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ART Team of Hubli Division of South Western Railways has developed a very effective Rescue Device for removing Coach window rods quickly. Hubli Division has developed two model variants : 1 m & 1.6m length Snapper tool with a C section Grip snapper made of HSS. The C Section Grip Snapper is having threaded connection to the Pipe as well as uniformly CO2 welded over the joint. The C section Grip Snapper is having opening of 13mm which holds & snaps the window rod from its roots very quickly & it can remove all rods of one windows in approx 30-45secs . It is manually operated. The Rescue staff has to grab the window rod with this tool & with slight force application , the rod will get removed from the base. This type of rod removal is very safe as compared to cutting of rods at corner by hydraulic devices since there is no sharp edge generated by this manual tool (which is there in hydraulic rod cutters,so Magnetic Covers were must to be used to avoid injury to passengers rushing out of the coach).

This tool is very fast in operation as compared to Hydraulic rod cutters. It can remove all rods of a window in 30-40 secs average as compared to 5 mins time with hydraulic rod cutters. Also it removes the rod from its roots, so chances of injury to passenger rushing out of coach is very less. It is very cheaper & can be fabricated very easily in shops.

OVERVIEW:

Android based POH cost App has been developed at Liluah Workshop.  This effort is the first of* its kind in entire Indian Railways  The main aim of this APP* is uniform distribution of Inspection activities with material booking with respect to Work Orders.  This APP will both be* Web Based and also freely downloadable from Play Store.  The users will be* provided with Login ID and Passwords

WORKING METHODOLOGY OF COACH POH COSTING APP:

• After initial login, the Inspector will make entry in the prescribed form coach wise and work order wise 
• After pre-inspection the* Shop Supervisor will make necessary entries after execution of POH work
• After completion of* POH, final inspection entries would be carried out by Inspectors.
• Necessary reports can* be generated.

SHOP SUPERVISOR ENTRIES IN COACH POH COSTING APP:

• Shop Supervisor will login after pre-inspection
• The pre-inspection timings would be now visible to the Supervisor
• Remarks can be put in case of disagreement with the preinspection times 
• After compliance of remarks, Material consumption (coach wise and work order wise) has to be entered 
• This will help in generating* material cost calculations as per coach
• Editing after final submission* can be done with the permission from ADMIN

ADVANTAGES:

• The APP ensures digitization of all inspection sheets
• This APP will reduce time by eliminating manual entries in all material and inspection sheets
• All data would be transferred to server ensuring data  safety and security
• Cost of every coach can be calculated instantly. This was not possible in the existing system.
• Reasons for variance between pre and final  inspections can be critically analyzed
• More than 20 types of custom reports can be generated and viewed
• The introduction of this POH cost based APP will* reduce POH cost in this Workshop by uniform distribution of resources.

IB valley region and Korba region have clusters of coal loading sidings. In each region 30 rakes each, coal is loaded every day. No. of wagons in a rake are rejected as unloadable. The unloadable return embedded empty, incurring loss in earnings.

SECR has undertaken works of attending these rejected wagons before loading by doing temporary repairs, thus making loadable for at least one movement. The work is outsourced using mobile van loaded with Generator and Welding sets. The repair raw material MS plates are also loaded in Mobile van.

The wagons rejected by siding authorities are attended and made temporary loadable. On an average 259 and 186 rejected wagons are made temporary loadable per day at IB valley region and Korba region respectively.

Thus loss of earning @ Rs. 16000/Wagons/Day to the tune of Rs.71.2 lakhs is saved. In the process expenditure incurred is Rs. 0.59 lakhs per day.

By this process SECR is saving/earning about 70.61 lakhs per day.

Stench removal from Bio-toilets/ normal toilets is a big challenge being faced on IR by coach maintenance wing. Many methods are being tried such as providing exhaust fans at location nearer to squatting pan, or fitting double ventury to have better natural ventilation. However, staff of YPR Depot of SWR looked at the problem a bit differently, they tried to pinpoint the source(s) of the bad-odour. They found that majorly stench emanates from Night Soil (NS) matter which gets stuck on inner surface of Straight Pipe and S- Pipe as well as on to the trash material ( like paper cups, etc.) inadvertently dropped by users in the toilet/pan.

To handle all these sources of stench, the staff initially thought of using a Robotic Arm but finally ended up evolving a Flexible-Shaft mounted Powered Cleaning-Tool. This tool not only is able to effectively traverse and clean the complete straight and S- pipe passage but is able to pull out as well as push out the trash material Cost: - The total cost of the powered tool would be in the range of Rs 4000 to Rs 5000 including spare set of chargeable batteries. Actually the Flexible Shaft and tool costs approximately Rs 500 only and the cost of Battery Operated Drilling Machine on which this tool is mounted is Rs 3000 to Rs 4000. Time Taken: 4 to 5 minutes per toilet are adequate to clean the inner surfaces and for cleaning the S- type passage. From single charging of battery, approximately 9 to 10 coaches can be effectively dealt. Action Plan: Use Flexible-Shaft mounted Powered Cleaning-Tool developed by YPR depot is replicated in all Depots of SWR. All Primary Maintenance Trains of SWR have been covered on 31-08-2018 and the process is being repeated continuously in all SWR depots. It is proposed to provide the tool to OBHS staff also so that effective cleaning is ensured en route.

Power point presentation about Failure Indication and Brake Application device

DMW has saved 942120 Kwh of electricity (resulting in 35.39% saving of electric energy) during 2018-19 in generation & supply of compressed air by adopting following measures:

• Under-ground supply pipeline has been replaced with overhead pipeline.
• Dedicated team has been nominated to deduct & address leakages.
• Voltage Stabilizers have been replaced with Phase Reversal/ Phase Failure Protection Relays, duly modifying the electrical circuit of compressors.
• Surplus delivery points of compressed air have been plugged in various shops.
• Two nos. Air Dryers (Cap. 1500 CFM each) have been commissioned to improve quality of compressed air.
• Air blow guns with silent Nozzle are being used during maintenance and on service points.  
• Isolating valve has been provided between HMS & PPS to control supply of compressed air.
• Use of baby compressors for intermittent supply.

 Above comprehensive measures resulted in saving of Rs. 79 Lakhs in generation & supply of compressed air.

In regular practice coil springs used in Bogie are being cleaned manually. During manual cleaning it is observed that dust particles are spread in the nearby area, which is not desirable. In addition to the above, carrying of spring from the dismntling area to the cleaning bench is also a laborious job.

To get rid of the above a “Multi dimensional spring cleaning device” has been made with the available resources. A rejected unserviceable conveyor system has been used by providing motorized reduction gear box with chain sprocket system. It’s two sides are having protecting wings for safety purpose and four types of brushing arrangements provided for cleaning of springs in different ways.

No new items used. Only scrap & unserviceable relevant items used. Hence total direct cost is Nil. Indirect cost for scrap value is Rs.10,000/- approximately  & cost of man power is Rs.8000/- approximately.

The following practices are being done during the corrosion attention of passenger coaches

1. Leveling of coach on trestles is being done for checking / measuring the camber loss and twist in bolsters.
2. Staggering of sole bar joints.
3. Staggering of  End Body pillar joints.
4. Minimum length of sole bar has been restricted to 1200mm.
5. Compulsory renewal of sole bars while headstock attention upto a length of 2700mm and 2500mm on either sides.
6. Additional strengthening of sole bar joints by providing  strengthening plate.
7. Thorough checking for cracks done after opening the side panel on sole bars near the bolsters.
8. Ensuring proper headstock alignment by inspecting headstock with water level according to the required camber and verticality of Outer Headstock with spirit level.
9. Provision of drain holes in turn under near doorway pillars in order to avoid accumulation of water and dust.
10. High performance epoxy painting of components done.
11. Ensuring proper edge preparations.
12. IS 9606 Qualified Welders are engaged in welding.
13. Welding consumables are procured from RDSO approved vendors
14. ISO 3834 qualified welding process.

     

Flush cock provided in the coach toilet is very hard to operate and is located at inconvenient location. This creates reluctance amongst passengers to use it. As a result faecal discharge remains in the pan and causes bad odour in the coach toilet.

To get rid of these problems the existing conventional western commode      replaced with  western commode inbuilt ‘S’ trap and Cistern for better flushing in three 1st AC coaches of train no. 18239/40 Shivnath Express on trial basis. Inbuilt S trap ensures smooth passage and establishes siphoning action. This is assisted by sudden discharge of limited quantity of water from Cistern (around 06 litres per flush), thus water efficient flushing. This also solve the problem of bad odour up to maximum possible extent by ensuring proper water column.

Two lavatories and two urinals were in abandoned condition in Coaching Depot, Bilaspur and the need of functional toilets was experienced several times for staff convenience as a welfare measure. However, that was requiring the complete dismantling of existing structure and rebuilding of new one along with connection to septic tank. Also the use of this existing toilet is unhygienic due to its outlet was open in atmosphere. The modification done by connecting the outlet of existing toilet with the serviceable biotank available in Coaching Depot by using 150 mm dia PVC pipe. Thus the problem of open discharge of defecation gets solved by biologically efficient way.

A gadget for bending of Air Brake Pipes was developed by a group of staff of Air Brake Section in the month of March’18 by utilizing one serviceable brake cylinder and some other scrap materials. It works with the aid of compressed air. The bending work carried out in cold condition of pipes. Due to cold bending grain structure of material do not changes as well as no stress develops. Desired angle of bend and finished are also achieved.

Bogie section of Motibagh workshop has manufactured one fixture for cleaning and painting of lower spring beam . It rotates at 360 degree resulting easy for painting and welding. Also improve the quality and save time for repairing and painting.

CTRB section of Wheel shop was developed and declared as a Centre of Excellence on 27/11/2017. Various resources available in the section are as follows,

1. For cleaning, The following machines are being used.

a) Grease purging machine b) Grease loosening machine and c) Cone cleaning machine

2. An air plug gauge (Make: Baker) is being used in Wheel shop which helps in measuring the diameter of double cup /cone assembly in CTRB bearings. This gauge can measure upto 0.1 micron and the tested data can be stored and retrieved from the system for reference.

3. Bore diameter of the cone is being measured using three legged digital micrometer. In order to measure other dimensions, seperate gauges are available which are being calibrated using a master gauge on regular basis.

4. Seperate storage area is available for storing various components of the CTRB bearing.

5. Laser engraving machine is being used for entering the details on CTRB bearing instead of manual etching process.

6. Automatic grease filling machine is being used after inspection instead of manual process.

In addition to above machineries and gauges, the following works have been carried out to develop this section as a 'Centre of Excellence'

a) Wheel Exhibit has been displayed showcasing the different set of wheels used in Indian Railways thereby preserving the Heritage assets.

b) Epoxy flooring has been provided in the CTRB section in order to ensure a clean workplace.

c) Wall panelling using compreg sheet, false ceiling facilities have been made as per RDSO checklist.

d) In order to achieve Energy efficiency, LED lights and natural pipe lighting arrangments have been made. Enegy efficient air conditioner is being used.

BASIC TRAINING CENTRE, CARRAIGE REPAIR WORKSHOP, HUBBALLI - CENTER OF EXCELLENCE

1. Building, Infrastructure and Amenities: 

Two units: New & Old Building.

Old Building has space with garden & The First Floor of Old BTC building is converted in to Welding Lab

New Building has been provided with: Floor Tiles in all 05 class rooms, with Benches and with CCTV in class rooms useful for monitoring especially during conducting of Exams. 

2. Models:

1. Buffer Cross Sectional View.
2. BMBC Cross Sectional View
3. Escorts Shock Absorber Cross Sectional View.
4. Bio-Toilet Model
5. Wheel Defect Gauges
6. Other Models

3. Courses:

INDUCTION TRAINING.

1. RRB App. SSE/UBLS
2. LDCE App. JE/UBLS
3. RRB/CG App. JE/UBLS, UBL/DIV/Others
4. Trainee Technicians RRB
5. Trainee Technicians CG
6. Training to Khalasi/Tr. Technicians of UBL/SBC/DIV/Others

ARTISAN STAFF

1. Refresher Course (Shop Floor Artisans) (Welder, Fitter, Painter)
2. Trade Conversion
3. Computer Training to UBLS Staff
4. Pre-Selection Training to Gr. ‘C’, Tech Staff for JE.
5. Pre-Selection Training to Gr. ‘D’ to ‘C’ Staff.

ACT APPRENTICE (1961 Act)

1. Ex – ITI Fitter
2. Ex – ITI Welder
3. Ex – ITI Turner
4. Ex – ITI Machinist
5. Technician Apprentice 1973 Act Graduate/Diploma Holder
6. Skill Development Course (Without Stipend).

Railway Board Stage Wise Training Module for Refresher Courses (Welders, Fitters, Trimmers, Painters) is followed

Special Refresher course for

1. Painters started from SEP – 2017
2. Trimmers started in Month of OCT - 2017

4. Area:

Total Area = 1460 Sq. Mt.

Covered Area:

1. New Building (First + Second Floor) = 936 Sq. Mt.
2. Old Building = 410 Sq. Mt.
3. Open Area = Nil
4. Garden = 114 Sq. Mt.

The Available Space adjacent to BTC in MSD was Annexed to increase the area by 120 Sq. Mt.

5. Conference Hall:  Capacity of 110 Available.  

The conference Hall was converted to AC to take off the training events like Seminars, Workshops, Group Discussions, etc. as organized by Railways and External Agencies.

6. LCD Projectors: Provided in all Class Rooms to make all the Class Rooms into Digital Class Rooms

7. Computers: 06 Computers available.

8. Workshop Machine & Plants:

1. 02 Center Lathes
2. 01 Shaper
3. 01 Pillar Drilling Machine
4. 01 Pedestal Grinding Machine
5. 39 Bench Vices.
6. 06 No’s of Arc Welding Plants.
7. 03 No’s of MIG Welding Machines.
8. 01 No. of Saw Machine.
9. 03 No’s of Oxy Fuel Gas Cutting Plants.
10. 01 Air Compressor.

9. First Aid Boxes: Provided

10. Blind heavy fabric folds for windows& ventilators, for all classrooms and Conference hall

SAFETY: 

100% provision of PPE to all workers, which include hard hats, safety gloves, safety shoes, ear dampeners and eye goggles.

Improved lighting in bogie component, bogie assembly, bogie on-wheel and both bogie shop entry. LED lighting is preferred for better light spread and also better efficiency.

Replaced kerosene with suitable water based cleaning agent for component cleaning.

INFRASTRUCTURE: 

Provided Industrial flooring in leftover areas of bogie shop (bogie component, bogie assembly, bogie stacking and bogie on-wheel area). 

Ample space for Shock Absorber Overhauling room with 3 working areas.Provision of False Ceiling in Shock Absorber Room

BMBC area was converted into stacking area for storage of bogie components such as: alternators and bolster springs.

Bogie stacking is done in current bolster assembly area.  

Layout Improvements: 

1. Bus Bar near rack and in on wheel area is shifted to Main Bus Bar.
2. Storage Racks are distributed throughout the shop for efficient storage and reduction in movement of materials.
3. Component Painting work station isn shifted, and separate storage bins for different bogie components are used.
4. Painting of Pillars

EQUIPMENTS:

Introduction of pressure testing rig for leakage in lower spring seat for better identification of cracks. The said machine was made in-house by Mechanical Millwright Shop 

Dot peen marking machines are used for marking of new components to aid tracking during component failure(s)

The Control panel for whiting jacks used in traffic for buffer height adjustment is replaced. 

Shotblasting machine: Bogie frame & Components are subjected to shot blasting, to increase identification of cracks, achive better surfacae finish/cleaning, also aids in reduction of failures by increasing quality of inspection.

HOUSEKEEPING:

5s is implemented at bogie shop as a part of house keeping. Provision of various scrap bins with different color codes.