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SN
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Financial Year
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Broad Area of Achievement
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Title of Achievement
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Description of Achievement
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Likely Benefits
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Current Status of Implementation
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1.
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2007-08
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Efficiency & Reliability
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Re-engineering of Stators of Traction Motors type 6FRA6068 making it more reliable.
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Insulation and brazed joint failures in the stators of three phase traction motors are primarily on account of excessive shock and vibration and unsupported long length overhangs. Failure of stators contributes to 60% failure of GTOs of the power converters. A trail was carried out to measure the actual shock and vibration level in various operating conditions for these locomotives .Based on the trial data, study of literatures, followed by Finite Element Analysis on various possible solutions led to support of the overhangs of stators to reduce the stress level drastically. Apart from supporting the overhang, augmentation in insulation scheme and improvement in manufacturing practices have also been done
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This modification has saved over $ 10.2 million , annually , just on locomotive maintenance account , apart from billions dollar of indirect annual savings on saving on section capacity by eliminating mid-section failure of locomotives.
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All new stators are being manufactured with this design . Repair of old stators are being undertaken with this design. In last four years , FRPCPY of new design of stators is zero
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2.
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2007-08
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Reliability
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Modified Motor Suspension Unit Drive System for WAG9/WAP7 class of locomotives, developed for segregation of lubricants used for gear case and DE bearing of MSU.
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Combined lubrication of gears and DE bearings of MSU results in seizure of bearings due to lack of lubrication ,due to any leakage in gearcases. This disrupts the traffic for hours. RDSO has evolved ttwo new designs for segregation of lubricants for gears and DE bearings of MSUs , which have been validated by FEA.
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This will prevent seizure of bearings of MSU on account of oil leakage from gear case and so disruption of traffic.
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Drawings and designs have been approved for both the schemes. Prototype of bearings and MSU have been manufactured with one scheme, wheel set assembly is under progress at CLW.
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3.
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2008-09
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Indigenization
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Development of Indigenous insulation system for Hitachi TMs
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RDSO has prepared functional requirement specifications for various constituents of resin systems and after type testing and Sealed Tube Tests of all Resins/ varnishes (16 nos.) as per relevant specification / IEC / ASTM standards , 20 items have been developed, which were imported from Japan for over ttwo decades.
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Availability of quality products at competitive price. Easay availability. Prevents wastage of material because of shorter shelf life.
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Hitachi TMs are also being manufactured with these materials and performance has been satisfactory.
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4.
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2008-09
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Reliability
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Evolution of Two Reliable Designs of Squirrel Cage Rotors for Three Phase Traction Motors type 6FRA6068 used in Locomotive Applications
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Frequent wheel spinning and stalling make the operating duties more arduous leading to breakage of rotor bars within two to three years of service. There are spurt of failure of rotor bars even in diesel locomotives on Indian Railways. A detailed study was carried out to analyse these failures, based on the trial data and study of literatures available worldwide. Excessive shock and vibration was singled out as the main cause of the failures of the traction motor. Two new designs of rotors have been evolved and validated by Finite Element Analysis for the first time on IR.
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Expected life of rotors is 18 years against 2-3 years of existing rotors. The modified traction motors have already been put in service on the IR and are performing satisfactorily. It is expected that these design improvements will fetch a saving of approximately USD 4.0 million annually to the Indian Railway apart from billions dollar of indirect annual savings on saving on section capacity by eliminating mid section failure of locomotives.
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All new rotors are manufactured with either of two designs. Repair of rotors are being done with Sch 1 design. Over 600 TMs are in service and first three years of failures are zero. Railway Board (ML) vide their letter no. 2005/Elect(TRS)/440/18/5(3ph) dated 17.04.2012 has approved the regular cut in of manufacturing of both the designs of rotors.
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5.
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2009-10
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Efficiency & Reliability
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Development of IGBT propulsion for 3 phase locomotives.
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Owing to the better efficiency and to meet technological obsolescence of GTO and other advantages a project for development of IGBT based traction converter and Auxiliary converter was taken with CLW. After framing of specification, PO were placed on M/s BT, BHEL, ABB and CGL. Type and routine testing has been done successfully and IGBT based converters have been provided in ten locomotives. Based on successful field trial, Railway Board has decided to use 50% IGBT based traction converter in annual production of 2012-13 and 70% in 13-14.
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Better efficiency and to meet technological obsolescence of GTO and to get rid of complex snubber circuitry and oil cooling requirement.
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More than three sources have been developed and indigenisation of imported technology is under way with M/s BHEL and M/s Medha.
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6.
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2009-10
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Reliability
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Development of Corona wire for converter fed motors.
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Amendment No. 03 to RDSO’s Specification No. E-10/3/09(Motor) of August’ 1997 for Single phase/three phase induction motors for Driving Blowers, Compressors and pumps for Three Phase Drive Electric Locomotives.
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It is expected that with the use of Corona Resistant wire, the Auxiliary motor failure will reduce.
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After studying the failure of converter fed motors on 3 phase locos, corona wire was developed. After monitoring trial performance for 2 years, its use has been specified vide this amendment on regular basis on all converter fed motors of 3 phase locos. Reliability of Auxiliary motors has improved.
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7.
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2009-10
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Safety &Reliability
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Development of polymer based gapless lightning arrester for 25 KV AC electric locomotives.
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Porcelain based gapless lightning arrester was being provided on the roof of the conventional locomotives. Bursting of porcelain lightning arresters can have damaging consequences like damaging nearby equipments due to blowing away of porcelain chips with great force against polymer housing which cracks at the time of bursting/failure. Violent bursting/shattering of porcelain chips may hit/harm other equipments& human beings nearby. Therefore, use of lightning arrester with polymer housing is considered safe on rolling stock
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Safety and reliability enhancement
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CLW has been advised to adopt polymer base gapless lightning arrester. CLW has started use of polymer based gapless lightning arrester on limited quantity basis.
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8.
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2010-11
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Green Technology
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Hotel load converter
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In order to ensure noise less and pollution free supply to Rajdhani and shatabdi trains, WAP7 locomotive has been provided with 2x500 kVA hotel load converters. Two power cars have been suitably modified to meet interface requirements.
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The development shall ensure noiseless and pollution free electric supply to coaches and requirement of DG sets is eliminated.
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After successful static and dynamic trials commercial services have started in Kalka shatabdi since Feb’11
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9.
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2010-11
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Green Technology
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Development of 6670 KVA transformer with Finalisation of specification for 9000 HP and 12000 HP freight locomotives.
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In the present system, WAP4 locos hauling passenger trains utilize the traction power solely for the hauling purposes whereas the power requirement for the coaches of the train are met either through Self Generating (SG) System with alternators/battery in individual coaches or the End-on-Generator (EOG) System with the help of power cars at either end of the train as in the case of Rajdhani/ Shatabdi Express trains. The development of a traction transformer with capacity suitable for traction as well as power for the coaches henceforth termed as "hotel load" was initiated. 6670 KVA transformer with hotel load capacity has been developed to cater to the load of 24 coach train.
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The development shall ensure noiseless and pollution free electric supply to coaches and requirement of SG equipments& DG sets is eliminated, there by generating more space for passengers. This system is also an energy efficient over conventional SG/EOG system.
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Transformer with hotel load capacity has been supplied to CLW for fitment and field trial.
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10.
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2010-11
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Reliability
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In situ Rotor Bar Crack Detection in Traction Motors type 6FRA6068 during various maintenance schedule
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There is a large population of rotors of V2 design and they are prone to rotor bar crack without giving any prior signs. Consequential damages to rotor bar crack are damage to stator windings followed by failure of valve set , isolation of a block and halving of haulage capacity of the locomotive. RDSO and sheds have carried out series of experiments and based on the field data , SMI no. RDSO/ 2010/ EL/SMI/0262, Rev. ‘0’ , sheds has been issued for detection of rotor bar crack and stator defect for traction motor type 6 FRA 6068 used on WAG9/ WAP7 class of locomotives
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Prevent line failure of traction motors and detention of locomotive due to bogie isolation.
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By following the process, recommended in this SMI large number of rotors with V2 design have been detected with bar crack in the shed
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11.
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2010-11
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Reliability
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RDSO/2009/EL/MS/0384(Rev-‘0’) Modification of loco control circuit for circuit breaker (DJ) opening and panto lowering by BLDJ and ZPT switch in 25 kv conventional locomotive equipped with microprocessor based control and fault diagnostic system (MPCS
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In MPCS locomotive DJ can be tripped &Panto can be lowered even if MPCS system fails.
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To provide safe operation
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Implemented by Railways in all MPCS fitted locomotives
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12.
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2010-11
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Safety & Reliability
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Development of Vigilance Control Device for tap changer locos
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As per Railway Board target of providing VCDs in all tap changer locomotive, RDSO has revised the specification, conducted repeat prototype testing as per revised specification in record time and based on the revised specification No. RDSO/2008/EL/SPEC/0025/Rev. 5 (March’2010) more than 2800 VCDs have been provided in tap changer locomotives.
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The provision of VCD shall enhance passenger safety by ensuring alertness of drivers.
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Zonal Railways have provided VCDs and performance of different make is under monitoring of RDSO.
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13.
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2011-12
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Efficiency & Reliability
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Development of DC Traction Motors for NGEF Rakes of Kolkata Metro
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Aging traction motors of in NGEF rakes have posed serious reliability and safety threats to the smooth operation of Kolkata Metros. Since there was no technology transfer, performance of repaired/rewound TM has been absolutely dismal. After getting the approval of Railway Board, RDSO has developed TMs with 200 degree class of insulation and field trial for a period of six months has also been concluded. Based on the experience of the field trial on prototype unit, a detail technical specification for these traction motors has been jointly prepared for future procurement.
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Availability of much demanded efficient , reliable and higher temperature class of traction motors for NGEF rakes of Kolkata Metro.
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Field trial completed successfully. For regular cut in procurement is under progress.
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14.
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2011-12
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Freight throughput
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Finalisation of specification for 9000 HP and 12000 HP freight locomotives.
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(i) I.R. plans to procure 9000 hp IGBT based electric locomotives against step loan from Japan for western DFC. RDSO has prepared the specification after detailed discussions held with Japanese industries. (ii) I.R. plans to procure 12000 hp IGBT based electric locomotives for eastern DFC Specification for 12000 HP has been prepared by RDSO and sent to Railway Board.
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The specifications prepared are prime requirement for locomotives being procured for Dedicated freight Corridors.
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(i) Specification No. RDSO/2010/ EL/SPEC/0108, Rev.‘1’ issued by RDSO on 3-9-12 for 9000 HP locomotive. (ii) Specification No. RDSO/2006/EL/SPEC/0044, Rev.12 issued by RDSO on 4-10-10.
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15.
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2011-12
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Reliability
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Development of Constant Spring Pressure Brush Holders for Hitachi TMs
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In order to get longer life of carbon brushes and so as to reduce the frequency of their replacement, RDSO has developed constant spring pressure brush holders for Hitachi TMs. Since the pressure on carbon brushes remains constant throughout its useful length, it not only improves the life of carbon brushes, but improves commutation, also.
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Longer brush life, better commutation , less maintenance of traction motors.
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Field trial on prototype units is under progress in WAG7 locomotives of Erode since Jan’2012.
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16.
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2011-12
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Reliability
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Design modification in 1312 KVA transformer for 25 KV AC EMUs for Mumbai Sub-urban Railways.
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There was no provision of paper insulation in existing 1312 KVA transformer. Failure cases were fragment. The same was analysed and the design was suitably modified. Core area increased, winding pattern changed from Disc to layer, higher conductor section selected and provision of PRV & breather was made.
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Lower losses, improved reliability.
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Approx. 11 transformers have been repaired with the modified design. These modified design transformers are provided in Central Railway. Performance is under watch.
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