Performance Highlights and System Improvement of

Mechanical Department for 2020-21

FREIGHT:-

1. Performance Parameters :-

Sr. No. Performance Indices Actual 2019-20 Actual 2020-21

1 Ineffective percentage 2.5 2.4

2 ROH Outturn 12634 11751

Equipment Failures

3 Train Parting 25 15

4 Hot Axle 27 38

5 Other Detachment 20 25

6 Spring breakage detachment 0 0

7 Poor Brake Power 0 0

2. Wagon ineffective was maintained at 2.4% during the year 202-21 as against

last year was 2.5%.

3. SEC Railway turned out 11751 ROH wagons against the Board’s target of

12000 wagons during the year despite severe Covid-19 pandemic, which is

affecting work throughout the year.

4. Hot axle detection Machine’ installed at Gondia: For the first time in SECR ‘Hot

axle detection Machine’ based upon infrared technology installed at

Gondia.

5. Over hauling bench for Brake cylinder of BVZI at PP Yard /Bhilai: BMBC test

bench for brake cylinders of BVZI has been developed in-house for

overhauling and testing. After this development, the overhauling and testing

of BVZI brake cylinder has been started at PP Yard BIA.

6. At Exchange Yard Bhilai, Two Nos. LOHA rake formed for the transportation of

26 Mtr. Long Rail from BSPC to Various destinations in Indian Railway on date

16.05.2020 & 23.05.2020.

7. Pipe Bending Fixture at PP Yard/Bhilai: Pipe Bending Fixture has been

developed in-house for improving maintenance quality of pipe line in air

brake system at ROH Depot PP Yard/BIA.

8. Bogie Bolster Manipulator at PP Yard/ Bhilai: Bogie Bolster Manipulator

developed in-house for improving maintenance quality of bogie bolster at PP

Yard/BIA.

9. Operating handle testing bench: 01 No. Operating handle-testing bench has

been developed in house with available resources in PP Yard, Bhilai. Depot is

now able to repair all damaged operating handles. A fixture has been

developed for checking of geometry of CBC operating handle at depot.

10. Working model of Door operation mechanism of BOBRN

wagon at PP Yard/Bhilai: A new activity of ROH of BOBRN wagon

commenced at PP Yard/Bhilai. To improve the knowledge on door operating

mechanisam of BOBRN wagon, a working model has been devloped with in-

house material and succefully commissioned. It is very useful for C&W staff &

supervisior for better understanding of real time working of door operating

mechanism with air pressure, so as to improve the maintainance standard of

ROH of BOBRN wagon.

11. Pneumatic Press Machine at PP Yard/BIA: A Pneumatic press machine has

been developed in house with available resources in depot for repairing bent

and unserviceable parts of wagon. PP Yard/BIA is now able to repair all

damaged door, hand brake wheels, operating handles, door lock eye and

other bent items using this device. To make this device, 02 Nos. old brake

cylinders and cut off valves were used with steel structure and platform.

COACHING :-

1. Performance Parameters:-

Sr. No. Performance Indices Actual 2019-20 Actual 2020-21

1 Ineffective % (AC Coaches) 7.4 6.2

2 Ineffective % (Non AC Coaches) 5.8 4.6

3 “C” Schedule/IOH (Per Month) 43.4 32.7

4 Enroute Coach Detachment

(Ownership) 2 0

5 Sec. Coach Detachment

(Territorial) 1 1

6 Sec. Coach Detachment

(Ownership) 3 0

7 Punctuality loss cases (Direct) 53 2

8 Punctuality loss cases (Indirect) 28 8

2. During Covid-19 pandemic, lot of coaches had become overdue for

POH/IOH/SS-I due to closure/partial operation of workshop. As per the directives

of the board, extension of POH/IOH/SS-I of following coaches were done during

2020-21 to keep these coaches operational for service.

Sr. No. Activity No. of Coaches

1 IOH Extension 158

2 POH Extension 254

3 SS-I Extension 81

3. A total of 23 shramik special, 03 kishan special and 128 parcel rakes were

formed and examined by Chg depots during 2020-21 apart from routine

maintenance activities.

4. BIO EFFLUENT TEST LAB developed by Coaching Depot, Durg:- It has Fully

Automatic double wall, Incubator, COD Digester with digester along tube and

condenser, PH Meter, Magnetic Mixing Platform, Vacuum pump, Laminar air

flow chamber, Digital micropipettes, Analytical Balance 4 Digit, Burret Class A50

ML, Petridish 100x20mm, Distilled water unit. It is very helpful in Bio-toilet effluent

testing and maintaining parameters withy in DRDO prescribed limits.

5. Remotely operated Ultra-Violet Sanitization Robot: Coaching depot, Durg had

developed remotely operated Ultra-Violet Sanitization Robot for sanitization of

coaches. Key features of the robot include – remote based movement of robot,

remote controlled blasting of UV-C rays to sanitize the coach, remote camera

based vision. It is a non-chemical based technology, thus there will be no issue

of residual contaminations. UV-C rays are effective in killing pathogens and

viruses. It helps in keeping safety of the sanitization team as there is no physical

presence is required.

6. WSP Test bench at Coaching Depot, Bilaspur: GM/SECR inaugurated the WSP

test bench cum working model on 13.10.2020. It is capable to test WSP parts i.e.

speed sensor, dump valve, microprocessor cards, and its connectors. The test

bench is very useful to impart training to Railway staff also. On the test bench,

WSP equipment of both M/s Knorr Bremse and M/s Faiveley can be tested. This

will be of great help in reducing wheel shelling problem on LHB coaches.

7. At Coaching depot Durg, Conversion of holding line into pit line work is

completed and inaugurated by GM/SECR on 08.01.21.

8. One dining car has been modified from WGACCN coach at Coaching Depot,

Bilaspur and commissioned on 04.01.2021.

9. A gadget developed in house at Coaching Depot, Bilaspur for assembly and

disassembly of brake cylinders of LHB coaches. Brake cylinders of M/s Faiveley

Transport and Knorr Bremse both can be handled by this gadget.

10. One MEMUDTC Coach SEC 20003 has been modified, furnished & converted

into SPIC in the month of March-21 in coaching depot Bilaspur.

11. Following bulk RSP work related to coaches were done during 2020-21.

Sr.

No.

Name of the work Agreement Qty Executed during

2020-21

1

RSP allotment for

Conversion of BG

coaches into ART/

ARME coaches. @ Rs.

13 lakh per coach.

PB No. 730/2020-21.

24 coaches 09 coaches

2

Provision of Fire

detection system in

7500 AC Coaches. @

Rs.3 lacs per coach.

PB No. 734/2020-21.

234 AC coaches 145 AC coaches

3

Distribution of work of

388 LHB Bogies with

140 KN air

suspensions for

conversion of LS2/LS3

type coaches into

LS5 type coaches

@Rs. 30 lakhs. PB No.

748/2020-21.

SECR-82 nos. (From ICF) 48

EnHM :-

1. There is 162% improvement in generation of renewable energy (solar) at

Wagon Repair Shop, Raipur in 2020-21 w.r.t. 2019-20.

2. Fresh water is utilised in Coaching depots and Workshops for cleaning

purposes. There has been a saving of 48.19% of fresh water consumption in

2020-21 w.r.t 2019-20.

3. All 13 LHB rakes of SECR have been made HOG compliant.

4. There has been a saving of 72.54% in non-traction fuel consumption in

workshops and divisions in 2020-21 w.r.t. 2019-20.

WORKSHOP:-

Wagon Repair Shop, Raipur:-

1. Wagon Repair Shop, Raipur outturn during the year 2020-21 was 4706 wagons

against the target of 5508 wagons despite Covid-19 pandemic, which was

affecting work throughout the year.

2. Systematic material stacking system in workstations was developed in body

shop at WRS/Raipur to enhance the productivity.

3. 4 nos. of fixtures for holding adapter and EM pad with side frame have been

developed and manufactured in bogie shop at WRS/Raipur. This will ensure

the safety of the lowering staff of CASNUB bogies on wheel sets.

4. Basic Training Centre of WRS/Raipur has started organizing online training for

apprentices and other trainees during this COVID situation so as to observe

social distancing norms. Google meet platform has been used for this

purpose.

2019-20 2020-21 % Tgt. Achieved

Target 6000 5508 85.4%

Actual 5128 4706 85.4%

5. Double ended CTRB mounting machine: In Railways all CTRB mounting

devices are single ended. However, this requires two operations for mounting

which needs more time and effort. Double ended CTRB mounting machine

has been fabricated/assembled with purchased spare parts. The machine

has been designed and fabricated to operate in manual as well as

automatic mode for bearing mounting and it is capable of tackling all sizes of

wheels by modifying wheel set lifting jack. This innovation has been awarded

by GM/SECR.

6. Repair of crack in centre sill of BRN 22.9 wagons was done by placing the

wagon upside down to facilitate downhand welding.

Motibagh Workshop:-

1. Performance parameters:-

S.

No. Activities.

Actual

2019-20

Actual

2020-21

1 BG Coach POH ( In VUs) 48 58

2 NG Coach POH ( In VUs ) 04 -

3 BG Tower Wagon POH 6.25 5.5

4 BG ICF Bogie IOH 1272 1051

2. Motibagh Workshop carried out overhauling of total 58 BG coaches (ICF-56,

LHB-02) during the year 2020-21 against the Board’s target of 36, which are

61% higher than Railway Board target.

3. During the year 2020-21, Motibagh workshop supplied 402320 Liters of

innoculum to different Zonal Railways.

4. Motibabagh workshop carried out IOH schedule of 921 coach bogies and SS-

I of 128 LHB bogies carried out during the year 2020-21 and fully met SECR

requirement.

5. Motibagh Workshop, Nagpur has turned out first SS-II schedule off coach SEC

17313, LWSCN . This is the first time when Workshop attended SS-II schedule.

6. For the first time in the history of Motibagh Workshop, Nagpur, Tower Wagon

SEC 6056, Mark- III of Bilaspur Division has been attended for complete

rewiring work during POH attention.

Disaster Management:

1. GPS Vehicle Tracker Device: GPS based Real Time Tracking device of M/s.

Trackway, Indore is installed and commissioned on Tool Van at Dongargarh

on 19.02.2021. This is to maintain common platform across all divisions of

Indian Railway for GPS tracking of DM vehicle.

2. Tool van, Dongargarh has been certified with Integrated Management

System (IMS) certification conforming to standard ISO 9001:2015, ISO 14001:

2015 & ISO 45001:2018.

General:

1. E-office has been successfully implimented in Mechanical Department in the

month of April-20.

2. At Exchange Yard Bhilai, Staff canteen inaugurated by PCME/SECR/BSP on

05.02.2021.

The following good works were done by Mechanical Department to combat

spread of pandemic COVID-19:

1. Total 61346 nos. of masks manufactured by Mechanical Deptt. and

distributed among Railway staffs/officers working in different units.

2. Total 111 coaches converted into quarantine wards as per Railway Board’s

guidelines.

3. 10000 Nos. COVERALL PPE manufactured by Mechanical Deptt. Of SECR.

4. 06 Nos. of hand free (foot operated) soap dispensers locally developed for

Sanitization / Hand wash at BMY and installed at 2 different locations (Division

office Raipur – 02 Nos. & Quarantine center BMY Hospital - 04 Nos).

5. 100 Nos. Hospital Bed Manufactured at Wagon Repair Shop, Raipur and

Handed Over to DRH Raipur.

6. One help desk has been made by coaching Depot, Bilaspur and provided to

Bilaspur Railway station for covid-19 awareness booth.

7. Daily sanitization of workplaces and office with sodium hypochlorite and

Fumigation of workshop with disinfectant is being carried out on daily basis at

WRS/Raipur.

8. Automatic sensor based hand sanitizer dispenser has been developed at

C&W/BMY. Dispenser cabinet is locally fabricated within house materials of 5-

ltr capacity.

Materials: IR sensor, 5V submersible pump, transistor, resistance and LED, 5V

power supply unit with battery and charger, cable and flexible pipe.

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