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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:

Ø     a)    Modification of 700HP DPCs Fuel oil system air lock:

In CIL make diesel engines of 700HP DEMU air lock in fuel oil system takes place now and then because of which the engine shuts down due to fuel starvation. The fuel shut off solenoid has a cap screw as shown in the picture (1). This cap screw is to be loosened by the crew enroute with the help of a spanner to remove the air lock in the fuel oil system. The whole exercise is a tedious thing and takes minimum 20 minutes. 

To make the above exercise easier to the crew the cap screw has been replaced by butterfly headed screw on the fuel shut off solenoid as shown in picture(2). This butterfly headed screw can easily be loosened manually without help of a tool and make the crew comfortable with this. 05 DPCs have been fixed with this type of screws so far and the performance has been satisfactory.

Picture - (1)

Picture - (2)


b) Relocation of Horn flutes in new HHP BEML make DEMUs:

The population of DEMU DPCs in Diesel Loco Shed, BZA is 37, out of which the recently commissioned 06 no of DPCs are of BEML design. In these BEML make DPCs the horn flutes are located at the top of the DPC as shown in Picture (1). These horn flutes cannot be attended enroute in case of exigency when the DEMU works under OHE lines. To obviate this problem the horn flutes have been relocated beside the classification lights as shown in picture (2) which is the same design already adopted in remaining DPCs of ICF make. This modification has been carried out on ‘05’ no of DPCs so far.



c) Developing of Cylinder head hydraulic test stand:

Diesel Loco Shed, BZA developed a new cylinder head hydraulic test stand with water tank of 200 lts capacity. This was fabricated with inhouse facilities. 2 Nos. of water heater elements of 1000 Amps each were  provided. With this modification testing of cylinder heads of WDP1/WDM2,  DEMU CAT/CIL engines can be carried out in two hours. Temperature of 90°C  can be achieved on this test stand to find out cracks in cylinder head. 

d) Overhauling of pump fuel transfer to avoid Air lock in fuel oil system of CIL Engines: 

Diesel Loco Shed, BZA is homing 19 no of CIL make 700/1400/1600HP engines. Each engine is provided with Fuel transfer pump which is used to remove air lock in fuel oil system of CIL engines. It consists of Top & Bottom covers, Cylinder and piston with seals.  These seals are prone to wear & tear because of which they are to be replaced. But the OEM does not supply the seal kit to overhaul the pump. The cost of new pump is Rs 25,000. It must have incurred at least an expenditure of Rs.1,00,000/- every time when procurement is made. It has forced to go for overhauling of the pump in-house.

DLS/BZA has conducted the market survey and purchased the above seals at a cost of Rs. 1,000/-. Bottom cover of the pump is made up of aluminum with inside threads. During fitment and removal in DPCs these threads are prone to damages causing fuel oil leakage. A metallic adapter has been provided in the bottom cover to avoid the problem of thread damage.

This has saved a minimum of Rs.1,00,000/- every time when procurement is made. 

    e) Fuel oil economy in Train No.17250/17249 Exp bet. BZA-MTM-BZA  section:

  • In Machilipatnam Express 17250/17249 link, two WDP1 Locos are operated in MULTIPLE to haul an actual load of 18 coaches. The average Fuel consumption while working the train is 500Lts. i.e.250 lts. per each loco.
  • A Trial has been conducted for the 17250Express train having load of 18 coaches to ascertain the fuel consumption and loss of punctuality with single WDP1 loco while keeping other Loco in IDLE condition from BZA to MTM except between GDV-KVM section. As a result, fuel economy of 100Lts has been observed and no time loss has also been observed.
  • Similarly the Trial has been conducted for the17249Express train having load of 18 coaches to ascertain the fuel consumption and loss of punctuality with single WDP1 loco while keeping other Loco in IDLE condition from GDV to BZA in MTM to BZA section. As a result, fuel economy of 100lts has been observed and no time loss has also been observed. A S.O.B was prepared and sent to Sr.DME(C&W). Sr.DME(C&W) was requested to implement the above.
  • In view of fuel saving, the following instructions are given through SOB for necessary action by CLI/LP/ALPs.
       a) While working 17250 EXP, the Engine control switch in the trailing loco should be kept in 
condition. b) While working 17249 EXP, the MU should be worked from MTM to GDV.
           From GDV to BZA,
the Engine control switch in  the trailing loco should be kept in IDLE
           condition to obtain
fuel economy.

    However in case of any exigencies, LP may utilize both locos power duly informing to PRC/Shed and entering in Log book.

  • Thus the saving of fuel oil 200 liters per day which costing about `.41,72,680/- (200x365x`.57.16) per year.


4 no of 10 car 1600 HP DEMU rakes were commissioned to cater the services of Krishna Pushkaram special trains.

The existing 9 car rakes of 700HP were augmented to 12 car rakes utilizing the available pool in DLS/BZA. 

One rake of 8 car 1400HP BEML make DEMU rake was received from DLS/MLY holding to supplement the existing rakes for augmentation of regular trains. All the 4 - 8 car 1400HP BEML make DEMU rakes were augmented to 10 car rakes.

The rakes of DLS/BZA worked in the following links during Krishna pushkarams

S. No

Rake Link No.










12 car rake










10 car rake










06 car rake








The details of the special DEMU trains that worked during Krishna Pushkarams from 11.08.16 to 24.08.16.



No of trains








BZA-OGL-BZA on 19.08.16



BZA-NS-BZA on 19.08.16



BZA-NLR-BZA on 20.08.16



BZA-VSKP-BZA on 21/22/23.08.16


                                  Total no of trains.


For smooth running of trains, the shed had arranged three trouble shooting points with staff from DLS/BZA. The details of TS points & staff are furnished below.



No. of men










In addition to the above, 49 no. of staff were deployed to accompany the Krishna Pushkaram special trains round the clock in three shifts to attended enroute troubles.

For the maintenance of 12 car DEMU rakes, LV-3 pit line of C&W was utilised during 10.00 hrs to 15.50 hrs except Thursday & Monday of every week. On Thursday & Monday maintenance schedules  have been carried out at MTM station on the same day during night.

The Service Engineers & Technicians from M/s Medha Servo Drives and M/s Cummins India Ltd., Pune also accompanied with the newly commissioned 1600HP DEMU Medha make trains round the clock in three shifts to attend the en-route problems for smooth running DEMU special trains.

All toilets in DEMU coaches have been closed, but the passengers travelling in train break opened the doors in some coaches and soiled them. In view of the above one SLI & Supervisor have been nominated in two shifts to check and coordinate with platform C&W staff to ensure the toilet doors shut on all outgoing platform return DEMU trains at BZA station.

As per the instructions of OSD Krishna pushkarams, one supervisor round the Clock was stationed in Platform Control Room to assist OSD in case of emergencies. 

g) Provision of power setter switch on WDP1 locos:

Diesel Loco Shed, Vijayawada is being running MU locomotives of WDP1 for Express services from BZA to MTM (17249/17250 Exp) and BZA to COA (17643/17644 Exp/17209/17210 Exp).

A trial was conducted from BZA to GDV on 17249/17250 Exp. & from BZA-RJY on 17643/17644 Exp. to save fuel oil without effecting punctuality loss by providing the power setter modification.

The Loco Pilot can isolate the power of rear loco from leading loco simply by putting power setter switch ‘OFF’ position then rear loco will run in idle without power.

Whenever loco pilot feels time not maintaining, he can put ‘ON’ power setter switch after bringing the throttle to idle position and will get rear loco power.

Thus was saved 100 liters from BZA to GDV and 200 liters from BZA to RJY on 17249/17250 Exp & 17643/17644 Exp respectively.

So far 9 locomotives provided with Power Setter Switch to work MUs on 4 units and the balance 8 locos will be completed by 15th November.

h) Provision of Fire alarm system in Heavy Repair bay of DLS/BZA:

In case of any fire or accident in Diesel Loco Shed, Vijayawada, there was no emergency safety alert system to alert staff. Fire or accident could arise due to the following;

Short circuiting of electrical wires,

Welding works,

Operating OHE cranes,

Operating whiting jacks

Disregard to safety equipments.

Shed has developed a manually operated alarm system to alert the staff working at different locomotives in Heavy Repair bay. The purpose of the alarm system is to

Overcome the likely fire/ accident.

To gather and assist the staff in case of injury.

To move away in case of any rolling stock.

The Accident & Fire alarm alert system was prepared with in-house facilities, manpower, materials. Assistance of CDO was taken regarding material.

The alarm system has been located at seven locations near the heavy repair electrical, under truck, heavy repair mechanical & traction machines bays. The fire alarm system consists of a switch box housing electrical switches visible through the glass cover. In case of any fire/accident or any emergency the glass could be broken and switch can be pressed. On switching ‘ON’ an audible alarm will ring at both ends of the Heavy repair bay. Staff nearby will be alerted by this alarm and will assemble for suitable action depending on the situation.

i) i) Integrated Management System Certification of Diesel Loco Shed, Vijayawada (comprising of ISO 9001:2015, ISO 14001:2015 & OHSAS 18001:2007 standards):

Diesel Loco Shed, Vijayawada has processed for certification of “Integrated Management System” for ISO 9001:2015, ISO 14001:2015 & OHSAS 18001:2007 standardsand during course of implementation, the following three stages of visits were made by certification body.

1) Gap analysis conducted by the certification body on 08.09.16.

2) Stage – I audit – Document review – was carried out on 08.02.17 & 09.02.17.

3) Stage – II audit – Certification audit – was conducted between 20.03.17 to 22.03.17.

4) Meanwhile six SSE of Diesel Loco Shed, Vijayawada were trained and certified as lead auditors for the above standards and issued certificates after evaluation through written examination.

After two stages of vigorous auditing, the certification body (IR class Systems & Certifications Pvt. Ltd) has recommended IMS certification for Diesel Loco Shed, Vijayawada on 22.03.2017.

Source : South Central Railway CMS Team Last Reviewed on: 22-04-2017  

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