ACHIEVEMENTS DURING 2017-18:
1.1 Special drives to improve reliability:
In addition to the regular super checks, Special drives are being carried out on outgoing locos/DEMUs to improve reliability:
a)For improvement in cleanliness and passenger amenities on DEMU coaches.
b)Fire safety drive on DEMUs and WDP1 locos
c)Monsoon precautions – for improving loco reliability.
d)Summer precautions – for improving loco reliability.
e)For ensuring brake power on diesel locos.
f)Checking of Safety Items
1.2 Safety/ Reliability improvement Modifications carried out Locos/DEMUs:
1) Development of EMD type Water Pressure Cap testing Gadget for ALCO locomotives:
Pressurization of cooling water system on WDP1/WDM2 locomotives are used primarily to reduce incidence of hot engine alarm. The pressurization of cooling water system will increase the boiling point of the cooling water. This in turn permits high engine operating temperatures, with a minimum loss of coolant due to boiling point increase. Pressurization also ensures a uniform water flow, minimizes the possibility of water pump cavitations during transient high temperature condition.
Pressure cap which is located on the water tank opens at 7 psi (0.5kg/cm2) and relives excessive pressure, this prevents damage of cooling system components. After release of excessive pressure it will come to normal working position.
For checking the working condition of pressure cap, Diesel shed BZA has developed a Gadget with in-house facilities. With this gadget, the pressure cap working condition can be checked before fitment on locomotive and also to check the caps running on locomotive during major schedules.
2) Modification of Air Spring in DPC 15036:
The new HHP 1400/1600HP DEMU DPCs Bolster suspension is taken care by Air springs instead of helical coil springs. Earlier in 1400HP DPCs i.e, 15035, 15036 & 15038 were provided with 150KN round base springs.
At present round base air springs production was stopped. Due to non-availability of 150KN round base air springs, 180KN air springs with high capacity rectangular base were provided for the new HHP 1400/1600HP DPCs for better suspension and high load carrying capacity. To improve better reliability of DPCs 15035, 15036 & 15038 has been taken up to modify with high capacity 180KN rectangular base Air springs.
While carrying out the modification work, four additional holes are provided on the base for fitment of rectangular base air springs. The 180KN air spring is slightly larger in size when compared to 150KN air spring, causing obstruction to the air hose adopter which supplies air to the reservoir of air spring. So the pipeline feeding air reservoir has been dummied and in place of it, one additional hose pipe line has been provided for feeding air to the reservoir and additional safety clamps are also provided for arresting vibrations. So far DPC 15036 is completed inducted in the service and balance will be completed by end of June 2017.
150KN air spring 180KN air spring
3) Modification of 1600HP DEMU DPCs fuel oil filling elbows:
1600HP DEMU DPCs had been received from ICF and commissioned in the year 2016 at DLS/BZA. The fuel filling pipe line had some problem for fueling due to 90° bend at start of pipe line. In turn this bend causes fuel filling pipe touch the body of DPC, and further obstructing of fuel oil pipe resulted delay in fueling at platforms/stations.
To overcome the above problem, shed made a modification in-house by changing elbow assembly 90° to 120° and accordingly vertical and horizontal dimensions modified. By incorporating above modification, the fueling is being done at the rate of 4 minutes /1000 liters and no delay observed on account of fueling.
So far, 3 DPC Nos. 15077, 11128 & 11129 completed and balance 3 DPCs will be completed by end of July 2017.
4) Modification of Air bleed valve of 1600HP DEMU DPC15080:
1600HP DEMU DPC No.15080 had been received from ICF and commissioned on 18.03.2017 at DLS/BZA. The Air bleed valve is located between the Fuel Pump Pressurized assembly and the fuel return line junction block. This Air bleed valve develops pressure up to 7.5Kg/cm2 before cranking and then only allows cranking the engine. While running the engine the air bleed valve got directed and failed to maintain 7.5kg/cm2 pressure and so engine got shut down and engine not cranked further. There is no spare Air bleed valve available in shed.
To overcome the above problem, shed has modified with the available fuel oil relief valve of WDP1 locomotive was set at a pressure of 7.5 kg/cm2 and provided in DPC 15080 in place of defective air bleed valve and working satisfactorily. This was avoided grounding of the DPC. BEFORE AFTER