Amps – x3, LT HRC fuse 500 V, 16 Amps(415V o/p)- x3
GUJARAT TECHNOLOGICAL UNIVERSITY 14 SSEC,BHAVNAGAR
341289
The Regulated Battery Charger (RBC) is used for charging the batteries of
LHB coaches and to supply power to all DC loads in the coach. This battery
charger is fed power with three phase 415 volts AC 4 wire at 50 Hz from
the750/415 V step down transformer fitted on LHB coaches.
Two types of Regulated Battery Chargers (RBCs), 4.5 kW under-slung with
on-board display unit and without on-board display unit are in use respectively
on LHB AC and Non AC type of coaches. this unit also incorporates Emergency Battery Charger into itand
helps reduce maintenance and maintaining different inventory.
The RBC is air cooled and is made using insulated gate bipolar transistor.
The input given is 415 V AC 3 phase at 50 hz frequency. The output is fully insulated on both positiveand
negative sides with a output voltage of 110 to 135 volts which could be setb bwith the help of a key pad.
The output current is 10 ampere and for other loads 20 amperes. The efficiency of RBC is greater than or
equal to 92%
VRLA battery requires no topping up under normal working conditions and minimal maintenance during
lifetime of battery. It has self sealing safety valve, which normally does not open out during service.
These coaches are provided with 19 monoblock batteries of 6 V or 57 cell of 2 V 120Ah, VRLA battery
in series in two/one battery box mounted in underslung. The auxiliary power required for charging is
supplied by a regulated battery charger at constant voltage based as required by the battery. Current limit
for battery charging is 20 Amp at constant voltage with the voltage setting at 122.0 ± 1.0 volt
Figure 11. Socket side feeder junction box with latch assembly
Two types of feeder junction boxes are provided on the LHB coaches as given under:
a. Socket side feeder junction box
b. Plug side feeder junction box
Figure 12. Wheel set earthing equipment with stainless steel braided earthing cable Figure 13. Earthing resistor assembly 0.1 Ohm
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This cubicle is made of stainless steel fabrication and mounted in under-slung in the coach. This panel
houses the disconnecting and earthing device, switchgear and fuses for 750 V, 415 V, 190
V, 110 V, Pump controller, Anti skid device, MMR, rotary switches for feeder selection etc. From the front
of the panel all the equipment can be access for maintenance. For this front covers are provided with hinges
and locking arrangement. The box is earthed with two earthing terminals on top and bottom on diagonally
opposite ends.
A disconnecting and earthing device along with high voltage fuses is mounted inside the panel. It is an OFF
load device rated for 63 amps at 750 volts fed from Generator Car through ZS couplings. It has two positions
ON & EARTH. The main function of this device is to separate the two feeders (input supply) and
simultaneously earthing 750 volts ac network of the coach in case of emergency like contactor jamming or
maintenance of coach even during running of coaches.
g. FANS
Brushless DC carriage fans of sweep 400 mm, working on 110 V DC supply are being provided
in railway coaches which requires min imum maintenance. The fan is suitable for working in voltage
range 90-140 V DC.The motor of the fan is permanent magnet type, light in weight, and small in size
without field winding, brushes and commutator. The permanent magnet is fitted on rotor embedded in
the slots. A band of colour of about 20 mm wide over the periphery of the fan body approximately at its
middle portion is applied as a colour code for the following:
Dark Green : BLDC fan without hall
sensorDark yellow : BLDC fan with
hall sensor
Interconnection of components.
There will be following voltage system for feeding the various electrical loads.
- 110 V DC
The complete supply arrangement in an LHB non ac Coach is shown in above diagram.
MEGGERING
Meggering of Signalling cable is done to test the continuity and insulation of the cable conductors. The
Meggering should be carried out at initial stages, before and after cable laying. For maintenance purposes
thesetests shall be performed periodically. Low insulation of cable leads to inadvertent energisation or
deenergisation of circuits. Check for insulation values periodically enables to ensure integrity of circuits.
If a sudden fall in the value of insulation is observed during the test, the cause should be investigated and
immediate action should be taken to repair or replace the defective cable.
This test is carried out to confirm that the core under test is either showing break between both ends or
continuous.
CONCLUSION.
As we can observe the integration of modern technologies and equipment in the workshop, indicates the
railway's commitment to staying updated with the latest electrical advancements in the industry. The
presence of safety protocols, equipment, and training sessions suggests thatthe workshop prioritizes the
safety of both its staff and the passengers who use the rolling stock. It aims to enhance energy efficiency,
safety features, and passenger amenities while focusing on maintain and repairing various components.
Also we can conclude that the demand for skilled workforce is very high the workshop employs a
dedicated team with expertise in handling electrical systems specific to railway operations. Thus
developing skills is a must for Problem solving in such a demanding workenvironment.
THANK YOU
YUVRAJSINH
EN NO.200430109002
SSEC, BHAVNAGAR