Reliability and Safety improvement

Submitted by vinod.kumar on Mon, 07/30/2018 - 11:30

CCB 1.5 Brake Valve testing bench is prepared in Quality Unit Air Brake of Diesel Shed Ratlam. After preparing this Test Bench all Pneumatic Brake Valve of CCB 1.5 system can be tested after the overhauling /necessary investigations after any line failure.

Railway

Western Railway

Subject

Reliability and Safety improvement

Name of Good Work

Test Bench for testing of CCB 1.5 Brake Valves.

Summary

Detailed Description

Computer controlled brake system (CCB 1.5) designed by the M/s Knorr Bremse is a powerful braking system, which make it possible to apply as well as release the Loco & Train brakes quickly thus prevents time loss and also ensures safety during emergency application of the brakes. The system involves various Pneumatic as well as electrically operated complicated valves to run this brake system efficiently. Malfunctioning of any of the associated valves needs to be identified and rectified promptly to prevent detention of the loco in the shed. RTM shed had received its first CCB 1.5 Alco Loco in 2010. Presently there are 3 HHP Locomotives in shed which are having this type of brake system.

CCB 1.5 brake System is having total 24 Brake Valves. M/s KBIL provides total 12 no. of Test Benches for the testing of all these Brakes valves. Each Test Bench is designed to test one or more than one types of valves only. RTM Diesel shed has made a single Test Bench to test 12 pneumatic valves of CCB 1.5 brake system. The total cost of M/s KBIL made Test Benches for testing of these 12 Valves are Rs.42 Lacs as per copy of a BQ available with us, whereas the shed has used available resources of Diesel Shed Ratlam to make this Test Bench.

Many times brake valves are needed to be overhauled and tested in out of course/in schedule, but due to non-availability of testing facility, RTM shed has to test the culprit valves in OEM premises, which increases downtime of the concerned locomotives besides loss of man power of the shed.

To overcome these entire issues, this Test Bench is made indigenously by available resources of Diesel Shed, Ratlam. As this Test Bench is made by scrap/condemn released material of Diesel Loco hence this Test Bench made by the RTM shed is not only a cost saver but also a very compact one, thus occupying lesser area on the shop floor. This will help to enhance the reliability of all 12 valves, those are supposed to be tested on this Test Bench.

Impact/Benefit

Helps to reduce BWMS cases pertaining to CCB 1.5 System

Uploaded support documents / Photographs/Diagrams