Green Initiative on Rail Coaches – A case study of Northern Railway

Some Green Initiatives Taken in Recent Past 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

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

Trial run results of December, 2014 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

Likely Generation in Summers 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

Challenges faced in system installation 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

Future ahead 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

Financial viability of system with complete roof covered with PV modules 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

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 Location With LED lights With Tube Lights 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

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Schematic diagram Solar Module JUNCTION BOX EXISTING BATTERY BANK,    300Wp JUNCTION BOX EXISTING BATTERY BANK, 110V, 120Ah CHARGE CONTROLLER, 110V, 30A LOAD Solar Module

Shifted Rotary Junction Box Charge Controller

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