INNOVATIONS DONE ON ZONAL RAILWAYS – OCTOBER, 2015

Eastern Railway

Fabrication of Test bench for assembling & Hydraulic testing of Radiator core:- Radiator core assembling was so far being done on the shed floor. This was posing severe space and maintenance problems involving excess time and man power.In order to overcome the above problems, Barddhaman Diesel Shed has recently fabricated a test bench for assembling & Hydraulic testing of Radiator core using internal shed resources, for ensuring its speedy assembly and Hydraulic testing with lesser time and man power. It facilitates assembling both two core and three core Radiator core of both WDM2 and WDM3A locomotives. This Bench also facilitates to view both sides of Radiator to notice any water leakage during Hydraulic testing at 3Kg/sq.cm water pressure with the help of hand pump without hanging or involving crane operation.

East Coast Railway

Development of WDG4 fuel pipe line testing gadget:- Fuel pipe line testing gadget has been developed for testing of leakages of fuel oil pipe lines for HHP locos. This will reduce fuel dilution cases of HHP locos.(Picture-1)

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North Central Railway

Traction Machine Shed, Kanpur has designed and erected a material handling lift along with a trolley in the limited space for transporting the coil between ground and first floor. This has reduced the possibility of damage of ready coil insulation and armature inter-turn insulation failure. Damage to insulation of coils during transportation has also been eliminated.(Picture-2,3)

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Oil bath heater for flywheels and gears:- For heating of flywheels and crown gears at controlled high temperature of 250°C, a new oil bath heater with auto cut system has been developed in-house by CPOH. Auto cut system will restrict the temperature at desired level to prevent any metallurgical changes in flywheels and crown gears during heating. This equipment will ensure proper assembly of tamping unit and axle components.(Picture-4)

(Picture-4) Tools cum work benches for shop floor:- Two new modern Tools cum

Work Benches have been fabricated in-house and installed at Shop floor to replace old and obsolete design Tool tables. Provision of pressurized pneumatic blow gun in these benches will be helpful in cleaning of small parts before use. This will improve the overhauling process and facilitate easy availability of long and heavy tools. It will also decongest the shop floor and time in tracing tools will also be substantially reduced. (Picture-5)

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Northeast Frontier Railway

Testing of wheel axle box and traction motor in assembled truck:- Line failures were reported due to smoke and unusual sound from gear case of Traction Motor/wheel en-route. To arrest such type of problems, Diesel Loco Shed, New Guwahati has developed a set of fixture for trial of complete bogie after OVH or line occurrence. This fixture helps to lift the motorized wheel and to run it at a speed of 375 RPM. It helps to lift the individual motorized wheel in the bogie and to rotate the wheel in three different speeds at 175, 250 & 375 RPM (Equivalent to about 80 KMPH on line) in assembled condition to observe any unusual sound, axle heating or smoke coming out from axle as well as in traction motor. The fixture has been fabricated by welding the U-clamp on both sides of the CBC housing for holding the CBC housing. No external agency’s assistance has been taken for fabrication of this fixture and it is completely fabricated by Under Truck & Traction Motor section.

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South Central Railway

Operation of TELS (Tractive Effort Limit Switch) in trailing loco of multiple units from leading loco cab:- ALCO locomotives equipped with MBCS (Microprocessor based control system) control system are provided with an option of limiting the tractive effort of the locomotive whenever required by keeping a ‘TELS’ in limit position. When the locos are operating in Multiple Unit (MU), the Tractive Effect Limit cannot be affected in trailing loco from working cab of the leading loco, since no interface exists through MU cable. This necessitates the LP to operate TE Limit in both the locos manually & individually, which cannot be done during run. In order to avoid this problem, SCR made a change in circuit duly utilizing the MBCS signal through MU spare lead to communicate the signal simultaneously to trailing loco also. This facilitates the operation of TELS of trailing loco from the lead driving cab. The details of the innovations have been forwarded to RDSO for study and standardization.(Picture-6)

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Modification in Spring Testing Machine to test springs of WDM3D & WDG3A:- Spring (outer coil) testing Machine in UT section was supplied by M/S PEECO Hydraulic PVT Ltd. and it was commissioned in the year 2004 in Diesel Loco Shed, Guntakal for testing WDM2 and WDM3A locomotive springs. For testing, WDM3D and WDG3A loco springs are being sent to Gooty Shed as they were not housing in this machine. To overcome this problem, modification was carried inside the shed by shifting the limiting Switch to suit test height for WDM3D and WDG3A locomotive springs. This modification has resulted in avoiding cumbersome handling and transportation of springs to Gooty Shed. (Picture-7,8,9)

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Western Railway

Integrated test bench for testing instruments:- Integrated test bench for testing following instruments, has been developed in-house by Electric Loco Shed, Vadodara:- (i) Twin beam headlight of 3-Phase & conventional locos.(ii) DC-DC convertor of 3-Phase & conventional locos.(iii) LED based flasher light of 3-Phase & conventional locos.(iv) Flasher unit of 3-Phase & conventional locos.

Polyurethane (P.U.) painting of LHB coaches:- Rajdhani and Shatabdi Express are the premium trains of Western Railway. As one time exercise, BCT depot has started in-house P.U. painting of LHB coaches with brush and roller and have completed the P.U. painting on exterior of coach no. 041220/LWACCN, the first ever coach as far as P.U. painting is concerned. The quality of P.U. painting on the coach has been found satisfactory. One more coach 030540/LWACCW has been taken up for P.U. painting and is likely to be completed shortly.Similarly, Depot has also started P.U. painting of Shatabdi NANO Metal painted coaches. The Nano coating on exterior is removed by grinding the exterior surfaces. Coach no. 080270/LWFCZAC has been spray painted with P.U. Paint. Painting of another coach is also in progress. In this coach too, the quality of

painting is satisfactory. (Picture-10,11,12,13)

(Picture-10) (Picture-11) (Picture-12) (Picture-13) Instructional video on maintenance and operation of Bio-Toilet

system:- A short video film on bio-toilet maintenance and operation was prepared in-house by Bandra Terminus Depot to improve the awareness and maintenance skill of staff. This video film will be uploaded on Indian Railways web site and You Tube so that other depots/divisions of Indian Railways may take benefit of this short video.(Picture-14,15,16,17,18,19,20,21)

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Booklet on operation and maintenance of Passenger Emergency Alarm System: An informative and handy booklet for operation and maintenance of Passenger Emergency Alarm System has been prepared and distributed by Surat Depot to C&W Open line maintenance and Operating staff. This booklet contains all the trouble shooting steps including inspection and testing of ACP as well as special instructions for front line operating staff who have to deal with the ACP en-route train passing.

Development of gadget for attending equalizing stay rod: Veraval Depot has developed a gadget for en-route attention of cracked/broken equalizing stay rod in ICF coaches. The gadget is light in weight and easy to handle. With the help of this gadget, broken/cracked stay rod can be attended and train can reach the destination safely. The use of the gadget leads to time saving and will avoid the train detention.(Picture-22,23)

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Provision of standby FPM (Fuel Pump Motor) on HHP locos: Several failures of FPM have occurred on HHP locos due to design deficiency. To avoid detention on line and for avoiding dead movement of the locomotive, Diesel shed Sabarmati has started providing an additional FPM on HHP locos. This FPM is used as an auxiliary/standby FPM in case of failure of main FPM. For this purpose rotary switch is provided in ECC#3 Cabinet to switch over to standby FPM. Additional COC is also provided to facilitate switching over of fuel suction and discharge pipelines to standby one. In addition to this, an information sheet is also provided in driver cab for awareness of crew.

West Central Railway5

Provision of additional compressor safety device- Presently in all compressors inbuilt safety device is provided which is known as over temperature tripping arrangement. The temperature of compressor is displayed on this device and in case of temperature increase beyond preset limit, this device starts functioning and shuts down the compressor. This is the only safety device provided in compressor. In case of failure of this safety device, there is possibility of damage to the compressor and human life.Considering the above situation and to ensure additional safety to compressor and human life, one parallel safety arrangement has been done on compressor by Millwright staff of Coach Rehabilitation Workshop, Bhopal. This arrangement indicates temperature of the compressor and in case of increase in temperature beyond pre-set limits, there will be siren with an indication by flasher light which will immediately alert the operator. The additional safety arrangement has been purchased from the market at the cost of about Rs. 20,000/- and fitted in-house by Millwright staff in one of the compressor. The functioning of the additional safety arrangement has been found satisfactory and it is planned to be fitted in other compressors also.(Picture-24)

(Picture-24) Fixture for repairing and testing of Bogie Mounted Brake System

(BMBS) brake cylinder by Wagon Repair Shop, Khutbav- Air brake system has undergone several modifications to add more and more improvement in its design for more efficient and simplified braking system.BMBS is the latest design of air brake system and this is being retrofitted to the existing CASNUB bogie of wagon. BMBS brake cylinder (10” dia.) is a new design of brake cylinder with inbuilt double acting slack adjuster. Due to difference in design and size from conventional cylinder, existing fixture is not suitable for repairing of this BMBS brake cylinder during POH in the workshop.A fixture has been fabricated in house by using scrap material for repairing of BMBS brake cylinder at a cost of Rs. 21,500/-. Dismantling and assembling of BMBS brake cylinder can be easily done with this fixture during overhauling of BMBS brake cylinder.BMBS brake cylinder is vertically placed on fixture base plate. Its body is fixed to a bracket on fixture by inserting a pin into holes of bracket and flange of cylinder body. Its ram assembly is hold by tightening wheel of a screw-nut assembly then opening nut bolt of dome cover and loosening wheel of screw nut assembly brake cylinder piston assembly is removed from its body and repaired by changing its damaged part.The overhauled piston assembly is fitted back to cylinder body with help of fixture and testing of cylinder can be also done on this fixture.

Advantage:- Safe and easy to repair BMBS cylinder with this fixture.6

Additional Safety

Compressor

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(Picture-25) (Picture-26) Ladder for welding and painting on BCNHL wagon roof- Kota workshop

has started getting BCNHL wagons for POH. The roof of these wagons is more slopped than conventional BCN/BCNA wagons. Due to more slopped design it is not safe to stand and work on the roof. The exiting ladder in the workshop is also not suitable for welding and painting on roof. The body repair shop of the workshop has fabricated a new ladder according to curved surface of roof.Fitting, welding and painting work can be done easily on the roof of BCNHL wagons with this ladder. It provides safety and ease to worker during working on roof of BCNHL wagon and costs about Rs. 1500/- only.(Picture - 27, 28)

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