Major Achievements 1 ISO 14001 and ISO 9001 Certifications Diesel Locomotive Shed, Bhagat Ki Kothi is first shed

in North Western Railway to achieve both these distinctions. Member ship of National Safety council Diesel Locomotive Shed, Bhagat Ki Kothi is the first shed over Indian Railway to be a member of such a reputed Institution. Model Class Room Shed has set up a model classroom in Diesel Traction Training Centre. This classroom is equipped with latest teaching aids and is host of other innovative features so that training becomes interactive and more effective. The main objectives are to design and develop a chalk-less model classroom, usage of modern training aids to cut down preparation time so that learning becomes more effective. This Model Class Room was inaugurated by General Manager North Western Railway on 22/07/2004. Regular Courses on Track Train Dynamics and Loco Trouble shooting are being conducted in this room. Management Information System (MIS) Shed has introduced in-house developed MIS for day today maintenance of locomotives. The entire data entry is being done at one place making the system quite simple. The software is so friendly that ministerial staff is using it without any difficulty. The main advantages of this system are:       Repetitive nature of data entry is avoided Sharing and easy accessibility of information from Junior to Senior level management It acts as performance register, Schedule register, Schedule history Setout analysis can be done from various aspects for betterment and corrective action Position of critical parameters i.e. LOC, BAP, HVIR, MV drop trend can be obtained Morning position is prepared through this system

System Improvements 1. Explosion Cover test stand Explosion covers are mounted on both sides of the base at the power take off end to protect the crankcase from damage. In case of an explosion, a diaphragm under the explosion cover blows out to relieve the pressures. In order to over the problem of leakage, a test stand along with vacuum and pressure gauges developed. All the explosion covers are tested for leakage after overhauling. As a result of testing before mounting on the locomotive, it has become possible to maintain vacuum pressure in side the crankcase, reduce stress on CC motor and oil throw from exhaust thereby reduction in lube oil consumption Quick mounting arrangement for small motors testing Earlier small motors (Fuel pumps) were being tested on test bench for their performance by tightening all the bolts. This was a troublesome practice besides wastage of time. As suggested by Chief Mechanical Engineer during his visit, shed has developed a mounting bench for testing the small motors. In this new simple

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arrangement, lower U clamp has been fixed and the upper U clamp is free for use and close gripping the motor. On this pattern, testing benches are also being developed for other motors like: CCE motor, Tacho Generator etc. 3. Instructions board in drivers cabin All the locomotives are provided with attractive colourful instruction board concentrating on Auto flasher and other precautionary measures to be taken by the driver on line in cases of hot engine and train parting. Course on Train Track Dynamics: Diesel Traction Training Centre, Bhagat - Ki - Kothi has been imparting training on train track dynamics. The CD received from RTM shed was in English which has now been developed in Hindi. This has enabled instructors to make trainees understand effectively how to start a train with out jerk, start a train after halt on heavy gradient use of dynamic brake & role of engineman ship towards the train parting. Thus this course will further improve engineman ship of driver . Milivolt Drop Testing of Power Contactors Shed has started milivolt drop testing of power contactors with facility developed in house. This testing ensures perfect working of blow out coil, no loose connections etc eliminating further possibility of power contactor failure on load. Compressor / Expressor lapping test stand Earlier loading / unloading of Compressor / Expressor could not be tested for its proper functioning during overhauling / Out of course. Shed has developed a test stand equipped with a main reservoir, AC governor, green filter, auto drain valve MR safety valve simulating to locomotive arrangement. A traction motor connected with 10 nos 12 v batteries drives the compressor, which has to be tested. This arrangement will also facilitate lapping of piston rings and avoid further testing of compressor / Expressor performance on locomotive. It is expected that with this arrangement, manpower and detention to the locomotive will be reduced significantly. The arrangement shall soon be converted to test full load performance of Compressor / Expressor. Case for procurement of Autotransformer with rectifier is under process. Air Drier test bench Shed has developed Air drier test stand in house. This has enabled to test overhauled air dryers ensuring their effective performance on line. Fixture for grinding of traction alternator slip ring Shed has developed a fixture for grinding of traction alternator slip ring in position. This has facilitated in situ grinding. Close circuit music system Shed has provided close circuit music system in all the Sub-assembly rooms. Musical background improves concentration, enhances working efficiency by reducing fatigue. Staff feedback is very encouraging both from work efficiency and inculcating pride in work point of view. Testing of Cylinder Head For crack detection of main engine cylinder head, hydraulic testing is prescribed. Often heads are found suspected of water leakage but not detectable during hydraulic testing. Shed has devised testing of heads in water with air pressure besides hydraulic testing. This system is very helpful since even if there is minute leakage, crack can be detected easily through air bubbles. Effluent treatment Plant for waste water

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Effluent Treatment Plant was inaugurated in 2003. During the occasion Divisional Officers and representatives of both the unions. This plant not only prevents outflow of polluted water but the treated water is used for improving the greenery all around in the shed besides locomotive washing, thereby saving about 30,000 liters water per day. Besides, the extracted oil is generating direct revenue for railways 12. Fuel Injection Pump (FIP) Section The FIP section has been renovated by providing dust proof environment, air conditioners, CFL and fluorescent lights, proper ventilation, doors of all workbenches modified for uniform aesthetic look, plastic bins etc. HP tube test fixture shifted inside the room. Other testing fixtures also relocated for maintaining proper process flow of activities. WW Governor room The room has been renovated by providing dust free environment. Chrome plating of governor working base plate got done. Palletized by providing plastic bins. Exploded view of governor displayed.

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Brief Photographic Overview

Of

System Improvements

GE GOVERNOR ROOM

Better working environment through improvement in lighting and tiling Better ventilation

Palletization of governor spares Exploded view of GE Governor displayed in the section

Better working environment     

Exhaust fan provided

Lighting improved by pulling two high reflective fluorescent lights

Re-arrangement of gauges, meters and other electronic items Two extra windows removed to make room dust free

Ceramic tiles on floor and side walls provided to maintain surgical cleanliness Palletization

 

Spare parts stored in plastic bins All electrical boards and lighting, machine etc relocated with elegant looking switches

De-congestion of working area 

There two work benches of different sizes. In lieu of that one work bench, which can also accommodate ready governor was made.

WW GOVERNOR ROOM

Better working environment by ensuring surgical cleanliness through tiling

Palletization of governor small spare parts Provision of boards with exploded view of the WW governor

De-congestion of working area Soothing colour scheme even for the test stands.

WW Governor room

Better working environment i Broken false ceiling replaced and ceramic tiles provided on the floor Chrome plating of governor working base plate got done Test machines and working tables properly painted All the electrical switch boards rearranged Electrical connection to both the air conditioners provided through MCBs Palletization i Spare parts stored in plastic bins De-congestion of working area, MG spare parts lying in the room disposed off Provision of Boards i Exploded view of Governor prepared and displayed at suitable location Outdated MG boards replaced with BG governor Mechanism

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LOCO CONTROL OFFICE & CONFERENCE ROOM

Separate handing-over/taking-over window for shunters. Separate room for shunters and pointsmen. Separate board for Loco-wise subassembly, Critical parameter , and special drives Floor and wall of conference hall with matching and soothing colours. Controlled environment and temperature for efficient working of control office

Computerized M I S for Avoiding repetitive nature of data entry More time to control people for better real time reaction Sharing and easy accessibility of information.

Control Office
1 2 3 4 5 6 7 8 9 Separate handing-over/taking-over window for shunters. Separate room for shunters and pointsmen. Conference table with chairs. Loco-wise subassembly board. Critical parameter board. Separate board for special drives provided. Floor and wall of conference hall with matching and soothing colours. Controlled environment / temperature for efficient working of control Computerized M I S for a b c Avoiding repetitive nature of date entry More time to control people for better real time reaction Sharing and easy accessibility of information from Junior level to Senior level management

FIP ROOM

Provision of surgical cleanliness by tiling Dust free environment Palletization Streamlining of electrical wiring and switch boards Improvement in layout for better space utilization.

Provision of better illumination on workbenches Improved ventilation

Fuel Injection Pump (FIP) section

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Provision of surgical cleanliness and better working environment For the purpose, ceramic tiles provided on floor upto working height of walls with provision of dust proof environment by providing air conditioners

Provision of better illumination on working benches

High reflective CFL and fluorescent lights have been provided at suitable locations for better illumination on working benches 3
Improved ventilation

Location of exhaust fan has been changed at suitable place to improve ventilation 4
Dust free environment

To make room dust and carbon free

i Grinder installed for carbon injectors nozzle shifted to outside the room Provision of window frame to arrest entry of dust Shoes stand kept outside the room Door closer provided

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Re-location of boards All boards have been placed at suitable location for effective use as well as for elegant look.

Chrome plating of injector opener and handle provision in other

Palletization

Almirahs door panels changed from wooden panels to glass for visibility and ensuring proper stacking of material

Doors of all workbenches modified for uniform aesthetic look

Plastic bins purchased for all spare parts and to ensure proper stacking.
All electrical boards of lights, machines etc relocated with elegant switches

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Floor tiles, workbenches, test stands and background walls painted in soothing and elegant look

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Washable distemper on walls for cleanliness and longer life

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Removal of congestion outside Sub-assembly section Incoming FIPs, injectors and HP tubes used to be kept just outside the room making it congested. Now a separate table and suitable location is earmarked, making entrance clear Maintenance activities inside Sub-assembly room HP tube test fixture installed outside room is shifted inside the room to centralize the work place and also for cleanliness of area. Other testing fixtures also relocated for maintaining proper process flow of activities

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Better sharing of information

Display board showing thrust areas, drives, important technical information shifted from inside the room to outside. 16
Removal of congestion from inside the room

Earlier there were three FIP testing machines. One has been transferred to Alambagh shed in order to have some more working space. Remaining two machines have been closely relocated 17
Streamlining of electrical wiring and switch boards

Electrical connections to both these machines were given through a single board of high capacity. In lieu of these MCBs of adequate rating were provided