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MINISTRY OF RAILWAYS
‘HAND OUT’
48th MEETING OF
CENTRAL BOARD OF RAILWAY RESEARCH
(CBRR)
SN Description Page
1.0
An Overview of RDSO
1.1 Introduction
In 1853, the Railways were introduced in India and with their expansion through the
twentieth century, several company managed and state-owned railway systems
grew up. To enforce standardization and co-ordination amongst various railway
systems, the Indian Railway Conference Association (IRCA) was set up in 1903 followed
by the Central Standards Office (CSO) in 1930, for preparation of designs, standards
and specifications. However, till independence, most of the designs and manufacture
of railway equipment was entrusted to foreign consultants. But with Independence
and the resultant phenomenal growth in country‟s industrial and economic activities
leading to increase in the demand for rail transportation, there was a complete shift
in emphasis in the field of design & manufacture. Consequently, a new organisation
called Railway Testing and Research Centre (RTRC) was set up on 1st
September,1952 with its headquarter at Lucknow for testing and conducting
indigenous applied research in railway technology. Later on, Central Standards Office
(CSO) and the Railway Testing and Research Centre (RTRC) were merged into a single
unit and thus in 1957; Research Designs and Standards Organisation (RDSO) came into
being as an attached office of Railway Board.
The status of RDSO has been changed from an „Attached Office‟ to „Zonal Railway‟
with effect from 1st January, 2003.
1.2 Functions
Final authority on all technical matters pertaining to Indian Railways & its Sister
Organizations, including approval of Technical Specifications and Standardization.
Research & Development of New and Improved Designs/Technology.
Advisor to office of Chair of Chairman Railway Board on all Technical Matters
related to Adoption/Proliferation of new Technologies.
Testing & Recommending authority for Statutory Clearances (including Metro
system).
Quality Assurance & Product Commercialization of delegated items.
Indian Railways‟ Platform for International interaction in R&D domain.
RDSO also offers international consultancy for design, testing and inspection of
railway equipment. RDSO is having wide infrastructure with number of laboratories
which are well equipped with research and testing facilities for development, testing
and design evaluation of various railway related equipment and materials.
1.3 Vision
To develop safe, modern and cost effective Railway technology complying with
Statutory and Regulatory requirements, through excellence in Research, Designs and
Standards and Continual improvements in Quality Management System to cater to
growing demand of passenger and freight traffic on the railways.
1.4 Organisation
At the head of the organisation is Director General who is assisted by four ADG‟s-
ADG(General Administration and Support Services), ADG (Design Standardization,
Services & Short term Research), ADG(Long term Railway Research) and ADG
(Quality Assurance and Product Development). Pr. Executive Directors and
Executive Directors, control the following directorates:
Administration
Bridges & Structures
Carriage
Defence Research
Electrical Loco
Energy Management
EMU & Power Supply
Engine Development
Finance & Accounts
Geo-technical Engineering
Metallurgical & Chemical
Motive Power
Psycho-technical
Quality Assurance
Research
Signal
Telecommunication
Track
Testing
Track Machines & Monitoring
Traction Installation
Traffic
Train set
UTHS
Wagon
Works
All the directorates of RDSO, except Defence Research, are located at Lucknow.
The Cells for Railway Production Units and Industries, which look after liaison,
inspection and development work, are located at Bangalore, Bhopal, Mumbai,
Kolkata, Jaipur, Hyderabad and New Delhi.
The center is headed by Executive Director in SA Grade who reports to DG/RDSO. Each
technical wing i.e. Civil, Electrical, Mechanical and S&T has one Director in selection
Grade assisted by SSEs. The activities & Methodology of Centre are as under:
Seeking to nurture a quest for excellence in the sphere of research, design and
development with its immense efforts, RDSO has today become one of the
distinguished institutions of Indian Railways. Marching ahead on its way to success,
RDSO has acquired the latest coveted ISO: 9001-2015 certification.
The Quality policy & Objectives of RDSO truly cherish and reflect the Organisation‟s
commitment for genuine intellectual & professional pursuit and growth:
Governing Council comprises; Chairman Railway Board as its Chairman, the Financial
Commissioner, Member Engineering, Member Mechanical, Member Staff, Member
Electrical, Member Traffic, Addl. Member (Plg)/Railway Board and Director
General/RDSO as the members. The functions of Governing Council are:
To identify and approve the R&D projects for technology development on Indian
Railways.
To review the progress of projects.
To determine the quantum of direct investment in technology development within
the overall allocation of funds under the plan head 'Railway Research'.
To give direction for improving the working of RDSO.
33rd Meeting of Governing Council was held on 12-02-2018 at RDSO, Lucknow in which
discussion/decisions on various projects like Dedicated Test Track, Switch over to EN
14363/UIC 518, development of Instrumented Measuring Wheel, Broken Rail Detection
System etc. were taken.
In order to explore and exploit the latest technology, RDSO regularly interacts and
works with various R&D organisations like IIT-Kanpur, IIT-Roorkee, IIT-Delhi, IIT-
Chennai, IIT-Kharagpur, IIT-BHU, NID, CSIR, DRDO and other prominent R&D
organisations- National as well as International like UIC, RTRI/Japan, KRRI etc.
through Memorandum of Understanding and CRR (Centre for Railway
Research)/Technical Chairs.
Recently Railway Board vide letter no 2015/E&R/7(13) 4. Dt/ 12-06-2019 has
empowered RDSO by extending existing Procedure Order to award consultancy
projects to the other institutions also like NITs, ISRO, BARC etc at national level as
well as to KRRI, RTRI, Russian railways etc at international level.
1.9 Infrastructure
RDSO carries out its activities through a sprawling campus spread over 159 hectares
which houses amongst other things a number of laboratories well equipped with
research and testing facilities for development, testing and design evaluation of
various railway related equipment and materials. Some of these are:
This centre has been established to guide and assist the maintenance personnel
spread over the entire Indian Railway system.
The seniority lists of all group „C‟ & „D‟ staff in all categories of posts have been
uploaded on official website of RDSO for information & perusal of all concerned.
Other than these, Question Bank, Model Answers, Book of Sanction, Status of
Compassionate Appointments, Pension Adalat Details, Data of Manpower, Selection
Notices, Syllabus of various Selections, Important letters/Notification of Pensioners‟,
Status of Inter Railway Transfer cases and various forms for use by officials of RDSO
have also been kept on Intranet/RDSO Website.
RDSO, with the support of Railway Board, has initiated a regular dialogue with
industry. Three dialogues have already been held at RDSO involving representatives
from Industry (CII, FICCI, ASSOCHAM etc.) and Railway Board. The first dialogue was
held in November 2018. The focus of these dialogues have been to suggest policy
framework for expediting induction of new technologies on IR, involving industries in
the process of drafting of technical specifications, identifying green channel
products/companies with the idea of implementing self-certification by the
manufacturers and doing away with the inspections in a phased manner. Last
th
meeting was held on 29 January 2019 at RDSO, Lucknow.
SN Cadre SS OR Vacancy
1 Group A 223 190 33
2 Group B 168 108 60
3 Group C (Other than Level 1) 2002 1623 379
4 Group C (Level 1) 866 672 194
Total 3259 2593 666
2.0
2.1 SAFETY
RDSO has issued following specifications for Automatic Fire/Smoke detection with
alarm system for IR coaches:
i. Spec No. RDSO/2008/CG-04 (Rev.-4) with amendment no.1: Schedule of technical
requirement for design, supply, installation, commissioning & maintenance of
aspiration type automatic Smoke / Fire detection with alarm system for Indian Railway
AC coaches has been issued to PUs/ Railways vide RDSO letter MC/ACF/Fire
Detection/AC dated 14.06.2017 and amendment slip no. 1 dated 04.12.2017.
ii. Spec No. RDSO/2013/CG-06(Rev.-1): STR for Design, Supply, Installation,
Commissioning & Maintenance of Automatic Smoke/Fire detection cum manual
suppression system for Pantry Car & Generator cum Brake Van of IR coaches (ICF & LHB
Design) has been issued to PUs/ Railways vide RDSO letter MC/ACF/Fire Suppression/PC
dated 18.12.2017.
New Specifications for Fire Retardancy:
All specifications have been revised for materials of coach interiors to make it more
fire retardant. In these specifications Heat Release Rate (HRR) as per EN 45545 have
been mandated. Revised specifications are effective from 01.07.2015.
Fog PASS (Pilot Assistance System for Safety) with Enhanced features
This is low-cost, portable equipment (Tiffin-box size, 1.5 kg, Battery powered) to be
carried by Loco Pilot while taking over duty-charge. It provides on-board real-time
information (Display as well as voice guidance) to Loco Pilot regarding Location of fixed
landmarks such as Signals, LC Gates etc. in advance to be used particularly in foggy
weather. Driver has to watch the landmark as per operating procedure. Driver has to
get Signal Aspect (Red / Yellow / Green) etc. from physical trackside signals.
AWS (OEM M/s Siemens) is installed on Mumbai suburban section for preventing SPAD.
Earlier, M/s Siemens was supporting supply of additional quantity of equipment for new
rakes but subsequently they indicated that due to obsolescence of some of the
components, it will not be possible to support on-board equipment and stopped quoting
for the quantity required for new rake manufactured by ICF.
Consequently, RDSO started the process of developing new vendors with features of
remote monitoring and EOI was invited in which eight firms participated.
To overcome the issues pertaining to supply crisis of imported system of AWS (analog
version), RDSO has enforced M/s Siemens to modify their design of existing AWS system
in accordance to AAWS specification to make it intelligent. In compliance to implement
AAWS specification [RDSO/SPN/204/2014 ver 1.0], M/s Siemens has modified AAWS
system (On Board system), got type tested and approved for limited use over suburban
section of C & W Railways in Dec‟2018.
Apart from this, one more vendor (indigenous) i.e. M/s Medha servo Systems Pvt. Ltd.,
Hyderabad has also been developed for item AAWS system and approved in Feb 2019
for better competition.
Train Collision Avoidance System (TCAS) is an Automatic Train protection (ATP) System
with cab-signalling, meant to provide protection by preventing trains to pass signal at
Danger (Red), excessive speed over turnouts / Speed restrictions and to avoid the
situation in which more than one trains are on the same track to cause collision, in case
operations are not able to control so. It also provides assistance to Loco Pilots by
means of real-time display of signal aspects in Loco Pilot‟s cab. It is based on the
determination of location of Trains through distance traversed from RFID tags installed
on track and transmission of signaling related information from Stationary Units through
Radio Communication.
The trial in automatic section are under progress since Feb‟19 in Sanathnagar-
Lingampalli (17 km) section of South Central Railways. The trials are likely to be
concluded by Nov‟19.
Failure Indication cum Brake Application (FIBA) device for Mainline Coaches:
RDSO has developed air spring failure indication cum brake application (FIBA) device to
provide failure indication system which can immediately communicate to driver about
the deflation of any air spring. RDSO had taken up service trials of three makes of FIBA
devices i.e. FIBA device of M/s Stone India Ltd., Kolkata and M/s Faively Transport
India Ltd/Hosur work on pressure differential system while FIBA device of M/s Knorr
Bremse India Ltd/Faridabad works on absolute pressure system. RDSO has issued
technical specification for this and the device has been introduced in rakes of mail
express trains.
FTRTIL make FIBA device & Indicator KBI make FIBA device &
Indicator
First 3-phase under-slung MEMU bi-directional 8-car rake formation consisting of two
DMCs on either side and six TCs in between with two cabs in DMC been designed and
manufactured by ICF in consultation with RDSO.
The key features are:
o Provided with 3-phase IGBT based propulsion system.
o All traction equipments are under-slung releasing on-board space for passengers.
o All coaches are provided with bogie similar to Train-18 – i.e. bolster less design with
pneumatic springs in secondary suspension and coil springs in primary suspension
with control arm.
o Wheel mounted brake disc with calipers.
o Electro Pneumatic Brake system.
o Fully sealed gangways in between the coaches for free movement of passengers from
one end to other.
o LED lighting.
o Aerodynamically shaped nose cones at both ends.
o Interior paneling with ACP/FRP.
o Cushioned seats.
o Two SS Modular toilets in each Trailer coach and one in DMCs.
o Air conditioned driver cabs.
o Stainless steel slip free flooring.
o Aluminium sliding doors.
o Aluminium luggage rack with glass bottom.
o Semi permanent coupler.
RDSO was instrumental in development and approval of design, testing and inspection
of the first ever indigenous EMU with 3-phase under-slung IGBT based propulsion
system. EMU Under-Slung fitted with under-slung 3-phase IGBT based propulsion system
is a 12 car rake formation in which there are 5 variant of coaches i.e. DMC, MC, TC,
TC1, NDMC having pantograph provided on trailer coach (TC). Rake formation of EMU
under-slung is as under:
CAB CAB
↓ ↓
DMC TC MC TC1 NDMC TC MC TC1 TC1 MC TC DMC
The salient features of 12 car formation BG Air-Conditioned EMU coaches are as under:
i) This EMU is fitted with under-slung 3-phase IGBT based propulsion system so as to
increase the number of passengers vis-a-vis on –board 3-phase EMU where in EMU
under-slung, the space for the on-board equipment has been utilized for the
passengers occupancy thus increasing the number of passengers capacity per
coach.
ii) This is also provided with Train-18 bogies in order to achieve better riding comfort.
iii) In this EMU the vestibules is in the same level with the floor of the coaches in
order to provide hassle-free movement of the passengers across the Train.
iv) 12 car formation EMU coaches are provided with air-conditioning.
v) In this EMU, pantographs are mounted over the roof of trailer coach for utilization
of single pantograph and transformer feeding both adjacent DMC and MC vis-a-vis
motor coach of on –board 3-phase EMU.
vi) This is provided with air suspension (pneumatic suspension) in secondary stage to
maintain the floor height from rail level under varying load of passengers.
vii) Speed certificate for oscillation trial has been issued for test speed of 120kmph.
viii) Under-slung EMU provides end to end connectivity for passengers in comparison
with on board EMU where on-board equipments do not allow end to end
connectivity. In earlier air-conditioned EMU manufactured by ICF, there is a ramp
for the fully sealed gangway. The same has now been avoided by lowering the
coupler height and this will give hassle-free movement of the passengers across
the Train. The problem of having ramp in the gangway was pointed out by User
railways as well as the travelling public in the earlier air-conditioned EMU.
ix) It is provided with EP brake with the disc brake and brake discs are mounted on
wheels thereby reducing braking distance. It has also regenerative braking.
x) These coaches have fully sealed gangways which are wider than the existing Air-
Conditioned EMU thus providing better access.
xi) Halogen free rubber flooring like in metro coaches and stainless steel seats.
Presently, rake is under going oscillation and emergency braking distance trials in
Central Railway. It is expected to put in service in July, 2019.
xii) Other features like automatic sliding doors wider windows for panoramic view and
air-conditioned driver cab are provided.
Indigenous Metro Rolling Stock with energy efficient technology (Medha Electrics)
Vande Bharat Express (Train-18) giving form to “New India New Railway”
IR by M/s GE till May‟19. The key technical features of WDG4G locomotives are as
under:
i) Electronic Fuel Injection for improved fuel efficiency.
ii) UIC 1 emissions compliant locomotive diesel engine .
iii) 12Cyl. Engine delivering 4500 HP instead of 16 Cyl. with Best in class Fuel efficiency
iv) Alternator start Engine mounted on isolators for reduced vibration
v) IGBT based traction system with Individual Axle Control for enhanced reliability / availability
vi) Multi-speed, motor driven auxiliaries for optimized load control
vii) Enhanced operator and cab amenities (HVAC, Hot plate, Heated windshields, Toilet, Four (4)
15” display screens/ cab).
viii) Cab frontal collision designed per EN12663 and AAR S580 Anti-climber
ix) Light weight bogie (bogie frame designed to EN13749) with minimal maintenance
x) Remote Monitoring & Diagnostics enabled for continuous fleet health monitoring
For better discipline and crew performance monitoring in Electric Locomotive , the
specification for Crew Voice and Video Recording System (CVVRS) having capacity of
retaining data for approximately 30 days has been finalized. Railway Board has directed
CLW for regular cut in of CVVRS in all passenger locomotives. Considering the
advantages of this system, Railway Board may consider retro-fitment of this device on
all locomotives in service.
First Indigenous Air-conditioned EMU for Mumbai sub-urban with 3-phase propulsion
system
Development of energy efficient HOG (Head on Generation) Train power system for
Indian Railways in WAP-7 Electric Locos
IR has gone for Head-On generation (HOG) scheme owing to its
advantage of being environment friendly and energy efficient.
The saving in energy shall also provide carbon credit to Indian
Railways. The other significant advantage is absence of any
noise which exists in DA set in power cars of EOG scheme. For
the first time in the history of IR, New Delhi – Kalka Shatabdi
Exp started its commercial operation on Head On Generation WAP7 loco provided with Hotel
(HOG) from Feb‟11. Load Converter of M/s Siemens
Based on the modification suggested by RDSO, 14 HOG compliant trains are running in
Indian Railways. At present per day saving in fuel consumption with HOG compliant 14
trains is Rs. 2183247/- (total KMs coverage of UP &DN trip is 28217& hours of both trips
363.45 hours). The list of HOG trains is as follows:-
SN Rly Train no. Total KMs Working of DA set during the UP & Total
coverage DN trip saving in
of UP & fuel @ `
DN trip Hrs. of working Total Fuel 55/- per lt.
of both trips consumption @
55 lts./hour.
1 NR 2006/2005 STB NDLS-KLK 528 8.17 898.7 49428.5
2 NR 12045/46 STB NDLS-CDG 480 7 770 42350
3 WR 12951/52 Raj BCT-NDLS 2770 31.17 5143 2,82,865
4 WR 12953/54 AK Raj BCT-NZM 2756 33.83 5582 3,07,010
5 ER 12301/02 HWH Raj HWH-NDLS 2890 34 5610 308535
6 ER 12305/06 HWH RAJ 2890 39.50 6517 358462
7 WR 12227/28 Duronto IND-BCT 1498 24.16 2657.6 146168
8 WR 22209/10 Duronto BCT-NDLS 2770 34.5 3795 208725
9 WR 12009/10 STB ADI-BCT 984 12.66 1393 76615
10 WR 12239/40 Duronto BCT-JP 2318 30.66 3373 185515
11 NR 12439/40 Ranchi Raj( (Bi 2610 33.50 5527 303985
weekly)
12 ER 12313/14 SDAH Raj 2935 35.5 5857.5 322162.5
13 ECR 12309/10 PNBE Raj 1804 25.3 4174.5 229597.5
14 SR 12243/44 CBE-MAS 984 13.50 1485 81675
28217 363.45 52783.3 2903081.5
Railways Board vide letter No. 2015/elec(TRS)/440/4 Pt IV dtd. 02/12/16 has advised
RDSO to frame specification for high horse power passenger locomotives with speeds up
to 200 Kmph. In this connection, the technical specification for passenger locomotives
with speed potential of 200 kmph (Specification No.RDSO/2017/EL/SPEC/0129, Rev.
„1‟) has been finalized by Electrical Directorate of RDSO.
Starting tractive effort: Starting tractive effort under dry rail conditions
shall be 400 kN.
Continuous rated tractive 360 kN between 0 - 80 kmph
effort:
Maximum Service Speed: 200 kmph.
Continuous rated power: 8 to 9 MW at wheel rim in between speeds
of 100 to 200 kmph on working voltage from
catenary from 22.5 kV to 27.5 kV.
Regenerative brake effort Max. possible braking effort over speed range of
the locomotive.
Pneumatic brake effort 10% - 20 % of gross weight.
Emergency braking distance 1100 m maximum for light engine from 200 kmph
(with pneumatic brake only) to standstill on level tangent dry track.
Parking brake An effective spring actuated and air released
parking brake shall be provided. Status of
application of parking brake shall be displayed in
the active cab, even under the Locomotive un-
energized condition. The parking brake shall be
capable of holding the Locomotive on 1 in 37
gradient.
Capability to work in flood The Locomotive shall be designed to permit its
water running at 10 Kmph in flood water level of 102
mm above rail level.
Proposed braking arrangement with IGBT Front End Converter: DBR Unit shall be
removed. During braking two separate group of motor armatures (bogie wise) shall be
connected in series i.e. Group-1 (M1-M3) and Group-2 (M4-M6). Each group shall be
connected across a combination circuit of Booster and front end converter. Front end
converters shall be PWM controlled to back feed DC power to AC transformer secondary
windings. Each group of 3 Motors maximum series current shall not exceed 900A and
voltage shall not exceed 1800VDC. DC Link is provided between Booster Chopper &
Front end converter for reducing ripples and to feed stable DC to front end converters
for a wide speed range.
Proposed arrangement is shown in Figure :
Design documents for High Rise OHE have been issued in April and December, 2014.
Work is in progress in REWARI – MANHERU - HISSAR of DELHI-JAIPUR-AJMER-AHMEDABAD
Section.
With a view to meet the requirements of satisfactory current collection under high rise
overhead lines of the proposed Dedicated Freight Corridors (DFC) of Indian Railway,
RDSO has developed reliable and maintenance friendly High Reach pantograph to
provide satisfactory current collection at varying heights ranging from 4.58 meter to
7.5 meter under all weather conditions, at operating speeds up to 140 kmph. The
pantograph uses state-of-the art technology (air springs in lieu of mechanical coil
spring) for its raising and lowering, thereby ensuring improved dynamic behaviour
during current collection. The pantographs are suitable for working on DFC as well as
under the existing OHE.
RDSO has developed direct air operated Pantograph for satisfactory operation up to
speeds of 250 kmph under OHE heights varying from 4.65 meters to 5.8 meters from the
rail level. Direct air operated Pantograph have distinct advantages of light weight,
improved dynamic behaviour, practically maintenance free operation over the
conventional metallic spring operated Pantographs. It has completely addressed the
major reliability problems being faced in conventional Pantographs such as breakage of
springs, servomotor failures and jamming of plunger.
The direct air operated Pantograph uses state of art air spring and does away with
more failure prone components such as servo motor and the metallic spring of the
conventional Pantograph. Improved dynamic behaviour of air operated Pantograph also
results in better current collection. Wind tunnel test has also been performed at
IIT/Kanpur to evaluate up-lift force acting on it at wind velocity up to 250km/hr. Cross-
wind stability of pantographs at wind speed up to 250 kmph has also been validated
through wind tunnel test. Pantograph is found to be stable for wind velocity up to 250
km/hr.
RDSO issued specification for under slung 500 KVA DA set in 2008. Two power cars have
been manufactured by RCF. Oscillation trials of power car have been successfully
completed in PALWAL-AGRA section up to the speed of 145 kmph on Rajdhani track.
Further, the oscillation trials at 115 kmph on Bareilly-Moradabad section (Main line) are
in progress.
Technical features:
o Self-Propelled vehicle with designed speed of 105 kmph
o No. of axles- 4
o Max. axle load-20t
o Pay load capacity- 15t
o Tare weight-58t
o Hauling Capacity- 65t
Functional features:
o Can carry 2 nos. 13m rails 60 kg or two sets of switch and stock rail assembly along
with fittings.
o Store and Carry Small Track Machines, Tools and Equipment as listed for MMU
o Seating arrangement for 12 officials
o Fitted with Pillar Jib of one ton capacity having 360° Swivelling Boom(Telescopic)
Type Hydraulic Crane for material handling
o Lifting capacity- 1 ton (at 8m)
o Diesel operated 5 KVA portable generator for general lighting, welding & other
works
New Track Tolerances on revised chords and in revised speed bands has been finalised.
a. The new High output Ballast cleaning Machine is a two screen High Output Ballast
Cleaning Machine is state of the art ballast cleaning machine with a performance of
cleaning a volume 900 m3/h of ballast which is nearly the twice as much as existing
ballast cleaners utilized by Indian Railways.
b. An integrated stabilizing unit enabling for the first time to compact the cleaned
ballast immediately after refilling and guaranties in that way a layer wise
compaction of ballast which supports a long-lasting track geometry and with it an
essential contribution to safety.
c. The machine is being commissioned in Central Railway. Sanction of Introduction of
High output Ballast cleaning Machine is under process at Railway Board.
a. The material conveyor and storage wagon MDU serves for storing the material or for
continuous conveying and storing, as well as for the subsequent removal of the
excavated material during ballast cleaning work.
b. The machine consists of four biaxial bogies, two chassis frame connected by a
coupling rod, pull and bumper on both sides, a built-up container with an inner
container strap and a swivel hinge which can be swivelled in front of the container.
The swivel belt is used to transfer the cargo to another MFS, a loading station,
transfer station, etc. or to empty the load. Maximum capacity of the hopper is 65
cum.
c. Sanction of Introduction of Muck Disposal Unit has been accorded by Railway
Board.The machine is being commissioned in Central Railway.
Design & Development of Ballast Less Track (BLT) with indigenous fastenings
In order to improve the quality of AT Welds, the AT welding technique for 52 Kg (90
UTS) & 60 Kg (90 UTS) rails with Compressed Air-petrol/LPG pre-heating, three piece
pre-fabricated mould (manually pressed zircon-washed) using Single Shot Crucible
fitted with Auto Tapping Thimble was developed.
To increase the track frame resistance, arrangement for Cross Bracing of PSC sleepers
developed vide drawing No.RDSO/T-8329. Tests were conducted with and without
cross-bracing arrangements to know the contribution of cross-bracing arrangement.
During lab trial, it was observed that track frame resistance increased by about 23%.
Field trial of cross bracing arrangement is in progress on ECoR.
Inspection regime for Thick Web Switch with imported end forged asymmetrical rail
Rail Free Fastening System (RFFS) & SEJ for H-Beam Sleeper
As per Railway Board instructions, the system is being installed for trial in approx 25 km
length each in two divisions on IR – ALD Div & MB Div
The system has since been installed and under trial in ALLD division on 60 kg rails. The
performance of system in MB division on old 52 kg rails were not found satisfactory and
trial is discontinued for improvement of the system.
Development of Common Rail Electronic Direct Injection (CReDI) system for 16-
Cylinder ALCO & HHP locomotive
RDSO has developed CReDI system for ALCO & HHP engines. Test bed validations on
ALCO engine has indicated 17% reduction in NoX, 42% in CO emissions. Improvement in
duty cycle fuel efficiency by around 4% in ALCO and 2% in HHP engines has been
observed.
RDSO has developed specification to record the Video and Voice in the Loco cab and
the view ahead of the locomotive for post-accident enquiry analysis and for training
purposes.
Specification covers basic technical requirements of the „Loco Cab Video and Voice
Recording System‟ (LCVR) for application on locomotives and any other self-propelled
vehicle treated as train. System consists of inward and outward looking Cameras,
Digital Video recorder with Encoder, Decoder and Processing system and data storage
memory(one TB), DC-DC Converter to feed the system from loco control voltage,
required cables and interfacing equipment, Hardware for mounting and cabling and
Microphone for voice recording. Further, specifications were upgraded by RDSO. DMW is
undertaking tendering for 500 nos., as per the revised specification.
TI Directorate of RDSO has developed the Supervisory Control and Data Acquisition
System (SCADA) for 25 kV AC Traction system for monitoring and controlling traction
power supply from a remote location (RCC). The salient features of improved SCADA
system is as under:
- Real time energy parameters can be transferred at RCC or any other location which
is the key requirement for plotting energy curve as close as possible needed for
power scheduling & forecasting in case the Railway enters into open access.
SCADA ARCHITECTURE
TI directorate of RDSO has developed a new design of foundation on Rocky Soil for OHE
mast. New design is with a Grouted HD Bolt inside the ROCK and Mast will be with
welded base plate.
Old Design:
In old design it was difficult to cast the foundation since large volume of ROCK need to
be cut.
With the new design above problem will be resolved and electrification process will be
faster.
RDSO has developed the design of Cylindrical foundations for masts to be used for
Electric Traction on Indian Railways. So far Indian Railways has been using
Parallelopiped type of foundations, for which excavation could be done only manually.
In-principle approval of Railway Board has been accorded for these type of
foundations.
Salient Features:
1. Diameter = 750-900 mm
2. Depth in soil = 6 m (Max.)
3. Grade of Concrete = M15 for foundation and M20 for grouting (min.)
4. Reinforcement = Nominal
5. Type = Mechanised
A total of 17 chair cars and 3 power cars for one rake produced at RCF in the first phase
has been turned out in September-2016. On date two WAP5 locomotives fit for 200
Kmph operation are available on IR. Assessment of technical inputs required for
DLW has produced 5 Locomotives. Further RDSO/DLW are working to reduce the height.
IGBT based 25 kV AC 3-phase propulsion system and equipment for MRVC Phase II
EMU rolling stock
- Proven Hinge-Flap Type sealed doors of higher height & adequate width, on
wagon sides (2 doors per wagon side) to enable quick unloading of bagged
commodities.
- Low weight structural design to enable salt loading of 68 T/ wagon compared to
61-62T being practically done in BCNA/ BCNHL wagons.
- Thus the throughput per rake will increase to 3944T (assuming PCC of 68T/
wagons for the new design) from 2904T for BCNA rakes (with PCC of 66T) and
would enable actual loading of 68T/ wagon as specified PCC of BCNHL wagons.
wagons (02 „A‟ car and 01 „B‟ car) on GOC workshop. Prototype wagon has been
manufactured and ready for squeeze load test. Speed certificate is under issue for
oscillation trial at Pipava-Rajula-Dhasa at WR.
RDSO has recently developed a parcel van, with increased volumetric capacity,
designed to operate as dedicated freight vehicle/ freight trains.
Railway Board, vide their letter no. 2011/M (N)/ 204/2 dated 05/11/2014, has
nominated M/s TouaxTexmaco Railcar Leasing Pvt. Ltd for manufacture of prototypes
of High Capacity Parcel Wagon. The prototype wagon has been manufactured.
Oscillation trials are under process at Mahoba-Khajuraho section of NCR.
Development and patenting of higher capacity steel coil carrying flat wagon of 22.9
ton axle load capacity
Wagon Directorate of RDSO has developed a new design of auto car wagon (BCACBM)
with twin deck with reduced cost of construction. All Cars on Indian Roads, including
SUVs, can be accommodated in the Wagon. A maximum of 318 cars (as against 265 in the
earlier design) can be accommodated. The first rake of BCACBM wagons was flagged off
in March 2014. Total 17 rakes have been manufactured till now.
Development and patenting of higher capacity steel coil carrying flat wagon of 22.9
ton axle load capacity
In terms of Railway Board‟s letter dated 28/01/2015, drawings of new Light Weight
Low Height 25 T axle load (LWLH25T) bogie (a variant of LWLH bogie suitable with AAR
K Class bearing ) has already been finalized and circulated to all bogie manufacturers
for development of prototype bogies. The specification of bogie [No. WD-40-LWLH 25-
Bogie (K-Class)] has been finalized.
After consideration of this Cast steel bogie (LWLH25) and its component as Category –II
item for inclusion in vendor directory by Railway Board as communicated vide letter
no. 2005/M(N)/951/43 (Corres) Vol. 1 dated 21/04/2016, the item has been included in
RDSO vendor directory and vendor development of the same has been initiated.11 firms
have applied for fresh registration of LWLH25 bogie and their applications are under
various stages of approval. Till date ten firms including M/s.BURN Standard Co. Limited
have been approved for manufacture and supply of these LWLH25 bogies.
Metro Railway Kolkata Supplied by M/s. CRRC Dalian CO. Ltd., China.
Railway Board Vide contract no. 2015/RSF/466/1(GP-217), dated 19.05.2015, has
placed order on M/s. CRRC Dalian CO. Ltd., China for supply and commission of
lightweight fully furnished 750 Volt DC Metro Rolling Stock (MRS) with 3-Phase Electric
Propulsion along with spares, tools documentation for use in Kolkata Metro.
Lightweight fully furnished 750 Volt DC Metro Rolling Stock (MRS) with 3-Phase Electric
Propulsion supplied by M/s. CRRC Dalian Co. Ltd.,China has been designed for
maximum service speed of 80 kmph.
These coaches have been fitted with semi permanent coupler for intermediate coaches
and Auto couplers for front end the rake.
The 8 Car rake formation of light weight fully furnished 750 Volt DC Metro Rolling Stock
(MRS) supplied by M/s. CRRC Dalian CO. Ltd., China is as under:
CAB CAB
↓ ↓
DTC MC TC MC TC MC MC DTC
Salient features of Kolkata Metro Rakes manufactured by M/s CRRC Dalian are as under:
i) State of Art Train Control Management System.
ii)Passenger Information System for inter communication between DTCs is available
through state of art Passenger Information System.
iii) Passenger saloon surveillance system using CCTV to monitor activities and recoded
in both Driver‟s cabins.
iv) Rakes are having automatic doors.
v) Air conditioning as per
international standard.
vi) Both Driver Cabs have air
conditioning features.
vii) Coaches having pre cooling facility.
The Safety features of Kolkata Metro
Rakes manufactured by M/s CRRC Dalian are as under:
i) Both DTCs cab have emergency door evacuation door.
ii) Coach doors have safety features door will not close if any obstacles of 10 mm arise
in door.
iii) Driver desk monitoring features is available to show 750 V DC power supply through
the 750 DC Volt meter.
iv) Driver desk monitoring features is available to show 110 V DC Battery Supply through
the 110 V DC meter.
v) The entire rake including axles, supper structure along with equipments double
earthed for safe operation.
vi) Head / Tail light interlocks when vehicle is moving in ‘forward/Reverse’ directions.
vii) LED flasher light provided adjacent to head light for the use of driver in case of any
emergency.
viii) LED markers light with white and red aspect provided to indicate during
running/parking.
ix) Master controller with dead man’s device for door operation.
x) MCB’s and fuses of various ratings provided at the origin of individual circuits for
protection against overload and short circuits.
xi) Each Coach has 4 no. (Each of 6 kg) fire extinguishers for fire safety moreover each
driver cab has 2 no. (Each of 6 kg) fire extinguishers.
xii) Wiper in driver cab has screen washing facility.
xiii) Driver cabin screen has facility for safety due to sun light.
Through Carriage Rehabilitation workshop, Bhopal, world class interiors have been
developed in all variant of BG ICF type of coaches and one rake with improved interiors
has been successfully trial tested by RDSO along with CRW, Bhopal. The improved
interiors consist of bigger mirror, platform washbasin, controlled discharged water tap,
odour control system, exhaust fan, LED lights, dustbin inside the toilet and fitted with
environmental friendly bio-discharged toilets. In the compartments ergonomically
designed Ladders for climbing up to upper berths provided in all coaches, Snack tables
provided for side berth passengers with innovative design side lower berth
arrangement. Windows have been provided with powered venetian blind and roller
blind instead of conventional curtains, LED based berth indicators provided for reserved
coaches, and all other illumination, more charging points for passengers. All interior
paneling has been provided with thermoplastic panel. For improving safety fire
extinguisher provided in all coaches.
Development of LED based Head code and GPS based Passenger Information system
for EMUs/MEMUs
It is a Microprocessor controlled and GPS based system. Informing the passengers about
the next halting station through audio announcement and LED based display inside the
coaches based on the GPS technology.
Display the direction of platform in audio visual form, safety related information in
audio visual form inside the coaches, the position of handicap compartment, slow/fast
and the length of the train on the Head Code. Display and announcement of the
originating and destination station. The motorman has to only feed the train number
and all the data for that journey is taken from the pre-fed memory.
RDSO has already developed 7 sources for GPS based PIS.
Development of Integrated passenger information system (PIS) for mainline and EMU
coaches
Currently 13 rakes have been delivered to Kolkata Metro and are in service.
The first Air conditioned EMU rake has been developed with 3-phase propulsion system
from BHEL having state of the art features. The salient features of the rake are as
follows-
Vestibuled 12 car EMU rake with a basic unit of six coaches (having two motor
coaches in each basic unit).
Maximum operating speed of 110 kmph.
Acceleration – 0.54 m/s2.
Energy efficient with regeneration value of 30%.
Air-conditioned (RMPU 2X15 T in each passenger coach), Air-conditioned Driving Cab
(1.5T AC in each cab).
Automatic & Electrically operated sliding doors (8 doors in each TC and 4 doors in
each MC).
State- of- the- art Passenger Information System (PIS) & PA with Emergency Talk
back (ETB).
Higher rating 300 Ah VRLA Battery for better back up.
State-of-the-art Train Control Management System (TCMS) Remote monitoring and
data downloading.
Oscillation, emergency braking distance, performance and S&T interference trials
completed. Railway Board sanction for operation has been obtained. Rake is under
operation in Mumbai Sub-urban (Western Railway).
Bow string arch bridge designs (30, 36, 42, 48, 54, 60
and 72m span) for general ROB issued by RDSO to
reduce the length of approaches and longer span.
Bow string arch bridge designs (42,48,54,60 & 72 m
span)
Design of 60 m - 2 lane-2 way (3-lane i.e.16.5m overall width) Bowstring ROB for
NHAI.
For NHAIROBs issued by RDSO.
Saving of Rs. 4 to 5crores in a 2 lane ROB due to this design.
IRS Code for Earthquake Resistant Design of Railway Bridges (Seismic Code):
A new code for earthquake resistance design of bridges has been developed and
released in October,2017.
It was needed after Bhuj (Gujrat) earthquake incidence, to include the provisions of
earthquake in design of bridges over Indian Railways.
It was developed with the experience gained over period of time and necessary
deliberations in 82nd, 83rd and 84th BSC Meetings.
Kochi Ahmedabad
3.0
Background of
Central Board for Railway Research
(CBRR)
1. DG/RDSO Chairman
2. AM(CE), Rly. Bd. Member
3. AM(ME), Rly. Bd. Member
4. AM(Elect.), Rly. Bd. Member
5. AM(Sig.), Rly Bd. Member
6. AM(Traffic), Rly Bd. Member
7. Adviser, Finance (X) Member
8. Adviser (Infrastructure)* Member
9. ED(E&R), Rly Bd. Member
10. ED(Plg.), Rly Bd. Member
11. ADG/RDSO Member Secretary
*(included vide Board Letter 2001/ER/3400/15/2 dated 19/2/2007)
1. Director/IIT/Kanpur
2. Director/IIT/Roorkee
3. Director/IIT/Kharagpur
4. Director IIT/Madras
1. A nominee of DG/CSIR
2. A nominee of Chairman/SAIL
3. MD/BHEL/Bhopal
4. Chief Controller (R&D)/DRDO/New Delhi
5. Executive Director/RDCI&S/Ranchi
1. Wagon Industry
2. Track Equipment Suppliers
3. Signal/Telecom Equipment Suppliers
4. Electrical Industry
Railway Members:
1. Director/IIT/Kanpur
2. Director/IIT/Roorkee
3. Director/IIT/Kharagpur
4. Director IIT/Madras
5. Director IIT/BHU
1. A nominee of DG/CSIR
2. A nominee of Chairman/SAIL
3. MD/BHEL/Bhopal
4. Chief Controller (R&D)/DRDO/New Delhi
5. Executive Director/RDCI&S/Ranchi
TMM Directorate
Testing Directorate
Justification: RDSO had earlier undertaken a project with IIT/Kanpur through which
RDSO has got the preliminary knowledge about instrumentation, data
transmission, calibration, and data acquisition related to Instrumented
Wheels.
This includes, inter alia:
• Strain Gage Selection and Installation on Wheel.
• Lead Wire Attachment and Routing of lead wires.
• Data Transmission from rotating wheels/axle using Slip-
ring/Telemetry.
• Acquisition of the transmitted strain data.
• Algorithm calibration matrix
However, problems still being faced by RDSO are as follows:
i. Procurement of telemetry system including, pick up device &
power supply (for signals digitization and for data transmission
from measuring wheel to DAQ system) with reasonable availability
and price.
ii. Software for data analysis based on algorithms provided by IIT
Kanpur.
iii. Test rig facility for calibration and verification tests of Measuring
Wheels.
iv. FEM analysis of wheel disc assembly with a purpose to accurately
locate strain gauge for minimum cross talk and other effect for
accurate computation of individual vertical and lateral forces.
Deliverables: Development of five Rolling stock Measuring wheels viz: BOXN, BOXNS,
WAP5, WAG9 & Train 18
Current status • Work for augmentation of rolling stock design evaluation and testing
capability at RDSO sanctioned as Item no. 37 of Pink book 2018-19
at a total cost of 47.2 Crores (The component of instrumented
wheels is about Rs. 23 crores)
• Purchase order for 5 types of wheels (BOXN, BOXNS, WAP-5, WAG-9,
Tr18/Tr20) placed on M/S CETEST Spain and all are stipulated to be
supplied and commissioned in phases with full project to completed
by 31/03/2020.
Increase in the speeds of rolling stock and speeds envisaged for future
deployment over IR system is another factor which has led the
continued emphasis by Standing Criteria Committee for assessment of
Rolling stock by UIC/EN standards based methods. The advanced
railway systems of the world operating high-speed trains have switched
over to statistical evaluation based methods as stipulated by UIC/EN
standards such as UIC-518/EN-14363 etc.
Justification The Standing Criteria Committee of RDSO had in its 3rd Report of
January 2000 recommended to switch over to UIC-518 standard for
testing of rail vehicles. This was re-iterated in the revision of this
report by the Standing Criteria Committee in May- 2013.
Signal Directorate
10. TCAS
Brief description: Train Collision Avoidance System], Indigenously developed ATP System
Justification: Prevention of SPAD
Ensuring control of train speed
Display of Signal aspect in Loco
Current status Three vendors approved for developmental order at 110 Kmph for
Absolute Block section.
Successful trials with WAP-5 (CCB type equipped with Medha Make
Loco TCAS) hauling 8 LHB coaches were carried out up to the speed
of 160 KMPH in Agra-Mathura Section of North Central Railway in
November-18.
Successful trials with WAP-5 (E-70 type equipped with HBL Make
Loco TCAS) hauling 5 LHB coaches were carried out up to the speed
of 160 KMPH in Agra-Mathura Section of North Central Railway in
May-19.
Installation of M/s FTRTIL modified E70 interface and Loco TCAS of
M/s Kernex in Loco no. 30132 at Ghaziabad ELS shed.
Revised FAT for the 03 station (MTV, LC-27 & ZB) has been
carried out after alteration in the control table.
All the firms has submitted design documents to CLW which are under
scrutiny and targeted to be completed.
India
&
Abroad
R&D Collaboration with different Research Institution of India & Abroad
In order to develop a long term frame work for Research Collaboration with National
Institutions, a MoU was signed between Railway Board & IIT Kharagpur on 13th February
2010 for setting up of Centre for Railway Research (CRR), the initial areas of R&D of
CRR were (a) Heavy Haul Technology, High-Speed Technologies, Material Sciences for
Railway related Composites including Rubbers, Polymers and Insulation Materials & Use
of Artificial Intelligence for Predictive Maintenance and Management.
Based on experience of CRR at IIT Kharagpur, four new CRRs has been announced in
Budget 2015-16 & Memorandum of Understandings between Railway Board & with
University of Mumbai was signed on 18.04.2015 & with IITs (Kanpur, Roorkee, Madras)
on 22.12.2015 for setting up of CRRs respectively.
Railway board vide its letter No 2014/E&R/& (7)/3 dated 13.03.2017 decided and
communicated the following domain areas of respective CRRs:
First Round table meeting of all CRRs were held on 10th February 2016 at RDSO in this
meeting issues like formation of monitoring bodies, concept plan for setting up of CRRs,
procedure of awarding of projects under CRR were discussed.
Second Joint Round Table meeting with Coordinators of CRRs [at IIT/Kharagpur,
IIT/Roorkee, IIT/Chennai and IIT/Kanpur] & Malaviya Chair (IIT-BHU) was organized on
11th January 2019 at RDSO. During the meeting status of current & future projects,
progress of setting up CRRs activities, Funding status, proposed Training areas, were
explored to expedite the joint R&D collaboration and cooperation for developing the
latest Railway Technologies in Indian Railways.
2. Memorandum of Understanding:
3. Areas of R&D:
4. Monitoring Bodies:
Status:
Permanent Building is completed & commissioned. Sanctioned cost of the
project i.e. Rs.19.60 Crore has been released to IIT.
Total 12 research projects have been sanctioned of cost Rs 20.27 Crore under
CRR at IIT KGP in 2010-11 & 2011-12;
i) Creep and Warping (including gauge widening) analysis of hot running loco
wheels towards development of design guidelines against gauge widening.
Status: Project completed/Final report submitted
2. Memorandum of Understanding
3. Areas of R&D:
xiii) Automatic Rolling –Stock Condition Motoring, Way Side And Onboard
4. Monitoring Bodies:
Status
Space has been identified and being used & expansion/furnishing will be
taken up as per requirement,
Website of the CRR has been launched.
1. Year of sanction:2015-16
2. Memorandum of Understanding:
3. Areas of R&D:
4. Monitoring Bodies
Status
2. Memorandum of Understanding
3. Areas of R&D:
4. Monitoring Bodies:
Status:
One wing of first floor with total area about 160 m2 of MSRC Building is
marked as CRR office.
CRR office is consisting of one Seminar Hall, Reception area with 6 rooms.
Contract for civil engineering works awarded. Indenting of Furniture and
other equipment is underway.
i) A five day course on „MATLAB‟ has been organized at RDSO IIT-KGP faculty from
23rd sept.13 to 27th Sept. 2013. In this course 27 officials were trained
ii) Training on „FEM‟ (Finite Element Analysis) has been organized at by IIT- KGP
faculty from 17th to 21st February 2014. In this course 25 officials were trained
iii) A course on High speed Railway Technology was held at IIT-KGP from 19th to 28th
December 2014. In this course 25 officials were trained
iv) M.Tech course in Railway Engineering has also been started since May 2015 at IIT-
Kharagpur
v) A unique short term course on condition monitoring for Railway engineers has
been organized at IIT Madras from 6.8.18 to 8.8.18 by its eminent faculties of
Mechanical Department at Machine Design Section. In this course 25 officials were
trained.
vi) A Short course on “Three Phase Propulsion System‟ was organized at IIT Kanpur
from 18th -21st Feb 2019 in this course 20 officials were trained. Following topics
were covered
a) Overview of course and Basics of Induction Machine
b) High performance induction motor drive for traction application
c) Front end converters
vii) A Short course on “MATLAB‟ was organized at IIT Kanpur from 25th -26st Feb 2019
in this course 23 officials were trained. Following topics were covered
a) Introduction to MATLAB, Array and Matrices, Indexing Vectorization,
b) Graphical Visualization
c) Functions, Variable scopes,
d) Programming with MATLAB
ix) 03 days short term international course on “Railway Vehicle Dynamics” under
ambit of Centre for Railway Research (CRR) has been organised at IIT/Roorkee
from 27th -29th May 2019. Total 30 officials from RDSO were trained. The following
topics were covered:
Friction and Wear Effects on Wheel-Rail Contact Dynamics
Vehicle Modelling
Creepages and normal forces in the wheel rail contact
Tangential forces in the wheel-rail contact
Running Stability and curving 53inalize of rail vehicles
Stability of Railway Vehicle Systems- Modelling & Analysis
i) Development of design of conical rubber spring for FIAT bogie with speed
potential of 180 Kmph for testing and 160 Kmph for operation
ii) Development of design of coil spring for LHB coaches having flexi-coil properties
with speed potential of 220 Kmph for testing and 200 Kmph for operation
iii) Development of design of cost-effective, longer life & light weight Seats & Berths
for LHB type Passenger Coaches
CRR at IIT/Kanpur
ii) Condition monitoring technique for 25KV solid core porcelain/composite insulators
CRR at IIT/Roorkee
CRR at IIT/Madras
iii) Using Inclinometer and GPS for event marking during oscillation trials.
Second Joint Round Table meeting with Coordinators of CRRs [at IIT/Kharagpur,
IIT/Roorkee, IIT/Chennai and IIT/Kanpur] & Malaviya Chair (IIT-BHU) was organized on
11th January 2019 at RDSO. During the meeting status of current & future projects,
progress of setting up CRRs activities, Funding status, proposed Training areas, were
explored to expedite the joint R&D collaboration and cooperation for developing the
latest Railway Technologies in Indian Railways.
A proposal for extension of validity of MoU (for „no fixed time limit‟) with IITs for
Centre for Railway Research (CRR) at IIT (Kanpur, Roorkee & Madras) along with
consent letters from IITs has been submitted to Railway Board.
The main objective of the Malaviya Chair is to promote research & development in the
field of new materials for use in various assets of Indian Railways
Funding:
Endowment Fund of Rs.5 Crore has been provided by Indian Railway to IIT-BHU. The
Fund was released in June -2015. Functioning of the Malaviya Chair is funded by the
interest accrued on the Endowment fund.
Scope of Work:
MOU aims at Collaboration between Indian Railways and IIT (BHU) in the field related
with “ Materials Science and Engineering”. Specific research areas include:
Structural and Micro structural Characterization, Micro structural Modifications,
Thermodynamics and Phase Equilibria
Processing of materials for better strength to weight ratio, joining of metals of
new grades
Fatigue and Fracture, Tribological studies
Ultrafine grain materials, Micro structural modifications, Bainitic steel
New materials for requirement of future needs
1. Development of light weight FRP runner (Impeller) for blower fan assembly of
Roof Mounted Package Unit (RMPU) fitted in AC coaches.
Status Material based on Nylon-6 based FRP using 30% Glass fiber and 5%
Fire retardant + antioxidant has been finalized & delivered.
During last meeting held on 11.01.2019 at RDSO it was mentioned
that manufacturing of fan for further trials is in progress with a
vendor
2. Development of long life polymer (nylon) bushes for alternator with suitable
material composition to avoid failure of bushes
DOC Jan-2016
DOC April-2016
Funding of the Kalpana Chawla Chair is being done through the interest accrued
on the endowment fund of Rs. 10 Crore (Rupees Ten Crore only) (Feb 2017)
provided by the Indian Railway to PEC.
This MOU aims at collaborative between Indian Railways and PEC in the following
field:
Sub- Areas
Broad Area
Geospatial Solutions for Rail Route Alignment Surveys
Land Cover surveys and related Land utilization
Geospatial Property surveys and related Property utilization
Technology Three dimensional modeling and visualization of Rail Route
Corridors
GIS based Rail Traffic Management and Monitoring Systems
Accident Mapping
Geological/ Environmental studies and investigations for
Rail Networks in Mountainous regions
KRRI is one of World‟s youngest & leading Railway Research Institute and to undertake
Railway project jointly a MoU between KRRI and RDSO was signed on 10 July 2018.
A two member team from RDSO visited KRRI in May 2019, Korea and discussed the
issues related to joint R&D, cost sharing for cooperation, technical training program
etc. The team also visited the test facilities available. Seven projects have been
shortlisted for execution with KRRI. Draft Memorandum of Agreement has also been
prepared. A study report (Report no-R117) has also been sent to Railway Board.
A meeting-cum-workshop of Russian Railway experts with experts from RDSO was held
during the month, regarding feasibility analysis running of semi high speed train
(200kmph) between Nagpur-Secunderabad section of Indian Railways. Various
technical points on the above subject were discussed in detail. Russian team apprised
of the documents which need to be submitted before starting the further work on the
feasibility analysis for evaluation, by RDSO. Same were handed over to Russian Team.
Russian Railways agreed on most of the observations and concerned raised by RDSO
experts. In addition to this workshop, an MoU between RDSO and Russian Universities,
was signed and handed over to Russian team.
i) Study and setting up of rolling stock test plant (capable of simulating the
condition of track and running trains up to a maximum speed of 520 kmph)
ii) Use of Micro-LABOCS Software package for analysis and process time series
data on track irregularities and coach vibration
iii) Monitoring of bridges & structures and to assess their condition/suitability and
life span
iv) Development of latest technology in Power Storage Systems
v) Analysis of the dynamic mutual interaction between the coaches and track
structures including contact stress analysis
5.4 A three member delegation from RTRI visited RDSO on 30th Nov‟16 to formulize the
three projects on; Design of Bogie including RS Test Plant, Bridge Monitoring and
assessment and Development of latest technology for Power Storage.
5.5 Another team of RTRI visited RDSO & RB in Jan‟2017 to discuss and study on rail
Fracture problem.
6. A delegation from RTRI also participated in INNORAIL 2016 and GTC May‟2017.
7. RDSO is planning to send a delegation to RTRI for taking activities to next level as
per MoU in August 2019.
1.7 Criteria For The Dynamic Analysis of Steel Railway Bridges (IIT
Roorkee)/ Project Unsuccessful
Deliverables: 5.6 Results of analysis consisting of:
6. All type designs of Plate Girder Bridges for MBG, HM, 25t and 32.5t
on the basis of CDA as per Bridge Rules
7. All type designs of Truss Bridges for MBG, HM, 25t and 32.5t on the
basis of CDA as per Bridge Rules
8. Comparison of results of (a) with dynamic analysis all type designs
of Girder Bridges for MBG, HM, 25t and 32.5t
9. Comparison of results of (b) with dynamic analysis all type designs
of Truss Bridges for MBG, HM, 25t and 32.5t
2. Procedure (Step by Step) to conduct dynamic analysis for the steel
bridges in general and type spans in particular.
3. Criteria to determine the requirement of dynamic analysis.
4. Draft provisions for incorporating in Bridge Rules/Steel Bridge
Code with design implications.
Current Status: This work was awarded with a clear cut requirement of
development of “Criteria for Dynamic Analysis of Steel Girder
Bridges for High speed loading”. The current practice of using the
CDA values for evaluating the impact load is limited to the speed of
160 Kmph. Beyond 200 Kmph speed for some frequencies the
Dynamic analysis of Bridges becomes necessary as per Euro Code.
The Indian Railways does not have provisions to deal with high
speed loading on bridges.
IIT-Roorkee submitted Final Report on 20th April-2017. However,
the report is incomplete and does not contain the required
information as defined in the MOU.
4.1 Design of Standard Gauge Bogie for Export Locomotive for Speed
potential of 120 Kmph
Deliverables: Develop bogie drawings for use in 4500 Hp loco, helping in export of
locos
Current status Drawings developed and issued to DLW for manufacture
4.3 Finite Element Analysis of Fabricated Bogie Frame of WAG9 loco for
25 t axle load
Deliverables: Carry out finite element analysis and accordingly assess design
adequacy
Current status Carried out finite element analysis - redesigning of traction and
braking components for the enhanced requirement required to be
done
Current status Report No MP.Misc-338 (Rev.00) Jan‟19 issued to DLW and Zonal
Railways
Rolling stock with 3 phase electric propulsion along with spare tools
Deliverable 14 Air conditioned Metro trains for Kolkata Metro
Passenger comfort, Low maintenance requirement, energy efficient
and corrosion free body.
Current Status: Approval of Design has been completed for most of the items. Type
testing of few major equipment has been completed. Trains are under
manufacturing by CRRC, Dalian in China.
9.1 Radio Based Advance Warning System for Unmanned Level Crossing
Deliverable/ Deliverable:
Benefits: Development & Trials of Advance Warning System (Radio & RFID based)
for Unmanned Level Crossing. This is to pre-warn road user about
approaching trains at unmanned level crossing gate. In this design one
system was installed at Level Crossing (LC) Gate and RFID Tags are
provided at 1.5 Kms away from the (LC) Gate. One of the locomotives
running in the section was equipped with RFID reader and GPS & Radio
Frequency (RF) Antennae.
Benefits:
Audio-Visual Warning of an approaching train to Road users at
Unmanned Level Crossing.
Current Status: System was developed and field trials were undertaken in Lucknow-
Kanpur section. Project completed & closed.
Final evaluation of the system has been completed & Report sent to
Railway Board in Feb‟ 2016.
Current Status: On the basis of inputs from Track Directorate of RDSO and field trial
report of SCR, RDSO specification No. RDSO/SPN/TC/105-2015 for VHF
based approaching Train Warning System for track maintainers was
developed.
Four firms were approved for restricted quantity. Based on the
suggestions received from SECR & Track Directorate of RDSO,
specification is under revision.
Current Status: Project completed and Closure report under vetting by Finance.
10.3 Primary facility for thermal rating of contact lines, load flow
capabilities of traction distribution system etc.
Date of Start: 2013-14
Deliverables: Software for Traction Power Simulation including estimation of
Thermal rating of contact wire.
Benefits: For getting the parameters for design and development of OHE and
TSS.
Current Status: The tender of software procurement discharged due to non –
compliance of terms & conditions of the tender. However, some of the
other auxiliary items of the works were procured costing around Rs.
41.80 Lakhs.
Simulation is to be carried out and based on simulation study
continuation/discontinuation of said project shall be decided.
Proposed Date of March 2020
Completion:
10.5 Design and development of 25kV Gas Insulated Switchgear (GIS) and
132/220kV Gas Insulated Switchgear(GIS) for Traction Sub-Station.
Date of Start: Dec.2015
Benefits: Less space is required with respect to conventional type air
Insulated switchgears.
Maintenance free and highly reliable.
Installation time is very less as units are factory assembled.
Current Status: Specification No.TI/SPC/PSI/HVGIS/0160 for 132/220kV GIS and
Specification No.TI/SPC/PSI/LVGIS/0160 for 25kV Gas Insulated
Switchgear (GIS) has been prepared and submitted to Railway Board
for approval vide letter dated 08.09.2016.
Current Status: Study has been completed and report No. TFC- 94 has been sent to
N.E. Railway, CRM/IRCTC and RCF Kapurthala for necessary action.
Date of Completion 12-07-2016
14.4 Development of Class “K” Cartridge Taper Roller Bearing (CTRB) for
25t freight rolling stocks.
Deliverables: 1. Axle, Wheel set & adapter has been designed for class “ K”
hearings
2. Minimum L 10 of class „K‟ CTRB is 1.6 million km as compared to
1.2 million km of Class „E‟ CTRB.
3. Fretting index for CTRB „K‟ is 0.5 whereas for class „E‟ the same is
1.0 hence leaser tendency for fretting wear of axle journal.
Current Status: RDSO STR No. AB/RB-41-2016 for class „K‟ (6 ½” x 9”) Cartridge
Tapered Roller Bearings has been 75inalized. At present indigenous
supplier as per AAR – M-924 (K class bearing) are M/s. NEI Ltd., M/s.
Timken & M/s. SKF. Vendor development as per STR for class „K‟ CTRB
(6 ½” x 9”) is in progress.
2. After fitment of bio toilets lavatory chutes has been removed and
exhaust fan has been provided but at higher operating speed of
vehicle it is found ineffective.
SL DIRECTORATE
1.0 BRIDGES AND STRUCTURES DIRECTORATE
1.1 Development of railway bridge Health Monitoring System with wireless
sensor network (IIT –CRR KGP)
1.2 Evaluation and management of longitudinal force on substructure of railway
bridges.(SERC/CHENNAI).
1.3 Assessment of efficacy of retrofitment of arch bridges (SERC/ CHENNAI).
2.0 CARRIAGE DIRECTORATE
2.1 Environment Friendly Coach Toilet Discharge System
3.0 GEO-TECHNICAL ENGINEERING DIRECTORATE
3.1 Design of formation for speed higher than 160 Kmph and upto 250 Kmph
3.2 Use of L.D. Slag as Railway Track Ballast
4.0 METALLURGICAL AND CHEMICALS DIRECTORATE
4.1 Development of Composition and Standardization of Properties of Composite Brake
Blocks for Application in Coaches of Indian Railways
4.2 Thermo-mechanically processed high strength bainitic steel rails for Indian Railway.
5.0 MOTIVE POWER DIRECTORATE
5.1 Design validation of HTSC Fab-II Fabricated Bogie Frame for HHP Locomotives
5.2 Design Validation of Fabricated Bogie Frame (Equaliser – less Bogie) for WDM3D
Locomotives.
5.3 Development of Bogie for Narrow gauge Railcar to be manufactured at Parel
Workshop.
5.4 Noise Mapping and Noise source identification for both exterior and interior areas and
ranking in WDP4D locomotives.
5.5 Development of energy efficient MGS (WDS6G)shunting locomotive.
5.6 Development of Dual mode locomotive
5.7 Design review and Development of 6000 HP WDG6G locomotive with M/s GE (PPP
project) at Marhowra
5.8 Development of Micro-Processor Based Governor (MPBG) for HHP locos
5.9 Field trial for use of 9 TBN crankcase oils in diesel Locomotives
5.10 Vehicle Dynamic Simulation of Standard Gauge Locomotive
5.11 Development of Run train Simulation Software
5.12 Development of Anti Pilferage Management System for Fuel
5.13 Introduction of 2000t-m(200T) Capacity Telescopic type Jib crane for IR & DFC
5.14 Introduction of 3-coach Diesel –Electric High Speed Self-propelled Accident Relief
Train (HS SPART) with maximum speed of 160 km/h
6.0 SIGNAL DIRECTORATE
6.1 Development of TCAS
7.0 TELECOMMUNICATION DIRECTORATE
7.1 SATCOM and SATNAV Based System for Indian Railways
7.2 LTE-R for Indian Railways
7.3 Trials of Rail Fracture & Intrusion Detection System on NC Railway and NF Railway
8.0 TRAFFIC DIRECTORATE
8.1 Revision in specification of LED based battery operated Torchlight cum flashing
H.S.Lamp
8.2 Inspect of GST on Parcel Traffic over Indian Railways
9.0 TRACK DESIGN DIRECTORATE
9.1 Ultrasonic Broken Rail Detection System
9.2 Improvement in rail quality and review of specification IRST-12:2009
10.0 TESTING DIRECTORATE
10.1 Procurement of 30t Universal Spring Testing Machine
10.2 Procurement of High inertia and high speed brake dynamometer
10.3 Procurement of measuring wheel calibration test rig in testing directorate
10.4 Replacement of 01 staff coach by high speed coaches (LHB shell with FIAT bogie)
3.1 Design of formation for speed higher than 160 Kmph and upto 250
Kmph
Deliverables: To assess the speed potential of existing track formation for various soil
groups
Identification of necessary inputs for increasing the speed potential of
d) Bainitic rails may replace Pearlitic rails in certain position where rail
life is considerably low.
e) Cost of 100 pieces of existing Pearlitic rail is 100 x Rs.40,000/- = Rs.
40.0 Lac.
f) Replacement of these rails by Bainitic rails increase the life by 90% and
as a result 100 bainitic rail pieces will be equivalent to190 pearlitic
rails
Hence 100 pearlitic rails will be equivalent to (100 x100) / 190 ≈ 53 nos
of Bainitic rail.
Current Status: AS per IIT/Kharagpur, fracture toughness test is to be carried out by NML
and machine is in break down. This test will be carried out after repairing
of machine by end of this year.
The sample for wear resistance test as planned has been received on
20.7.2017 and testing is to be carried out in M&C Dte
Proposed Date 31.03.2018
of Completion:
5.1 Design validation of HTSC Fab-II Fabricated Bogie Frame for HHP
Locomotives
5.2 Design Validation of Fabricated Bogie Frame (Equaliser – less Bogie) for
WDM3D Locomotives.
5.4 Noise Mapping and Noise source identification for both exterior and
interior areas and ranking in WDP4D locomotives.
Deliverables: Development of specification of driver cab with reduced noise level
(85 dBA) and prototype locomotive for trial.
Reduction in noise level in driver cab to reduce fatigue level and
enhance crew comforts.
Current status Loco cab modifiedin one loco according to IIT scheme by M/s
AcropolyMetal industry, Jamshedpur
Results found satisfactory
Final report awaited from IIT/Kharagpur.
Afterwards, specification shall be prepared and issued to Zonal
Railways for implementation
Proposed date Dec‟19
of completion
7.1 SATCOM and SATNAV based system for warning at LC gate for Indian
Railways
Date of Start: 2015
Deliverables: Deliverable:
Development and trial of SATCOM and SATNAV based system for
warning at LC gate for Indian Railways
Benefits:
The trials are expected to mainly demonstrate following capability:
Warning in the Locomotive and at the UMLC gate.
Train tracking and display position of various trains on
screens at central hub and at divisional control offices.
Navigation Aid to driver to draw his attention towards important
milestones. These mile stones may be next signal, next UMLC gate,
approaching gradient, neutral section, nearest EC socket etc.
Emergency messaging by Loco(capability for the message to
automatically reach the concerned divisional control office)
Current Status: Five Manned LC-gates were equipped with prototype equipment in
Hajipur- Bachhwara section of Sonpur Division of East Central Railway. As
directed by Railway Board, 6 Nos. of WAP-7 locomotives were equipped
alongwith equipment of RTIS project being done by CRIS/NDLS and
attached with Guwahati Rajdhani Exp. (Train No. 12424/12423).
Two rounds of PoC field trials on prototype-equipment had been
conducted during Nov’2017 & Jan’2018.
Interim Report of these PoC field trials has already been submitted to
Railway Board vide this office letter No. STT/SAC/794 dated 29.01.2018.
Though, basic satellite communication is demonstrated during the trials,
however, issues were observed regarding reliability and accuracy of the
system i.e. ON/OFF timings of Warning, Location reporting accuracy, solar
supply failure etc.
Various issues as described in Interim Report sent by RDSO are yet to be
resolved/ demonstrated by ISRO.
The trials so far are conducted in very limited and controlled conditions
where only one train was approaching the LC-gate at a time.
A meeting was held with SAC/ISRO/Ahmedabad on 08.01.2019. SAC/ISRO is
unwilling for further trials unless the end use of the system is assured by
the Railways.
The UMLC gates have already been eliminated from Indian Railways.
Railway Board vide this office letter dated 26.03.2019 is appraised of the
status and requested to issue further directives, if any in this regard.
Proposed Date Dec‟2019
of Completion:
7.2 Long term Evaluation (LTE-R) for Indian Railways for High Speed Voice
and Data transmission in running train.
Date of Start: 2016
Deliverables : Study for building a solution for Indian Railways based on LTE
technology and demonstrating the same in a field scenario for the use
of various communication requirements of Indian Railways.
The total cost of of the PROJECT is Rs. 29.57 Lakhs. The payment of First
Installment of First Phase of Rs. 10.35 Lakh has been made in Dec-2016.
First Interim Report has been Submitted by IIT/M on “Requirement of
Wireless communication in Indian Railway” and accepted by RDSO.
As per MoU terms, the payment of Second Instalment of Rs. 10.35 Lakh has
been made in March‟2019.
7.3 Trials of Rail Fracture & Intrusion Detection System on NC Railway and NF
Railway
Date of Start: 2018
Deliverables : Installation of OFC based Rail Fracture & Intrusion Detection System on
NC Railway and NF Railway
Field trials on the system
Report of the field trials.
Current Status: Two new works were sanctioned by Railway Board for the year 2017-18
and appearing at S.N. 33 & 34 of PB/2017-18.
Project transferred to Telecom Directorate from Signal Directorate of
RDSO as per Railway Board‟s directives.
As per Railway Board‟s Directives, “Functional Requirement Specification
(FRS) for Trials of Rail Fracture & Intrusion Detection System” (Using
Distributed Optical Fiber Sensing) Version 1.2 has been Issued in Sep‟2017
to NC Railway and NF Railway.
During 33rd GCM it was decided to restrict the trial to one Zonal Railway
Only.
Accordingly, as known to RDSO, tender has been cancelled by NFR.
Tender has been finalized by NCR and work has been awarded M/s TVM,
Bangalore.
It is decided by Railway Board vide letter No.
2017/Sig/WP/IR/RF&IRF&Ids/Pt. dated 24.09.18 that these works shall be
application.
Test rig is necessary for testing /calibration of Instrumented Measuring
wheel of Rolling stock in static and dynamic condition for ensuring
accuracy of measurement. Test rig enables the satisfactory working of
Instrumented Measuring wheel sets after certain period of wheel
running. The test rig simulates the Instrumented Measuring wheel sets
to the field conditions in dynamic and static condition to calibrate the
wheel sets.
Current Status: Tender is in advanced stage of finalisation.
Proposed Date December 2019.
of Completion:
10.4 Replacement of 01 staff coach by high speed coaches (LHB shell with
FIAT bogie)
11.1 Design and Development of 25t axle load wagons for existing IR systems
Date of Start: May 2011
Deliverables: 1. Assessment of various forces using simulation software viz. Train
Energy Model and Train Operation Simulation Model.
2. Stress Analysis of the entire wagon component based on forces as
assessed.
3. Fatigue stress analysis of various wagon components
4. Design of wheel/axle & bogie with track friendly features
5. Acquisition of design tools such as various computer modules for
design calculations and assessment of wagon performance
6. Design, Development, testing & design validation including oscillation
trials in India, of two types of state of the art prototype wagons
7. Series production of two rakes in India for each type of above wagon
8. Monitoring of field trials jointly for three years to validate the
components life and working out corrective actions on failures if any.
Current Status: A contract has been finalized with M/s ARI, USA for design, development,
prototyping and validation of 25t wagons. This shall create capability to
design and develop world class freight cars for Indian Railways and the
DFC. Till date following activities in the contract has been completed:
been shipped to India. The oscillation trials of the same have been
completed over CTC-PRDP section of ECoR Railway.
iv. Training covered under para 5.3 & 5.4 of contract has been
completed.
v. Further activities in the contract are in progress.
Proposed Date Dec‟2017
of Completion:
11.2 Development of new design of 22.9t Axle load Bogie flat wagon
BFNSM22.9 for transportation of steel coils
Date of Start: Dec 2014
Deliverables: 1. Easy loadability having continuous through pocket, loading of coils
having max. diameter 2600 mm.
2. Securing of coils without any wooden dunnage.
3. The wagon is designed with speed potential of 100 kmph
4. High Reliability
5. Liner provided to prevent metal to metal contact of steel coil
6. Amenability to covering arrangements
Current Status: The modified design is lighter one, improve gross to tare ratio and
enhance the through put by 68%. Oscillation trial of prototype wagon is
under process. RDSO has filed the application for patent for the wagon
design and its key features with Indian Patent Office
Proposed Date Dec 2017
of Completion:
11.3 Development high capacity Draft Gear (WD-71-BD) for higher axle load
freight rolling stocks
Date of Start: April 2014
Deliverables: 1. To replace the imported WD-66 BD draft gear with fully indigenous WD-
71-BD draft gear.
2. Suitable for 25t axle load wagon
3. High Official Capacity of 45000 ft-lb.
4. Lower cost as compared to imported WD-66-BD draft gear
Current Status: A project on “Development of Upgraded Draft Gear for Freight Stock:
Development of Testing Regimes” was undertaken in collaboration with
Indian Institute of Technology, Roorkee. The objectives of the project are
to analysis the behaviour of the draft gear and develop test regimes for
high capacity draft gear. Till date 8 vendors have applied for registration
for manufacture & supply of High capacity Draft Gear to this specification.
Proposed Date Dec‟2017
of Completion:
and evaluate the bogie. The bogie design shall be based on Solid and
flexible multi body dynamic models of across bogie components and
their analysis along with the design / drawings of various bogie
components and assemblies.
3. Weight and cost optimization methodology along with its calculations
4. Methodologies on material selection and fatigue life calculations
based on the worst possible stress cycle data as per AAR as provided
by RDSO.
5. Guidelines for manufacturing and quality assurance (both for type
approvals at new manufacturer and normal production tests and
inspection) for casting or fabrication (as applicable) and assembly.
6. Development of Two Wagon sets of prototypes; Lab testing,
assessment of dynamic performance in field under the superstructure
of the worst hypothetical Wagon; Re-evaluation of the design, and
manufacture, after field trial experience.
7. Training of requisite officials of RDSO for all the above deliverables
for future in- house work.
Current Status: Extensive deliberations on this project have been held amongst RDSO,
IIT/Kanpur, KTH/Sweden and Lulea University/ Sweden. Meeting of the
concerned persons was also organized in Delhi and Kolkata on 9th and 10th
November 2016.
11.5 Design Development of 25t axle load BCSA/BCSB container flat wagons
Date of Start: Jan-2015
Deliverables: 1. Platform height is 1009mm.
2. Designed for both Uniform distributed and point loadings
3. Capable to transport tank containers.
4. Through put increased by 17.25 %.
Current Status: Prototype under manufacture at GOC/SR. Speed certificate for conducting
oscillation trials at a speed of 75 kmphboth in loaded and 110 kmph in
empty condition on Palanpur – Samakhiali section of Western Railway was
issued on dated 13.12.2016. CRS sanction awaited for conducting
Oscillation trials.
Proposed Date Dec.2017
of Completion:
11.6 25t Light Weight Low Height Bogie along with „K” class bearing
Date of Start: May 2015
Deliverables: 1. Weight optimization has been preformed to achieve 4% material
saving.
2. The bogie if fit for 25t axle load
3. Life of the CTRB has been enhanced
Current Status: The oscillation trials of BOXNS wagon fitted this new LWLH25 bogies has
been completed successfully over SER up to max speed of 110 km/h in
empty and 100 km/h in loaded condition.
The specification of bogie has been finalized and development of sources
to manufacture and supply of bogies are in progress.
Proposed Date Dec-2017
of Completion:
PROPOSAL
• With introduction of these new coach variants on LHB design
platform, as a substitute of LHB EOG Non AC coaches, noise and
dust issues can be resolved with provision of AC facilities and speed
potential of Mail/Exp. trains can be upgraded.
5. After fitment of bio toilets lavatory chutes has been removed and
exhaust fan has been provided but at higher operating speed of
vehicle it is found ineffective.
software systems.
• It may cost around Rupees 10 crore for this project.
Justification: LHB design coaches are equipped with FIAT bogies which are provided
with flexi-coil springs in the secondary suspension. When the
technology was imported , the details of springs provided in these
coaches were provided to IR. However, know how to design the spring
is not available. These are special type of springs and know how to
design the spring is not available. These are special type of springs and
the know how required for designing the suspension system is
presently not available in RDSO. As IR has already decided to migrate
to LHB type of coaches, it is necessary that the capability to design
the flexi-coil spring suspension is developed at RDSO. RDSO is also
required to develop the expertise for analysis of the spring failure.
Hence, it is proposed to acquire the facilities and develop the know-
how for designing the suspension system using the flexi-coil springs
and also for failure analysis and investigation of this type of springs.
RTRI.
• Prof Nagai of RTRI, Japan visited RDSO on 29th &30th June, 2017
to discuss the project.
• Reminder given to ED/Research on 24.06.2017 to expedite the
signing of the project proposal with RTRI.