INNOVATIONS DONE ON ZONAL RAILWAYS – NOVEMBER, 2015

Eastern Railway

Installation of computerized Specific Fuel Consumption (SFC) machine at Diesel Shed, Barddhaman- Computerized Specific Fuel Consumption machine has been installed at Load Box Pit for checking Specific Fuel Consumption of every locomotive during their M12, M24, M48, M72, Off POH and Off RB Schedule. By this test, consumption of HSD oil by the loco can be monitored. If it is noticed that loco is consuming excess HSD oil then corrective action can be taken for proper consumption of HSD oil by loco. Thus wastage of HSD oil can be prevented and huge railway revenue can be saved.

East Coast Railway

Cooling arrangement of SIV- Electric Loco Shed, Angul has indigenously modified three nos. of existing 3-phase cooling fan of SIV of M/s AAL make as an economy measure.

Trouble shooting kit for VCB closing circuit- Trouble shooting kit for bifurcating the fault, which exists either in VCB or in VCB circuit is developed by Electric Loco Shed, Visakhapatnam during the month. (Picture-1)

Picture-1Northern Railway

Use of external 750V supply for feeding EOG trains during maintenance hours in washing lines- EOG rakes are energized with 750V, 3-phase AC supply which is not available at washing lines due to being non standard supply. As per existing practice, 1-2 nos. D.G. sets of a power car are normally operated during primary maintenance of these EOG rakes. In order to minimize working of D.G. sets and to save the fuel cost, an innovation was done by Delhi division by providing external electrical feed of 750V in Shatabdi Complex. Subsequently, it was done at Nizamuddin, Anand Vihar, Delhi Sarai Rohilla, Amritsar, Jammu Tawi, Dehradun and Chandigarh Depot. A net saving of about 5675 litres HSD oil was achieved during the month. Cumulative saving of HSD oil using HOG & external supply for 2015-16 is 119340 litres. 13 out of 38 washing lines have so far been provided with this facility. Instructions have been issued to all divisions for providing energy meters and monitoring the consumption of electricity by this external 750V supply for feeding EOG trains.

Wagon Care Centre, Tughlakabad has developed a Bottom Discharge Scrap Bin which has replaced the old hand trolley. Major advantages of Bottom Discharge Scrap Bin over conventional hand trolley are:- (i) Large amount of scrap can be handled as its carrying capacity is more. It

can be lifted by road mobile and reduces both transportation and handling time.

(ii) Single person is required to operate the Bottom Discharge Valve bin. It is easy to operate and saves man power.

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North Central Railway

Device for pneumatic testing of safety valve for BTPN Stock- A device for pneumatic testing of safety valve for BTPN Stock has been developed in-house at Tank Wagon Depot, Baad. Safety valves are being secured by nut bolt on the top of this device and air pressure is being maintained through pneumatic pipe line. The cock and safety valves are being tested on requisite pressure level i.e. 1.4 kg/cm2 (as per RDSO pamphlet G-90) of air pressure.(Picture-2)

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Development of new Tamping unit for CSM and WST machines: In its continued pursuit of indigenization and development, CPOH has achieved a milestone by developing a new variant of tamping unit for CSM/WST machines with fusion of the best features of CSM & Tamping Express tamping units. This is a unique tamping unit having combination of split type Vibration shaft assembly & Arm assembly with facility of holding straight tools similar to Tamping Express tamping unit and remaining features of CSM tamping unit. It is expected that it will lead to trouble free service with ease of maintenance.(Picture-3)

Picture-3

North Western Railway

One Pneumatic Pressure Jet Gun has been developed by C&W depot, Bikaner for cleaning of trolley components, under gear components & hidden items like screw coupling threads, draft gears & interior corners where accessibility for cleaning is difficult. This is being done in sick line entering coaches, which has improved cleanliness of components for thorough examination by the fitters.

Southern Railway Special tool to remove window bar at accident site- At accident spots

window bars are required to be removed to rescue trapped passengers. Existing system of cutting of window bars with cold cutting equipment consumes much time and labour. For easy removal of window bars, ART team of Shornur Depot has developed a window bar plucking tool. This tool consists of a special forged bar-bending tool welded to a pipe of 1200 mm length. This tool is compact, light in weight and easy to operate. Since bar is plucked, no protruding portion of bar remains which may hinder rescue operation. No external source of power is required for operation. The operation of this tool was demonstrated during the joint mock drill of NDRF and Railways at Shoranur on 19.10.2015. The performance was appreciated by NDRF authorities. (Picture-4)

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Picture-4

Western Railway

Provision of modified CBC operating handle in WAP4 loco- Electric Loco Shop, Vadodara has provided modified CBC operating handle in loco no. 22560 (WAP4) during AOH (as per MP.MOD.LD 05.10.2011 Rev.’0’ dated 18.07.2011). (Picture-5) Following are the advantages:- Damages of operating handle due to CRO/bend of operating handle can be

avoided as it is provided above CBC. CBC can be opened from both sides. Deployment of man power will be reduced.

Picture-5

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Existing system of removing window

barNew system of

removing window bar

SKETCH OF THE WINDOW BAR PLUCKING TOOL

Trouble Shooting Model of Fuel Oil System for WDG4 Loco- Diesel Traction Training Center, Sabarmati has developed a Trouble Shooting Model of WDG4 Loco Fuel Oil System. The model is designed and fabricated departmentally using spares available in the shed and is having electronic display.The working model helps in easy and effective understanding of the fuel flow system, indentifying the components and their functions. The electronic display trouble shooting model enables easy trouble shooting of faults. Instructors can simulate a fault to make the trainees undertake the trouble shooting. This model will help in imparting training to loco running staff as well as maintenance staff and will improve their knowledge and troubleshooting skills. (Picture-6)

Picture-6

Fixture for fitment of axle pulley- Whenever a wheel set fitted with pulley is required to be changed and required diameter wheel with pulley is not available, it becomes necessary to fix the pulley over the axle of new wheel. It is very difficult for the staff to set and align the pulley accurately ensuring proper alignment of two halves with each other. Since, the axle pulley is tightened with the studs having thread on both side, it requires extra effort and care to tighten the studs evenly so that even stress is taken by both side threads. The entire fitment process therefore requires minimum 4 artisan staff over a total time of 45”. Coaching Depot, Surat has developed a fixture for fitment of such axle pulleys. This fixture has made the pulley fitment very simple, accurate and less time consuming. In the fixture there is provision of hydraulic jack in order to reduce the distance between two halves which makes effortless fitting of studs. The entire fitment process requires maximum two artisan staff and a total time of 25”. Thus there is saving in manpower and time. (Picture-7)

Earlier Practice

Improved Practice (Fixture in Use)

Top view of fixture

Picture-7

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West Central Railway

Modification in TSS Gantry by providing 04 nos. isolators - The gantry maintenance in TRD is a very peculiar aspect, as it requires UP & DN power and traffic block simultaneously, which hampers the traffic for at least 01 to 1:30 hrs. To solve this problem, Kota Division has provided additional 04 no. isolators at gantry of TSS/GURLA. By this modification, TSS gantry can be isolated from OHE side without affecting OHE supply and movement of traffic. This will also be helpful to maintain quality of work in TSS gantry maintenance due to non restriction of shut down time. (Picture-8)

Picture-8It will reduce down time in case of internal fault in gantry equipment LA, PT and insulator failure. This modification has been executed departmentally by officers and supervisory staff of TRD Depot, Kota.

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Before Modification After