INNOVATIONS DONE ON ZONAL RAILWAYS – AUGUST, 2014
Central Railway

Service Register of the employees has been computerized on Bhusawal
Division during the month.
East Coast Railway

Push/Pull Trolley
To carry out under-gear examination of freight stock at examination
line during night time, C&W Depot/Kantabanji of Sambalpur Division
has indigenously developed one Push/pull trolley (920mm x 700mm x
890mm size) with provision of 03 nos. (500 Watt) Halogen lights. The
trolley can also carry tools and jacks with freight stock materials like
CC pad, EM pad, Adaptor, Brake block, Brake block key, knuckle pins,
split pins, Spring, control rod, cotter etc for repair & maintenance of
wagons.

Digitization of Land Plans
Digitization of land plans has been started in Waltair Division and
during the month, the Division has scanned 178 Kms of land plans.
This is considered as very important step in preservation of the most
important data without any fear of loss.

Rail Piling by Manilla Rope instead of steel Chains
In Restoration of bank washout site between Jarati-Malligura on KR
line in Waltair Division, instead of regular practice of rail-pile handling
by steel chains. Manilla rope of adequate strength was used, which has
reduced the erection time from 12-15 min to 2-4 min. Thus 4 days’
work with present practice was completed in only 01 day thereby saving
labour and reducing the restoration time considerably.
Northern Railway

Solar powered narrow gauge coach by using released Solar Panel
As an energy conservation measure and to promote use of renewable
energy resources, possibilities of installation of “RELEASED SOLAR
PANELS” on the roof of narrow gauge coaches were explored and these
were duly designed, developed and commissioned on narrow gauge
coach no. NG28/NG/FC at Kalka on 16.08.2014. This coach is now
running successfully on Kalka-Shimla section. Eight nos. 12V, 35 WP
Photo Voltaic Solar Panel have been provided on the roof of the coach.
These released solar panels were arranged from S&T department of
Moradabad Division, where they had become surplus due to new
Railway Electrification work. The coach is running successfully since
25.08.2014.
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
Fabrication of shunting winch at Kalka Workshop
Outgoing coaches in Kalka are coupled ahead of Diesel loco and 8-10
men were used to push these outgoing coaches ahead of diesel loco. To
automate this process, one electric shunting winch has been developed
and commissioned with internal resources in Carriage Repair (CR) shop
Kalka. Now only one shunting staff is required to pull outgoing coach
ahead of the diesel loco.
North Central Railway

Indigenous development of Toothed wheel for cutting chain of
FRM
Toothed wheel for cutting chain in FRM 1871(NR) were in badly
damaged condition and required replacement. After detailed study of
sample, all eight toothed wheels have been developed by forging with
high carbon alloy steel. Imported cost (from OEM) for one set guide is
approx. Rs. 42 lacs, whereas indigenized cost of one set is approx. Rs.
2.76 lacs only. Thus there is net saving of Rs. 39.24 lacs per machine.

POH of VPR 02-17
VPR machine of NWR was out of order since last twenty months on
account of badly damaged wheel/axle, electronic system and
pneumatic system. During the process of POH, complete electronic
panels have been repaired with latest and modern type of electronic
components. Pneumatic and hydraulic systems have been renovated
with user friendly available parts. All the four axles have been made
functional. It is worth mentioning that machine was working with three
axles since last six years. Now machine has been tested and is ready
for dispatch.
Northeast Frontier Railway

Fixture for Centre Pivot Bogie Liner Welding
There were number of cases of loco failure due to Centre Pivot Bogie
Liner welding crack. This occurs due to loose holding of the liner during
welding as there is no arrangement to hold the liner tightly. This fixture
helps to hold both ends of the liner firmly during welding.
A push rod is welded with a bolt & its nut is welded in an iron pipe so
that the total length can be increased to hold the liner tightly. This
modification was carried out by the Under Gear Section without any
assistance from any external agency.
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South Central Railway

Provision of LSGRR to indicate the GR-0 position of rear loco in
leading loco
An additional signal lamp LSGRR is provided on driver’s desk to
indicate about the GR-0 position of rear loco, while working Multiple
Unit. The LP can take timely action to avoid rail burns in case GR
(Graduator) is not in zero in rear loco. This modification has been done
in one Multiple Unit loco (28268+28351) on trial basis, by Electric Loco
Shed/Vijayawada of Vijayawada division.

Modification in 28 series AERO dynamic cab WAG-7 locomotives’
marker light for easy maintenance
In 28 series aero dynamic cab WAG - 7 locomotives, replacement and
maintenance of marker lights is possible only from inside the cab which
is very inconvenient and time consuming process. In order to facilitate
easy replacement/ maintenance of marker lights, Electric Loco
Shed/Vijayawada has modified fixing arrangement to allow replacement
and maintenance from the outside. This arrangement has been done in
35 locos so far.

Over aged coach No: 89220 CN SC was converted as inspection carriage
and provided with both ends inspection windows, at Lallaguda
workshops. With this lot of shunting is avoided for reversal of
inspection coach for want of rear window.
South Eastern Railway

SE Railway has gone on path breaking initiative of installing
Transparency boards at conspicuous places at work sites in
station/colony premises under the title “पारदर्शिता की
ओर बढ़ते कदम”
These boards display the scope of work planned along with the
specification of important materials to be used in the work. This also
contains the mobile numbers of officers right from AEN to DRM in the
division and up to CPDE level in the Head Quarters. Till date, 438
such Boards have been installed on different
worksites
since
March ’12. It has earned appreciation from Rail users, Unions, Media
and officers. In the above regard, a CE Circular No. 271 dated
19.04.2013 has been issued, to be applicable on all worksites on SER.

Civil Engineering Training Centre, Kharagpur (CETC/KGP) under South
Eastern Railway is imparting training to SSEs/JEs/( Works/P.Way) of
three zones- SER, ECoR & SECR from 2005. S.E. Railway is always
striving for better quality control in the field. Recently, one Ballast
Testing Laboratory has been installed in Geo Tech Lab of CETC/KGP
which was inaugurated by Principle Chief Engineer on 10.09.2014.
Most probably, CETC/KGP is the first Zonal Training Institute where
ballast testing equipments have been installed for better practical
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exposure of trainees so that they can ensure best quality control in the
field.
Moreover, ballast testing of SER was being done either at
Visakhapatnam of East Coast Railway or at other recognized
Engineering colleges. But after installation of these equipments at Geo
Tech Lab at CETC/KGP, ballast testing can be done in-house and also
it will ensure better quality control in the field along with
transparency.
Western Railway

Liner sleeve Pressing Fixture developed at RTM diesel shed
Cylinder liner bores in engine blocks are required to mate perfectly
with the liner sleeves and the liners, to avoid stress concentration on
the liner due to point contact. Conventionally, liner sleeves were being
machined on lathe machine from inside & outside, separately.
Progressive reduction in its thickness due to this machining mould
causes ovality in the sleeve even before fitment in the engine blocks. A
fixture has been developed by Ratlam diesel shed to hold the sleeve
during machining from outside, so as to ensure uniform & precision
machining without ovality being generated. This has completely
eliminated the need to machine the cylinder liners, even in exceptional
cases.

Portable light trolley developed at Indore
Depot
Indore Depot of Ratlam division has developed a portable light trolley
locally.
This trolley comprises one 12V-26Ah dry battery and 2 bulbs
only. The bulbs have adjustable angle feature. The battery requires no
maintenance being dry type. The light weight trolley has 3 wheels and
hence easy to drag inside the pit. The battery can be charged easily
without removing it from its place and can last throughout the night.
West Central Railway

Arrangement of push type flushing valve
Bio digester tanks are now fitted in coaches. The effective function of
bio tanks mainly depends upon the availability of sufficient water
during use. Push type flush valve fitted in coaches need approx 7 Kgs.
pressing force. Passengers feel inconvenience to operate the same,
resulting in insufficient quantity of water flushed in the Lavatory pan.
To overcome this problem, operation of flushing valve is eased by
providing lever arrangement to the existing push type flush valve. By
this improved method, flush valve can be operated at very low pressing
force, 1.5 kg approx, and required quantity of water is released.
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
Fixture for assembling and dismantling of BSS(Bolster Spring
Suspension) hanger with spring plank in ICF bogie fitted in BVZI
(Goods brake van with eight wheels) wagon
The assembly and dismantling of BSS hanger with spring plank in ICF
bogie is a tedious work. In present practice, a load of approx 2 Ton is
put on the spring plank to assemble or dismantle the BSS hanger. In
the present practice, one scrap bin filled with scrap of approx 2T was
put on the spring plank by means of 20 T crane. This practice is very
crude, cumbersome and unsafe.
The innovation is a very simple design assembly of a frame made of
channel and screw and nut assembly made at a cost of only Rs 1500/-.
This fixture is fixed over the bogie frame and the spring plank and
tightened by means of the screw & nut assembly facilitating the
assembly / dismantling of BSS hanger.

Manufacturing of stainless steel channels for end top coping of
BOXNHL wagons by Die and Punch
Kota workshop has started getting Stainless steel wagon for POH. The
top coping of these wagons very often needs to be repaired, because of
damage.
The tool room section of the workshop has developed a die and punch
to make SS channel (175 x 55) mm for making the top coping. The die
and punch had been made at a cost of only Rs 31,000/-. This
innovation will help the workshop to make the top coping.

Jig for measuring gap
Electric Loco Shed/Tughlakabad has developed jig with its own
resources for measuring gap between speed sensor and generating ring
to improve reliability of speed sensors.

Computer
based
software
has
been
developed
by
Tr.
Department/Jabalpur division to monitor various maintenance
activities of Tr. Department. This will be useful to monitor overdue
maintenance of assets.

An innovation on BCM machine has been done by Kota workshop
facilitating disposal of muck away from loop line during deep screening
in yard. This was successfully carried out on 13th and 14th Aug’14 on
UP mainline of Rohal Khurda (RLK) yard.
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