INNOVATIONS DONE ON ZONAL RAILWAYS – JULY, 2014

Central Railway

  • Electronic Face Recognition Attendance Management System

“Electronic Face Recognition Attendance Management System” has been introduced at DRM’s office Nagpur. Further in order to improve the efficiency and productivity, Nagpur Division has started “Silence hours” on all working days w.e.f. 01.07.2014 between 09:45 hrs to 12:30 hrs. Thus, once attendance of staff is registered, no exit till 12:30 hrs. and no outsiders are permitted during the silence hours.

East Coast Railway

  • SpecialTraining Module for Contractors’ supervisors to ensure safety

A special training module of 3 days introduced in Divisional Engg. Training School, Sambalpur, exclusively for training the contractors’ supervisors focusing on safety at work sites & safety measures to be adopted while working near the running track. This has improved the safety environment at work sites and revenue of Rs.1.75 lakhs was earned as course fee.

Northern Railway

  • Repair of Hydraulic Steady Rest Roller of CNC ATL Machine at Amritsar

The CNC ATL machine was under repair due to non-availability of steady rest rollers. Although purchase order No. 15128003187076 dated 13.2.2014, cost Rs. 1.31 lacs was placed on M/s SUNCAP Company. The firm was approached many times for repair of machine. But the firm failed to supply the material despite of regular chasing. Due to urgency, the innovative work was taken in hand. New steady rest rollers have been manufactured and Double Row Ball bearing were fitted after machining new rollers in house and now the machine is working satisfactory. This innovative work not only put the vital machine in working order for continuing manufacturing of Axles for BVZI wagons but also saved lacs of Railway revenue.

North Central Railway

  • A test bench for testing various sensors used on ALCO locomotives (WDM3A, WDM3D, and WDG3A) has been developed in-house to check the performance of sensors before fitment on locomotive. The test bench will also help in proper testing of sensors incase of malfunctioning and improve reliability of locomotives.

Types of sensors which can be tested on the test bench are:

a)Engine speed sensor (ESS),

b)Traction motor speed sensor (TMSS),

c)Voltage sensors,

d)Current sensors,

e)Lube oil pressure sensor,

f)Fuel oil pressure sensor,

g)Water and lube oil temperature sensors,

h)Brake pipe pressure, brake cylinder pressure, M.R. pressure sensor and

i)Load ammeter calibration.

  • Material trolley has been developed by Coaching Depot, Agra with in-house efforts for transporting material for IOH. Trolley provides different compartments to carry all must change components of bogie, for one coach.

Northeast Frontier Railway

  • Gas cylinder unloading ramp is refurbished at New Bongaigaon Stores Depot utilising 12 mm COMPREG sheet on both sides of which used elastomeric pads of axle pulley are attached using adhesive as well as 5 numbers self taping screw. This assembly is fixed on top working surface of gas cylinder unloading ramp to provide resilient and sturdy surface. This surface absorbs shocks due to unloading of gas cylinder and at the same time avoids damage and bouncing of cylinders.

Empty gas cylinder loading platform of 6 M wires 12 Metre is fabricated and installed using in-house efforts and mostly scrap materials. This empty gas cylinder loading platform is at loading height of tracks and therefore manually loading of empty cylinders from ground level to truck height is eliminated. It also provides very good working area for the staff which otherwise work on bare soil even during monsoon.

South Central Railway

  • Platform Branding

‘Platform Branding’ a first of its kind under Commercial Publicity on this railway was awarded at Guntur station in Guntur division, with an annual license fee of Rs. 2 lacs.

South Eastern Railway

  • On SER a design of precast concrete speed breaker (made of M-30 concrete and with nominal steel reinforcement to withstand handling stress) has been developed which will work as maintenance free speed breakers for UMLCs on kutchaa roads having width 3.0 to 3.3 m approx. In this design, precast segments are cast in the shape of speed breaker of approx weight of 157 kg. each. The width of each segment is 15 cm.
  • For improving safety on Manned LC gate, an auto banner flag has been developed on S.E. Railway. In this system, red banner flag is automatically erected on track by lever operation from Gate Goomty before LC is opened to road traffic. This is quite simple and economical and has great bearing on enhancing safety and punctuality of rail traffic. A video clip demonstration showing its working has also been uploaded in “You Tube” website. Till date this has been proliferated on 41 nos. of manned LC gates on SER.

Western Railway

  • With a view to provide better and faster ticketing to the passengers, a red line is marked in the queuing hall of the booking offices from where passenger will get ticket in 10 minutes at the stations. The main objective is to assure that they will get the ticket in 10 minutes. The scheme is introduced in Churchgate and Andheri station suburban section and at Vapi, Valsad & Surat station in non-suburban section on the trail basis. This had been suggested by CRB during his visit to Mumbai.
  • Pratapnagar workshop has developed a fixture for removal of axle box housing, eliminating the present practice of hammering the housing during its removal.
  • The palletized material issue System has been introduced inthe bogie shop of Bhavnagar workshop for issue of bogie components for undertaking POH and IOH of bogies. 3 different colour coded pallets are being used for supply of spares for easy identification by the staff. The repairable items are taken to another work centre where they are attended to defects/wear and if found beyond the repairable condition replaced by new ones. Each pallet contains exact number of items required for overhauling one ICF bogie. With the help of these palletized material issues system 100% traceability and accountability is ensured.
  • Testing Jig for ‘H’ type Coupler

During the month Electric Loco Shed,Vadodara Yard has developed a special Jig for compatibility testing of “E” type coupler of loco with “H” type coupler of adjacent LHB coach. For this a special trolley mounted with “H” type coupler has been developed and matching with loco coupler during AOH/IOH is being ensured by physically coupling WAP4 loco with test coupler. In cases of mismatching, the loco coupler can be attended in shed to avoid cases of CBC not locking while attaching on load with ‘H’ type coupler coach.

West Central Railway

  • WW Governor Power Piston Mounting & Dismounting Tool

Diesel loco shed, Itarsi has been continuously striving for improving the infrastructural facilities for the maintenance and upkeep of the HHP locomotives, (WDP4B/4D). These locomotives have been equipped with F-8572-828 type W.W. Governor. In this month Diesel Lose Shed, Itarsi has developed a fixture for mounting and dismounting W.W. Governor Power Piston assembly with the help of available resources. This item is required for Mounting & Dismounting the power piston assembly during overhauling of WW Governor. This tool is helpful in improving the work efficiency as well accuracy in maintenance of WW governor of WDP4B/4D locomotives.

  • Manufacturing of grinding machine to polish test piece

To get desired result of spectroscope testing, test piece is required to obtain certain of surface finish. This surface finish used to be achieved by rubbing the test piece manually on emery paper which was a tedious and also time consuming job.

A grinder has been manufactured in-house by available released material at CRWS/BPL. In this grinder an emery belt is driven by 1 HP motor. Both ferrous and non-ferrous test pieces can be suitably polished.

  • Provision of insulated net

30 insulated net have been provided on Drop Arm and Boom of portals to prevent formation of Bird nests at Katni Murwara & Rithi yard.

  • Upper face of bogie nose in M/s Ved Sassomechanica make bogies is having sharp bend which leads to development of crack and thereby failure of locomotive. The curvature is being increased by suitable method as advised by firm. Out of 20 bogies, shed has completed this work in 11 such bogies of WAG 9 locos. Work to be carried out by firm in nine bogies of WAP7 locos, out of which two bogies have been completed.
  • Electric Loco Shed, Tughkakabad has developed a test jig for on load testing of power supply cards i.e. KUB 921A01 of CEL (VCU) rack to test regulation of power supply card and also check during fault of lifesign missing by multiple processor cards simultaneously.
  • Innovation of detection of loose inner race of Axle Journal in-situ by ultrasonic testing of WAG7 loco in service

Based on RDSO code of procedure, new test procedure for WAG7 locos has been developed. So far, 153 axles have been tested. Defect was found in loco no. 27678, axle-3 and major on-line failure was averted.

  • In compliance to Board’s letter no. 2001/Elect(G)/170/2 Pt.-I dated 22.10.13 and looking to fruitful results of provision of Circuit Breaker in place of BM (Breaker Main: Interrupter) at Sawaimadhopur/SSP for FCI siding/Kota division, now circuit breaker in place of interrupter at MTPC/SSP for feeding supply to MTPC marshalling yard of RVNL Thermal siding has been provided, so whenever fault occurs in siding & associated lines, then main line OHE is not interrupted which is controlled by separate BM-36.

1