INNOVATIONS DONE ON ZONAL RAILWAYS – MARCH, 2015

East Coast Railway

  • Safety pin in the modified CBC couplers- Some cases of uncoupling of the tight lock coupler type CBC were noticed due to false impression of locking to the operating crew. To avoid such failures a safety pin has been provided at the bottom of the coupling, which fits only in case of proper coupling. Thus, it avoids false impression of locking to the crew and prevents uncoupling of CBC while on run. 7 WDM3D locos have been covered so far, and the remaining locos will be covered with this modification in a phased manner.
  • Gadget for holding axle box of locos-Diesel Loco Shed, Visakhapatnam has developed a special gadget for holding the axle box of WDM3D/WDG4 locos during wheel turning on Pit Wheel Lathe. Previously, there was a necessity of removing the shock absorbers of the WDM3D/WDG4 locos due to fouling with the existing holding arrangement on the Pit Wheel Lathe. By use of this special gadget a lot of man power and time is being saved.
  • Stripping of bolster spring for Bolster rectification-One new fixture has been developed in CF shop of Carriage Repair Workshop, Mancheswar for stripping of bolster spring for the purpose of Bolster rectification.

Earlier, the Bolster springs were compressed by a manual fixture provided with square threaded screw rod involving excessive manual labour. Thus a gang of five people used to get completely exhausted after rectifying one coach set (each coach set having 08 bolster springs to compress and change packing, requiring more than 3.5 Ton load manually on each spring). The new fixture has been designed with provision of hydraulic telescopic bottle jack to compress the bolster springs and release the hangers. After releasing the bolster springs and suitable packing provided, the bolster springs are again compressed to fix the hangers.

North Central Railway

  • Diesel Loco Shed, Jhansi- A new fixture for uncoupling and coupling of inlet and discharge valve of Compressor/Expressor has been made in Jhansi shed. This fixture is benefitting shed by saving time and manpower during M-2 & above schedules. Previously, these valves were uncoupled and coupled after tightening them on vice which was causing distortion and stress in compressor valves.

Western Railway

  • Intelligent test kit for Master controller of Diesel Locos- After overhauling Master Controller Switch Gear, the open and closed condition of switch was checked by continuity tester using multi meter and buzzer. This was time consuming and error prone as 18 switch operations had to be checked individually. Vatva Diesel Shed has designed and developed a simplified, intelligent, portable testing arrangement for stick type Master Controller with double coupler, for checking the operational features after overhauling.

Benefits:-

  • One technician can carry out the entire testing instead of two in the old method.
  • Simultaneous operation checking of switches enables substantial saving of time.
  • Defects like open and/or short circuit can easily be detected in the test bench.
  • Short circuit in the wire bunch can be detected by checking its operation.
  • The need to take the Heavy Master controller to locomotive for checking its operational features is obviated.
  • The testing arrangement is portable and can be used to check correct Master controller operations on locomotive itself.
  • Compressor trial run test stand- HHP locomotives are Computer Controlled brake system locomotives, equipped with an engine driven air compressor. Sabarmati shed has developed a test stand for functional testing of compressor after its overhauling in six yearly schedules. This has been developed in-house with the available resources. The compressor can be run for bedding/running in and its operational parameters can be checked. The compressor remains protected in a cage during testing.
  • Modified wheel skid block- Anti wheel skid devices are safety item and required to be provided on SLRs of all trains. Earlier, these were made from wood, which are liable to get damaged or stolen. Later, wedges using condemned composite brake blocks were developed, but these were also found to getting cracked and were not durable. Bandra Terminus(BDTS) Coaching Depot has made suitable modifications and has made a metal fabricated Wheel skid block from serviceable materials with a provision to clamp it to the track and sleepers. Its profile is such that it keeps itself in position by gripping the rail and the wheel tread. It is strong and more durable than the earlier made wedge.
  • Radio-frequency identification (RFID)based OBHS monitoring system-Mumbai Central(BCT) and Bandra Terminus(BDTS) coaching depot have started RFID based OBHS monitoring system in trains 12951/12952, 12953/12954 and 12925/12926. The system consists of RFID tag (fitted in various locations in coaches) and a biometric thumb impression device (available with OBHS staff). During the journey, whenever OBHS staff commences work they mark their attendance on the RFID tag in the coaches. Upon completion of return trip, the data (time/date is stamped) is downloaded in primary maintenance.
  • Renovation of Inspection Carriage ERC–12- Four wheeler inspection carriage ERC–12 built in 1953 by M/s. Jessop & Company, Kolkata has been completely renovated by Coach Care Centre, Mumbai Central through departmental in-house efforts. It is a heritage coach.
  • Modification in LHB pantry cars- Parel workshop took up the modification of 3 LHB pantry cars as advised by RDSO. The present design of LHB pantry cars does not have effective system for removal of exhaust gases. In the modified LHB pantry cars, the provision of stainless steel exhaust gas chimney with duct opening on the roof of the coach, similar to ICF coaches has been provided.
  • Linen Counting Machine-Mumbai Central(BCT) and Bandra Terminus(BDTS)coaching depot have installed a linen counting machine. The machine contains a box having sensors and a digital counter display. Whenever any object is dropped in the box, the same is sensed by sensor and is displayed on counter.

West Central Railway

  • Developed a fixture to assemble Head stock and Bio tank bracket by CRWS Workshop- In Body shop during corrosion repair of coaches, a fixture is used to assemble Headstock, Auxiliary head stock, Centre stiffener, Floor stiffener and Yoke bracket. After full welding of these components, the whole assembly is fitted on coach. Then Bio tanks brackets are fitted by marking. Even after taking all precautions the bio tank bracket used to get distorted and there was difficulty in fitting Bio tank along the brackets.

To overcome this problem a fixture has been developed in house, in which Bio tank bracket is assembled with Headstock, Auxiliary head stock, Centre stiffener, Floor stiffener and Yoke bracket. Now the problem of misalignment of brackets with bio tanks will be eliminated.

  • Conversion of 17 mm Fuel Injection Pump (FIP) into 18 mm FIP by Diesel Loco Shed, New Katni Junction(DLS/NKJ)-Since long, 17 mm FIPs were in use in diesel locomotives for the timely delivery and measured quantity of fuel in the combustion chamber. Due to technological up gradation, 18 mm FIPs were introduced and 17 mm FIPs are required to be replaced with 18 mm FIPs. As such large number of 17 mm FIP’s became obsolete. Further with condemnation of 15 locos, 240 FIPs got released.

In DLS/NKJ to make use of 17 mm FIPs, plunger and barrel assembly of 18 mm FIPs were retro-fitted in 17 mm FIPs and calibrated to the desired value. In this way 16 nos. 18 mm FIPs are made ready for use. This will facilitate conversion of 17 mm FIP into 18 mm FIP by changing only plunger and barrel of 18 mm FIP. The cost of one 18 mm FIP is Rs. 20,341/- and cost of plunger and barrel assembly is Rs. 5334/-. Therefore with the retro-fitment, total amount of Rs. 36,01,680/- will be saved.

  • Provision of stand by inverter for ac fuel pump motor using inverter of AC cyclonic motor of 50 Hz frequency by Diesel Loco Shed, New Katni Junction(DLS/NKJ)- DLS/NKJ had started modification for provision of additional standby inverter for AC fuel pump motor so that in case of failure of fuel Pump Motor(FPM) inverter, Loco Pilot can change the position of rotary switch to another position.

As per RDSO modification sheet no. MP.MOD.EM-01.01.11 (REV.00) dt. 17.02.2011, AC cyclonic motor of 60 Hz frequency output is recommended. As per this modification advice at least one DEBM is required to have 60 Hz frequency output. At present existing DEBMs are of 50 Hz type. The shed has started using AC cyclonic motor of 50 Hz frequency. In that case, only RPM will get reduced but fuel oil pressure remained almost same. However, with less fuel oil pressure the loco may not work for long in that case an instruction to work the loco up to destination is pasted in the cab.

Shed has carried out this modification with the help of unused MCOS (Motor cut-out switch) removed from ‘E’ type locomotives with modification to suit the operation of rotary switch. Till date 32 locos have been equipped with this modification.

  • Sealing of additional Cutout Cock (COC) by Diesel Loco Shed, New Katni Junction (DLS/NKJ)-To prevent wrong position of additional COC of Brake Pressure Pipe leading to non-application of brakes, DLS/NKJ has started sealing of additional COC for BP/FP and bogie brake cylinder. This has been implemented from 24.03.2015 and applied in all the locomotives released since 24.03.2015. Till now additional COC has been sealedin 50 locomotives.
  • Washable Apron Clamps(WAC)-Jabalpur Division has developed Washable Apron Clamps (WAC) for emergency repairs of track laid on washable apron during fracture of rail as ordinary clamp cannot be used for the same.

This clamp shall fix normal fish plates, 1m fish plates and Joggle Fish Plates. It is prepared in two parts fitted with two threaded bolts and a common fixing bolt.

The salient features are as follows:-

•Easy to fix.

•Low cost (Rs. 400/-only).

•Durable.

•Torch light helmet-Jabalpur Division has developed Torch light helmet which shall be a part of the Patrolman equipment and shall enable them to perform their duties much efficiently. This equipment has proven to be of great use to the Patrolman especially during emergency repair of track.

The salient features are as follows:-

•Easy to wear and adjust.

•Low cost (Rs. 1200/- only).

•Durable.

•High visibility.

•Rechargeable.

•Water resistant.

•Shock proof.

•Telescopic Patrolman Staff(TPS)-Jabalpur Division has developed a Telescopic Patrolman Staff which can be easily fitted on any type of rail with the help of fixing screw. It is telescopic, which allows it to be fixed at any height. It has provision for placing a red flasher light during night and red flag during day.

The salient features are as follows:-

•Easy to fix and adjust.

•Light weight.

•Easy to carry.

•Economical (Rs. 500/- Only).

•Durable.

•Sturdy.

•ERC(Elastic Rail Clips) greasing kit-A kit has been prepared by Jabalpur Division for doing proper and correct ERC greasing to avoid seizing of ERC and damaging of M.C.I. inserts and sleepers.

The Kit has 05 items:-

•Small Hammer- For removing rusting under liner and rail flange.

•Wire Brush- Used for cleaning of rail flange.

•Round copper brush with handle of M.S. rod 6mm dia- For removing rust inside M.C.I. insert.

•Painting brush- 25 mm size brush used for painting of M.S. liner and rail flange seat.

•Tooth brush- This brush used for greasing of ERC lug and inside M.C.I. Insert.

•All items kept in a small rexine bag of size – 32 cm X 140 mm X 70 mm.

•Miniature electrical hooter-Jabalpur Division has prepared an Electrical hooter, which shall enable gangs and Track Machine Organization to warn and protect at work sites. This hooter is rechargeable and is easy to use.

The salient features are as follows:-

•Easy to use.

•Lightweight.

•Enables effective protection.

•Loud sound.

•Rechargeable.

•Durable.

•Economical (Cost Rs. 750/- only).

•LED tricolour torches for patrolman- Bhopal Division has developed LED tricolour torch light fixed with staff which has easy fixing arrangement with track by clamping. This will be a part of the Patrolman equipment and shall enable them to perform their duties much efficiently as it is lighter in weight and easy to handle. This equipment will be of great use to the Patrolman especially during emergency. In this torch, slight modifications have been made, so that Patrolman can show all the three colours i.e. green, red and normal light by operating one switch only. This LED tricolour torch facilitates patrolman not to carry tropical HS lamp with them.

The salient features are as follows:-

•Easy to fix.

•Easy to handle.

•Low Cost (Rs. 291/- only).

•Durable.

•In one handy torch all the three lights can be shown.

•Instrument to eliminate misalignment from track– An innovative work was done by Engineering department to invent an instrument to eliminate misalignment from track by measuring side slew value with respect to straight line of collimation established between two good points selected at the interval of 100 meters to 300 meters as per site conditions. TGI (Track Gauge Irregularity) value of Group ‘A’ route on Kota Division has been improved using this approach.

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