Innovations & Best Practices

Your window to the world of Indian Railways

Indian Railways Directorate for Efficiency and Research

Monthly Report of innovations done on Indian Railways

 


PROJECT WORK

For Railway Intranet Users, project reports of Officers who undergo training at the Academy are at the following hyperlinks. 

Project Reports of Advanced Management Programme (18-20 years’ service)

http://10.140.2.6/spie/index-amp.html

Project Reports of Management Development Programme (6-8 years’ service)

http://10.140.2.6/spie/index-mdp.html

Project Reports of Foundation Programme for Promoted Officers

http://10.140.2.6/spie/index-bfp.html

These reports are for internal circulation only, they can be shared on specific requests, the Faculty Members details are provided on the Academy's website. 

 


 

You can send your ideas to the Ministry of Railways, India also directly, here.

Ministry of Railways (Railway Board) has constituted an Innovation Council called "Kayakalp" headed by Shri Ratan Tata. 

This Council has been setup by the Railway Minister in accordance with the vision of Hon'ble Prime Minister for Innovation, Technology Development and Manufacturing. The Railway Budget 2015-16 speech has mentioned that every dynamic and thriving organization needs to innovate and re-invent its practices and hence the council has been setup for the purpose of business re-engineering and introducing a spirit of innovation in Railways. It has been proposed to institute a reward to provide technical solution to problems peculiar to the Railways and approach towards identifying global benchmarks relevant to the Railways regarding Operations and Maintenance of Railways.

Please visit the National Innovation Council website also

 

Innovations shortlisted by Railway Board in 2014

 

UNIT Name of Innovation   Contact Details Month/ Year  Brief Description
CORE Introduction of "Freight Factor" concept in Stores tenders.

Bhaskar Narang, COS/CORE

Y Kumar, CMM

S K Verma, Dy CMM

I J Katiyar Dy CMM

HQ Purchase Office

Apr 2013

Cost of Innovation

Nil

Saving Achieved

Efficient finalization of tenders

Introduction of "Freight factor" concept in stores tenders has been effectively used to simplify the complicated tender settlement and contract management process in multi consignee situations normally prevailing in Railway. This has been achieved without any investment and within the existing frame of rules. This has added transparency, speed and flexibility in tender settlement and contract management process.

CR Punching Die for E type Lock Cover V V Tipre, SSE/Machine Shop, Signal & Telecom. Workshop, Byculla, Mumbai Jan 2014

Cost of Innovation

Rs. 46000/-

Saving Achieved

Rs. 2.86 Lakhs/ Month

Die and Punch Set for E Type Lock Cover.

E type Lock Cover was being manufactured manually. It has very complicated shapes cut on the external surface for the extraction of Key. This process used to consume lot of labour and only one cover per day could be manufactured. To overcome this problem, Die and Punch set has been indigenously designed and developed to punch these complicated shapes on the external surface of the Lock Cover. Requirement is 240 covers per annum. With existing manual practice required 240 day to manufacture 240 covers. But with this die and punch set. It is possible to punch 240 covers in a single day's shift of 8 hours.

CR Common Line Box System

Vijay Bodele,

Sr. DEE(TRO)BSL, Bhusawal Division

Oct 2012

Cost of Innovation

Nil

Saving Achieved

Rs.52,28,640/-per annum

Instead of individual line box (with tools) of each Loco Pilot a common pool of line boxes is made. These common line boxes are now loaded and unloaded at Divisional boundary skipping line box changing after every crew change. This has resulted in huge saving in procurement of line box and tools. Also, requirement of Box-boy has reduced at intermediated crew changing point. This system is now extended between LTT-BSL-NGP-LTT. Detention of trains due to line boxes has been eliminated. 

ECoR e-pass (Electronic Pass for Automating issue of Privilege, Duty Pass & PTO)

Hansraj Sharma,

Dy. CM (IT)

Manoj Kr. Mishra, Secy. to GM/ECoR/ HQ

Aug 2013

 Cost of Innovation

Rs. 3.92Lac

Saving Achieved

Yet to be calculated

Web based automation if Issue of Privilege Pass, Duty Pass & PTO with a proposal for change of existing stationary making it more secure. Save time & manpower in issue of pass and future scenario will enable requisition and issue of passes from any location / on remote. It further helps in capturing all relevant data for taking quick managerial decisions in future.  

ECoR DRUMS (Driver Un-satisfactory Management System)

Hansraj Sharma, Dy. CM (IT)

Manoj Kr. Mishra, Secy. to GM/ECoR/ HQ

July 2013

Cost of Innovation

Rs. 3.72 Lac

Saving Achieved

Yet to be calculated

DRUMS – SMS based solution for driver unsatisfactory – problems/ hindrances on tracks as seen by loco pilot & reported to crew controller, remedies attended by service departments on real time basis.

Will improve operational efficiency and safety. It further helps in capturing all relevant data for taking quick managerial decisions in future.

NCR Re-girdering of stretchy Bridge/Agra

Sh. Satish Kumar,

Principal Chief Engineer, NCR, Allahabad

Dy CE/Bridge/L/Agra

Nov 2013

Cost of Innovation

Nil

Saving Achieved

Rs. 3.86cr./ per month

Rail cum road bridge no 167 (strachey bridge) having span of 2x12.2+9x46.94m over river Yamuna on Raja Ki Mandi-Yammuna Bridge section was declared distressed in the year 1972 and SR of 20 Kmph imposed since then. Regirdering of this bridge was planned. One approach and eight main span out of eleven spans of open web girders were launched by side slewing during 2011-13. However, one approach and main span no. 9 were located over a busy city road Yamuna Kumara Road in densely populated area making side slewing of girders impossible. After brain storming session. It was decided to construct a diversion road under span 8 and in site dismantling of existing girders and assembling / erection of new girders for main span no. 9 and approach span. By meticulous planning and better coordination with State authorities, work was planned and completed safely and successfully in 45 days by round the clock 24 hour working in shifts.

NCR Indigenous development of tamping units of UNIMAT – 4S Track machine

Sh. Satish Kumar,

Principal Chief Engineer, NCR, Allahabad

Mukesh Garg,

CE/TMC/NCR

CPOH Workshop NCR/ALD

Dec 2013

Cost of Innovation

Rs. 50,00,000/-

Saving Achieved

Rs. 560 Lac (approx) per set.

Cost of one set of imported tamping units is Rs. 660 lacs. Hence in order to reduce dependence on import and to reduce the cost, it was planned to develop the tamping unit indigenously at CPOH, Allahabad. First drawings of all the 139 types of components of sub-assemblies have been developed by staff of CPOH workshop. Most of the major components have been got manufactured indigenously. Finally the tamping unit have been assembled and tested at CPOH, Allahabad during Dec.2013 with approximate cost of Rs. 50 lacs per set (one set consists of 4 units). Indigenized tamping bank is expected to give the half life as compared to original bank.

NCR Innovation for replacement of cracked Rail Bearer with help of modified Riveting dolly

Sh. Satish Kumar,

Principal Chief Engineer, NCR, Allahabad

Ramesh Chandra, CBE/NCR

Dy. CE/Bridge/L/Agra

Jan  2014

Cost of Innovation

Nil

Saving Achieved

Rs. 46.70 Lakh (one time)

Rail bearers of 18.30m semi through plate girders of RUB  nos 1398/1 (km 1398/4-6) and 1399/2 (km 1399/6-8) between Mathura-Bhuteshwar stations on Mathura – Alwar section of Agra divisions were found cracked at 17 & 27 locations respectively during painting in January 2013 and SR of 20 kmph was imposed on both the bridges. In these bridges, 2 nos stringers stringers in pair were existing because of which there was little space between stringers for holding the rivet head with standard rivet dolly of width 6". The original scheme was finalized by replacing main girders with RH girders and then to change the cracked rail bearer and again put in the main girder after removing RH girders.

The scheme was modified and the width of rivet dolly was redesigned & reduced from 6" to 3" which could be accommodated between pairs of stringers. Cracked rail bearers have been replaced and stringers of both the bridges have been riveted with cross riders. Replacement work has been done at reduced cost.

  

NCR Controlled cutting of RCC Platform shelter for construction of 20 feet wide FOB

Sh. Satish Kumar,

Principal Chief Engineer, NCR, Allahabad

Ramesh Chandra, CBE/NCR

Dy. CE/Bridge/L/Jhansi

Dec 2013

Cost of Innovation

Nil

Saving Achieved

Nil

At Gwalior station, 20 feet wide FOB connecting PF no 1,2/3, 4/5 was sanctioned at a cost of 3.2cr. Later on provision of escalator has also been added.  For execution of this work, there was need to cut the existing platform shelter of Reinforced Cement Concrete (RCC). This RCC PF shelter is on main platform of Gwalior (PF No.1). This was a tedious job to dismantle the RCC slab because adjacent structure might also be affected due to impact/vibrations. With meticulous planning, RCC slab was dismantled with controlled cutting. Whole RCC slab was cut in the block of 1m x 1m with diamond tip disc cutters in controlled manner without affecting the adjacent existing structures and avoiding any inconvenience to the passengers. Thereafter columns have been erected and girders have been launched successfully.

NER Simplified Ball Valve Opening & Closing Mechanism

Lokesh Singh,

Sr. DME/C&W/NER

Lucknow Jn.

M M G Waris Baeg,

CDO/NER/ Lucknow Jn.

Coaching Depot, Lucknow

Jun 2013

Cost of Innovation

Rs.1000/- approx

Saving Achieved

Rs. 15000/- per Bio-toilet

A simplest Ball Valve opening & closing mechanism for bio-toilets has been developed/ innovated by C&W Divisional Training Centre. NER/LJN and this new mechanism has been provided in one of the coach on 20th June 2013 for experiencing the efficacy of innovation. So far trial results were encouraging & if it gets successful, a saving to the tune of Rs. 15000 per bio-toilets shall be made in addition to ease in maintenance.

NER Box system for invitation of application form in LARSGESS Amiya Raman, Sr. DPO, Varanasi Division, North Eastern Rly Jan  2014

Cost of Innovation

Rs. 2500/-

Saving Achieved

Nil

The introduction of this system has introduced transparency and has reduced delay in processing of applications.  (Brief is in Hindi)

NFR Automatic operation, Intelligent Synchronization and operation of DG set

Dev Kr. Sonwani,

Sr. DEE/RNY/NFR

SSE/Elect./Rangiya  Divn/ N.F. Rly

Feb 2014

 Cost of Innovation

Rs. 17,99,507/-

Saving Achieved

Rs. 1,01,600/- per month

At Rangiya, the emergency power supply to station, street light in colonies, DRM building and pumping installation is fed through DG-Set installed at new power house. Whenever the SEB power supply goes OFF, the operation of DG Set and ON/OFF of individual breaker feeder wise was done manually. Due to augmentation of new additional load there is a need to augment the DG set capacity and also for the operation of DG set there was requirement of staff. To overcome the situation, new system by providing EOCB type breaker and microprocessor based intelligent synchronization of DG set has been introduced in addition to existing arrangement. Due to this system, the operation of DG set and parallel operation to cater the emergency load is done automatically.

NFR Steam Condensate Recovery System at KYQ Laundry

Anant Kumar,

Sr. CDO/GHY

Munnaf Ali Choudhury,

SSE/Laundry/KYQ

Mechanized Laundry, Kamakhya

Feb 2014

 Cost of Innovation

Rs. 7000/-

Saving Achieved

Rs. 2,85,460/- per month

A steam condensate recovery system has been developed in house at Mechanised laundry, kamakhya to recover a substantial amount of water from the steam which was earlier exhausted to atmosphere. A set of 09 aluminium coach roof mounted water tanks are used to collect the condensate and with the help of an automated pump the water is pumped to another set of four similar tanks kept overhead. This water being soft is directly fed to the boiler and thus a substantial amount to the tune of 15,000 liter of water is recovered per day.

NFR Mitigation of Elephant Mortality due to train hits Sr.  DEN/C/ APDJ Feb 2014

 Cost of Innovation

Rs. 2.43 cr.

Saving Achieved

Rs. Not possible to evaluate

Steps taken

a) Clearing of vegetation on both sides of railway track within railway boundary.

b) Providing passes and ramps to allow safe movements of elephants.

c) Conducting sensitizing programmes for train Driver/ Guards / Station Masters.

d) Keeping railway track free from food waste that attracts elephants.

e) Imposition of speed restrictions:

Innovative steps: Apart from above, the following innovative steps have been taken in the Alipurduar – Siliguri Jn. Section (west bengal) under Alipurduar Divn to mitigate the problem of elephant mortality.

Construction of Passes.

Construction of Ramps.

Construction of Girder Bridge And Fencing.

NFR Opening of New Goods Shed at Ranipatra (RNX) B B Gupta, Sr. DCM/ Katihar Division Sep 2013

 Cost of Innovation

Rs 20 lakhs.

Saving Achieved

The earning of Ranipatra increased by 100 times in comparison of last year.

Purnea is a business hub of Eastern Bihar dealing good numbers of Inward and Outward rakes, but due to congestion and short line capacity of Purnea Goods siding i.e. only 28 wagons capacity, it was felt necessary to develop an additional Goods Point at nearby station with full rake handling capacity. Ranipatna Railway Station is approx 7 KM away from Purnea and ½ KM away from NH. So, it was decided to develop Ranipatra as an alternative Rake point and it's 2nd Loop line was selected for the purpose. The earth work was managed with the help of Civil Administration under MNREGA Scheme and the metallic toping was done by Railways (Katihar Division). As a result of this joint effort of the Division and the District Administration/Purnea, a full fledged rake point was developed. And the cost on the part of the Railway was approx 20 lakhs which was incurred in metallic toping.

NR Web based Water Supply Monitoring and measurement by GPRS based system

Mehtab Singh, CEE/NR

A K Singhal, CEGE

Delhi Divn/ HQ NR

Jan  2014

 Cost of Innovation

Rs. 3,60,640/-

Saving Achieved

Rs. 27,550/- per month

Northern Railway, New Delhi is taking water from NDMC at SP Marg Officer Colony. In order to have a transparent and common water accounting and monitoring system, it was envisaged to have an automated web based system for rate and volume of incoming water flow.

There are two incoming connections from NDMC at SP Marg, New Delhi. The current solution is deployed at one of the incoming connections as a Pilot Project. The old system did not provide any visibility of rate and volume of incoming flow of water on daily/ Weekly/ Monthly basis. Also, there was a lack of clarity on the actual piping network which was supplying water to the underground tanks. Lot of engineering & technological efforts especially in design of complete system engineering, field studies, enhancement has gone into this project to make it a success.

NR Pressurized flushing arrangement in Railway Coach toilets

Arvind Nautiyal,

Sr. DME/C&W/DLI

Jugal Kishore, SSE/C&W/NDLS Coaching depot, DLI Division

Aug 2013

 Cost of Innovation

Rs.  30,000/- per toilet.

Saving Achieved

Existing CDTS being provided in Rs. 1,40,000/- per toilet approx.

This pressurized flushing arrangement not only flushed very effectively, but also prevents spilling of water on the toilet floor. It does not require electric power and is free of PLC, solenoid valves, etc. making it more or less maintenance free. This arrangement is considered having tremendous potential and may change the way the flushing was so far achieved in the coach toilets.

NR Modification in By-pass mechanism of Bio-toilet.

Atul Singh, CDO/NZM

Zakir Hussain, SSE/Hazrat Nizamuddin (DLI Division)

Nov 2013

 Cost of Innovation

Rs. 1800/- Approx.(For each variant)

Saving Achieved

Rs. 3500/- to Rs. 13,000/- approx per Rake and Pinion mechanism.

Throwing of undesired/non biodegradable objects viz. Bottles, cups, napkins, polythene, Gutka pouches etc. in bio-toilets causes choking and is a matter of serious concern. To obviate the above, a ball value mechanism has been provided in the bio-toilets, on operation of which the trapped undesired objectives as above can be directly discharged on to the track without these objects getting into the main tank of bio-toilet.

NR Fixture for Disc Brake cylinder, Special Tools and Test bench of LHB Coaches (FTIL make)

Dhyan Singh, SSE/CRL

Carriage Lifting Shop, Jagadhri Workshop

Oct  2013

 Cost of Innovation

Rs. 1,50,000/- Approx.

Saving Achieved

Rs. 2 Crores per year.

There are about 600 Nos.  LHB coaches coming for IOH/POH in Jagadhri Workshop, out of which about 300 Nos. are fitted with Air Brake system FTIL make. The work of overhauling of LHB coaches, which were imported from M/s ALSTOM Germany has been entrusted to Jagadhri Workshop of NR for the first time in the Indian Railway which was a challenging job or us as there are no specific drawing and literature available with the workshop for maintenance of Air brake system of LHB coaches.

NR Skate Trolley to clear block section.

Upkar Vashisht, SSE/C&W/JUC,

Freight depot, FZR Division.

Mar 2014

 Cost of Innovation

Rs. 5000/-

Saving Achieved

No comparison as this is new design.

It is substitute of towing equipment of ART meant for clearing block section incase of axle locking & roller bearing seizure of rolling stock. The trolley moves over four wheels of small size as of PWI dip lorry. Coach/Wagon is required to lift up-to one feet with help of jacks and than rest over the trolley frame inserted below the wheel position. Thus means the isolation of coach wheel from rail contact.

NR Smart control system for detecting smoke, flame and high temp in diesel Locomotive.

P K Pandey, Sr. DME

Samir Bhengra, ACMT

Diesel shed, Alambagh

Mar 2014

 Cost of Innovation

Rs. 14,000/-

Saving Achieved

Safety Feature.

 This device is Microcontroller based control system. The specially designed sensor detects smoke as well as flame and high temperature in the surrounding.  Input signals are analyzed and logics are used for taking corrective action.

NR Driver Loco Cab Surveillance System Vijay Arora, Sr. DME/DSL/ SSB Diesel shed, DLI Division. Mar 2014

 Cost of Innovation

Rs. 63,625.50/-

Saving Achieved

Safety related innovation.

Salient features:-

  • 600 TVL fixed lens cameras equipped with IR LEDs suitable for clear Day and Night images.
  • Mobile Digital Video Recorder with "Aviation Grid Connector" suitable for mobile platforms.
  • 11 TB storage capacity, sufficient to record events in the cab for 30 days. Simple process for downloading the data.
  • High sensitivity condenser microphones for recording conversations between Pilot and Co-Pilot.
NR Wheel Mounted Track Cleaning Car. Vijay Arora, Sr. DME/DSL/ SSB Diesel shed, DLI Division. Mar 2014

 Cost of Innovation

Rs. 64.8 lakhs.

Saving Achieved

Safety and Hygenic related innovation.

This equipment has been fabricated by associating M/s TPS infrastructure Ltd, New Delhi wherein a High Performance, high capacity Centrifugal Blower having Air handling Capacity of 18000-24000 Cu.M/Hr. developing vacuum upto 1200~1400mm WG for managing suction power for the machine.

RWF Re-location of Rotator drive unit of Drag Tilter Rollover

S Marimuthu,

SSE/MMR

Wheel Unit/ RWF

Oct 2013

 Cost of Innovation

Rs. 45,000/- approx

Saving Achieved

Rs. 1,40,00,000 approx

 Drag Tilter Rollover is one of the critical online equipment in mould room. The surface of drag boxes soon after casting process is cleaned by sand blasting process.. Prior to implementing this innovative modification, the roll over which is driven by an electric motor and gear box assembly, was located in a close congested location beside the operator who does the inspection part of the drag boxes. This besides a hindrance to the operator was a major constraint to the maintenance personnel.

The maintenance team of Mould Room had taken up this task as a challenge and could accommodate the entire drive unit to a ideal location which is away from the operator. This has not only improved the safety of the staff working on this equipment but is easily approachable to the maintenance team for regular inspection and attention. This has drastically reduced the downtime of the equipment. 

SCR Method for reducing train partings due to uncoupling of wagons

Hemsingh B Sr. DME/O&F/SC

U Ramesh, ADME/C&W/RDM

Ramagundam Freight Depot, Secunderabad Division, SC Railway

Oct 2012

 Cost of Innovation

 Nil

Saving Achieved

Rs. 1,01,36,790/- per month

There was abnormal increase in freight train detentions in the section/ stations on SC Railway on account of train partings which is mainly due to uncoupling of CBC's. To overcome this problem the ROH depot at Ramangundam (RDM) carried out detailed investigation and came up with a modification for the CBC assembly. With the modification, the formation was moved and in the process of run the operating handle was constantly given pull to have simulation of lock piece lifting. It was observed that the lock price was not lifting and the toggle assembly was not pulled upwards and thus avoided the train parting. This is due to auxiliary anti-creep lug of lock lifter touching the bottom portion of CBC housing and not allowing the lifting of lock piece. In this case, because of increased uncoupling angle to 105 degree, the operating handle is not allowing toggle assembly to go upward when constant pull is given to the handle and thus the uncoupling of CBC's  is avoided. There is tremendous reduction in parting cases from 152 in 2011-12 to 69 in 2013-14.

SCR E-Procurement of Medicines

Dr. S K Gupta, CMD/SCR/SC

Headquarters/Medical Department

May 2013

 Cost of Innovation

Nil.

Saving Achieved

1). Saving of Rs.3.19 crores, approx. out of the 15.50 crores, worth of POs value.

2). Savings Rs.30,000/- per month approximately (for Stationery and Postal charges)

Financial savings through better and fair competition. Procurement process got totally streamlined even with the limited staff. Record keeping got improved. Made the procedure faster, transparent and verifiable resulting in all companies looking forward to do business with the Railways. E-Tenders are being regularly opened and on an average 20 tenders per day were processed. There is no hitch and delay in the procurement process. Time and money is saved. By switching over to IREPS, valuable know how and insight has been gained. Process is quick and fast, 100% accuracy than manual tendering. No delay in re-tendering, manual tender witnessing is not there. Manpower of Accounts and Medical Personnel is saved.

SCR HYLITES (Hyderabad Live Train Enquiry System) an Android App.

S K Mishra

DRM/SC/SCR

M V S S Murthy,

SSE/T/CTO/SC

Secunderabad Division

Feb 2014

 Cost of Innovation

Nil

Saving Achieved

Nil

There are Three major coaching terminal stations to cater to the needs of passenger services in Hyderabad, the heritage and hi-tech city. These are Secuundrabad, Hyderabad & Kacheguda. Multi Model Transportation System (MMTS) is highly popular travel service in twin cities, which provides a cost effective and convenient suburban rail transport service to the citizens. Around 1.5 lakh of commuters utilize these MMTS services each day. In addition to existing Real time information facilities (like LED display monitors etc.), SCR has recently launched HYLITES an android based smartphone application which provides live data on rail services and also relevant information on a host of other issues needed by passengers.

SECR Quick Fixing & Auto Reverse Emergency Chain Device

K P Chouhan,

Sr. Section Engineer/

P. Way/ Balaghat

Feb 2013

 Cost of Innovation

Rs. 3000/-

Saving Achieved

NIL

Emergency chain is an alternate arrangement of Gate barrier and used when gate barrier is damaged by road users or under repair at manned level crossing gate.  The chain fixing process is a very cumbersome one as the chain is wrapped around  one rail post and while unwrapping the chain, chain links get entangled and it takes 5 to 6 minutes time in fixing the chain.

A solution has been found for quickly fixing & unfixing emergency safety chain in which safety chain is wrapped around a spindle with the help of a spring and the whole chain assembly is encased in a drum. While fixing the emergency chain, one end of the operation takes less then half a minute. Similar spindle and chain arrangement is fixed on the other side of the track side of the track also. Opening of the chains takes hardly 10 seconds and is very quick as against old system taking 4 to 5 minutes. This device ensures orderly operation during closing & opening the gate as against chaotic situation prevailing in old system. 

SECR Detection of Bolt Hole Cracks by 45 probe

S K Barhate

SSE/P Way/USFD/NGP

Dec 2013

 Cost of Innovation

NIL

Saving Achieved

NIL

During course of testing with 0o probes it is felt difficult to distinguish peak from bolt hole and peak from bolt hole cracks just initiated or minute in nature. With 45o probes scanning even minute cracks and cracks just initiated can be clearly identified. Hence this practice can be considered advantageous to detect bolt hole cracks with 45o probe at locations such as back leg of crossing on major and important bridges etc.

SECR Emergency Backup System Provided in DUO-8116 track machine

Abdul Rub

SSE/TM/NGP

N K Banerjee

SSE/TM/NGP

DUO-8116 Track Machine/ Zonal Base Depot/NGP

Dec 2013

 Cost of Innovation

Rs. 32,000/-

Saving Achieved

50 Minutes saving in clearing block section in case of machine failure.

Duomatic track machines are fitted with 2 tamping units, 2 lifting units (LU) & 8 nos of track Lifting Rollers. These units work with the help of hydraulic power built up by hydraulic pumps which are driven by Cummins make diesel engine model NTA 8551. In 99% engine failure cases lifting rollers are to be opened with crow bars, tamping units and lifting units are to be lifted with  jacks & emergency hand pump. It takes around 1 hour to do the above work if everything works well. Till then block section cannot be cleared.

During IOH of track machine DUO-8116, a major breakthrough has been achieved by simple alterations in hydraulic circuit with this alteration folding the units in case of failure of engine is independent of reflexes of machine operator. In case  of engine failure, tampring units can be lifted, lifting roller can be opened and lifting unit can be lifted up to 60-70% height even after 10 minute of failure of engine.

SER CCTV camera at L. C. gate No. KA-90 at BQA station of ADA Division

Arvind Mital

DRM/Adra

Madhusudan De

SSE/Tele/Bankura

ADRA division of South Eastern Railway

Sep 2013

 Cost of Innovation

Rs. 1,83,012/- for one gate.

Saving Achieved

Operation of L/C gate became smooth & safe. L/C gate dashing cases have decreased

Interlocked L.C.Gate No KA-90 is operated from the West Cabin of Bankura. As the LC gate is more than 100 meters, from the cabin, the gateman does not have proper visibility of road traffic while closing and opening the gate. To overcome this problem, CCTV consisting of four cameras have been provided at the LC gate, 2 each fixed on the height gauges on both sides by which the gateman gets a clear view of the vehicles approaching and passing through the LC all the time right on his table.

SR Renewable Dust bins in coaches

A V Praveen Kumar,

SSE/Carriage & Wagon Depot/ MAQ-PGT/ Division

Apr  2013

Cost of Innovation

Rs. 2,63,213/-

Saving Achieved

Rs. 18,41,956/- per month

Brief description: Renewable dust bins were manufactured using shade net cloth & stainless steel wires. 4 nos. of such dust bins were fitted in every coach of the vestibule area; thereby passengers could deposit food waste and garbage into that. The damaged dust bins were renewed whenever they are unusable. The renewable dusts bins provided in the coach has made a change in the entire scenario of the passengers' feelings.

SR FRAMES (Fault Reporting Analysis Monitoring Evaluation System)

Md. Faisal, Sr. DFM,

Palghat Division

Satheesan, SSE/SRR

Nov 2012

Cost of Innovation

Rs. 250/- per month

Saving Achieved

Cannot be quantified

FRAMES is a SMS cum web based application that is initially used for monitoring the Track and Signal Defects reported by pilots. The Scope of the system is widened to cover any system which requires a feedback. SMS based Colony Complaint Management system is now part of frames. FRAMES was launches on 30th November 2012 by General Manager, Southern Railway.

SR Modified Lifting Barrier

S Anbalagan,

Divisional Engineer, CTR/MAS

Open line, Chennai Division

Feb  2011

Cost of Innovation

Less comparing existing lifting Barriers

Saving Achieved

The total savings effected is Rs. 2.5 crores

The failures arising in conventional LB have been addressed and the design has been made accordingly. The wire rope has been replaced with 32mm dia rod and mechanical advantage is gained by providing series of gears. The inventory of parts in lifting barrier also has been reduced substantially. Maintenance effort has been reduced and reduction in failures improved punctuality of train services. 

WR Special tool for removing SR oil circulating pipe

Harikesh Meena,

ADEE/TRS

Shivakant Saxena/SSE

Electric Loco Shed Vadoara W. Rly

Apr  2013

Cost of Innovation

Rs. 1500/-

Saving Achieved

Rs. 2,41,425/- per year

For the first time on IR, Electric loco shed Vadodara has developed special tool for removing SR oil circulating pipe for attending SR oil pipe leakage.

Advantages by using innovated special tool:

  • In position Replacement of hose pipe can be done. Loco roof not required to be lifted.
  • Replacement can be done on out pit. No shunting of loco as well as crane area is required.
  • Only 1 staff can replace the same in only 01 hour.
  •  Loco down time is reduced to 1 hour from 30 hours.
WR Test Bench for Pressure Sensor, Temperature Sensor (Transformer and SR), Earth Fault Relay and MVR of 3 Phase Loco.

Pradeep Gupta, SSE

Anil Bhaleja, Sr. Tech.

Electric Loco Shed Vadodara W. Rly

Dec 2013

Cost of Innovation

Rs. 15,000/-

Saving Achieved

Rs. 7,61,000/-

Electric loco shed has developed a test bench for testing the

1. PRESSURE SENSOR (transformer & converter)

2. TEMPERATURE SENSOR (transformer & converter)

3. EARTH FAULT REPAY AND

4. MINIMUM VOLTAGE RELAY OF 3 PHASE LOCO.

 This test bench is capable to test all the parameters as per standards given by the manufacturers.

 Digital display is used for minimizing the human error. Air pressure gauge, Digital AC & DC Voltmeter, AC & DC Ammeter are used. Banana pins are used for connection and testing of temperature sensors.

 With the help of this test unit, reliability of above equipments will be improved.

WR Bogie Frame Manipulator.

Narsi Kaba,

Gr. I, Motor Mechanic

Carriage Workshop, Bhavnagar Para

Feb 2014

Cost of Innovation

Rs. 2,49,262/-

Saving Achieved

Rs. 30,81,277/- per month

The design of Bogie Frame Manipulato is built for 360o rotation with changeable spigots enabling flexibility for mounting various bogie types (both AC and Non-AC bogies).  Manipulator lifts and lower & rotate bogies frames to enable the inspection, repair and assembly to be carried out safely and efficiently without risk of damage to the frames & operator, working staffs.

WCR 24x7 Monitoring of health of signaling cables through Networked Data Loggers with the help of ELDs (Earth Leakage Detectors)

H C Yadav,

DSTE/Signal/Jabalpur/

WCR

R K Dubey,

SSE/Signal/JBP

Oct 2013

Cost of Innovation

Saving Achieved

Improvement in reliability and safety

The earth leakage detector is an extremely useful devise as it is detects earth faults in signaling cables. Cables failure cases result in signal / point/ track etc. failures.

WCR Flap door straightening device

Rajkumar Shrivastava

SSE (C&W) NKJ/JBP Divn

Sept 2013

Cost of Innovation

Nil

Saving Achieved

Rs. 12,75,426/- per month

To meet the shortfall of Flap doors, this depot has designed a device for Flap door straightening by this Shed staff & material to repair/straighten of bend doors of BOXN wagons which got damaged during loading and unloading of rakes at loading /unloading points.

This fixture working on hydraulic pressure manually generated by means of hydraulic pump, so it does not require any electricity or compressed air for its working thereby resulting in saving of energy. With the help of the device minimized condemnation of flap doors. Total 627 Nos. of doors are repaired/ straightened by this device up to 31st Dec.13 and saved Rs. 5101702.

SR HTFT (High Tech Fish Trolley)

P A Dhananjayan,

Sr. DCM/ Palghat Division,

Rajagopalan, CCI/CAN

Nov 2013

Cost of Innovation

-

Saving Achieved

Maintaining Clean and hygienic station Platforms, without compromising on earnings through Fish and perishables.

Design of a suitable trolley eliminating all negative aspects of Fish traffic handling on Railway premises. This will help in maintaining the hygiene of the station in handling Fish and Other perishables without investment by Railways.

SR Theme Parking-An innovative Parking Model at Railway stations

P A Dhananjayan,

Sr. DCM/ Palghat Division,

Shyam Sunder B P,

CCI/Gen/Palghat Division

Mar 2014

Cost of Innovation

-

Saving Achieved

Product promotion clicked at PGT achieving Rs 30,000/- for two days display.

Innovative method of earmarking the area with raised pavement markers with reflectors and glow sign paints, similar to the one adopted for traffic control on National Highways and airports in Railway premises may help to solve the perennial problems in parking on Railway. This will also open up plethora of opportunities at parking lots, that Railway can explore.

Innovation approach to encash the potential hubs over Parking lots and eye ball value during Festival seasons.