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   Divisions
      Guntakal
         DEPARTMENTS
            MECHANICAL
               HIGHLIGHTS


 
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HIGHLIGHTS



Highlights/Innovations:

1. Effort has been made to improve system of working with introduction of shift tool room for ROH depot.

 

2. In order to improve quality of work and to improve availability of tools a shift tool room has been started for yard. The tool room is operative for 24 hours.

3. Separate Staff rooms have been provided for male & female staff in yard and in sick-line. It was a long standing demand from the staff. The staff room has been provided with lockers facility which has help in elimination of age old boxes scattered in the depot.

4. To reduce stress on work man a designed bogie overhauling station has been commissioned.

 

5. To improve safety of the staff at workplace, helmets are made compulsory for all staff, supervisors and officers.

6. System of unit exchange of bogies has been started in order to reduce cycle time and to improve quality of ROH.

7. Efforts have been made to reduce parting and to improve reliability of ROH turned out wagon, by starting dye penetration test (DPT) of CBC body

 

 

8. An aluminum ramp has been provided for easy loading and unloading of material in ART.

 

 


 

 

 

9.Light weight Portable hydraulic jacks of 10 Te & 20 Te capacity are being use to attend wagons in yard. This has reduced sick detachments due to defective CC pad, EM pad and springs.

 

 

 

 

 

 

10.Working model of Load Empty device

A working model of Load Empty device was fabricated within house Resource to demonstrate piston strokes (Empty 85±10mm, Load 130±10mm)by changing the load empty handle

 

 

 

13. Welding Plant Stand Fabrication

A suitable welding plant stands are fabricated and fixed at 61 cms height from the ground level without any obstruction to the working staff, thus the following advantages can be achieved.

ØWorking place is increased.

ØFire accidents can be avoided.

ØCleaning of floor is very easy.

ØSafety to the workmen.

ØElectrical power losses can be achieved.

 

                                                                                     

          

 

14.Draw & Buffing Gear Components FittingTable:

The conventional method for fitment of draw & buffing gear components are difficult, since the height of revitting work is above the shoulder level which causes poor quality of revitting, excess time taking and staff feeling inconvenient for attending repairs. Due to the draw & buffing gear components are at higher level i.e., 1575 mm, which is very much inconvenient for the staff to attend revitting work such as yoke support plate, draft gear support plate andtop pivot.

                                                                   

         

 

 

15.Assembling of Empty / Load Set:

This depot is under crisis of Empty/Load device due to heavy damages taking place during loading/unloading points by the pay loaders and the required materials are insufficient for replacing the damaged Empty/Load sets. To overcome the crisis, this depot has innovated to assemble the Empty/Load sets by getting all loose components and assembling for use.


16. Huck Bolt Tooling System:

At present, the riveting work of wagons has being done with pneumatic system which involves lot of man power, time and preparation of work added to this the most disadvantage of sound pollution.

To overcome above disadvantages the Hydraulic Tooling System for fitment of Huck Bolts has been introduced.

 

 

      

 

        

17. Air Cooled Diesel Engine Driven Portable Welder:

To overcome electrical power failure an Air Cooled Diesel Engine Driven Portable Welding Machine has been introduced in the system, thus achieving the following advantages.

 

Advantages:

  1. The machine is having low current adjusting feature, thus BCN HL wagons welding repairs is can be attended.
  2. In event of electrical power failure it can be used, thus out turn cannot be effected.
  3. Since it is a portable welding machine, welding repairs is can be attended in yard.
  4. This machine also is use for train examination lighting purpose, since having a feature of electric power generator.
  5. Sick wagons at enroute/out station also attended.

18.Modification of BCN HL Wagon Door Locking Arrangement

BCN HL Wagons are recently introduced in the Indian Railways for increase the train load. 13 BCN HL rakes has been inducted in Guntakal Division as Blue Star CC Rakes the total holding of BCN HL wagons are 788

 

 

 

BCN HL wagon doors locking system design is similar to the Steel Almarah locking system where the locking arrangement is made on one door wing from inside. Since, the heavy commodities loading in the BCN HL wagons, the available design is not withstanding the dynamic load falling on locking arrangement, thus resulting most of the wagon doors mechanism getting defective and resulting ineffective of wagons increasing day by day. 


To strengthen the door mechanism, both the doors are provided the additional locking arrangement from outside and as well as from inside of the wagon on trail bases.


19. Provision of Safety Washer on BCN HL Door Lower Bolt


BCN HL wagon door locking mechanism is often getting defective due to the following reasons:

Door lower bolt securing arrangement is week due to provision of aluminum rivet.

Due to mishandling of loading/unloading hamalies, the aluminum rivet is getting breakage and giving way to door lower bolt falling down.

Due to the above problems an average of 4 BCN HL wagons are marked sick on every train examination.

 

20. Strengthening of Locking Bolts

On BCNHL wagon the locking bolts are getting disengage and causes dropped/missing. Disengaging of Top & Bottom Locking Bolts are due to aluminum rivet is used for engaging the bolts. At loading/unloading points, the hamalies are forcibly locking the doors, which get the aluminum rivet breakage, and causing disengaging of locking bolts.

To overcome the above problem MS Bolt with Nut of same diameter of has been provided to avoid disengage of locking bolts, which in turns missing of locking bolts can be avoided.

 


21. ‘No Go Gauge’ for brake beam pocket liners:

CASNUB 22W, 22NL, 22 NLB and 22 HS bogies are fitted with unit type fabricated brake beam that slide in the guide cavity provided in the side frame with Silico Manganese steel liners.During brake applications and releases, the brake beam tends to move to and fro in side frame pocket over silico manganese liners. Hence the silico manganese liners are subjected to wear and tear which are required to be replaced during ROH repairs.

The dimensions of the silico manganese liners thickness:

New – 5 mm, Condemned – 3 mm

Servicing limit during ROH repairs 3.5 mm

  




If the silico manganese liners are not replaced in time it may leads to

1. Brake beam may get jammed which causes brake binding.

2. Uneven wear of brake blocks.

3. Hard pulling of train.

4. Misalignment of brake beam

5. Fast wearing of brake blocks. 

Staff Training:

C&W training center at GY was established in the year 1986 and is recognized by Railway Board.

No. of staff trained at C&W Training center- GY:

 

Course

Duration

Staff

Year

2009-10

2010-11 up to Nov-10

Refresher Course Group – C

12 Days

Artisan

188

99

Refresher Course Group – D

12 Days

Helpers

131

84

Refresher Course Other Division

12 Days

Artisan

-

-

Refresher Course NC

12 Days

Artisan

01

03

Pre-promotional Course

21 Days

Technicians / Supervisors

177

9

Air Brake Course for C&W Staff

15 Days

Supervisors

-

12

Technicians

34

24

Air Brake Course for App. DSL. Assts.

06 Days

App. DSL. Assts.

72

101

One-Day Course on Train Operation & Trouble Shooting for Running Staff.

01 Day

DSL. Drivers / DSL. Assts.

64

181

Guards

-

-

Points men

228

63

C&W Staff

08

24

Air Brake Course for NC Staff

03 Days

NC Staff

-

-

Air Brake Course from Other Divisions

Artisan

-

4

ART Specials:

 

 


Location

AMC

Make

YB

Prev.

Inspection Dt.

Prev. Trail

trip Dt.

From

To

GTL

26.03.10

25.03.11

LUKAS-HRE

2003

05.01.10

25.08.10

GY



JESSOP-

COWANS

1990

29.09.10

09.12.10

DMM



BEMCO

2008

01.07.10

20.10.10

RU



BEMCO

2009

10.07.10

16.09.10


MRV Specials:
 

 






Location

AMC

Make

YB

Prev.

Inspection Dt.

Prev. Trail

Trip Dt.

From

TO

GTL



ALMETRO-HRD

2002

05.01.10

22.10.10

DMM



BEMCO

2008

01.07.10

20.10.10

RU



LUKAS-HRD

1989

10.07.10

20.10.10


En-route Carriage Watering:


RU

KDP

MALM

TOTAL

No. of trains watered/day

14+ 4

7+0.3

18+3.4

47

No. of non daily trains/week

24

2

26


Coaches watered/day

334

117

296

747

Water requirement/day (K.Lit.)

501

176

444

1121

No. of hydrants

876

305

184

1365

Electronic In-motion Weigh Bridge:

Electronic in motion Weigh Bridge shall consist of

·Weigh rails

·Track switches/sensors for speed and wagon type detection.

·Control console with electronic cards for implementing track switch logic and receiving signals from load cells for further processing.

·A personnel computer of latest design or a VDU, a key board & printer

computer directly linked to control console, for operation, viewing and printing.

·Any other kind of equipment required for satisfactory performance of Weigh Bridge.

Location

Manufacturer

Cost (in Rs)

Date of installation

AMC

Stamping

GTLW

Rice lake weighing systems LTD, Chennai

7,48,381

12.04.97

19.05.10 To 18.05.11

08.07.10

NRE

Rice lake weighing systems LTD, Chennai

11,57,484

31.12.05

11.08.08 To 10.08.10

18.11.09

KOU

Rice lake weighing systems LTD, Chennai

11,57,484

21.03.06

26.08.10 To 25.08.12

11.01.10

HGI

Digital weighing systems LTD, Bilaspur

12,64,492

10.01.09

Warranty-2 yrs

11.01.10

MLK

Digital weighing systems LTD, Bilaspur

12,64,492

28.02.09

Warranty-2 yrs

27.02.10


Wheel Impact Load Detector

The WILD system has been supplied by M/s. Apna Technologies & Solutions Ltd, Chennai, on 13.12.07. The system was installed in between TIM and NKDO of GY-GTL section on up main line at the Km No. 437/3-2. The installation work has been completed on 28.01.08 and got the first report. As a part of the commissioning test the system was tested on 13.06.08 in that the calibration was not satisfactory. After rectification of the problem again system was tested on 23.09.08 and 16.10.08 the test results were satisfactory. System was successfully commission on 16.10.08. After two months the tests were repeated on 23.11.08 and found that all results were satisfactory and finally the PTC has been issued on 25.11.08.




WILD- Wheel Impact Load Detector is an indigenously developed product that helps in scientifically to detect wheel flats in rolling stock.

WILD is high reliable system that does not require manual intervention, WILD uses the high impact loading on the rails to detect the wheel flats. The detection is online and the reports generated are communicated wirelessly through GPRS.

System software is highly customizable and is capable of indicating the fault on the exact axle, detecting defective wagons, speed of the axles, type of wagons etc, while taking about 10 to 15 minutes for analysis and report generation and sending the report to the central server. Thus the report for a passing train is available within minutes of the train crossing the system.


Various alarm levels for various maintenance levels are possible with features like alarm intimation through SMS. System can store reports for a maximum of 20,000 trains for each installation.

The WILD system is being monitored in the Rolling Stock Control round the clock. When every any defective wheel comes the same information will be given to the next train examination point i.e. at GY which is 23 KM away from the WILD site. There the defective wheels are being examined critically and depending on the nature of defect they are taking decision to allow or detach the defective wheel wagon/coach.

All the information of maintenance and critical alarms is being fed into the computer and maintaining a database of the WILD alarms. The information is being sent monthly to the RDSO/LKO for their analysis and modifying the alarms limits. The system is being monitored very effectively and the feed back of the results is sending regularly to the headquarters and RDSO.

Guntakal division has put lot of efforts for successful testing and commissioning of WILD system. Division has formed two defective test specials (Coaching, Freight) for practical testing of the results given by WILD and their correctness, which was not given in RDSO test procedures. Efforts were also put in shifting the WILD location from a remote location which is not having GPRS connectivity, proper security and transportation facilities to a location which is having all the above said facilities and can also cover most of the coaching trains. Division has also suggested to RDSO for varying the limits of ILF values by close monitoring of data and their results. With all the efforts made by the division, system is working satisfactorily without any problems.





Source : South Central Railway CMS Team Last Reviewed on: 20-07-2012  


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