POWER CAR.pptx

This is the description of power cars attached to railway passenger coaches.

1. POWER CAR INTEGRATED MODULAR EQUIPMENT

2. Histories Power car are needed to proved power supply to End On Generation type coaches in Indian railway. There was Single Engine power car of Rolls Royce make diesel Engine with Lancashire make Alternator .320BHP / 300KVA Before 1992 There was twin Engine Power car of Kirloskar Cummins Make Engine Rated for 235 BHP at 415Volt . After 1992 High capacity power car were introdused in IR of Caterpillar and Cummins make rated 425 BHP at 750 volts.

3. FEEDER EARTH FAULT PROTECTED BY FEL EXISTING SUPPLY ARRANGEMENT OF POWER CAR

4. Power supply arrangement Two 500KVA Alternator feed power supply to EOG coaches at 750 Volt independently. 200VA Instrument transformer are provided to supply instrument like frequency meter , AEL , KW meter ect . Alternator Earth leakage relay are provided to shut down Engine in case of fault. The ACB are provided to control Alternator out put supply. Separate 60 KVA Transformer are provided to step down 750 volt to 415 volt for Radiator motor / Ventilation motor operation . Feeder contactor are provided to control out put from power car, which is protected with Feeder Earth leakage relay.

5. 21.6 LTR,640BHP, RAIL USE 490BHP GREAVES ENGINE

6. CUMMINS ENGINE 19 LTR,600BHP, RAIL USE 490BHP

7. ENGINE ACCESSORIES AND PARTS

8. OIL COOLER GREAVES ENGINE CUMMINS ENGINE

9. COOLENT PUMP GREAVES ENGINE CUMMINS ENGINE

10. TURBO CHARGER GREAVES ENGINE CUMMINS ENGINE

11. AFTER COOLER CUMMINS ENGINE GREAVES ENGINE

12. FUEL PUMP CUMMINS ENGINE Greaves Engine Injector Pump

13. SPEED G0VERNOR GREAVES ENGINE CUMMINS ENGINE

14. INJECTOR CUMMINS ENGINE GREAVES ENGINE (Cracking of welding Pipe line)

15. ECPG GEVERNOR CUMMINS ENGINE

16. ELECTRONIC GEVERNER SYSTEM

17. CYLINDER HEAD CUMMINS ENGINE GREAVES ENGINE

18. PISTON LINER

19. BY PASS FILTER CUMMINS ENGINE GREAVES ENGINE

20. SAFETY CUT OUTS

21. OVER SPEED CUT OUT (CUNMMINS ENGINE) SELECT MAKE MMR WITH FEQUECY TRIPPING

22. LOP CUT OUT LOW COOLENT LEVEL 1.5 BAR TRIPPING

23. ACB / UVR / ELR 1. Short circuit 2. IDMT and Overload 3. Earth Fault 400/380 VOIL 1.5 TO 2.5AMP

24. ALT ACB CBCT 200 mA TRIPPING CURRENT ALTERNATER EARTH LEAKAGE RELAY

25. Earth leakage relay S. No. Name of firms Settings Secondary Setting Primary 1 M/s Design & Prototype 600 µA 300mA 2 M/s Navago 20mA 1Amp

26. ALT ACB CBCT 200mA TRIPPING CURRENT FEEDER EARTH LEAKAGE RELAY FEEDER CBCT BUS COUPLER

27. SAFETY LOOP Relay used for safety loop instead of Darlington pair as used in conventional Coaches (Micro switch problem)

28. SMOKE DETECTOR PROVIDED OVER GREAVES ENGINE WITH FIRE BALL

29. Diesel oil consumption Load Kw Lt /min Lt/ Hr 50 0.33 19.8 100 0.51 30.6 150 0.77 46.2 213 0.901 54.06 270 1.182 70.92 301 1.264 75.84 358 1.48 88.8 384 1.62 97.2

30. Lub oil Consumption Cummins Engine ,1 lt /72 Hrs working of Engine Greaves Engine , 1 lt /48 Hrs working of Engine

31. Problem to concentrate Ventilation Fan centre bolt, replacement of vent fan motor Assy. WR modified end cover motor to give more strength . Greaves Radiator Base Frame. Greaves Engine monitoring gauges. Engine Monitoring System(EMS ). Exhaust Flexible bellow for greaves Engine. Over heating of Cables terminal. Lub oil consumption Greaves Engine. Fire prevention in Greaves Engine Compartment . Breakage of Crank shaft of Greaves Engine. Breakage of coupling of Greaves Engine.

32. Ventilation Fan assembly Replaced End cover with flange

33. Alternator Crompton Greaves Replacement of Greaves Coupling with Cummins

34. Thermograph of Electrical system

35. Alternator supply incoming current transformer terminal lug normal temperature is 30.80 ˚ C ,Y phase temperature was 62.90 ˚ C of Y phase ,lug was loose –tighten the lug. (delta t=32.10 ˚ C)

36. NEUTRAL CURRENT REACTOR Block 3rd harmonic component

37. 17.Excessive neutral current in power car   Trials were conducted and it was observed that about 100 Amp full load current was flowing in the neutral feeder. This was attributed to third harmonics generated by the alternators as the loads are fully balanced. A reactor was designed by KEL and placed in the alternator circuit. The neutral current was reduced to 1.4 Amps only. With this it was now possible to make the earth leakage protection system fully functional. Earth faults were created and the protection scheme was found to be fully functional.  M/s KEL will supply these reactors to W Rly to be provided on all power cars.

38. LIVE INSULATION MONITOR

39. INSULATION MONITORING DEVICE   Insulation Monitoring Device is being provided in the Imported LHB Coaches, which gives indication in case the insulation of the system is less than the preset value of the device. Insulation measuring device monitors the insulation resistance of unearthed AC three phase four wire AC . A measuring Special Hi frequency-low voltage is created in the device. One pole of measuring device connected to the Star point and the other pole is connected to earth through an electronic measuring circuit. These terminals are permanently monitored and in case of failure (when ohmic insulation between mains and earth falls below the set value and closes the measuring circuits) a signal LED flashes and a luminous display on the switch cabinet door is activated.

40. Ensure Thermo Imaging of Power Panel on Load Check and ensure proper cleaning of radiators. Clean by water jet machine 4.9-5.6 kg/cm2 (70-80 psi) with OGR and ID-27 or any other suitable cleaning agent MAINTENANCE SCHEDULE

41. Modifications : Problem The Engine was not stopping when radiator motor gets failed. Solution The control Circuit was suitably modified to ensure the engine tripping in the event of radiator motor failure.

42. 15.Isolation valve for diesel tank in power car   Diesel tank consists of two halves connected through a pipe. There has been a case were entire diesel has been wasted due to damage to tank due to cattle run over. Now a isolation valve has been provided in between the two halves to avoid this waste of diesel in cases of exigencies . Now a days RCF providing Metal flexible pipe line in place of rigid steel pipe line, which get chocked within year as it is meant for water.

43. 3 Interlocking of fire alarm with the trip circuit of the breaker of DG sets   Two smoke detectors have been provided in the power car. One in the engine portion and other in the switch board cabinet. At present, on detection of smoke, an alarm gets activated. It has not been interlocked with the trip circuit of the breakers to shut down the DG set.  

44. THANKS