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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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Crew comfort
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Development of Cab Air Conditioning System for Diesel Electric Locos
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Cab air conditioning system includes one AC unit in the driver’s cab with input power supplied by an auxiliary source. An inverter of 5 KVA capacity is therefore required to convert 72V DC to 230V, 50 Hz, single-phase supply suitable for input to these motors.
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The locomotive cab air conditioner assembly shall be used to provide interior cab temperatures in a comfortable range throughout the year.
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Installation of Cab ACs have started at DLW.
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2.
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2007-08
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Economy
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Conversion of cast HTSC truck frame of HHP (EMD) locomotive in to fabricated design
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Design of fabricated version with high strength rolled plate
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Cost reduction
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Running in service since December 2009
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3.
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2007-08
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Export
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Design & develop-ment of 1400hp/ 2300hp Cape gauge & meter gauge loco-motive bogie for export to Senegal/ Mali/Sudan
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Fabricated box section three axle bogie design with Tetramount suspension
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Exposure in export design
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Locomotive exported to relevant countries
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4.
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2007-08
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Export
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Design of meter gauge 14t axle load 1-Co-Co-1 four axle bogie for Tanzania
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First time bogie design for meter gauge with four axle
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Exposure in export design
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Design ready on drawing board, not implemented
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5.
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2007-08
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Export
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Design of Co-Co trimount fabricated bogie for cape gauge under WDM7 locomotive for export
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Conversion of old WDM7 locomotive for cape gauge application
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Exposure in export design and asset utilization
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Locomotive exported from GOC
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6.
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2007-08
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Freight Throughput
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Development of WDM3F 3600 HP locomotive with GE Electrics.
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GE electrics with enhanced capacity
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Increased horse power.
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Manufactured
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7.
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2007-08
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Indigenisation
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Indigenous development of water cooled air compressor for EMD locomotives
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Specification of water cooled air compressor for WDG4/WDP4 diesel locomotives.
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To save foreign exchange by 50 % or more
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(i) As improvement in system reliability, modified with gear pump and GD type valves & 3 nos. compressor are under trial. (ii) One more vendor is in under process.
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8.
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2007-08
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Passenger amenities
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Development of 3-phase 1600 HP AC-AC DEMU
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Design and development of 3 phase AC/AC DEMU has been undertaken by RDSO.
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Less maintenance of DEMU is required.
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Prototype likely to roll out by October’12.
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9.
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2007-08
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Reliability
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Development of traction alternator with Silicone-Rubber based insulation for EMD locomotives
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EMD make alternator has been indigenized by adopting the original insulation scheme.
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Has a number of advantages, such as reduced temperature rise, mechanical durability etc.,
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M/s BHEL and CGL have developed this alternator with the silicon insulation scheme.
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10.
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2007-08
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Reliability
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Design and development of Advance trimount high speed (ATHS) bogie frame for WDM3A & WDS6Adt locomotives
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The bogie has been designed with advanced suspension elements
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Ease of maintenance and cost reduction
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Running in service since 2011
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11.
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2007-08
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Reliability
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Development of Fully Machined Ductile Iron, Cast Engine Blocks along with Main Bearing Caps for ALCO 251 (16 cylinder) Diesel Engines
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Specification for procurement of fully machined ductile iron, cast engine blocks along with main bearing caps for ALCo 251 diesel engines had been framed. Accordingly in a global tender, the work was awarded to M/s Sichuan Yibin Push Group Co. Ltd, China for 50 nos.
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Strengthened engine block for increased horse power of 3300 and above so as to avoid the problem of bore misalignment, distortion, shrinkage and thermal loading.
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RDSO has cleared Cast engine block drawings submitted by M/s Sichuan Yibin Push Group China and given go ahead for carrying out FEA.
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12.
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2007-08
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Reliability
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Remote Monitoring and Management of Locomotive and Trains (REMMLOT)
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Development of remote monitoring technology for diesel locomotives.This system provides almost real-time information about the locomotive location and its operational and health status.
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Optimization of the asset. Platform for condition monitoring and predictive maintenance.
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Approximately 400 locomotives equipped. Fitment on another 1200 locomotives sanctioned in RSP.
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13.
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2007-08
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Safety
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Development of TFT LCD Display for Driver’s Cab [Called “Dials” - Digital into Analogue LCD- Based System] for Diesel Electric Locomotives
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Increasing features on the locomotive requires a more complex human machine interface. The DIALS specification and equipment was developed for meeting this requirement. DIALS provides - A single display system with multiple pre-configured screens to provide all information required by driver for running the train Ø LCD screen with various button keys having fixed and context sensitive functions
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Improvement in operational safety.
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Approximately 250 locomotives equipped.
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14.
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2007-08
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Safety
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Design optimisation to develop light weight HTSC fabricated bogie for twin cab passenger version of HHP locomotive‘
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Light weight to reduce the axle load
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Cabin crew Safety
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Running in service since Oct’2010
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15.
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2007-08
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Safety
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Development of WDP4B 4500 HP locomotive in place of WDP4 locomotive.
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Improved driver visibility at long hood direction with wider cab
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Improved Visibility, Increased Tractive effort.
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Switched over this design from 2009
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16.
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2008-09
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Economy
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Development of low mean pore size fuel filters to improve the reliability and life of fuel injection equipment as well as the life of the filter itself on ALCo locomotives.
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Mean pore size reduced to 10-16 microns for Primary and 6-10 microns for Secondary filters respectively. Life of the filter enhanced to 4 months to coincide with the existing quarterly schedule
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Improvement in reliability of fuel injection equipment and periodicity of replacement has been doubled.
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Railways have started using low mean pore size fuel filters
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17.
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2008-09
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Economy
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Energy efficient FTTM Blower
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The AC-DC ALCo locomotives have rectifier that is either cooled by air of plenum chamber in view of the alternator mounted rectifiers, the air requirement from the blowers has reduced and the blowers have been redesigned for 9500 cfm in place of existing 12000 cfm.
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In these designs reduction in the blower capacity has lead to significant reduction in its power consumption.
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RDSO has revised the specification
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18.
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2008-09
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Freight Throughput
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Design and development of higher capacity radiator fan for 4500 hp EMD locomotives following successful benchmarking of indigenous fans
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The EMD locomotives have been upgraded to 4500 GHP (CV) from the existing 4000 GHP (CV) This increase in power results in increased thermal loading of the engine. It was decided to increase the sweep of the fans from 52” to 54” to increase the air flow capacity,
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The increased air supply shall enable increased HP rating of 4500.
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Complete switch over to the 54” design has been made.
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19.
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2008-09
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Indigenisation
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Indigenous development of complete 3-Phase Electrics and its Controls (except TMs) for WDG Locomotives
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The complete traction control system of EMD locomotive comprising TCC ECC 1, 2, 3 and the LCC has been indigenized successfully.
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Addition of more sources and reduction in cost.
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As per RDSO’s specification, development and bench testing of IGBT-based TCC had been completed
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20.
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2008-09
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Passenger amenities
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BG DEMU for J&K
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Diesel Electric Multiple unit for J&K section with speed potential of 100km/h has been designed as per RDSO’s Specification with the following features. · Powered by 1400hp diesel engine · Provision to meet the cold climate of J&K · Aerodynamic driver’s cab · Coach layout similar to Janshatabdi coaches.
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DEMU (J&K) has provided an economic, efficient and reliable supplement to the existing means of transportation to the people of Kashmir Valley.
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DEMU (J&K) was commissioned on 11.10.2008. · So far 6DPCs has been supplied by ICF.
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21.
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2008-09
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Reliability
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Design & development of High adhesion high speed (HAHS) equaliser less bogie for WDM3D locomotive
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Reduction of unsprung mass of the bogie by elimination of compensating and equaliser linkage
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Ease of maintenance
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Running in service since 2009
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22.
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2008-09
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Reliability
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Design of new, reliable and maintenance friendly bogie for WDP1 locomotive
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Bogie has been designed with provision of rubber spring in secondary stage and wing type axle box
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Rehabilitation of old WDP1 locomotives
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One locomotive has been modified and running since June’10
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23.
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2008-09
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Reliability
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Upgradation of specification of IGBT-based AC-AC system for 4500 hp locomotive
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Specification for procurement of complete electrics including TCC, ECC and LCC has been upgraded by including DIALS (display of loco parameters and LCD/ TFT monitor) and REMMLOT (remote monitoring of locos).
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State of the Art features for improved driving and reliability.
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Specification issued.
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24.
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2008-09
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Safety
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3-coach HS SPART
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On the recommendation of high level committee, 3-Coach High speed Self-propelled Accident Relief Train has been designed as per RDSO’s spec with the following features. Maximum operating speed: 132 km/h under slung power pack with hydrodynamic transmission Aerodynamic driver’s cab Equipped with relief & rescue devices.
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Enhanced speed will help in quicker start of relief and rescue operations in Golden Hour.
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First prototype has been allotted to SWR in Dec-2009. · Awaited for Oscillation trial.
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25.
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2009-10
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Economy
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Development of a specification for more cost effective Thermal Insulation Kit for Exhaust manifold.
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Specification issued to all railways to use the new design which is costing approx. Rs. 45000 against Rs. 120000 per loco of old design.
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Price of this product has reduced drastically.
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IR is using this product as per specification.
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26.
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2009-10
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Export
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Design of 19.5t Flexi float Standard gauge bogie for export to Syria
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Design of three axle bogie for 1435mm gauge with flexi float suspension upto 120kmph speed
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Exposure in export design
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Design ready on drawing board, not implemented
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27.
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2009-10
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Export
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Design of 16.5t axle load Co-Co bogie for Holcim locomotive for export to Sri Lanka
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Design of Co-Co bogie with 10’6” (3200mm) wheel base with trimount single stage suspension
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Exposure in export design
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Design ready on drawing board, not implemented
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28.
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2009-10
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Indigenisation
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Design and development of Indigenous wheel for WDG4 loco
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Indigenous development of wheel for HHP locomotive
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Easy availability of wheel discs
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29.
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2009-10
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Passenger amenities
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Design of EMD family WDP4 variant locomotive with Hotel Load capability
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Indian Railway has decided to eliminate power car from Rajdhani / Shatabdi rakes for releasing space, to increase more revenue-earning coach by providing hotel load facility in the locomotives, for supplying hotel load to train.
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Reduction in number of power cars would result in increased passenger throughput.
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The first locomotive has recently been deployed in commercial trials in passenger train.
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30.
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2009-10
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Safety
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Development of EP Assist Brake System
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Development of EP Assist Brake System PO was placed by RDSO on 12.10.10.
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Reduce the EBD & coupler forces
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Prototype inspection was completed. Material is expected to come on Oct-12.
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31.
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2009-10
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Safety
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Development of 4500 HP dual cab WDP4D loco.
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Provision of cab at both end.
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Crew visibility improved In the both direction.
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3 Locomotives have been manufactured and are successfully in the service.
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32.
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2010-11
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Export
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2300 HP Diesel loco for Sri Lanka Railways.
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Roof mounted DBR, stainless steel superstructure.
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Stainless steel super-structure is corrosion resistant in coastal and tropical area
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Manufactured and exported
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33.
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2010-11
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Freight Throughput
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Indigenous design development of WDG5 loco wheel.
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Indigenous design of wheel for 23 t axle load,5500 HP WDG5 locomotive
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Achieved the target time and timely manufacture of prototype locomotive
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Wheel has been manufactured at DSP for prototype locomotive.
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34.
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2010-11
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Passenger Amenities
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NG Diesel Hydraulic Railbus (610 mm Gauge) for Neral - Matheran Section.
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On the request of Central the specification has been finalised by RDSO in consultation with Central Railway alongwith the following important features. Bi-directional unit with driving cab at both end Self-propelled by 150hp diesel engine Hydrodynamic transmission Max. Operating speed of 20 km/h Ergonomically designed driver’s cab & seat
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Single unit, light weight, low initial cost, no need for reversal, low maintenance cost etc.
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Final specification has been sent to Central Railway on dated 14.6.2011.
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35.
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2010-11
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Safety
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Design of compact version of wheel set trolley to handle the wheel axle lock situation
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Easy to handle and assembly at site
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Fast clearance of blocked section due to loco failure
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Trolleys are available with different sheds
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36.
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2011-12
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Freight Throughput
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Design & development of 5500 HP WDG5 Diesel locomotive
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20 cylinder engine, unitized E locker, radial DBR ect.
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High horse power, higher T.E
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Loco is ready for oscillation trial
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37.
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2011-12
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Green Technology
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Development of Specification for procurement of New Generation Power Pack keeping in mind state-of –the- art emission control and fuel injection system
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Final specification for New Generation Power Pack sanctioned against PB item no 1037 of 2011-12 has been finalized and a copy of the same sent to Rly Board for necessary action.
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To achieve higher horse power i.e in the range of 3300 HP with low emission and high fuel efficiency.
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Tender for procurement of New Generation Power Pack has been floated by DMW/PTA.
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38.
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2011-12
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Passenger amenities
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NG Diesel Hydraulic Railcar (762 mm Gauge) for Kalka-Shimla Section of N. Railway
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As per directives of Railway board the specification has been finalised in consultation with N. Railway with the following important features. Bi-directional unit with driving cab at both end Self-propelled by 200hp diesel engine Max. Operating speed of 35 km/h Hydro-dynamic transmission Ergonomically designed driver’s cab & seat
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Single unit, light weight, low initial cost, no need for reversal, low maintenance cost etc.
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Specification has been sent to Railway Board vide letter on dated 29.6.2012.
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39.
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2011-12
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Reliability
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Modification of Exhaust Manifold from existing Three Entry to Modified Single Entry design for ALCO locos fitted with ABB TPR-61Turbocharger to improve its reliability
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To overcome the problem, Single Entry exhaust manifold with improved features was developed and the same has been tested for its performance on the engine test bed as well as in the field and the results obtained were satisfactory. Therefore, it was decided to implement the single entry exhaust manifold.
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Implementation of modified design will reduce pulsation on turbine blades, consequently reduction in turbine blade failures and also improve the reliability of turbochargers.
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Implementation is under process in zonal railways.
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40.
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2011-12
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Reliability
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Introduction of hybrid bearings in AC crank case motor
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Railways have reported bearing related problems on AC crank case motors. Use of hybrid bearing has been seen as a better solution than the existing bearing. In order to validate this concept, existing crankcase motors have been fitted with hybrid bearing and imported oil seal for evaluation of the performance.
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Reliability of bearing is likely to increase.
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Thirty-four nos. of locomotives fitted with such crank case motors have been put on trial at AMV and Gonda Diesel sheds. The same is under monitoring.
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41.
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2011-12
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Reliability
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Design of light weight maintenance friendly (LWMF) bogie for passenger version of HHP locomotive
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Bogie has been designed with optimised weight achieved through FEM and low maintenance features have been adapted
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Ease of maintenance
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Under development process
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42.
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2011-12
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Safety
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Development of inter-operable Distributed Power Control System (DPCS) of diesel electric locomotives
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RDSO has developed DPCS with the following important features i.e. interoperability across different makes of the DPCS made possible with requirement of common protocol for radio frequency communications, improved integration with locomotive systems, improved logic for loss of communications, improved software interlocks for increased safety and reduction of operator errors and analysis of failure modes effects and criticality analysis has been made mandatory at the design stage. Additional software interlocks have been provided for improved safety.
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Increased through put
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DPCS to the older specification has been deployed on 47 locomotives. · Sanction for implementation on 260 locomotives issued by Railway Board.
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.bmp)
