1

EASTERN RAILWAY
Sub: Vocational Training of Engineering Student
Date and Place of Training :
23.06.2014 to 26.06.2014 - SSE/ACC/RAJ/SDAH
.2
Rajdhani coaches are LHB(Linke Hofman
Busch).LHB coaches are passenger compartments
of Indian Railways that have been developed by
Linke Hofman Busch of Germany. These coaches
are made of stainless steel and the interiors are
made of aluminium which make them lighter as
compared to conventional rakes. As we know that if
the coaches are lighter then it become easy to
increase their speed as the load decreases . Each
coach also has an "advanced pneumatic disc brake
system" for efficient braking at higher speeds,
"modular interiors" that integrate lighting into ceiling
and luggage racks with wider windows. The
improved suspension system of LHB coaches
ensures more riding comfort for the passengers
compared to conventional rakes. The air conditioning
system of the LHB coaches is of higher capacity
compared to the older rakes and is controlled by a
microprocessor which is said to give passengers
better comfort than the older coaches during summer
and winter seasons. Rajdhani mainly generates
power in EOG (End On Generation) i.e. it has two
power generating point at two ends. It also has
RMPU (Roof Mounted Package Unit).
3
1. Power car
2. Pantry
3. A.C first class
4. A.C two tire and three tire
Rajdhani has mainly four parts and these are-
Rajdhani has 21 coaches including two pantry cars
,two power cars, A.C. first class ,A.C. two tires and
three tires
In Rajdhani power is generated through
EOG(End On Generation) , in past MOD(Med On
Generation) was used , but now in LHB coaches it
is not used. The engine of the train runs by the
power supplied through Traction over head. But
through traction power can not be supplied to the
coaches, so power cars are needed to generate
and supply power to the whole train. If due to any
reason power car is not able to supply power then
there are 9 cells of 12V 70Amp/Hour in each
coach to supply power , but after some time those
batteries get discharged. So we need to charge
them and for that purpose we use RBC(Regulated
Battery Charger) .It turns 415V
POWER SUPPLY SYSTEM IN RAJDHANI
4
AC 3-phase to 110V DC and if RBC is failed to
do its job then EBC(Emergency Battery
Chargers) is used which do the same as RBC
but with less efficiency.
So power is generated in power car through
two generators and one alternator and then
through coupler(contactor) power goes to the two
power engines of each coach and then to the
step-down transformer (750V/415V) and there
after to the disconnecting and earthing device of
the power panel of each coach and then to the
another step-down transformer(220V/110V).
From here power goes to two ways , one , to the
appliances which run on 110V and two , to the
choppers to step down to 24V DC, to run the
appliances such as music system, toilet flush ,
water pumps etc.The power panel has
microprocessor control to control all the breaking
systems. Earthing is done here through the metal
wheels of train.
POWER CAR COPPLER
POWER
ENGINES
TRANSFORME
R(750V/415V)
DISCONNECTI
NG AND
EARTHING
DEVICE
TRANSFORME
R(220V/110V)
LIGHT,MOBILE
CHARGING
POINT etc
CHOP
PER
MUSIC
SYSTEM,TOIL
ET FLUSH etc
5
POWER CAR
Power car generates power to run all the electrical
appliances of the train such as lights, A.C. ,pantry
appliances, water pumps etc.The power car has
three 750V/415V step-down transformers .From
power car power goes to two sets of Power engines
(set-A and set-B) which runs on Diesel and are
situated on two ends of each coach. Power is
carried through couplers (these are contactors and
Zumbo Socket) . The total power supply of Rajdhani
depends on power car. Power car consists of
different generating parts, these are as follows -
Generator-Two generators of 500KVA
Alternator-Two alternators of 385Amps
Radiator Motor-Radiator motor of 40HP

ALTERNATOR
STATOR MOTOR
Stator Motor- Stator motor is used to start
the generator .It is used as prime mover. It
needs 24V battery supply.
6
Here two types of batteries are used-
1
st
type : 4battery of 6V 120Amp/hour
2
nd
type: 3battery of 8V 450Amp/hour
Here guard break is also present
SMOKE DETECTOR
Smoke Detector is present in power car for safety
purpose.
Train Lamp-At both end of the train there are
lamps of dipper red to indicate the light clearly for
safety purpose.
A.C. System
Control Panel-power panel consists of
RBC,EBC,pump controller, microprocessor
controller,chopper,transformer,AC and DC controlling
switches etc
CONTROL PANEL
MICROPROCESSOR CONTROLLER GENERATOR
7
PANTRY CAR
There are two Pantry cars in the train adjacent
to the A.C. 1
st
class. It serves foods to the
passengers of the train.From power car it gets
power and has two step-down transformers to
supply power to all appliances in the pantry car. It
has different parts such as-
A.C. System-Same as power car
Power panel-it consists of smoke detector,RBC
,EBC, pump controller, microprocessor controller
etc.
Chimney-Three chimneys are there to sack the
smoke.

Insect Killer-There two insect killers are
present.
Spiral Coil-These are heaters , to cook
food. There are two types of coil :
4coils of 2KW.
9coils of 1.1KW.
INSECT KILLER
SPIRAL COIL
8
Bottle Cooler
Deep Fridge
Water boiler-Three water boilers of 2KW/3KW
is present.
Hot case-Three hot cases of 220V are there to
keep the food hot.
Toaster-One toaster of 2KW is used.
WATER BOILER
Fridge-It is 330litre and double door.
9
A.C. FIRST CLASS
A.C. System- Same as power car and pantry
RMPU ,having standard temperature of 19C -
23C.
Control Panel-having microprocessor controller,
EBC,RBC,chopper,transformer etc.
Transformer-one transformer of 750V/415V.
Lights-Both A.C. and DC lights are present in the
coach.DC lights are present for emergency
purpose.
here bottle cooler , deep fridge , hot case are
not present as pantry car is just adjacent.
A.C. first class is adjacent
to the pantry car and it has-
10
A.C. TWO TIRE AND THREE TIRE
A.C. 2 TIRE
A.C. 3 TIRE
A.C. two tire and three tires of
Rajdhani Express have-
A.C. System-Same as power car, pantry.
Control panel-having microprocessor controller,
EBC,RBC,chopper,transformer etc.
Transformer-one transformer of 750V/415V.
Lights-Both A.C. and DC lights are present in the
coach.DC lights are present for emergency
purpose.
As these are situated far from pantry so they
have bottle cooler , deep fridge , hot case.

11
A.C. SYSTEM IN RAJDHANI EXPRESS
Rajdhani Express has RMPU( Roof Mounted Package
Unit) and here the refrigerant used is R-22 (mono
chloro dyfluro mythen). Power is supplied through
power car, here 415V three phase power is needed.
Here copper rods are used for manufacturing purpose.

It has mainly seven parts or five steps of
cooling, they are-
i. Two Condenser Coil
ii. Two Compressor of 3.75 ton
iii. Dryer
iv. Cooling Coil(Evaporator)
v. Capillary or Expansion Valve
vi. Blower fan of 1HP
vii. Blower Motor of 1.5 HP

12
13
EASTERN RAILWAY
Sub: Vocational Training of Engineering Student
Date and Place of Training :
27.06.2014 to 30.06.2014 - SSE/TL/SDAH
14
TRAIN LIGHTING
In express train and in mail train ,in non A.C.
coaches this train lighting system is applicable.
These coaches are SG(Self Generating)Through
this system lights and fans get power. Here two
types of power sources both AC and DC are
present. Its parts are as follows
Alternator-Brushless
alternator of 120V,
4.5KW,3 , star connected ,
fitted with 4-grouped(V-
grouped) pulley is the
source of AC power in the
coach , to run light and fan
.Here V-belts are used and
mechanical energy converts
to electrical energy.
ALTERNATOR
Cell-When alternator is standstill i.e. there is no
generation through alternator , then these cells
supply power. Cells supply DC power to the
coaches. Cells use 18 6.6V monoblock batteries.
Here two boxes are present having 9 monoblocks
each are in series. So total 118.8V ,120Amp/hr.
Here two types of batteries are used , these are-
15
LMLA :Low Maintenance Lead Acid Battery
VRLA : Valve regulated Lead Acid Battery . It is
also known as Shield Maintenance Free Battery.
When the cells get discharged we have to
apply 6.9V to each 18 monoblack battery ,to charge
the cell. Cells get power from mainly alternator, the
alternator generates AC power and a bridge
rectifier is used to convert the AC into DC . And
then the cell use the power. At present two types of
battery chargers are used
RRU: Rectifier And Regulated Unit.
ERRU: Electronics Rectifier And Regulated Unit.


JUNCTION BOX
JUNCTION BOX:
Each coach has a
Junction box ,
which
Consists Light-
1,Light-2,Fan
16
circuit ,IPC(Emergency Feeding Terminal) in the
positive side and a negative side. It controls the
supply to the fans and lights of each coach.

Alternator Regulation: when the cells are
fully charged and lights and fans are not in use
or consumes minimal amount of power ,then
the alternator should be regulated. There are
two ways to regulate the alternator-
i. Speed Control
ii. Field Control
But speed control is not used as it
minimizes the train speed ,so we use field
control.
For RRU magnetic field regulation is used.
For ERRU we use-
i. IGBT
ii. Hall Effect Sensors
iii. Microcontroller
Two hall effect sensors are used
For speed monitoring and load
monitoring.


17
HALL EFFECT SENSOR
MICROCONTROLLER
IGBT
FIELD CONTROL
ALTERNATOR REGULATION
REGULATION PROCESS OF ALTERNATOR:
Mounting Device:
i. Suspension Pin
ii. Cutter Pin
iii. Locking Plate
Safety Device:
i. Tension Rod
ii. Tensioning V-Belt
iii. Safety chain
iv. HRC fuse for safety of light
18
19
20
21