Innovations Done on Zonal Railways January, 2014

INNOVATIONS DONE ON ZONAL RAILWAYS – JANUARY, 2014

Central Railway

A wheel dia measurement gauge exclusively for WAG-9 has been developed by Electric Loco Shed Kalyan in-house, so that wheel dia can be measured at inspection pit itself.

Eastern Railway

 Modification in cooling arrangement

In order to reduce the cost of maintenance and to ensure availability of material, Electric Loco Shed, Angul has indigenized the cooling arrangement of M/s AAL make SIV by replacing German make motor with an existing motor of locomotive.

 Protection quad to jig for removal of line contactor articulation bolt

Protection guard has been provided around jig for removal articulation bolt of line contactor for protection of staff Electric Loco Shed/Visakhapatnam.

 Development of PCB for Knorr-Bremse Air Dryer

Electric Loco Shed/Visakhapatnam has developed a PCB for purging cycle of Knorr – Bremse make air dryer and has been provided on trail basis.

North Central Railway

 Addition of extra base plate for the safety of Radar fitted for speed in WDG4

To provide the safety from ballast in running condition, a plate is provided on the frame of radar to deflect pieces of ballast.

North Eastern Railway

 Due to repeated complains of damage and broken toilet ceiling by security and others for storing suspicious material inside the ceiling, the toilet ceiling has been modified in house by the Tinsukia Division of this Railway.

Western Railway

 Bhavnagar workshop has designed a fabricated coaching bogie frame manipulator during the month. The manipulator can re-position a bogie frame at any angle in 360 1 degree rotation as required for down hand welding during maintenance. The bogie manipulator is a portable unit that can be positioned as per requirement. With the introduction of this bogie manipulator, the dependence of EOT crane is done away.

 At Lower Parel workshop a newly refurbished Fiat bogie shop, set up by converting corrosion repair shop for maintenance and overhaul of Fiat bogies was inaugurated on 25th January.

 During the month, a simple gadget has been designed and fabricated by the staff of coaching Depot, Indore. It is used where the defective buffers are required to be changed when the coach is out of position and no EOT crane is available. This gadget is made of coach screw coupling and channels.

 During the month, with available resources and man power, Coaching Depot Ahmedabad (BG) has developed “Pressure Test Bench” for Control Reservoir/Auxiliary reservoir/Brake cylinder. This bench is made from Trestle, Wooden Bench, 03 nos. Pressure Gauge & high pressure flexible Pipe.

 Diesel Traction Training Centre, Sabarmati has developed a software “Gyan Kasoti” for evaluation and improving the knowledge of trainees. Objective types of questions on loco trouble shooting have been included. The trainees have to practive on the software till desired performance is attained. This will improve the knowledge and trouble shooting skills of the maintenance staff.

 Commissioning of lapping Machine

Lapping & polishing machine of M/s Speed fan for lapping of valve & valve plates was commissioned on 9th January’14 at Sabarmati shed. This machine is designed to produce lapped/polished surface within flatness of 0.3 micron and surface finish of 0.02 Ra with uniformity. This machine will help in improving overhauling of valves during yearly schedule and thus will improve the MR efficiency of HHP locos.

 CCTV Cameras have been installed with internet connectivity at Junagad laundry for proper monitoring of laundry operation, linen washing & staff availability from Bhavnagar divisional office. 3 CCTV cameras have also been installed at DTTC/RTM at different angles with monitors provided at Principal’s and DME(DL)’s chamber for monitoring.

 Rajkot division has acquired ISO 9001:21008 Certification for train no. 19575/19576 OKHA-NDT Express. All the required work for passenger amenity, passenger awareness and safety has been carried out to achieve ISO certificate.

 GPS based track monitoring system

Taking clue from the acceleration monitoring system developed and used on Central Railway, we have developed an OMS machine which acquires real time data of vertical & lateral oscillation from Inertial Measurement Unit (IMU), locations from Global Positioning System (GPS), perform online analysis, report the result and issue real time

2 SMS alerts indicating location needing attention to track. This machine will completely eliminate human interface and track defect can be pin pointed without any need to look outside for punching of Kms while on run. This machine has also facilitated OMS run in night time too. Trial with this machine has been successfully done on BCT-BRC section. Performance of the machine is being closely monitored so as to put in place a GPS assisted track monitoring system based on measurement of acceleration at axle box level.

 Cranes on BFR

Handling of 3 rail panel in field was very much problematic earlier. Engineering Workshop, Sabarmati has manufactured 3 sets of jib cranes with 2 Ton capacity electric hoist fixed on 3 BRHN wagons. This arrangement has facilitated the handling of 3 rail panels in field with ease & made loading/unloading faster.

 Formation of new EUR rakes with air brake for movement of rails

During the year, one new EUR has been formed by modification of BRHNEKS wagons allotted by Railway Board. With this WR have four EUR rakes with air brakes for movement of rails.

 Wheel Flange Lubrication system in EMU rake

Wheel flange lubrication system has been developed, supplied, installed and commissioned on two wheel sets of rake. This has been fitted on leading wheels of both driving cabs on trial basis on 30.12.13. Oil is injected with predefined pressure and quantity on front wheel set having advantage of considerable reduction of wear in the wheel & rail, distinct reduction of noise & reduction of the tractive resistance and thereby saving of energy.

West Central Railway

 Cleaning of Roller bearing components (CRWS/BPL)

At the time of commissioning of roller bearing cleaning plant, only roller bearings were cleaned. This shop has developed a process and a steel mesh container and started cleaning of axle box housing assembly items like hex head bolt, retaining ring & ring. Now the quality of cleaning of components has improved which will help in intensive checking of components. It will also reduce the health hazards to staff during manual cleaning by kerosene and cleaning time.

 Development in Procurement of Bio Tank bracket. (CRWS/BPL) Railway Board has instructed to fit bio tank in all coaches during MLR at CRWS. Accordingly 244 sets and 400 sets of bio tank brackets had been arranged from trade and RCF respectively. The welding quality of these brackets has not been found

3 satisfactory and transport from RCF was also uneconomical. Another supply of brackets which was arranged on work order basis received was in unassembled condition and has to be welded. To solve this problem, a survey was conducted to explore sources in local market. Finally, M/S. Mayur Enterprises, Bhopal was guided to manufacture mounting brackets on work order basis. Corton steel was supplied by CRWS. M/S. Mayur Enterprises has successfully delivered 46 coach sets of mounting brackets in this month and the quality is satisfactory. As such CRWS has become self reliant in arranging mounting brackets for bio tanks, the issue being regularly chased by Railway Board.

 Formation of Tender cell: - A step towards system improvement (WRS/ KTT)

There are many works which are being done through Tender/Contract. Presently the tendering processes are being done through so many different groups of people of different sections. All the people are not sufficiently trained to handle the tendering process and there could be mistakes in the tendering process due to less knowledge. Also control on the tendering process and actual execution of the work through contract was not good. So, a tender cell has been formed with people with good knowledge. A policy matter as to how the tender cell will work and how the actual execution of contractual work will be done has been issued. It is expected that this system improvement will eliminate/minimise any mistakes likely to happen in the tender/contract in the workshop.

 Compressor Air Valve Testing Stand (Diesel Shed/NKJ) – Various air pressure valves are provided on all type of compressors, which operate at different air pressures through compressed air. Earlier, overhauled valves were being tested with oil for leakages. Diesel Shed/NKJ has now started to test these valves through compressed air on a test stand made with Shed resources. This test stand is attached with two reservoirs. From one reservoir, the compressed air is sent into the valve and the valve is put in compressed air circuit.

 Modification of Control Cansol wiring of WDP4 At present diesel loco shed Itarsi is holding 17 nos. of WDP4 locomotives for maintenance. Sometimes in all these locomotives, due to improper forward /reverse feedback, the control console unit starts to malfunction due to which failure of locomotives on line started to occur regularly. In order to rectify the fault, a detail investigation was conducted. During the investigation it was found that while mounting the unit the space got reduced so much that the connection wire pocket got rubbed continuously, resulting in loosening of connection terminals which effected the operation of locomotive on line. Due to cover over the wiring and partial disconnection, it was not possible to visualize the fault immediately. After finding the reason for the failure, in order to curb the failure, connection terminals are being soldered due to which they remain intact even after friction and continuous stress. After the modification, no such failure has been reported for the said cause.