Green Initiative on Rail Coaches – A case study

of Northern Railway

1. Solar Powered BG Coach

2. LED Lights in existing Rail Coaches

3. External feed during maintenance of EOG trains

4. Adopting Head on Generation (HOG) system – Feeding EOG train from Locomotive

Some Green Initiatives Taken in Recent Past

Use of Solar Energy to Power Rail Coaches

N.Rly for the 1st time experimented feeding of lighting load on Narrow Gauge rail coaches of KLK-SML & Kangra Valley sections by Solar PV cells in 2012

The cost of Electrical energy in SG/EOG systems is above Rs 15-20 per unit

Solar PV based electric energy on the top of coaches can reduce to power Rail Coaches with benefit of green energy

Narrow Gauge Rake with Solar PV cells on the top

After getting success on NG coaches One BG GS coach was provided with Solar PV units for technology demonstration.

Unit details: Area available on the coach = 40 m2 12 Panels of 300Wp each = 3.6kWp Area covered by 12 panels = 24 m2

Area left uncovered = 16 m2

Each Module has 72 cells (0.416V) Solar Panel System voltage = 120 V Rating of Charge Controller = 110V, 30A (Voltage

range 90-135VDC) Total weight of system @ 22 Kgs/module = 264 Kgs

The system uses existing coach battery of 120Ah, 110V

During Winters:

Generation period = 7 Hrs (10.00 to 17.00 Hrs)

Average generation is about 6.5 Amps

Maximum current generated = 13.5 A

Average Power generated = 5.1 kWh

Power req. with 12 hrs working/day in winters with LED lights = 3.17 kWh

Trial run results of December, 2014

Generation period = 12 Hrs (06.00 to 18.00 Hrs)

Power generated = 11.4 kWh Total power requirement/day in summers with

12 hrs working = 13.5 kWh Enhanced Capacity of the system covering

full roof area = 9 kWp Generation with full roof covered = 19 kWhp This can meet requirement of Non AC coach

with over 15 Hrs coach working

Likely Generation in Summers

Designing the system to take care of wind pressure upto a speed of 120kmph

Giving aerodynamic shape to the complete assembly

Matching the channel of the panel with the coach body channels

Taking extra precaution by strengthening & welding the bolts & channel together

Ensure no water leaks from the bolt fixing points

Challenges faced in system installation

Keeping height of panel within SOD Reducing coach electric load by

providing LED lights & BLDC fans Fixing of Charge Controller inside the

coach above Rotary Junction Box Providing facility of connection with the

adjoining coach

Challenges faced in system installation

A system can be adopted wherein the solar PV module coach can work independently without alternator & having TC with the adjoining coach

This will greatly increase the coach availability as line failures on account of Alternator/Belt will reduce

Higher capacity PV cells can be explored to enhance generation capacity

PV cells may be of laminated type and provided as part of roof only

Modules may be provided on the side & End walls of the coach to enhance the capacity by 30%

Higher capacity VRLA battery bank be used

Future ahead

1. Cost of provision of solar panel = 6.0 Lacs/coach

2. Saving with solar panels/coach/annum = Rs 1.27 Lacs

• Av. Generation by solar energy for the complete year = 9.55 Units/Day

• Saving with solar panel per annum = 3486 Units

• Saving of revenue @ 15.88/Unit = Rs 55,358.00/Annum

• Saving due to low maintenance = Rs72,000.00/Annum

• Effective saving per year = Rs 1,27,358.00/Annum

3. ROR is about 5 years

Financial viability of system with complete roof covered with PV modules

LED Light retrofit in existing Rail Coaches

Existing coaches are provided with FL tubes of 18/20W or 2 CFLs each of 11W

N.Rly developed specification for retro-fitment with LED lights of 9W replacing existing 18W FL

Lux level improved by more then 40% Passenger Feedback is excellent Improved lights giving better aesthetic &

feeling of safety Colour temp. 6000-7000k (White Light) Colour rendering index ˃ 70 Protections for Short Circuit & current limiting The ROR in non AC/LHB coach is about 2 yrs

Use of Energy efficient LED lights in TL coaches

Improvement in Lux level with LED lights in TL coaches – Train no. 12472/71

Location

With LED lights With Tube Lights

Lumen Lumen

Cabin 1 87 46

Cabin 4 85 44

Cabin 8 88 47

Provision of 750V External supply during maintenance for EOG trains

This provides an average saving of 240Ltrs HSD/rake Average saving of DG set running ≃ 4-5 Hrs/day/rake Average annual saving per rake ≃ Rs 25 Lacs Used existing system/equipment (50/60 kVA Trs.) Provided at NDLS, NZM, DEE, ANVT, ASR & JAT

depots

HOG Scheme Running of 12005/06 NDLS-KLK Shatabdi

Express on HOG scheme started from 21.2.2011

Second STB, 12045/’46 CDG-NDLS started on 16.05.2014

Approximate fuel saving – 1500 Ltrs per trip @ Rs 75000.00 per trip

Thanks for remaining interactive

Schematic diagram             

 

                   

   300Wp  300Wp  

           

   

           

 

         

  300Wp 300Wp  

                     

       

                 

 

                 

   300Wp         300Wp  

                   

           

                   

 

                 

   300Wp         300Wp  

                   

           

                   

 

                 

  300Wp         300Wp  

                   

           

                   

 

                 

300Wp         300Wp  

                     

         

           

JUNCTION BOX 

EXISTING BATTERY BANK,110V, 120Ah CHARGE CONTROLLER, 110V, 30A 

 

 

LOAD

Solar Module

Charge ControllerShifted Rotary Junction Box

Coach with Solar panel

without alternator

Normal Coach with 4.5 kW alternator

Coach with Solar panel without

alternator

Normal Coach with 4.5 kW alternator

Saving due to maintenance in solar coach

For a rake of 20 coaches Minimum 2 skilled & 2 unskilled staff

are deputed for underframe Minimum staff/day/coach = 0.1 skilled

& 0.1 unskilled Staff expenditure/coach/month =

0.1 x 35000 + 0.1 x 25000 = 3500 + 2500 = 6000.00

Staff expenditure/coach/year = 12 x 6000 = 72000.00