Industrial Training Report

On
INDIAN RAILWAYS MECHANICAL WORKSHOP GORAKHPUR (UTTAR PRADESH]

Conducted at:

Under supervision of:

Atul Singh
JE
INDIAN RAILWAYS
Submitted By:

Ujjwal Kumar Jaiswal

Roll No.: 2107350200050

Session: 2024 – 2025

Submitted To:

Dr. Archana Sharma & Dr. Mohmmad Ahmad

(Assistant Professor, Department of Electrical Engineering)

Rajkiya Engineering College, Bijnor, Uttar Pradesh 246725

Affiliated to Dr. A P J Abdul Kalam Technical University, Lucknow, U. P.

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 TABLE OF CONTENTS

CERTIFICATE ..................................................................................................... iii

DECLARATION ................................................................................................... v

ACKNOWLEDGEMENTS .................................................................................. vi

ABSTRACT ........................................................................................................... vii

LIST OF ABBREVIATIONS ...............................................................................

INTRODUCTION ……………………….............................................................. 1

1.1. MEMU............................................................................................................... 1

1.2. DEMU.............................................................................................................. 1

1.3 EMU............................................................................................................….1

[Link] TRANSMISSION LINE.........................................………………2

[Link] ……………………….......................................................... 4

2.3CUREET TRANSFORMER….…..................................................................6

[Link](400A,30KV)………………………………………………………………..6

2.5. MAIN TRANSFORMER………………………………………………………..9

2.6. TRANSFORMER RECTIFIER……………………………………………..10

[Link] WAVE RECTIFIER………………………………………………………11

[Link] WAVE RECTIFIER…………………………………………………….12.

2.9 TRACTION MOTOR…………………………………………………………….15

2.10 .AUXILIARY CONVERTER………………………………………………….15

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 CERTIFICATE
This is to certify that Project Report entitled which is submitted by Ujjwal Kumar Jaiswal in partial
fulfillment of the requirement for the award of degree B. Tech. in Department of Electrical Engineering of
Dr. A.P.J. Abdul Kalam Technical University, U.P., Lucknow., is a record of the candidate own work carried
out by him under my/our supervision. The matter embodied in this thesis is original and has not been
submitted for the award of any other degree.

Date: Supervisor

iii
iv
 DECLARATION
I hereby declare that this submission is my own work and that, to the best of my knowledge and belief, it
contains no material previously published or written by another person nor material which to a substantial
extent has been accepted for the award of any other degree or diploma of the university or other institute
of higher learning, except where due acknowledgment has been made in the text. Signature

Name

Roll No.

Dat

v
 ACKNOWLEDGEMENT
I am deeply grateful to the Indian Railway Mechanical Workshop Gorakhpur for granting me the opportu
nity to complete this enriching internship. I extend my sincere thanks to my mentor, Atul
Singh, for their invaluable guidance and support throughout my time here. Their expertise and
patience greatly enhanced my learning experience.

I also wish to thank the entire staff at the workshop for their cooperation and willingness to share their k
nowledge. The hands-on experience and insights gained here have been instrumental in shaping my
understanding of mechanical engineering in a practical setting.

I would like to express my heartfelt thanks to my college, Rajkiya Engineering

College,Bijnor, for providing the platform to undertake this internship. The encouragement and support f
rom my professors and administration have been invaluable. Their belief in the importance of practical le
arning has empowered me to explore and apply theoretical concepts in real-world scenario

Signature:

Name - Ujjwal Kumar Jaiswal

Roll No- 2107350200050

Date -

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 ABSTRACT
The abstract is to be in fully-justified italicized text, at the top of the left-hand column as it is here, below
the author information. Use the word “Abstract” as the title, in 12-point Times, boldface type, centered
relative to the column, initially capitalized. The abstract is to be in 10-point, single-spaced type, and may
be up to 3 in. (7.62 cm) long. Leave two blank lines after the abstract, then begin the main text. All
manuscripts must be in English. An Abstract is required for every paper; it should succinctly summarize
the reason for the work, the main findings, and the conclusions of the study. The abstract should be no
longer than 250 words. Do not include artwork, tables, elaborate equations or references to other parts of
the paper or to the reference listing at the end. The reason is that the Abstract should be understandable
in itself to be suitable for storage in textual information retriev

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[Link]
The Mainline Electric Multiple t or MEMU is a commuter rail system in India operated
by the Indian Railway for semi-urban and rural areas.
1. MEMU trains are designed for semi-urban and rural areas, unlike EMU trains that
are designed for urban areas. MEMU trains also have end vestibules not found on
EMU trains. Also, unlike EMU , MEMU trains have lavatories.
2. On Indian Railways, the MEMUs are electric multiple unit (EMU) trains that serve
short and medium-distance routes in India, as compared to normal EMU trains that
connect urban and suburban areas. The acronym stands for Mainline Electric
Multiple Unit.
3. DEMU and MEMU are examples of Multiple Unit which are selfpropelled train
carriages which when coupled with other Multiple Units can be controlled by a
single terminal. MU train is not hauled (pulled) by separate locomotive.
1.1 MEMU's known as Main Line EMU. It was first introduced in
1993 by ICF so that it can be operated in more areas. Unlike the EMU's they have
vestibule connection (gangway connection) and lavatories. MEMU motor car seats
76 and trailer coach 108 with a top speed of 105 kmph. They are equipped with
electro-pneumatic brakes.
1.2 DEMU (Diesel Electric Multiple Unit) , it works on the same principle as the diesel
locomotives. Diesel generator of 750 HP produces electricity which is fed to the traction
motors of the power car and in the trailer car having traction motor. Usually, traction
motors are provided at both ends of the rake. A new aerodynamic design of DEMU
introduced in 2004 on the SCR. It consists of 8 car rakes (Two motor car and six Trailer
cars).
1.3 EMU (electric multiple unit) are preferred for suburban section as it have
high acceleration and phenomenal stopping distances allowing them to achieve higher
speed at a short time and stopping efficiently hence it ultimately offers high throughput.

MEMO TRAINS

FIG.1 1

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 2.1 POWER TRANSMISSION LINE
Electrical power transmission involves the bulk movement of electrical energy from
a generating site, such as a power station or power plant, to an electrical substation
where voltage is transformed and distributed to consumers or other substations.
 Transmission system plays an important role in supply of power to the
consumers through the vital link between the
generating stations and the distribution system. The energy resources like
coal, hydro and renewable are unevenly distributed in India.
 There are four main types of power transmission – mechanical, electric, hydraulic
and pneumatic.
 Primary transmission
 A basic representation of a power grid, with transmission highlighted in blue.
 A basic representation of a power grid, with transmission highlighted in blue.
 (Source: Solo Nuno via ResearchGate)
 When it is generated at a power station, electrical energy will typically be
anywhere between 11kV and 33kV. Before it is sent to distribution centres via
transmission lines, it is
stepped up using a transformer to a voltage level that can be anywhere between
100kV and 700kV or more, depending
on the distance that it needs to be transmitted, the longer the distance, the higher the
voltage level.
 The reason electrical power is stepped up to these voltage levels is to make it
more efficient by reducing the I2R losses that take place when power is
transmitted. When voltage is stepped up, the current reduces relative to the
voltage so that power remains constant, thus reducing these
I2R losses.
 This stage is known as primary transmission—the transfer of a large
quantity of electrical power from the initial generating station to the substation
via overhead electrical lines. In some countries, underground cables are also used
in cases where transmission takes place over a shorter distance. Secondary
transmission.

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 FIG.1 2

❖ When electrical power reaches a receiving station, the voltage is stepped back
down to a voltage typically between
33kV and 66kV. It is then sent to transmission lines emerging from this receiving
station to electrical
substations closer to “load centre’s” such as cities, villages, and urban areas. This
process is known as secondary transmission.
 When electrical power reaches a substation, it is stepped down once more by a step-
down transformer to voltages
closer to what it was generated at—usually around 11kV.
From here, the transmission phase graduates to the distribution phase, and electrical
power is used to meet demand from primary and secondary consumers.

FIG.1 3

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 MEMU COACHES DIAGRAM

2.2 PENTOGRAPH

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 The unit and hold it against the conductor or, when springs are used to effect the
extension, to lower it. As a precaution against loss of pressure in the second case, the
arm is held in the down position by a catch. For high-voltage systems, the same air
supply is used to “blow out” the electric arc when roofmounted circuit breakers are
used. Pantograph is an apparatus which mounted on the roof of electric train to
collect power through with an overhead tension wire. It lift or down on the basis of
the wire tension. Typically a single wire is used with the return current running
through the track. It is a common type of current collector. Typically, a single wire is
used, with the return current running through the track.

 The electric transmission system for modern electric rail systems consists of an
upper, weight-carrying wire (known as a catenary) from which is suspended a
contact wire. The pantograph is spring-loaded and pushes a contact shoe up against
the underside of the contact wire to draw the electricity needed to run the train. The
steel rails of the tracks act as the electrical return. As the train moves, the contact
shoe slides along the wire and can set up acoustical standing waves in the wires
which break the contact and degrade current collection. This means that on some
systems adjacent pantographs are not permitted.

 Pantographs with overhead wires are now the dominant form of current collection
for modern electric trains because, although more fragile than a third-rail system,
they allow the use of higher voltages.

 Pantographs are typically operated by compressed air from the vehicle’s braking
system, either to rais

 Pantographs may have either a single or a double arm. Double-arm pantographs

are usually heavier, requiring more power to raise and lower, but may also be more
fault-tolerant

FIG.1 4

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2.3CURRENT TRANSFORMER
A current transformer is a device that is used for the transformation of current from a
higher value into a proportionate current to a lower value. It transforms the high
voltage current into the low voltage current due to which the heavy current flows
through the transmission lines is safely monitored by the ammeter.

The current transformer is used with the AC instrument, meters or control apparatus
where the current to be measured is of such magnitude that the meter or instrument
coil cannot conveniently be made of sufficient current carrying capacity.

FIG.1 5

The primary and secondary current of the current transformers are proportional to
each other. The current transformer is used for measuring the high voltage current
because of the difficulty of inadequate insulation in the meter itself. The current
transformer is used in meters for measuring the current up to 100 amperes.

2.4 VCB (400A,30KV)

VCB stands for Vacuum Circuit Breaker. In vacuum circuit breakers, the
vacuum is used as the arc quenching medium.
Vacuum offers the highest insulating strength. So it has far superior arc
quenching properties than any other medium (oil in oil CB, SF6 in SF6
circuit breaker).

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 FIG.1 6

For example, when contacts of a breaker are opened in the vacuum, the
interruption occurs at first current zero with dielectric strength between
the contacts building up at a rate thousands of times higher than that
obtained with other types of circuit breakers.

The degree of vacuum is in the range from 10^-7 to 10^-5 torr.

The technology is suitable for mainly medium voltage switchgear

application. For higher voltage vacuum technology has been developed
but not commercially viable.
2.5 Principle of Vacuum Circuit Breaker

The production of arc in a vacuum circuit breaker and its extinction can be explained
as follows:

When the contacts of the breaker are opened in the vacuum (10^-7 to 10^-5 torr), an
arc is produced between the contacts by the ionization of metal vapours of contacts.

However, the arc is quickly extinguished because the metallic vapours, electrons, and
ions produced during arc rapidly condense on the surfaces of the circuit breaker
contacts, resulting in a quick recovery of dielectric strength.

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The salient feature of vacuum as an arc quenching medium is that as soon as the arc is
produced in the vacuum, it is quickly extinguished due to the fast rate of recovery of
dielectric strength in the vacuum.

Fig:1.7

2.5.1 Construction of Vacuum Circuit Breaker

Typical parts of the vacuum circuit breaker are shown in the figure.

It consists of fixed contact, moving contact and arc shield mounted inside a vacuum
chamber (vacuum interrupter). It is shown as an insulating vessel in the given figure.

The movable member is connected to the control mechanism by stainless steel

bellows. This enables the permanent sealing of the vacuum chamber so as to eliminate
the possibility of the leak.

Fig:1.8

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Parts of a Medium Voltage Vacuum Circuit Breaker.

A glass vessel or ceramic vessel is used as the outer insulating body.

2.7What is the rod gap?

The arc shield prevents the deterioration of the internal dielectric strength by
preventing metallic vapours from falling on the inside surface of the outer insulating
cover.

Rod Gap Arrestor:

In such type of arrester, there is an air gap between the ends of two rods. One end of the
arrester is connected to the line and the second end of the rod is connected to the
ground. The gap setting of the arrester should be such that it should break before.

FIG.1.10

2.8What is a main transformer?

The main power transformer is a device used to change the AC voltage using
electromagnetic induction means. It has a main member or the primary coil, the
secondary coil, and a core. The function of this transformer includes voltage conversion,
current conversion, impedance transformation, isolation, and regulation.

Fig:1.11

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What is Transformer Rectifier: Working, Features & Applications
April 10, 2020 By Wat Electrical

The transformer rectifier, also known as the transformer rectifier unit (TRU) has
versatile applications due to its robustness and efficiency. It is mostly used in the
aviation industry because of its mobility and lightweight. The transformer rectifier unit
combines the characteristics of a transformer and a rectifier. With the use of this unit, a
variable DC voltage is obtained from AC voltage. Initially, the AC voltage is varied to a
different level usually

stepped down by using the transformer principle and then AC is converted to DC by the
rectifier principle.

2.9What is the Transformer Rectifier?

It can be defined as, “It is a static electromechanical energy conversion device, which
transfers energy from one part to another part, and converts from fixed AC to variable
DC”. It constitutes of two parts; one is a transformer and the other one is the rectifier.
The transformer steps up or down the voltage based on a number of turns. The
transformer rectifier unit, which mostly consists of a step-down transformer, takes the
input AC supply and steps down to a lower level based on application.
Fig:2.8.2

FIG.1.12

2.10 Transformer Rectifier

As shown in the above figure the transformer which has an input of 240 V, steps down
the voltage and gives it to the rectifier unit as input.

Transformer Principle

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It works based on the principle of Faraday’s Law of electromagnetic Induction. When
the Primary windings, which are connected to supply are excited with AC source, they
create an alternating flux which links the primary winding. The same primary
alternating flux links to the secondary winding by passing through the core of the
transformer.

The core forms the magnetic path for the flux to flow from primary to secondary. When
the flux links the secondary winding, secondary emf is induced. This is called mutual
induction.

Based on a number of turns on secondary winding, the magnitude of induced emf is

determined. The transformer emf equation is given by

E=4.44 Nf
As can be seen from the equation, the induced emf is proportional to a number of turns,
frequency, and flux. It is to be remembered that, the transformer is constant power,
constant flux, and constant frequency device. Hence, the induced emf is directly
proportional to a number of turns. The ratio of induced EMFs on primary and
secondary is also known as the turns ratio. The same principle is for the induction
motor also.

E1/E2 =N1/N2 =k

Rectifier Principle

The rectifier is a static device which converts fixed AC to variable DC. The input
alternating voltage is converted to DC voltage by the diodes. The circuit diagram for a
half-wave rectifier is shown below

Fig:1.13

2.10.1 Full Wave Rectifier

As shown in the circuit diagram, four diodes are used to convert AC to DC. Such a circuit
is called full-wave rectifiers. The operation of the rectifier can be classified into two
modes.

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Mode 1: In this mode, i.e. during the positive half cycle of the supply voltage, Diodes D1
and D2 conduct at the same time. The path of conduction for this cycle is A-D1-Load-P-
D2-B. During this mode, the first half of the output voltage (as shown in figure 1) is
obtained. The load is taken as a resistive load.

Mode 2: In this mode, i.e. during the second half cycle of the supply voltage, diodes D3
and D4 conduct at the same time. The path of conduction for this cycle is B-D3-Load-P-
D4-A. During this mode, the second half of the output voltage as shown in figure 1 is
obtained.

In one full cycle, we obtain two positive pulses, for this reason, it is called a full-wave
rectifier. Instead of two positive pulses, If we have obtained on pulse per cycle, it would
have been called as a half-wave rectifier. Similarly, we have a single-phase and three-
phase rectifier also. A mobile charger

is one of the common days today examples of a rectifier that converts AC to DC for
charging mobile.

If the devices used in the rectifier unit are diodes, it is classified as an uncontrolled
rectifier. In an uncontrolled rectifier, we cannot control the magnitude of converted DC
voltage. Only we obtain fixed DC from fixed AC. Moreover, if we used devices like Silicon
Controller Rectifier (SCR) or other devices belonging to the thyristor family, then it is
classified as a controller rectifier. We can control the output DC voltage by varying the
firing angle of the thyristors. They are also known as phase-controlled rectifiers.
Together, the transformer and rectifier form the transformer rectifier unit (TRU). Hence
this unit can, step down the input AC supply voltage and convert it into DC for further
use.

2.12Halfwave Rectifier Transformer

In the half-wave rectifier transformer unit, the input AC voltage is stepped down to AC
voltage based upon a number of turns. The stepped-down AC voltage is converted to DC
by using a half-wave rectifier circuit. The difference between half-wave and the full-
wave rectifier is

• In the full-wave rectifier unit, four diodes or SCRs are used, but whereas in the
half-wave rectifier unit, only one diode is used.
• In the half-wave rectifier unit, we obtain one pulse per cycle, but whereas in the
full-wave rectifier unit, we obtain two pulses per cycle.

2.10.2 Half Wave Rectifier

As shown in the figure, the input supply voltage is converted to pulsed DC by using a
single diode. It won’t have any negative cycle. Since the number of diodes used is less, a
halfwave transformer unit is less costly than a full-wave transformer unit.

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 Fig1.14

The efficiency and the average output voltage are high for the case of the full-wave
transformer unit as compared to the half-wave transformer unit.

The ripple factor, power factor, form factor, etc. are less for a half-wave rectifier unit as
compared to the full-wave rectifier unit.

Features of Transformer Rectifier Unit

Other features of the transformer rectifier unit include the following.

• It is available with an air cooling facility. Cooling is essential for proper heat
dissipation.
Since the input is given from the transformer, tapings can be provided from the
output side for voltage regulation.

• The unit can be controlled with remote or SCADA.

Recent technologies even include IoT based transformer rectifier units.

• Because of the transformer, it is long-lasting and less maintenance.

• Since we have a full rectifier as an output unit, the fullwave rectifier consists of a
lot of harmonics, since output waveforms are not symmetrical. Therefore,
transformer rectifier units are also harmonic filtering blocks.
• The range of output voltage varies from 30V-110V DC. Generally, we have more
number of applications based on low voltage DC i.e. 30 V.

• The range of output current can vary from 10 A to 40 A.

2.14 Transformer Rectifier Applications

As mentioned before, due to its rugged nature, it has a number of applications. A few of
them have been shown below

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 • Aircrafts used for military purpose

• Industries

• Helicopters for military purpose

• Laboratory applications

FAQs
1). Does the transformer rectifier unit provide an AC output voltage?

No, the transformer rectifier unit provides DC output voltage.

2). Does the input to Transformer rectifier unit is DC?

No, the input to the transformer rectifier unit is AC

3). Does the transformer rectifier unit step up the input voltage?
No, the transformer rectifier unit, steps down the input voltage and then converts to DC.

4). Can the transformer rectifier unit be used as a battery?

Yes, the transformer rectifier unit can be used as a battery. Since the output voltage is
DC

5). Can the transformer rectifier unit work on DC supply?

No, the input to the transformer rectifier unit must be a DC supply

Hence, we have seen how does a transformer rectifier unit working its applications. Due
to the conversion of AC voltage to DC, this unit has a number of applications and
versatile in nature. Further, the output DC voltage can be connected to chopper i.e. DC-
DC converter and hence we can obtain regulated DC voltage. And by varying the firing
angle of the unit, DC voltage of different magnitudes can be easily obtained. This
particular device has numerous applications in the aviation industry. Here is a question
for you, what is the overall efficiency of the transformer rectifier unit considering the
fact that the transformer is one of the most efficient devices, while the rectifier has low
efficiency?

What is tap changer and its purpose?

The purpose of a tap changer is to regulate the output voltage of a transformer by
altering the number of turns in one winding and thereby changing the turns ratio of the
transformer. There are two types of tap changers: a deenergized tap changer (DETC)
and an on-load tap changer (LTC).

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TAP CHANGER (1000V AC)

Fig. 1.15

RECTIFIER BLOWER FAN: -An air blower uses a rotating impeller/rotor to create
a vacuum. This vacuum causes air to rush into the blower. The air enters the centre of
the impeller and is divided by the rotating blades. Centrifugal force increases the speed
of the air and volume of the air stream within the housing.

2.9 What does a traction motor do?

Fig:1.16

Traction motors are powered by electricity and generate the power to rotate the wheels
of the train. The turning force produced by traction motors is transmitted to the wheels
via the driving gear unit and axle. Traction motors are typically mounted in trucks
where the wheels are housed.

2.10 What is auxiliary converter?

Auxiliary converters and drives are an integral part of the main traction drives.
Auxiliary converters provide cooling of main drives, traction motors, diesel engine,
charging the vehicle's batteries and feeding of control circuits in entire locomotive. How
many types of relays are there in railway?

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(i) Shelf type: Relays, which are loosely kept on shelves.
(ii) Plug in type: Relays, which are plugged in to a pre- wired plug board
(iii) According to their connection and usage, they are classified as: Track
relays: Relay, which is directly connected to the track, to detect the
presence of vehicle.

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