Achievement-TDD for Website

8/12/2019 Achievement-TDD for Website

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Important Achievement of Track Design Directorate during Last Five Years

SN Financial

Year

Broad Area of

Achievement

Title of Achievement Description of Achievement Likely Benefits urrent Status of

Implementation

1. 2007-08 Safety Development of ATwelding technologies with

three piece molds and

compressed air petrol

preheating.

!DS" sccessflly developed AT welding techni#es with threepiece mold and compressed air petrol preheating for $2 %g&'0(TS

and higher rail sections. The se of this techni#e has )een made

mandatory on *!.

*mproved #ality of welds and inservice performance.

*mplemented

2. 2007-08 Safety 1. Development and trial

of corrosion resistant +i-,r-, +,, !ails.

The corrosion of rail is the very significant factor reslting in

prematre renewal of rails. A new metallrgy was developed asreslt of stdy condcted in pro/ect on ,orrosion prevention of

rails nder Technology mission on railway safety. This

metallrgy has )een developed /ointly )y !DS" **T 3anpr and

SA*4. 705T of these rails rolled )y 6S were pt nder limited

field trial on i/aiwada-9dr section of S,!. The new metallrgy

has shown )etter corrosion resistance.

!edced corrosion of rails in corrosion

prone coastal areas.

:;tensive field trial in

progress.

elds is dependent on

95T of the section. >ith introdction of higher a;le loads andincrease in traffic the traffic density on varios rotes has increased

significantly. De to increased traffic density (S=D testing isre#ired to )e nderta%en more fre#ently reslting in increase of

the wor%load of (S=D testing is manifold. To facilitate faster

testing and mitigate the increased wor% load of (S=D testing!DS" developed Indian Railway standard specification for

ultrasonic testing of rails/welds using vehicular system,

Provisional, 2009and issed on 1$.0?.200'.

*ntrodction of state-of-the Art

ehiclar (S=D testing system on*ndian !ailways. This will also help in

effective monitoring of flaw growthpattern.

Tender nder progress at +!.

$. 2010-11 Safety Development of =orged@nction !ail

At locations of change of !ail Section in trac% the @nctionfishplates were sed. *t was not feasi)le to contine 4>! at sch

location. !DS" developed the drawing and provisional specifi-

cation of $2%g B0%g forged /nction rail. This will redce

instances of =ailre of /nction fish plates and facilitate continance

!edction in /nction weld failre *mplemented


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of 4>!.

B. 2011-12 Safety Development of trac% )ased

gage face l)ricating

system

The gage face 4)rication is re#ired to enhance service life of

!ails particlarly on sharp crves. *n order to assess sita)ility of

mechaniCed l)ricators 12 imported 8 indigenos l)ricators

were installed in ,! >,! and:,o! in 2008 with trial period of

two years. 6ased pon the e;perience gained Draft specification for

l)ricators has )een developed and s)mitted to !ailway 6oard for

consideration.

!edction in wear of rail gage face

specially at crved locations.

Draft Specification is nder

!ailway 6oards

considerations

Achievements

Development of recording facility for ultrasonic rail testing machines: RDSO successfully developed data logger for existing ultrasonic

machines for testing of rails.

Data Logger for Double Rail Tester

Development of AT elding technologies ith three piece moulds and compressed air petrol preheating: RDSO successfully developed

and implemented use of aluminothermic rail elding ith three piece mould and compressed air petrol preheating for !" #g$%&'TS andhigher rail sections to improve (uality of elds and in service performance.

AT )elding ith * +iece ,ould- Single Shot rucible ith Auto Thimble


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Development of digital ultrasonic rail testers: RDSO successfully developed digital single and double rail testers ith digital technology in

association ith industry.

+late: Digital Rail Tester and /A/ Scan Representation on the Screen

Development of ,aximum ,oving Dimensions 0,,D1 and 2ixed Structure 3auge for Dedicated 2reight orridors 0D21: RDSO

developed ,,D and fixed structure gauge for adoption on D2

,,D and 2ixed Structure 3auge for )estern and 4astern D2

Development of specification for ultrasonic rail testing on outsourcing basis: RDSO developed technical specifications for ultrasonic testing

of rails on outsourcing basis in order to maximise rail head scan area and mitigate or#load increase on account of operation of heavieraxle loads.

Development of specification for ultrasonic testing of rails using vehicular test systems: RDSO developed technical specifications for

ultrasonic testing of rails using vehicular tests systems to introduce state5of5 the art testing technology for rails. Trials on 6R is beingdone.

Development of 77& 'TS rails: RDSO successfully developed 77& 'TS rails in association ith SA8L for use on the heavy axle load

routes of 8R and D2. 2ield trials is yet to be done.

+late: Rail ,anufacturing +rocess and 77& 'TS Rail Developed by RDSO


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Development of corrosion resistant rails: RDSO developed corrosion resistant rails in association ith SA8L 0u5,o1 and another

chemistry 06i5r5u1 in association ith 88T 9anpur. These rails are under trial presently. 2ield trial of 7&-&&&,T Rail has started.

+late: orrosion of Rail and +erformance of Anti orrosive Rail Developed by RDSO

Development of special rails: RDSO developed special rails such as niobium rails for improved fracture resistance and vanadium rails for

better ear resistance. These rails are presently under trial.

Revision of specifications of Rails 08RS5T57"1:RDSO revised specification of rails in order to incorporate developments in the technology of

rail manufacturing.

Revision of ,anual for 'ltrasonic testing of rail and elds: The ,anual for ultrasonic testing of rails and elds as upgraded and reprinted

in order to ma#e rail testing more effective especially for detection of rolling contact fatigue defects in rails and half moon shaped defectsin elds.

Rolling ontact 2atigue Defect in Rails

Design of trac# structure for "!t axle load: The trac# structure for operation of "!t axle load as firmed up enabling operation of the same

on 8ndian Railay.

Design of +S sleepers for *".!t and "!t axle load: The design of +S sleepers for *".!t and "!t axle load has been done by RDSO for

use on 8R. 2ield trial is going on.


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+S Sleeper Designed by RDSO for *".! tonne Axle Load

Design of fastening assembly for "!t and *".!t axle loads:The design of fastening assembly 0elastic rail clip- rubber pad and liner1 for "!t

and *".!t axle load as completed.

+late: 24 Analysis of 4R

8mproved S4:The existing design of S4 has been improved upon for more service life- better riding (uality and lesser maintenance

efforts for higher speed and heavier axle load.

)eldable ,S crossing:The design- draings and specifications for 7 in 7" and 7 in ;.! eldable ,S crossings have been developed to

facilitate continuation of L)R through points and crossings apart from other advantages.

)eldable ,S rossing


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Thic# )eb Sitch: 2or better riding comfort- enhanced service life- higher speed and heavier axle load design and draing of 7 in 7" and7 in ;.! thic# eb sitches have been developed.

,ovable Sitch Diamond:To improve safety on diamond crossings the design of 7 in 7& movable sitch diamond ith double slip- single

slip and ithout slip on +S sleepers have been developed and put on trial.

2an Shaped +S Layout for Turnouts on sharp curves:The +S sleeper arrangement for turnouts ta#ing off from main line on sharper

curves has been developed.

g and !"#g rails have been developed.

Spring setting device:2or better housing of tongue rail ith stoc# rail spring setting device have been developed for 7 in 7" and 7 in ;.!

turnouts.

Development of draing for apron in station area:The development of draing of ballasted ashable apron on specially designed +Ssleeper and ballastless apron ith components as done for improving effectiveness of drainage and cleanliness in the station area.

,isc designs of +S sleepers: RDSO designed several types of +S sleepers for special applications such as sleeper for fish plated ?oint-

rerailing ramp for !"#g running rail and !"#g guard rail- +S sleeper for !"#g$%&R running rail and !"#g$%&R chec# rail for ,3 levelcrossing and anti sabotage +S sleeper for >&9g rail.


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Design of turnout sleepers: Design of turnout sleepers for ,3 7in ;.! turnout and =3 7 in ;.! and 7 in 7& diamond crossing ith movable

sitch ithout$ith clip as completed.

Design of S38 insert for use in +S sleeper for D2: 6e design of S38 insert for use in *".!t axle load sleeper in D2 ascompleted.

Scrutiny of SOD of D,R for =3 and Standard 3auge: RDSO scrutini@ed the document from technical angle and submitted

recommendations to Railay =oard.

Development of specifications for improved AT elding technology: RDSO developed specifications for improved AT elding technology

for enlistment of global leading firms ith significantly improved service performance of AT elds. orrection slip to AT elding ,anualand specifications has been sent to Railay =oard for approval.

,onitoring of Defect 3eneration Rate in rails and elds on higher axle load routes: RDSO monitored defect generation rate in rails and

elds on routes having operation of "".;"t axle load and submitted three reports to Railay =oard on the sub?ect.

o 8n /situ reconditioning of ,S crossing: RDSO is developing the techni(ue for in /situ reconditioning of ,S crossing as removal

of crossing from trac# is avoided for reconditioning purpose.


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Important Achievement of !otive "o#er Directorate during Last Five Years

SN Financial

Year

Broad Area of

Achievement

Title of Achievement Description of Achievement Likely Benefits urrent Status of

Implementation

2007-08 ,rew comfort Development of ,a) Air,onditioning System forDiesel :lectric 4ocos

,a) air conditioning system incldes one A, nit inthe drivers ca) with inpt power spplied )y ana;iliary sorce. An inverter of $ 3A capacity istherefore re#ired to convert 72 D, to 2.

2007-08 :conomy ,onversion of cast ETS,trc% frame of EE :5Dlocomotive in to fa)ricateddesign

Design of fa)ricated version with high strength rolledplate

,ost redction !nning in service sinceDecem)er 200'

2007-08 :;port Design develop-ment of1?00hp& 2D57locomotive for e;port

,onversion of old >D57 locomotive for cape gageapplication

:;posre in e;port design and assettiliCation

4ocomotive e;ported from9",

2007-08 =reightThroghpt

Development of >D5D? diesel locomotives.

To save foreign e;change )y $0 F or more i As improvement insystem relia)ility modifiedwith gear pmp and 9D typevalves < nos. compressorare nder trial. ii "ne more


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vendor is in nder process.

2007-08 assengeramenities

Development of D5DSBAdt locomotives

The )ogie has )een designed with advancedsspension elements

:ase of maintenance and cost redction !nning in service since2011

11. 2007-08 !elia)ility Development of =lly

5achined Dctile *ron ,ast:ngine 6loc%s along with5ain 6earing ,aps for A4,"2$1 1B cylinder Diesel:ngines

Specification for procrement of flly machined

dctile iron cast engine )loc%s along with main)earing caps for A4,o 2$1 diesel engines had )eenframed. Accordingly in a glo)al tender the wor% wasawarded to 5&s Sichan Gi)in sh 9rop ,o. 4td,hina for $0 nos.

Strengthened engine )loc% for increased

horse power of


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passenger version of EElocomotiveK

1$. 2007-08 Safety Development of >D?6

?$00 E locomotive in placeof >D? locomotive.

*mproved driver visi)ility at long hood direction with

wider ca)

*mproved isi)ility *ncreased Tractive

effort.

Switched over this design

from 200'

1B. 2008-0' :conomy Development of low meanpore siCe fel filters toimprove the relia)ility andli fe of fel in/ectione#ipment as well as the lifeof the filter itself on A4,olocomotives.

5ean pore siCe redced to 10-1B microns for rimaryand B-10 microns for Secondary filters respectively.4ife of the filter enhanced to ? months to coincidewith the e;isting #arterly schedle

*mprovement in relia)ility of fel in/ectione#ipment and periodicity of replacementhas )een do)led.

!ailways have started singlow mean pore siCe felfilters

17. 2008-0' :conomy :nergy efficient =TT56lower

The A,-D, A4,o locomotives have rectifier that iseither cooled )y air of plenm cham)er in view of thealternator monted rectifiers the air re#irementfrom the )lowers has redced and the )lowers have)een redesigned for '$00 cfm in place of e;isting12000 cfm.

*n these designs redction in the )lowercapacity has lead to significant redction inits power consmption.

!DS" has revised thespecification

18. 2008-0' =reightThroghpt

Design and development ofhigher capacity radiator fanfor ?$00 hp :5Dlocomotives followingsccessfl )enchmar%ing ofindigenos fans

The :5D locomotives have )een pgraded to ?$009E , from the e;isting ?000 9E , Thisincrease in power reslts in increased thermal loadingof the engine. *t was decided to increase the sweep ofthe fans from $2 to $? to increase the air flowcapacity

The increased air spply shall ena)leincreased E rating of ?$00.

,omplete switch over to the$? design has )een made.

1'. 2008-0' *ndigenisation *ndigenos development ofcomplete D9 4ocomotives

The complete traction control system of :5Dlocomotive comprising T,, :,, 1 2 < and the

4,, has )een indigeniCed sccessflly.

Addition of more sorces and redction incost.

As per !DS"sspecification development

and )ench testing of *96T-)ased T,, had )eencompleted

20. 2008-0' assengeramenities

69 D:5( for @3 Diesel :lectric 5ltiple nit for @3 section withspeed potential of 100%m&h has )een designed as per!DS"s Specification with the following featres.L owered )y 1?00hp diesel engine L rovisionto meet the cold climate of @3 L Aerodynamicdrivers ca) L ,oach layot similar to

D:5( @3 has provided an economicefficient and relia)le spplement to thee;isting means of transportation to thepeople of 3ashmir alley.

D:5( @3 was

commissioned on11.10.2008. L So far BD,shas )een spplied )y *,=.


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@anshata)di coaches.

21. 2008-0' !elia)ility Design development o fEigh adhesion high speed

EAES e#aliser less )ogiefor >D5D1 locomotive

6ogie has )een designed with provision of r))erspring in secondary stage and wing type a;le )o;

!eha)ilitation of old >D1 locomotives "ne locomotive has )eenmodified and rnning since@ne10

2D9?

*ndigenos development of wheel for EE:asy availa)ility of wheel discs


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loco locomotive

2'. 200'-10 assengeramenities

Design of :5D family>D? variant locomotive

with Eotel 4oad capa)ility

*ndian !ailway has decided to eliminate power carfrom !a/dhani & Shata)di ra%es for releasing space to

increase more revene-earning coach )y providinghotel load facility in the locomotives for spplyinghotel load to train.

!edction in nm)er of power cars woldreslt in increased passenger throghpt.

The first locomotive hasrecently )een deployed in

commercial tr ia ls inpassenger train.

D?D loco.

rovision of ca) at )oth end. ,rew visi)ility improved *n the )othdirection.

< 4ocomotives have )eenmanfactred and aresccessflly in the service.


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Technology for procrement of +ew9eneration ower ac%%eeping in mind state-of Nthe- art emission control and

fel in/ection system

sanctioned against 6 item no 105= )ogie for passengerversion of EE locomotive

6ogie has )een designed with optimised weight

achieved throgh =:5 and low maintenance featreshave )een adapted

:ase of maintenance (nder development process

?2. 2011-12 Safety Development of inter-opera)le Distri)ted ower,ontrol System D,S ofdiesel electric locomotives

!DS" has developed D,S with the followingimportant featres i.e. interopera)ility across differentma%es of the D,S made possi)le with re#irementof common protocol for radio fre#encycommnications improved integration withlocomotive systems improved logic for loss ofcommnications improved software interloc%s for

*ncreased throgh pt D,S to the olderspecification has )eendeployed on ?7 locomotives.L Sanction forimplementation on 2B0locomotives issed )y


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increased safety and redction of operator errors andanalysis of failre modes effects and criticalityanalysis has )een made mandatory at the designstage. Additional software interloc%s have )een

provided for improved safety.

!ailway 6oard.

Achievements$ Design Development of Traction Stock for I%

>DS< Diesel 4ocomotive 69B$0 hp gross powerDal service i.e. main line shnting5AG6A,E 5D?


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>D5


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>DD9? ,lass Diesel :lectric 4ocomotiveJ =reight Service 6road 9ageJ 1B cylinder 2-stro%e fel efficient 71096 engineJ ?000 hp gross power J A;le load 21 tJ 5a;imm operating speed 100 %m&hJ Eigh Adhesion ETS, ,o-,o )ogieJ


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>D? ,lass Diesel :lectric 4ocomotiveJ assenger Service 6road 9ageJ 1B cylinder 2-stro%e fel efficient 7109


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Diesel Eydralic 5ltiple nitJ assenger Service 6road 9ageJ 700 hp gross power J Speed potential pto '$ %m&h J A;le load 17 tJ (nder-slng ,mmins engine and oith transmission

J assenger capacity 8$? seating


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!ail)sJ assenger Service 6road 9ageJ 1$2 hp gross powerJ Speed potential pto 70 %m&hJ A;le load 1? tJ =rame monted ,mmins engine hydralic transmissionJ assenger capacity 1$2 seating 7B standing 7B

!ail)sJ assenger Service 5eter 9ageJ 120 hp gross power

J Speed potential pto $$ %m&hJ A;le load 11 tJ =rame monted Asho% 4eyland engine hydralic transmissionJ assenger capacity 120 seating B0 standing B0


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Diesel :lectric 5ltiple nitJ assenger Service 6road 9ageJ 1?00 hp gross powerJ Speed potential pto 100 %m&hJ Air springs on the )ogies for comfort ridingJ Transmission-electricalJ assenger capacity 10'2 seating


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+D5B ,lass Diesel 4ocomotiveJ assenger Service on B10 mm +arrow 9ageJ 5anfactred for +eral - 5atheran hill Dar/eeling-Eimalayan sectionwith 1 in 20 grade 127P crve 1


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Diesel 4ocomotive for 6angladeshJ 5eter 9ageJ 1?00 hp gross power J A;le load 12.$ tJ 5a;imm operating speed 80 %m&hJ A,-D, Transmission

Diesel 4ocomotive for Srilan%aJ 6road 9ageJ 2B00 hp gross powerJ A;le load 1B.$ t

J 5a;imm operating speed 80 %m&hJ +ew 6ogie design with shorter wheel)aseJ A,-D, Transmission

Diesel 4ocomotive for 5alaysia& 5oCam)i#eJ 5eter 9age &,ape 9ageJ 2


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Diesel 4ocomotive for ietnam 59J 5eter 9ageJ 1


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1?0 t diesel hydralic 6rea%down ,rane ,owans Sheldon designJ A;le load 20t in train orderJ +m)er of a;les crane B match trc% ?J ropping )ase B meterJ +o. of otriggers ?J ,apacity 1?0 t at $.$ meter radisJ 5a;imm radis 1B meter minimm radis $.$ meterJ !ange of lift of main hoist a)ove rail level 17 meter )elow rail level?mJ "perating speed 100 %m&h

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