INNOVATIONS DONE ON ZONAL RAILWAYS – MAY, 2015
Central Railway
· Introduction of upgraded dining car in Deccan Queen Express: Parel workshop has converted CZ coach to Dining Car for Deccan Queen Express during “Customer Facilitation Fortnight” which has been kept ready for the occasion of 86th Birthday of Deccan Queen Express. Dining car is ‘a restaurant facility’ provided with improved amenities like; Mirror finish table tops, Roller shades of all windows, Aesthetically designed wash basin counter, Unbreakable large mirror, Stainless steel service counter, Energy efficient refrigerator, Energy efficient illumination and a tea vending machine. (Picture -1)
Picture -1
· A test bench has been developed in house by Electric Loco Shed, Kalyan for ALSTOM Make SI unit of AC/DC locos for testing of PCB of control unit, new signal cables and Reed relays mounted on PCB, Simulator test of Inverter, Chopper and Safety Thyristor, Data downloading and software uploading. (Picture -2)
Picture -2
East Coast Railway
· Gadget for lash removal for WDG4 locos: Diesel Loco Shed, Visakhapatnam has developed a special gadget for lash removal of WDG4 locos. The valve bridge is placed on the fixture. By hitting at the stem, both the lashes come out. This tool is essential to change lashes during schedule activities. Whenever the lashes get stuck up due to improper action of the spring, it needs to be changed. (Picture -3)
Picture -3
· Air dryer test bench: Air dryer test bench has been fabricated by Electric Loco Shed, Angul and the testing of air dryer has been started during the month. (Picture -4)
Picture -4
· Gadget for Snap Ring Fitment in Valve Bridge Assembly of WDG4 Locos: Diesel Loco Shed, Visakhapatnam has developed a special gadget for fitment of snap ring on the valve bridge assembly. The valve bridge is placed on the fixture in reverse position. The spring is pressed by the lever and the snap ring is fitted. This tool is essential whenever the spring needs to be changed. (Picture -5)
Picture -5
North Central Railway
· Water pump modification: There are two types of water pump fitted on locomotives having 42 and 46 nos. gear teeth. It has been noticed that water pump having 42 nos. gear teeth are failing due to less lubrication. RPM of water pump in gears having 42 teeth is about 300 more than water pump having 46 gear teeth which results in increase in temperature. To reduce the temperature, a modification has been done in Diesel Loco Shed, Jhansi by providing extra pipe for lubrication. This has helped in reducing the above mentioned failure. (Picture -6)
Picture -6
North Western Railway
· T-28 style working with Hydra Cranes: Points & Crossings are normally laid/dismantled by T-28 machine or manually. T-28 machine is helpful in laying/dismantling complete turnout. In the section of Keshav Ganj (KVJ) - Swarupganj (SRPJ), complete turnouts were assembled outside and laid with the help of 05 to 08 nos. of Hydra Cranes (as per site conditions) all operating in synchronous. Similarly, wherever dismantling of turnout was involved, plain track panel of equal length was made ready and laid by the use of 05 to 08 Hydra cranes. These arrangements not only reduced labour requirements drastically but were very helpful in laying turnout accurately. Such arrangements of laying points with hydra cranes were used in parallel at multiple locations in the same or multiple yards in the same traffic block. This innovation was the key to success in the NI work of KVJ-SRPJ in completing works in advance of schedule.
Southern Railway
· Energy efficient ceiling fans: 24 Nos. Energy Efficient Brushless DC (BLDC) fans in place of 230 Volts, AC ceiling fans have been provided first time in Southern Railway at Coimbatore Junction as a trial measure. The fans are manufactured by M/s. Versa Drives Private Limited, Coimbatore-24 in the brand name of Superfan. These fans are basically energy efficient, low voltage, brushless DC fans, driven by electronically controlled inverter. It is light in weight and consumes about 40% less power than the conventional AC ceiling fan and having better air delivery.
Salient Features:-
1. Energy savings about 50% (Rated power 35 W, 233 volts).
2. Speed on remote control without regulator, 350 RPM.
3. Higher air delivery, 220 m3/min (CMM).
4. No change in speed due to variation in supply or low voltage.
5. Power factor better than 0.9
6. No noise.
7. Warranty period of 5 years.
8. Payback period - 3.5 years.
· GSM based PF lights control system: GSM based light control system has been installed at platform no. 1 of Erode station to control 100 lights.
Salient Features:-
1. Easy operations of lights & fans using mobile phone.
2. Can be operated from remote area.
3. The system can be operated by 5 persons namely Depot supervisors, Duty SM, Rolling examination staff and Switch room staff etc.
4. System can be used for controlling not only lights and fans but also for any electrical devices.
5. Cost of the equipment is Rs.12,000/- only.
6. Energy saving is 9125 units per year, i.e approximately Rs.-63,875/- per year.
South Eastern Railway
· New type automatic Banner Flag device developed by one of our SSE(P.Way) has been installed at one manned gate on trial basis. This is designed to take care of some deficiencies noticed in lifting type auto banner flag developed earlier. This modified automatic banner flag device does not rest on track hence there are no chances of its damage due to hitting by running trains. The possibility of its entanglement with the running trains is also remote unlike previous one. It is also economical in comparison with previous version. (Picture -7)
Picture -7
Western Railway
· On Vadodara division, dilapidated old CC apron at BRCP Line-2 has been repaired with State of the art method in continuous block of 60 hrs. CC apron at BRCP was in depilated state and track parameters were going beyond maintenance limit. As an innovation, non shrink free flow cementations grouting material was used for filling of the cavities under and around the sleepers. Using the special characteristic of the material of gaining high strength in less than 12 hrs, the CC apron has been strengthened in least possible time. Condition of repaired CC apron is being monitored closely.
· Modification of Pre-Priming Motor for utilization as spare Fuel Pump Motor by Ratlam shed: Several failures on account of defect on the Fuel Pump Motor have been reported. A modification has been carried out in which Pre-Priming Motor has been converted into Pre-Priming-cum-Additional Fuel Pump Motor by providing an extra booster ½" COC Cock and 15 amp additional circuit breaker. With the help of this modification the failures of locos on account of defect in Fuel Pump Motor can be minimized as Pre-Priming Motor will serve as standby Fuel Pump Motor.
· Extractor tool for Compressor Crank shaft hub: An extractor tool has been fabricated by Sabarmati Diesel Shed for removing the crank shaft hub of WDG4 or WDG4D compressor. This will be extensively used during Y6 schedules and will make the operation safer, quicker and more ergonomic. (Picture -8,9)
Picture -8 Picture -9
· Development of fixture for systematic stacking of ICF coach overhead tanks: Surat Depot has 12 nos. unit exchange overhead water tanks used for replacement against leaky water tanks of ICF coaches. These defective/leaky water tanks are then replaced with unit exchange basis from Lower Parel (PL) workshop. These water tanks were earlier kept on ground in different areas of the Depot occupying valuable space. A need was felt for the water tanks to be stacked properly with proper identification. Therefore, the Depot has taken the initiative of fabricating a small fixture using released pipes. It is designed in such a way that arms of the fork lift can be easily placed underneath the tank to load/unload the tanks without disturbing other tanks. Proper identification plate is also welded on each tank on which details of each tank i.e. the status of the coach water tank either serviceable or defective, coach no., train no., date of replacement, date of arrival etc. can be written. (Picture -10)
Picture -10
West Central Railway
· Solar panels on GS coach in Jabalpur Division: Solar panels on GS coach no. 94408 have been provided for charging batteries and feeding electrical load during day time. Two trials have already been conducted in train no. 51701 (Jabalpur - Rewa Pass). Additional trials are also being planned to establish reliability of this system. (Picture -11,12)
Picture -11 Picture -12
· Improvement in Air brake pipe cutting by Carriage Repair Workshop, Bhopal: During final air brake testing leakage cases were regularly reported. To overcome this problem, fitment system was critically examined and noticed that during cutting activity pipes were not properly supported, resulting pipe cutting done at 80°-85° instead of 90°, which leads to mismatching of end fitting with pipes. (Picture -13)
Picture -13
Now, a fixture has been developed to support pipe so that cutting is done at 90°. After the development, reports of leakage during final Air brake testing have been observed to be drastically reduced.
· Automation of power factor correction by Carriage Repair Workshop, Bhopal: In order to improve power factor, in sub-station no. 1 & 2, manual power factor correction panels were provided. Now they have been modified, in house, to work as automatic power factor correction panel by CRWS staff.
· Trolley for fitting of flap door in BOXN wagons by Wagon Repair Shop, Khutbav: Flap doors of BOXN wagon received for POH are mostly deficient or in badly damaged condition. During POH of BOXN wagon flap, doors are needed to be replaced frequently. In the present practice, the fitment of BOXN door is manual and crude work, which is very tedious and labour some involving 04 persons. The door is a heavy and big structure. Manual lifting of the door by 04 persons, holding the door at the level of door hinge, align the holes and fitment of pin etc. is really tedious and hurt prone.
The developed innovation is a very simple design assembly on a platform made of channel and screw and nut assembly with two handles provided at both end of it. Four rubber mounted wheels arrangement are also provided in it to carry out it on working place. A door holder channel’s end are joined by means of four lever arms two each side of door holder and another end of these arms are connected by movable joint on left and right threaded portion of screw and nut assembly. (Picture -14)
When handles of this screw nut assembly are rotated then nuts of screw nut assembly come close and door holder lifted upwards. If handle’s direction of rotation is changed then door holder comes down. Maximum lift and angular displacement of this are 150 mm and 45° respectively. A door to be fitted is placed in door holder by keeping its hinges on top, then it is lifted by rotating screw nut assembly handles up to the height of wagon’s door hinge foot after matching holes of hinges and a door pin is inserted. After this door holder is released and removed. (Picture -15,16,17)
Construction details:- The following scrap items were used.
1) Screw and nut assembly with LH and RH thread (Dia - 25 mm & Length - 1590 mm) – 01 Nos.
2) Base channels (150 X 75 X 1020) mm – 01 Nos.
3) Channel (85 X 75 X 810) mm – 01 Nos.
4) Plate strips (55 X 10 X 510) mm – 02 Nos.
5) Lever arms (80 X 10 X 590) mm – 02 Nos.
6) Lever arms (80 X 05 X 690) mm – 02 Nos.
7) Brackets (80 X 10 X 70) mm – 04 Nos.
8) Rubber mounted wheels – 04 Nos.
This innovation has been developed at the cost of Rs. 1500/- only.
Benefits:-
1) Fitting of flap doors in BOXN wagon can be done easily with less effort.
2) This process is simple and safe so it reduced IOD cases.
Picture -14 Picture -15Picture -16 Picture -17
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