SUMMER TRAINING

REPORT
ELECTRICAL ENGINEERING
DEPARTMENT

SUBMITTED TO: Electrical Engg. Dept.

SUBMITTED BY: Hariom Meena
11510255(E4)
Electrical Engineering

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 ACKNOWLEDGEMENT

I would like to thank CARRIAGE & WAGON WORKSHOP JAGADHARI , YAMUNANAGAR

for providing me exposure to the whole Electrical Network used in Railway System. I’d also like
to thank Mr. Prem Singh Meena for their enduring support and guidance throughout the training.
I am very grateful to the whole Electrical Department in workshop for their support and guidance.
I am also very thankful to the workers and employees near the machineries in charge for their
support to my training.

Yours sincerely,
Hariom Meena
B. Tech, 4th year (EE)
Roll No. -11510255

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 INTRODUCTION

Jagadhri Workshop is situated in the state of Haryana at a distance of about 55 km from

Ambala Cantt and 35 km from Saharanpur (UP) and has an independent railway station on
Saharanpur-Ambala section of Ambala Division named JAGADHRI WORKSHOP (JUDW) for the
convenience of staff working in the workshop.

In 1947, after independence, the truncated North Western Railway, renamed as East
Punjab Railway, had no workshop to undertake repairs of Broad Gauge rolling stock. For some
time, the repairs to the stock were carried out at Kalka. Later, it was decided to set up the first
major post-independence Carriage and Wagon Workshop of Indian Railway at Jagadhri as part of
Northern Railway and foundation stone of the workshop was laid on 08/02/1952. The workshop
was set up for undertaking the POH of 75 units of coaching stock and 225 units of goods stock
per month.

The workshop capacity has since been expanded and developed and over a period of time
the target outturn of the workshop has been increased to the current level of 480 VU of Wagons
and 125 VU of Coaches per month; this includes 31 AC coaches and 95 non-AC coaches. Besides,
IOH of 35 AC and 50 non-AC coaches is also carried out every month in the workshop. The
outturn of the workshop is slated to increase further in the coming months.

A proud moment for the workshop was when in theDec’2003it became the first workshop
to be nominated for the POH of state-of-the-art LHB coaches initially imported from M/s Alstom,
Germany and later manufactured in the country with the transfer of technology from there.
Presently, Jagadhri workshop is doing POH of 21 LHB AC coaches every month.

Some important facts about the workshop are as follows:

i. Total area = 1.20 Sq. Kilometers

ii. Total covered area = 0.07 Sq. Kilometers
iii. Total track length = 50 Kilometers
iv. Work force employed = 6058 Nos.
v. Energy consumption per month = 0.36 MUs (average)
vi. Contracted Maximum Demand = 5.2MVA
vii. Total Machinery and Plant = 929 Nos.
viii. Nos. of staff quarters = 1962 Nos.

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Broadly Electrical department at Jagadhri workshop can be divided in five different sections i.e.
A Train lighting Section
B Air Conditioning Section
C Power Car Section
D Production control organization &
E General Power Supply

Activities of Electrical Department:

i. POH of Non AC TL Coaches: Monthly outturn: 74 Coaches

ii. IOH of Non AC TL Coach Bogies: Avg Monthly outturn: 65 Bogies

iii. POH of EOG AC Coaches: Monthly outturn 47.8 Coaches (Conventional, IRY, GaribRath&
LHB type EOG AC Coaches including Power cars)

iv. Maintenance of Power Supply system in the Workshop with one 66kV MRS and ten 11
kV substations

v. Maintenance of Cranes, Traversers, Pit wheel Lathes and other M&Ps for Carriage,
Production & Wagon shops (500 wagons/month)

vi. Water Supply Arrangements for workshop

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 Staff Strength of Electrical Branch

A. Supervisory As On 01.10.17
Sanctioned
SN Designation On Roll Vacancy
Strength
1 SSE 38 31 7
2 JE 16 10 6
Total 54 41 13
B. Ministerial
1 Ch.OS 3 1 2
2 OS 16 10 6
3 Sr. Clerk 6 9 +3
4 Clerk 1 3 +2
5 Steno 1 0 1
6 Office Kh. 1 1 0
7 Bang. Kh. 1 1 0
Total 29 25 4
C. Train Lighting & Ac Shop
1 Sr. Tech. 91 87 4
2 Tech. Gr.-I 251 234 17
3 Tech. Gr.-II 113 105 8
4 Tech. Gr.-III 119 119 0
5 Helper 148 148 0
Total 722 693 28
D. Power House
1 Sr. Tech. 21 20 1
2 Tech. Gr.-I 58 55 3
3 Tech. Gr.-II 27 27 0
4 Tech. Gr.-III 28 29 -1
5 Helper 50 36 14
Total 184 167 17
G. Total 989 926 63

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 TRAIN LIGHTING SHOP

A. Activities of Train Lighting Shop:

The Train Lighting Shop is working under incentive scheme to carry out POH of present
out turn of 74 coaches per month. The whole Train Lighting Shop is divided into following
sections:

1. Wiring Section
2. Alternator / Regulator Section
3. Battery & Battery Box Section
4. Fan Section
5. Electroplating Section
6. Winding Section

1.0 Wiring Section

The repair and rewiring works of TL coaches are being carried out by this section. With
passage of time various inputs have been given in this section, to improve the quality of
work and Electrical equipment/items being used in the passenger coaches. Brief details of
the same are as under:

1.1 Renovation of Wiring Section:

To improve the working environment, renovation of wiring section with the provision of
proper seating arrangements, storage almirahs and new working benches for staff has
been developed in house by the sincere efforts of the existing staff.

1.2 Testing & repair of Electronic Ballasts & light fittings before fitment in the coaches
There was no testing facility available for the electronic ballasts & light fittings and to
attend the defects in wiring section. To solve this problem, a test bench for testing of
electronic ballast, emergency light & CFL fitting has been developed in house by the
utmost dedication and sincere efforts of the existing staff which has resulted in saving of
valuable time and manpower as each of the fitting got tested for its proper working
before fitment in the coaches.

1.3 Testing of Fuses & MCBs to ensure their proper working at fault condition
Earlier there was no facility available to check performance of HRC Fuses and MCBs being
used in passenger coaches due to which their actual performance under the fault
conditions could not be ascertained. Therefore to check the important parameter like
Fusing, Non Fusing and gate current (limiting values within which the Time-Current

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 Characteristics should lie) of different type of HRC fuses and Tripping characteristics of
MCBs, a test bench has been developed by workshop where important parameters of
fuses & MCBs are being checked as per the guidelines of respective IS:13703 & 60947.

Test bench for testing of fuses as per IS: 13703 (Part-1) – 1993

1.4 Testing of different type of Rotary switches before fitment in the coaches
Cases of no light/smoke emission from the Rotary junction boxes on account of defects in
the rotary switches were regularly being reported by the field units as the only criterion
available for ensuring the quality/performance of these switches was manual checking of
their mechanical operation whereas their electrical health/performance which get
affected by the wear & tear of the contacts with passage of during service has no check on
it. To ensure trouble free field service, monitoring of electrical parameter like IR and
voltage drop values of every POHed/New Rotary Switch before putting them in service has
been started by the JUDW.

Test Bench for Rotary Switch

The switches which pass IR test and have “Milli-Volt Drop” between 10-15mV are allowed
to put in the service. As a result the cases of overheating & sparking in rotary switches
have been eliminated.

1.5 Testing & Repair of LED based Accidental Emergency Lights

To meet the intended objective of provision of Accidental Emergency lights, testing &
repair has been started by the workshop where fault diagnostics and repairs of sub-
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 assemblies of AELs like LED blocks & control circuits is being done and revival of deep
discharged 12V batteries is done through slow charging rate.

2.0 Alternator / Regulator Section

The overhauling of 4.5 kW Alternator and Rectifier cum Regulator Unit is being carried out
in this section. After overhauling, these are tested on test bench with control panel to
check performance and output. Four test arms including one of automatic type for
alternators upto 25 kW are provided and all of them are working with variable speed
motors. On an average 60 nos. alternators with regulators are being POHed every month.

3.0 Battery & Battery Box Section

The batteries after stripping from the coach and cleaning are put on charge and discharge
in this section. 100% capacity test of the batteries & revival process if required is also
performed and the batteries having capacity more than 80% are put back into the service.
Since last five years, batteries having life more than 4 years from Lug date having capacity
above 80% has been put back in service that has saved revenue to tune of Rs. 7.2 Crore to
the Railway by this section.

On an average 1400 batteries per month are being POHed and 425 new batteries are
being provided for replacement of old/ condemned/ deficient batteries. A demineralizing
plant having capacity of 200 liters per hour and 02 Nos. distilled water plants of capacity
15 ltrs/hr is installed in this section.

In addition to this 04 Regenerative type static battery chargers for proper charging &
discharging of VRLA & LMLA batteries have been installed in the section. Using
regenerative type battery chargers per annum saving to tune of Rs 75000/- per battery
charger on account of energy saving is being ensured.

Strengthening & repair of Battery boxes:

Battery boxes and supporting frame & suspension arrangements are checked for any
corrosion/rusting and for their strength. Defective battery boxes are not allowed in
service and replaced with new ones.

4.0 Fan Section

On an average 2000 carriage fans are being POHed every month. Before fitting them on
the coach every POHed fans is being tested for continuous run to ensure reliable
performance. Apart from overhauling of old TL fans per month 150 new BLDC fans are
also provided to replace old/ deficient/ damaged fans. As an improvement measure and
to carryout POH activities of DC carriage fans in assembly line format following
improvements have been done in the fan section.

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 Dismantling: Released DC Fans from incoming POH coaches are dismantled in a separate
earmarked area and damaged cage and body of fans are identified. Only serviceable
parts are utilized for POH.
Thorough cleaning of different parts of fans: Carriage Fan guard, fan body & fan blades
are cleaned thoroughly by high pressure hot water jet cleaning after cleaning in sodium
hydroxide. Apart from this, fan motor, armature and bearings are properly cleaned by
kerosene oil with newly installed spare parts cleaning machine.

Cleaning of fan body & blades Cleaning of with Kerosene oil

with hot water jet

Overhauling & Testing: Overhauling activities of armature and reassembly of field unit,
fan motor and fan cover, fitting of carban brush and its connection, fitting of fan guard
blade and testing of fan are being perfromed on separate Work benches.

Achievements: With these arrangements the POH quality of DC fans has improved which
resulted in reduction of undue noise in fan bearings and improvement in insulation value
upto 10 Mega ohm.

5.0. Winding Section

Winding section of Train lighting shop performs the rewinding work of motors upto 250
HP including blower, condenser, compressor motors of AC coaches, 4.5/12 KW
Alternators of TL coaches and motors of cranes & traversers etc. to improve the quality
of work following qualitative inputs has been given to this section:

5.1 Introduction of Dust free environment for rewinding activity

Earlier the activities like dismantling repair/rewinding and assemblies of wound machines
were being carried out at the common place and dust & moisture present in the open
work place was affecting the quality of newly rewound jobs. To improve the quality and
reliability of the equipment being rewound, a new dust free room has been developed to

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 adhere to the guidelines issued by RDSO for rewinding of motors/alternators/
transformers etc.

5.2 Installation of Vacuum pressure impregnation plant (VPI Plant)

The presence of air & moisture in the windings after manual varnishing affect the
performance of wound machines. To overcome this drawback of manual varnishing, a
300 Ltrs. Vacuum pressure impregnation plant (VPI Plant) has been installed in the
Armature Winding section for vacuum impregnation of motors. Provision of gantry
arrangement surrounding the plant to lower and lifting the motors has also been made
to make best use of it to its maximum capacity.

6.0 Electroplating Section

Fans blades, guards, handrails and other saloon/coach items are being chrome, copper
and nickel plated in this section.

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 AIR CONDITIONING SHOP

Activities of Air Conditioning Shop:

The Air Conditioning Shop is broadly divided into Power Car Section and Air
Conditioning Section, the sub-sections of the AC section are:

1. Roof Mounted Package Unit Section

2. Electronic Repair section
3. Wiring Section
4. Compressor and Water Pump Section
5. AC Control Panel and Gauge Panel Section
6. Motor Section
7. Evaporator and Condenser Section
8. Pantry Section

1.0 Roof Mounted Package Unit Section

In this section complete overhauling and testing of Roof Mounted AC Package Unit is
being done. Condition of health of RMPU AC units with variation in ambient conditions
subjected during year especially during winter is being monitored by this section.
Performance of each of the RMPU is monitored in RMPU testing room developed in
the workshop in line with the facilities available with OEMs which consists of the
following:
i. Hot Chamber where RMPU is subjected to desired temperature testing.
ii. Cooling Chamber where actual loading and humidity conditions are being
created for the RMPU
iii. Control chamber where microprocessor based control panel is installed for
operation control and monitoring of parameters of the RMPU AC unit during
test.

Fitment of RMPU in hot chamber for desired ambient conditions

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 Cooling chamber for measurement of RMPU parameters Control room for monitoring and Recording during test.

Benefits:
 Assessment and pinpointing of health of different components of RMPU
(Compressor, Cooling/ Condenser Coils, Quantity of Refrigerant, Thermal
Expansion devices etc has become possible.
 Assessment of actual cooling capacity of POHed RMPU in Ton is being done.
 Assessment of health & proper working of control pressure switches, HP/LP
cutouts, OHP, working of sensors etc in the specified range of operation can be
tested
 Assessment of Super heat & Sub cooling parameters of each refrigeration cycle can
be monitored and if required can be corrected.
 Elimination of human Error in assessment of health of RMPUs

2.0 Electronic Repair & RMPU Final Testing Section

Testing & Repair of electronic items like Microprocessors for RMPUs,
Regulated/Emergency battery charger, Measuring & Monitoring Relays, Overheat
protectors, thermal overloads, electronic thermostats is being done by this section.
Performance of RMPUs after loading in the coaches is also monitored by the section.
To improve working and ensure reliability of the equipments/safeties following inputs
have been given in the section:

2.1 Testing & Repair of Microprocessor Controller (MPC) of LHB RMPUs

JUDW has developed a testing facility for Microprocessor unit of LHB coaches for
testing them in Real Time as well as in Simulation mode to see their characteristic in
the entire operational range before fitment in coach during POH. This has resulted in
detecting the defective Microprocessor controllers as well as their Sensors.

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 Testing Panel Repair Console

Also some of the defects observed during testing are being rectified during
maintenance. 100% working of AC system through Microprocessor Controller unit is
being ensured in LHB Coaches.

2.2 Repair & Testing of Regulated & Emergency Battery Chargers (RBC & EBC) of LHB
Coaches:

Earlier, these units were tested inside the coach Switch Board Cabinet during
overhauling to see their working but were being sent isolated, if found defective in
case their replacement with new was not available.

The RBC & EBC units are tested on Switch Board cabinet placed in Testing Room
before fitment in coach.

2.3 Test benches for Electronic thermostat, OHP, MCB, Thermal OLR & MMR:
Earlier there was not proper testing facility of different types of safety relays &
switches fitted in AC Coaches was being done in the coaches only as there was no
proper testing facilities were available for testing of their requisite electrical
parameters. Separate test bench for Electronic thermostat, Miniature circuit breaker
& thermal over load relay, measuring & monitoring relay test bench and electronic
equipment repair console has been developed in separate AC room which also having
the facility to impart training to the staff.

2.4 Pull Down Testing of every AC Coach

Earlier RDSO Recommended & prescribed Pull down Test for AC coaches was not
being carried out in accordance to the specified test conditions. Details have been
collected from RCF/KXH which is being followed by them for newly manufactured LHB
coaches. Similar arrangements have been developed at JUDW and standard practices
are being followed for carrying out Pull Down Test during POH of each AC coach and
since July’13 pull down test of every AC coach is being ensured.

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Achievements:
 Performance of AC unit got checked in the coach during the POH
 Importance of proper sealing of doors is understood by the staff involved in the
POH of the AC coaches.
 Factor affecting performance of AC system such as Blockage in air duct, leakage
of conditioned air from doors/louvers is identified and got rectified at workshop
level.

3.0 Wiring Section

This section is responsible for the repair/rewiring works being carried out on AC
coaches. Necessary modifications related to wiring and power control systems as per
HQ directives are also being carried out during POH by this section. As system reliability
improvement measures following activities have been taken up by this section:

3.1 Overhauling of Power contactors

As a system reliability and improvement measure, all power contactors are being
stripped from the coaches and overhauled in newly developed contactor overhauling &
repair section where condition of contactor coils is being monitored and defective
contacts are being repaired/replaced on condition basis.

3.2 Up gradation of Current carrying capacity of IV Coupler of Power Cars &Shatabdi/

Rajdhani Express coaches.
Work for provision of modified IV coupler (300A) and wheel ratchet assembly by
replacing existing low capacity IV couplers is being carried out on regular basis in all
arising High capacity Power Cars of Shatabdi/Rajdhani Exp. during POH. As per Hq
instructions necessary planning has been done to modify existing IV coupler to further
higher capacity of 500A.

3.3 Concealed wiring for Mobile charging points in IRY coaches.

Work for provisioning of complete concealed wiring of Laptop/mobile charging socket
on metallic fixing base in place of open casing wiring in IRY Coaches is being carried out
on regular basis during POH. This work is being ensured each such coach.

The loose wiring of Laptop/ Mobile charging points in steel Laptop/ Mobile charging sockets provided with shock proof
casing having dangers of electrical shocks. concealed wiring to avoid passenger interference

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4.0 AC Control Panel and Gauge Panel Section
In this section complete overhauling and testing of AC Control Panel including Gauge
Panel is being carried out during POH of coaches. All safety devices i.e. thermal
overload relays, power contactors, MCBs, HRC fuses, relays and gauges/cutouts are
being tested as per recommended setting/rating.

5.0 Evaporator and Condenser Section

Dismantling, cleaning, testing and fitting work of evaporator units, condenser units
and liquid receivers is being done in this section. Apart from these works this section
has undertaken the work of AC duct cleaning by opening the duct. This work is being
ensured in every LHB AC Coach since July’14.

6.0 Compressor and WRA Section

In this section complete overhauling and testing of ACCEL make compressor and
mono-block pump/WRA are being carried out during POH of coaches.

7.0 Motor Section

In this section complete overhauling and testing of all type of motors i.e. compressor
motor, condenser fan motor, blower fan motor, WRA motor and 50 kVA transformer,
3 kVA transformer and battery charger used in AC coaches is being carried out.

7.1 Stripping & overhauling of 60 KVA transformers in LHB AC coaches:

Earlier these transformers are not being removed from the coach for carrying out
complete overhauling as per the laid down procedures due to especial type
suspension/hanging arrangements. Now these transformers are being stripped from
coaches for their complete overhauling and this practice is being followed for last one
and half year.

8.0. Pantry Section

In this section all pantry and sub-pantry equipment provided in AC Pantry Cars and AC
Coaches are being overhauled. After POH, all pantry equipment are tested for their
proper working prior to loading in coaches.

As a system improvement measure, old and obsolete designed Modular composite

Pantry of IRY Coaches received for POH is being replaced with new separate Pantry
equipment being used in GaribRath coaches (Bottle cooler cum deep freezer, Hot case
and new Hot water boiler of 30 Ltrs. capacity) to overcome public complaints due to
repeated failures of the modular pantry equipment.

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 Water Boiler Bottle cooler cum Deep freezer Hot case

Power Car Section

The POH of Alternator, Diesel Engine and Power Panel along with various electrical
equipment of the Power Car are being carried out in this section.

1.0 Replacement of over aged old engines in Power Cars.

As system improvement measure and on the line of instructions from Hqs office, over
aged low capacity engines of power cars are being replaced with high capacity engines
at JUDW. During past three years 21 Diesel engines sanctioned under RSP were
replaced by JUDW. A proposal for replacement of 62 overage engines has been submitted in
Hqs office during 2016-17.
NS requisitions against sanctioned RSP for 19 DG sets also in process at Hqs level.

2.0 Cleaning of Fuel tanks of every Power cars:

To avoid on line failure of diesel engines of Power cars on account fuel restriction
during train service, the work of proper cleaning of Diesel tanks of power cars has been
undertaken.
Earlier fuel tanks of conventional power cars are being cleaned after decanting HSD oil
during POH whereas fuel tanks of LHB power cars were not being cleaned due to
constructional difference. But now the proper cleaning of the fuel tanks of every power
is being ensured after decanting during POH to avoid any fuel line restrictions during
service.

3.0 Flushing of Lubricating oil during POH:

Work for Flushing of engine lubricating oil & filling up fresh oil in the sump after proper
cleaning of oil sump is being carried out on regular basis in all the power cars received
for POH.

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4.0 Removal and cleaning of Radiators of LHB &GaribRath Power Cars :
The radiators of the LHB and Garibrath type Power cars could not be taken out for
cleaning due to inaccessibility of mounting bolts from the toilet side, as the walls of the
toilet are fabricated after fitment of radiators during manufacture at RCF. To overcome
these constraints, removal of radiators without damaging the body of the coach is being
done on regular basis. To ensure reliability of Radiators their filling with distilled water is
being ensured during POH.

5.0 Removal and Overhauling of Roof Extractor Motors of LHB & Garibrath Power Cars:
The roof extractor motors of LHB & Garibrath Power cars were not being taken out and
overhauled due to difficulty in their access. The removal of RE 1 & RE 4 is not possible
without opening engine accessories and the removal of RE 2 & RE 3 is not possible
without opening the Air intake filter assembly of engine. Removal & overhauling of
these roof extractor motors is being done on regular basis as system improvement
measure.

6.0 Developing Testing facility for Diesel Engine to test overhauled engines:

Jagadhri Workshop is doing POH & IOH of 09 Power cars per month. Earlier there was
no testing facility available to test overhauled diesel engines on the shop floor and
attend the defects, if any, before loading the same on the Power car or sending to
division. Non-availability of such facility was causing a lot of difficulty on account of
defects being noticed after loading in the Power car. To solve this problem a proper test
bench shown below has been developed in house by Jagadhri Workshop staff and
testing of every engine upto 250/300A Electrical load is being ensured before loading of
same in the Power Cars.

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7.0 Proper securing of cables and cleaning of Cable trenches:
To improve the POH quality and safety in power cars work of proper securing of cables
and cleaning of cable trenches is being ensured on 100% basis.

Dirty Cable Trench Cleaned Cable trench

D Production Control Organization (PCO)

Apart from above, Production control organization (PCO) is provided for stage
inspection and end inspection to check each activity during POH of coaches; this is to
ensure proper quality of POH of coaches. This organization also has the responsibility of
coordinating with stores branch for arranging/bringing all stocked material. This
organization also conducts time study for new jobs and review of the existing job times
as and when required, and maintains a log of all times taken for different POH activities
on a daily basis.

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Certifications:
We are proud of Jagadhri Workshop has been accredited with ISO: 50001 since
Aug’15

Jagadhri Workshop is the first unit of Northern Railway to get IMS certification which
cover ISO 9001:2008 ISO 14001:2004 and OHSAS 18001:2007 certificates.

ISO 9001:2008 ISO 14001:2004 OHSAS 18001:2007

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Power Supply Arrangements:

1. Energy Bill:

Monthly Avg Energy Avg monthly Amount Paid

Consumption (kwh) (Rs.)
Place
2016-17 2017-18 2016-17 2017-18

Workshop 373714 351823 35,41,860.00 32,80,786.00

Colony 527167 521053 48,88,061.00 48,58,819.00
Total 901014 872875 84,29,921.00 81,39,651.00

2. 66/11 kV Main Receiving Station:

The electrical power supply was being fed from UHBVN substation at Yamuna
Nagar situated at a distance of 5 KMs from JUDW at 11 kV level since 1957
through a single railway feeder. From February 2002 power supply is being fed
from UHBVN at 66 kV level to railway’s own substation located in the workshop;
this arrangement has increased the reliability/quality of the power supply in the
workshop and the colony. With the gradual growth of M&P and other electrical
assets to increase the outturn of wagon and coaching stock, the electrical load has
also increased substantially and the present connected load and maximum
demand are as under:
i. Connected Load
(a) Workshop = 10.923 MW
(b) Division (Colony) = 2.365 MW
Total = 13.288 MW

ii. Contract Demand = 5.2 MVA

Requirement of electrical load for the railway colony situated outside the
workshop and falling within Ambala division is also met with from the workshop
through one single 11 kV feeder to colony sub-stations.

66 KV Switching Room 20 66 KV Substation Yard

3. Distribution:

The existing 66 kV supply from UHBVN is being availed at 66 kV Main Receiving

Station and is further stepped down to 11 kV and thereafter distributed at 11 kV
to ten sub-stations in the workshop and three sub-stations in the colony. All ten
11 kV sub-stations are connected to HT Ring Main as under:
Ring Main 1 - 66 kV – 1 – 7 – 2 – 8 – 3 – 1 – 66 kV
Ring Main 2 - 66 kV – 5 – 4 – 9 – 6 – 10 – 66 kV

4. The transformer capacity of each sub-station in the workshop is as under:

Sub Stations Transformer Capacity Total Capacity

(MVA) (MVA)
66/11 kV MRS 2 x 7.5 15

S. Stn. No. 1 2 x 1.25 2.5

S. Stn. No. 2 2 x 0.5 1.0

S. Stn. No. 3 3 x 0.8 2.4

S. Stn. No. 4 2 x 0.75 1.5

S. Stn. No. 5 2 x 0.75 1.5

S. Stn. No. 6 2 x 0.75 1.5

S. Stn. No. 7 2 x 0.5 1.0

S. Stn. No. 8 2 x 0.75 1.5

S. Stn. No. 9 2 x 0.5 1.0

S. Stn No. 10 2 x 0.5 1.0

5. Emergency Power Supply Arrangements:

To meet with the essential load requirement during power outage, two nos. of
stand-by DG sets of 500 kVA & 1750 kW capacity are installed.

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Energy Conservation Measures:

 ISO:50001 for energy management implemented at JUDW in Aug’16

 Energy Audit of Jagadhri workshop got done in Sep’2015 and KLK in Aug’16
 All Incandescent Lamps replaced with energy efficient light fittings.
 100% Automation of operation of water pumps & shed/yard lighting.
 Replaced 45 nos conventional fans with 35W energy efficient ceiling fans
during the month Feb’17.
 Regenerative type battery charger to utilize discharge energy of batteries.
 Replaced 90 nos HPSV/MH high bay lights with 36W led high bay lights in 4
wheeler wagon shop.
 Replaced 70 nos of 400W MH tower lights with 140W LED based tower lights
 Replaced 13 nos of 250W HPSV high bay lights with 100/150W LED based
high bay lights
 Replaced 70% of high wattage ceiling fans with 60W Energy Efficient Ceiling
fans.
 Replaced 45 nos of high wattage ceiling fans with 35W smart fans.
 65% of conventional fan regulators replaced with energy efficient electronic
regulators & 100% chokes of tube lights replaced with electronic ballasts.
 Running of Air compressors & welding plants etc has been regulated and their
idle running has been minimized.
 Demand for replacement of 1600 nos conventional tube lights with 18W
Energy Efficient LED tube lights is in process in Hqs.
 Provision of Energy Savers for welding plants has been planned, PO issued
material awaited
 Average monthly Power factor is being maintained at least 0.96 since last 06
years.

Provision of 150W LED lights in Towers for Yard

lighting

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Green Energy Initiatives:

To proliferate the use of Non-conventional Green Energy actions taken by JUDW:

a. Provision of 3 kWp grid connected Solar PV plant was made in Nov’2015. Avg
Yearly yield of this solar power plant is 4152 kWh.

Provision of 3KWp Solar Power panel on Roof of Accounts office/JUDW

b. HQ has approved provision of 3 MWp (2.5 MWp for JUDW & 0.5 MWp for KLK)
solar power plant in Oct’16.

c. M/s CEL, Sahibabad (MNRE nominated Agency) had surveyed JUDW and KLK
workshops proposed provision of 940 kWp& 284 kWp Solar PV plants on roof
tops of sheds at JUDW& KLK workshops respectively.

d. NIT for the same has been published during the month of May’17, opening
date for the same is 19.12.17.

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 Water Supply Arrangements:

To meet with the daily requirement of water in the workshop, seven tube wells have
been installed and are working regularly. The details of these tube wells are as under:

Storage
Pump Type Of Rating Hours of Tank
Location
No. Pump (hp) operation capacity
(in ltrs)

Near 8 Wheeler Submersible

1 22.5 06 50000
Wagon Shop Pump

Near Sub Station Submersible

2 22.5 15.5 50000
no. 10 Pump

Near Connecting
Submersible
3 Gate General 22.5 15.5 50000
Pump
Store

Submersible
4 Near Colony Gate 22.5 12 50000
Pump

Submersible
5 Near 66 kV MRS 06 12 50000
Pump

Submersible
6 Near Wheel Shop 17.5 13 50000
Pump

g ent since last two years.

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