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GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

‘HAND OUT’

48th MEETING OF
CENTRAL BOARD OF RAILWAY RESEARCH
(CBRR)

July 08, 2019


(Monday)

LUCKNOW – 226 011


CONTENTS

SN Description Page

1.0 An Overview of RDSO 1-10

2.0 Important activities & projects undertaken/completed by RDSO 11-35

3.0 Background of Central Board for Railway Research (CBRR) 36-37

4.0 Important Projects in Hand 38-45

5.0 R&D Collaboration with Different Research Institutions of India 46-59


& Abroad : CRRs, Technical chairs etc

6.0 Recently Completed Projects 60-77

7.0 On-going Projects 79-96

8.0 New Projects Proposed 97-106


An Overview of RDSO

1.0

An Overview of RDSO

48th Meeting of CBRR 1


An Overview of RDSO

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

RDSO functions as a centre for acquisition, absorption and development of new


technology and upgradation of existing technology for the Indian Railways. RDSO is
specifically entrusted with the following mandate:

 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.

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An Overview of RDSO

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 Indian Railways Centre for Advanced Maintenance Technology (CAMTECH) at


Gwalior is also functioning under the administrative control of RDSO.

The centre undertakes activity for upgrading maintenance technology on Indian


Railways. The centre‟s objective is as follows:

"To upgrade maintenance technologies and methodologies and achieve improvements


in productivity and performance of all railway assets and manpower which inter alia
would cover reliability, availability for use, utilization and efficiency".

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:

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An Overview of RDSO

 Development of maintenance manuals, handbooks, reports, pamphlets etc.


on maintenance of railway assets.
 Development of video films on maintenance of railway assets.
 Imparting training through seminars on maintenance of railway assets (Skill
Development) followed by issue of publication.
 Development of guidelines for infrastructure (facilities and layout)
requirements for maintaining railway assets.

1.5 RDSO - An ISO: 9001-2015 Certified Organisation

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.

1.5.1 Quality Policy

The Quality policy & Objectives of RDSO truly cherish and reflect the Organisation‟s
commitment for genuine intellectual & professional pursuit and growth:

 To achieve excellence in designs, standards and evaluation of railway technology.


 To meet statutory and regulatory requirements.
 Research, development and human resource upgradation.
 Effectiveness of Quality Management System.
 Upgradation of performance levels.
 Infrastructure and quality norms for vendors.
 Provide safe, reliable, comfortable and cost effective transportation to meet
customers‟ need.

1.6 Governing Council

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.

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An Overview of RDSO

1.7 Collaboration with Other Research and Academic Institutions

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.

1.8 Standards Committees

For effective adoption and implementation, new designs, standards, specifications


and studies done at RDSO are examined by Technical Standards Committee
comprising of concerned departmental heads of all Zonal Railways as members and
concerned Executive Director of RDSO as member secretary. The recommendations of
these committees, after approval of the Railway Board, are adopted on the Railways.

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:

i) Air Brake Laboratory is equipped with facilities for


simulating operation of air brakes on freight trains up to
132 wagons and 3 locomotives as also for simulation of
passenger trains of both ICF and LHB with EP Assist up to
30 coaches.

ii) Brake Dynamometer Laboratory has facilities to


develop and test brake friction materials for
locomotives, coaches and wagons. This laboratory, being
unique of its kind in India, has also been used by R&D
organisations of Ministry of Defence like DMRL, DRDL and
HAL for indigenisation of brake pads for defence
aircrafts.

iii) B&S Laboratory has a 6m x 14m heavy duty testing floor


for testing of full scale models of beam, slabs, columns,
towers, shells and other concrete and steel components
under static and dynamic loads. A high frequency
ranging 250-700 cycles/min pulsator for the application
of a pulsating loads varying from 2 to 20 tonnes and a
maximum static load of 40 tonnes on heavy duty testing
floor. The Laboratory is equipped with analogue strain indicator, multi-channel
dynamic strain recording system, switching & balancing units, acoustic emission

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An Overview of RDSO

equipment, data acquisition system etc. for recording various parameters.

iv) Diesel Engine Development Laboratory has four test


beds capable of testing diesel engines from 100 to 6000
HP with fully computerised systems for recording of over
128 test parameters at a time. This facility has already
enabled RDSO to develop technologies for improving fuel
efficiency, reliability and availability of diesel engines as
well as to extract higher output from existing diesel
engines.

v) Fatigue Testing Laboratory for testing prototype


locomotive and rolling stock bogies, springs and other
railway equipment subjected to stress and fatigue so as
to ascertain their expected service life.

vi) Geo-technical Engineering Laboratory is equipped with


facilities for determining strength parameters of soil in
lab and field condition. The Laboratory is equipped with
Computerised Tri-axial Shear Test Apparatus,
Computerised Direct Shear Test Apparatus, Computerised
CBR Test Apparatus, Automatic Proctor Compaction Test
Apparatus, and all other requisite testing facilities for
determining the strength of soil as well design of embankment.

vii) Metallurgical & Chemical Laboratory is capable of


destructive and non-destructive testing of metals,
polymers, composites, petroleum products and paints.
The M&C laboratory has Scanning Electron Microscope,
Direct reading spectrometer, Ultrasonic Flaw Detector
and other non-destructive examination equipment,
polymer and composite evaluation facilities, thermal
analyser, corrosion engineering evaluation facilities including weatherometer,
static 760 hour AR test rig for grease testing, V2F dynamic test rig for grease
testing, lube oil filter evaluation rig, Cetane rating machine & 50t machine for
rubber deflection characteristics.

viii) Psycho-Technical Laboratory has the facility for


assessment of safety-critical cognitive and psycho-
motor attributes of essential train operation staff
such as Loco Pilots before their deployment on
trains running at speed more than 110 Kmph to
facilitate safe and efficient train operation on
Indian Railways.

ix) Signal Testing Laboratory is capable of testing of


all types of signalling equipment such as safety
signalling relays, block instruments, power supply
equipment, point machines, signalling cables,
electro-mechanical signalling equipment/

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An Overview of RDSO

components etc. There is an exclusive environmental testing section equipped


with environmental testing facilities. These include programmable heat,
humidity & cold chambers, mould growth, dust, rain chambers. Signalling
Equipment Development Centre has been set up in the Signalling Lab. In this
Centre, working signalling equipment & systems have been set up. The working
systems include SSI, universal axle counter, VLSI axle counter, AFTCs, block
instruments etc. In addition, equipment developed by RDSO, such as Indian
Railway Train collision Avoidance System (TCAS) signalling relays, poly-
carbonate lenses, LED signal lamps, triple pole double filament lamps, power
supply equipment etc. have also been displayed.

x) Track Laboratory for testing full scale track panels


under realistic dynamic load patterns and fatigue
testing of welded rail joints. Stresses at various
locations of track components under simulated
load conditions are measured and recorded for
analysis. This has helped in rationalising and
optimising design of track structures for Indian
conditions. The facility of fatigue testing of welded
rail joints is also available. Special rail tensioning system for application of
longitudinal forces on rail samples to simulate the thermal forces has been
indigenously developed, installed and commissioned in track lab. This system,
with capacity of up to 150 tonne in static condition, is being used to conduct
testing of different rail samples.

xi) Mobile Test Facilities for recording of track


parameters, locomotive power and conducting
oscillograph trials for evaluating vehicle-track
interaction and also for monitoring track
conditions:

• Oscilliograph Cars for vehicle parameters and


track and vehicle interaction studies.

• Facilities for conducting rating and


performance trials of locomotives and also
braking effort and coupler forces.

• Special Purpose Car for testing and recording


parameters of overhead traction equipment.

• Emission Test Car for measuring the Exhaust


emissions of Diesel Locomotives homed at
different Diesel Sheds over Indian Railways.

• Laser Contactless sensor based Track


Recording Cars for measuring Track geometry
parameters and Rail wear.

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An Overview of RDSO

xii) Vehicle Characterisation Laboratory for


conducting vehicle characterisation tests on railway
vehicles to study the behaviour of suspension
systems and to determine natural frequencies.

xiii) Central Library consisting of 30,000 important


books, 80 technical journals & Membership of 7
national / international societies, specifications,
reports and other technical publications, is a
valuable source of information and knowledge.

xiv) Subscription of e-Resources has been done and


their access is made available to officers and staff
of RDSO through intranet.

1.10 Centre for Advanced Maintenance Technology, Gwalior

This centre has been established to guide and assist the maintenance personnel
spread over the entire Indian Railway system.

1.11 Uploading of important information on Intranet/RDSO Website for easy


accessibility

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.

1.13 Improvements in Vendor Development and approval process

In a bid to bring transparency, it was decided to launched an online vendor


registration system in RDSO which will allow small and medium enterprises to
become railway vendors. After launching the on-line vendor system, the vendor need
not come to RDSO for any activity related to his case for registration, while the
process of documents scrutiny and physical verification of the vendor's facility has
been made a parallel exercise. It is for the first time that the RDSO has also invited
expressions of interest (EOI) for all the 600 plus items such as automatic twist locks,
components for diesel locomotives and anti-friction coatings required by the sector
and kept the window open with no timelines to enable wider participation.
Total 45 vendor meets have already been organized in various cities countrywide.

1.14 Railway-RDSO-industry dialogue

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

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An Overview of RDSO

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.

1.15 Manpower Strength (Gaz. & Non Gaz.) as on 01.05.2019

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

1.12 Financial Position (Budget Grant for RDSO)


(Fig. in crores of Rs.)

BUDGETARY POSITION OF RDSO - REVENUE

Head 2015-16 2016-17 2017-18 2018-19 2018-19


Actuals Actuals Actuals (OBA) Actuals
Demand No 2 194.66 244.79 246.22 332.40 268.50
Demand No 13 7.51 12.58 13.64 13.00 14.46
Demand No 14(b) 5.35 8.92 8.92 8.92 8.92
Total Revenue 207.52 266.29 268.78 354.32# 291.88

BUDGETARY POSITION OF RDSO - Demand 16

Head 2015-16 2016-17 2017-18 2018-19 2018-19


Actuals Actuals Actuals (OBA) Actuals
DF 22.56 10.35 19.31 23.00 11.62
DRF 2.15 1.84 2.04 15.00 12.07
RRSK 0.00 0.00 0.00 0.10 0.00
Total Demand No 16 24.71 12.19 21.35 38.10* 23.69

* OBA of Rs 50.10 Cr reduced to Rs 38.10 Crores by Board

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An Overview of RDSO

RDSO- Receipt Profile

S.N. Receipt Head 2015-16 2016-17 2017-18 2018-19


Actuals
1 Drawing Charges 2.16 0.71 26.75 0.84
2 Consultancy & Design 3.05 1.70 37.49 74.48
Loan Charges
3 Testing Charges 2.16 1.71 4.15 5.84
4 Inspection 12.63 12.95 68.20 37.40
Charges(Non-Metro)
5 Metro Certification 6.81 6.54 0.00 0.00
charges
6 Other Misc Receipts 10.53 5.02 5.00 12.88
Total 37.33 28.63 141.59 132.44

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Important Activities & Projects undertaken/Completed by RDSO

2.0

Important Activities & Projects


Undertaken/Completed By RDSO

48th Meeting of CBRR


Important Activities & Projects undertaken/Completed by RDSO

2.0 Important Activities & Projects Undertaken/Completed By RDSO

2.1 SAFETY

 Fire Detection and Suppression Systems

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.

It displays approach indications of next three


approaching fixed landmarks such as Main Line
Signals, Level Crossing Gates, Neutral Sections,
Speed Restrictions, Stations etc. accompanied with
voice message at ~ 500m on approach.

Around 60000 nos. were in use in 2018-19 on various


Railways during fog.

 Development of Indigenous Advanced Auxiliary Warning System (AAWS)

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.

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Important Activities & Projects undertaken/Completed by RDSO

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.

 Development of Train Collision Avoidance System (TCAS)

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.

After completion of successful trials, demonstration to compliance to specification with


all key features like SPAD Prevention, Speed Supervision, On Board display of signal
with Multi-vendor interoperability. Three firms are approved under developmental
orders for use in Absolute Block Section for speeds upto 110 kmph.

As a part of further advance implementations of TCAS, Phase-II with the following is


being planned:-
 Trials at speeds upto 160 kmph
 Trials in Automatic Block section
Two firms have completed demonstration of TCAS for speeds up to 160 kmph. The third
firm is likely to complete demonstration by end of June 2019.

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.

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Important Activities & Projects undertaken/Completed by RDSO

 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

 Development of conical springs for primary suspension for EMU coaches:

• RDSO has developed the conical rubber spring in


primary suspension of ICF type EMU coaches.

• The specification no. RDSO/2010/CG-07 for conical


rubber spring has been issued.

 Development of Derailment Detector:

In order to restrict damages due to accident Carriage


Dte. has developed specification of Derailment Detector
for Coaching Stock vide specification No.2016/CG-04
with this the train will be automatically stopped when
derailment is detected by a sensor (high value of
acceleration in vertical direction). Further, ICF has
awarded 05 rakes in October, 2017 for fitment of
derailment detector with RDSO specification for trial
and validation purpose.

2.2 OPERATIONAL EFFICIENCY

 First 3-phase on-board MEMU:

First 3-phase on-board MEMU bi-directional 8-


car rake formation consisting of two DMCs on
either side and six TCs in between with two
cabs in DMC has been designed and
manufactured by ICF in consultation with RDSO.
Oscillation and emergency braking trials have
been conducted. Rake is likely to be introduced
in service in July, 2019.

The key features are:


o The mode of traction of vehicle is self-

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Important Activities & Projects undertaken/Completed by RDSO

propelled 3-Phase IGBT Based propulsion System.


o Complete 8 coach rake formation has been provided with vestibules for easy
movement of passengers during run and in case of emergency.
o The coaches are fitted with semi-permanent Schaku coupler.
o The primary suspension is of helical coil spring and pneumatic air-springs are
provided in secondary suspension.
o The body shell of coaches is made of stainless steel.
o MEMU is equipped with Electro Pneumatic (EP) air Brake system
o LED lighting
o CCTV cameras with recording facility is provided in each passenger compartment.
o Air-conditioned driving cabs are provided on both ends of MEMU.
o Double leaf Aluminium sliding doors with user friendly lock and latch are provided.

 First 3-phase under-slung MEMU:

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.

Oscillation and emergency braking distance trials are planned to be conducted in


July, 2019 over Central Railway. Rake is planned to be introduced in service in
August, 2019.

 First 3-phase UNDER-SLUNGEMU

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:

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Important Activities & Projects undertaken/Completed by RDSO

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.

48th Meeting of CBRR 15


Important Activities & Projects undertaken/Completed by RDSO

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.

48th Meeting of CBRR 16


Important Activities & Projects undertaken/Completed by RDSO

 Indigenous Metro Rolling Stock with energy efficient technology (Medha Electrics)

Key features of this rolling stock include:


o 3 phase, IGBT based energy efficient propulsion system
o Regenerative and dynamic braking
o Fully suspended 3 phase asynchronous Traction Motor
o State of the art TCMS (Train Control Management System) with Train Control
Network as per IEC 61375 (ETB as Train level backbone and ECNB at basic unit level)
o State-of-the-art step-less master controller
o State of the art Passenger Information System (PIS) & PA
o Remote monitoring and data downloading
o Touch screen type Driver display unit
o Higher rating 300 Ah VRLA Battery for better back up.

Trials Completed: oscillation, emergency braking distance, performance and S&T


interference trials completed. Railway Board sanction for operation has been obtained.
Rake is under operation in Kolkata metro.

 Vande Bharat Express (Train-18) giving form to “New India New Railway”

Hon‟ble Prime Minister of India flagged off first ever


mainlinetrainset of India, named Vande Bharat Express,
a sixteen coach formation, on 15th Feb‟19 at New Delhi
Station, setting it off on way to Varanasi. It is has been
designed and manufactured by ICF in a record time of
18 months, as “Make in India” initiative. Most of the
components used in this train have been sourced
indigenously. RDSO was closely and actively involved in
its development and subsequent static and dynamic
trails to assess the speed potential, riding quality,
stability, etc. Subsequently, COCR trials were also
conducted on New Delhi-BHK route.

Main features of this train are:


 Operational speed -160 km/h speed, test speed- 180
km/h
 Maximum Axle Load –16.5 t
 Starting Acceleration – 0.77 m/sec2
 Deceleration – 1 m/sec2
 50 % Powering
 4 Car Basic Unit, One Pantograph per each BU
 New generation bogie with wheel mounted brake disc
 Automatic plug doors with sliding foot step
 Fully sealed double layer gangway
 Bio-vacuum toilet
 Continuous windows for better view
 Aesthetically designed interiors and lighting
 360 degree rotatable comfortable seats in Executive Class

 Introduction of Advance Technology Diesel Locomotive (WDG4G)


An per agreement signed between Indian Railways and M/s GE
Diesel Locomotive Pvt. Ltd, M/s GE manufactured two prototype
WDG4G locomotives of 4500 HP and offered to IR for oscillation
trials and rating & performance trials.
RDSO after requisite testing, issued Prototype Clearance Report in
Sept‟18 for regular operation. 92 locos have been handed over to

48th Meeting of CBRR 17


Important Activities & Projects undertaken/Completed by RDSO

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

 Development of Crew Voice and Video Recording System(CVVRS)

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

1stprototype rake after successful tests & trials has been


pressed into service trials w.e.f. 25.12.2017.There has been
very encouraging feedback from passengers.
Key features of this rake are :
i) 12 car rake with a vestibuled basic unit of six coaches
(including two motor coaches)
ii) Maximum speed 110kmph.
iii) Energy efficient with regeneration features.
iv) Air-conditioned (RMPU 2X15 T in each passenger coach)
v) Air-conditioned Driver Cab (1.5T AC in each cab)
vi) Automatic, Electrically operated sliding doors (8 doors in each TC and 4 doors in
each MC).
vii) State of the art Passenger Information System (PIS) &PA(Passenger
announcement) with ETB (Emergency Talk back).
viii) Higher rating 300 Ah VRLA Battery for better back up.
ix) State-of-the-art TCMS (Train Control and Monitoring System)
x) Remote monitoring and data downloading

 High Capacity Milk Tank Van

In association with RITES, RDSO has developed high


capacity (44600 lts.) Milk Tank Van. The first
prototype RMTV is already manufactured and has
undergone oscillation trial. Three wagons have been
subsequently manufactured. New Milk Tank Van has
following State of the art features:
o Use of HCC MEMU bogie
o Use of steel suspension
o High tensile AAR „H‟ type tight Lock Coupler with transition coupling
o Axle load capacity of 20.32t

48th Meeting of CBRR 18


Important Activities & Projects undertaken/Completed by RDSO

 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

 Specification for passenger locomotives with speed potential of 200 kmph

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.

Performance requirements of proposed locomotive as mentioned in the specification


are as below:

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.

48th Meeting of CBRR 19


Important Activities & Projects undertaken/Completed by RDSO

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.

Following major equipmentsare envisaged to be upgraded:


a) Main Transformer
b) Propulsion System comprising traction converter, auxiliary converter and VCU
c) Traction Motor
d) Transmission system (if required)

 Regenerative braking in WAG-7 loco

RDSO is working on the provision of regenerative braking in WAG-7 locomotives. In


modern era, where more efforts/researches are taking place for energy conservation,
energy saving, use of renewable source of energy etc. to reduce the dependency on
conventional source of energy, provision of regenerative braking in the locomotive such
as WAG-7 loco is much needed. It will not only save the energy in form of electricity
which about 15% of the consumption of the loco but will also pay the cost of
modification in 3 to 4 years. Regenerative braking beside energy saving has many other
advantage such as reliability, environment protection, extended braking range.

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 :

48th Meeting of CBRR 20


Important Activities & Projects undertaken/Completed by RDSO

 Design and Development of High Rise OHE

First of its type, unique in the world, Traction


Installation Directorate have designed the High Rise
OHE, for running Double Stack Container‟s and Three
Tier Auto-Car Wagon having speed potential of 140
kmph.

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.

 High Reach Pantographs

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.

 High speed pantographs

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.

 Development of under slung DA set for power car/SLR

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.

48th Meeting of CBRR 21


Important Activities & Projects undertaken/Completed by RDSO

 Rail Borne Maintenance Vehicle (RBMV)

Mechanized maintenance of track requires quick mobility of


men and material. RBMV is a track maintenance vehicle
being incorporated on Indian Railways as part of MMU
intended to be used for speedy transportation of men and
material to the work site. This has been designed by TM
directorate with the assistance of Carriage and MP
directorate.

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

New Track Tolerances on revised chords and in revised speed bands has been finalised.

 Track Quality Index

Track Quality Index based on new track tolerances finalised.

 Induction of High output Ballast Cleaning Machine performance of cleaning a volume


900 m3/h (twice of existing machine on IR).

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.

48th Meeting of CBRR 22


Important Activities & Projects undertaken/Completed by RDSO

 Induction of Ballast/Released material Handling Systems (Muck Disposal Unit) for


multiple tracks work.

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

Salient features are :

• First ever BLT design for full speed (110


Kmph) with fitness for 25 t axle load.
• Completely indigenous fastening system
costing about 1/3rd of any imported
fastening system.
• Also suitable to be used as washable
apron & tunnels.
• BLT-IFS design has been completed including
prototype development & testing. The drawings
and construction guidelines have been
approved by the Railway Board and under trial
at Zonal Railways.
• This design will help in having a „Make in India‟
design of ballastless track.

 Development of Single Shot Crucible technique

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.

 Development of Cross Bracing Arrangements for LWR/CWR on Sharp curves

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.

48th Meeting of CBRR 23


Important Activities & Projects undertaken/Completed by RDSO

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

Inspection regime developed to facilitate large scale


procurement of Thick web Switches considered essential for
heavy axle load, high GMT and high speed routes due to
technical superiority over over-riding switches in respect of
safety, service life and maintainability, Inspection Regime
circulated by Railway Board to all Zonal Railways in Oct. 16 for
incorporation in Tender Document.

 Rail Free Fastening System (RFFS) & SEJ for H-Beam Sleeper

Design of RFFS & SEJ for H-Beam


Sleeper developed to facilitate LWR
on steel girder bridges; Trial ordered
in 6 Zonal Railways; Tender awarded
for RFFS by SER. For trial of RFFS &
SEJ for H-Beam Sleeper, NR & SER
respectively have been nominated by Railway Board as Nodal Agency for procuring trial
quality on behalf of all 5 nominated Zonal Railways.

 Ultrasonic Broken Rail Detection System

The UBRD system for broken rail detection was


shortlisted by RDSO after detailed literature
survey of the system being used worldwide.
This system is designed by IMT/South Africa to
inspect rail status for continuity at very short
predetermined intervals down to 5-6 minutes
interval and transmits guided ultrasound
waves between stations spaced at
approximately one km interval and check for
these signals at the receive station.

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.

48th Meeting of CBRR 24


Important Activities & Projects undertaken/Completed by RDSO

 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.

 Loco Cab Video and Voice Recorder

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.

 Development of Improved Composite Insulators for 25 KV OHE

In order to improve the


reliability of Composite
Insulator, TI directorate of
RDSO has developed the new
improved Silicon Rubber
Composite Insulator for 25 KV
OHE system. RDSO has revised
its specification (TI/SPC/OHE/INSCOM/1071 rev-1) in December 2016. The improved
Composite Insulators having better bonding between FRP rod and Silicone Polymer and
NDT testing has been incorporated in its type testing to improve the quality. Also
Controlled Compression Technique during crimping of metal end fittings have been
incorporated

 Development of High speed 2mbps SCADA system based on TCP/IP Communication

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:

- TCP/IP based communication as per IEC 60870-5-104 in the range of 2 mbps.


- There is a redundancy in the communication scheme by forming ring through
another E1 channel from other end STM. In case of OFC cut the communication will
not stop and as such downtime of SCADA will drastically reduced
- Data transfer speed will increase many fold, thereby reducing the communication
time and fast execution of the commands with feedback.
- High speed data transfer will facilitate the transfer of fault wave data stored in
communicable relay. The fault wave data establishes the nature of fault on analysis
of the same.

48th Meeting of CBRR 25


Important Activities & Projects undertaken/Completed by RDSO

- 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

 Foundation Design of OHE Mast on Rocky Soil

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.

RDSO Drawing No. ETI/C/060- Mod-D(Old design)


New design:

With the new design above problem will be resolved and electrification process will be
faster.

RDSO Drawing No. TI/DRG/CIV/ANCH- FND/00001/17/0(New Arrangement)

48th Meeting of CBRR 26


Important Activities & Projects undertaken/Completed by RDSO

 Design of Cylindrical Foundation for Railway Electrification Project

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.

In case of the Cylindrical Foundation, excavation can be done through mechanized


process and results in faster casting of foundation. This will help improving the pace of
electrification on Indian Railways.

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

 Up-gradation of LHB Coaches for 200kmph

LHB Coach Design has been


tweaked in line with
recommendations of Alstom at
the time of TOT to obtain a
speed potential of 200 kmph.
Improved aesthetics adds to
passenger comfort.Automatic
body side door and superior design seats along with infotainment system provided on
individual seats. Exterior colour scheme developed with assistance from NID.

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

48th Meeting of CBRR 27


Important Activities & Projects undertaken/Completed by RDSO

upgrading track structure (tightening of track tolerances), OHE installation, signaling


and communication equipment for running 200 Kmph trains is in process. Measuring
wheel is essentially required for assessing rail-wheel interaction at higher speeds.

DLW has produced 5 Locomotives. Further RDSO/DLW are working to reduce the height.

 Development 9000 HP Locomotive for DFC

RDSO has developed Specification for 9000 HP locomotive.


The 9000 HP locomotives are being procured through JICA
(STEP loan for western DFC).The induction of 9000 HP kW
high horse power locomotives by IR over the heavy haul
Western DFC and on the IR feeder routes would be a big
leap forward in terms of locomotive technology on IR.A superior traction and braking
capabilities, higher reliability, availability and energy efficiency of these locomotives
would contribute significantly and thus maximizing the transportation throughput on
the DFC.

 IGBT based 25 kV AC 3-phase propulsion system and equipment for MRVC Phase II
EMU rolling stock

Induction of new 72 rakes under MUTP Phase II


project will result in to a saving of approx.105
million units of electrical energy/year equivalent to
the financial savings of approx. Rs.680 million per
year. Increase in number of services will reduce the
passenger density of rakes in Mumbai suburban.
Train control has been designed with improved
redundancy for higher reliability, passenger amenities, reduced noise levels due to
state-of-the-art propulsion equipment, ergonomically designed driver‟s cab and
enhanced coach interiors.

 Design & Development of New Wagon for Salt Loading

In a record time of 4 months, RDSO has developed two


designs of wagons which are suitable for carrying salt as
well as other commodities. These designs enable top
loading of salt in order to utilize the full loading potential
of the wagon.
i) Open wagon with FRP lining (variant of BOXNHL wagon)
ii) Covered wagon with Sliding roof (variant of BCNHL
wagon)

i) Open wagon with FRP lining

The design features of this wagon are:


- Top-Open to enable easy, quick bulk loading of loose salt.
- Container-Type sealed doors of full height & adequate width, on wagon sides (2
doors per wagon side) to enable quick unloading/ discharge of bulk salt on
wagon sides, during manual unloading.
- Internal wagon surfaces including floor, copings & door flaps) coated with multi-
layered FRP lining, to provide smooth flowing surface for salt along with
corrosion resistance for sustained loose salt transport.

48th Meeting of CBRR 28


Important Activities & Projects undertaken/Completed by RDSO

- Low weight structural design to enable salt loading of 70 T/ wagon compared to


64T for BCNA wagons and 68T for BCNHL wagons (Actual salt loading, being
practically achieved is 61-62T in these 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.

ii) Covered wagon with FRP Sliding Roof

The design features of this wagon-


- Suitable for top loading/ unloading, would
enable for the first time loading of salt in
higher quantity bags (100 kg/ 200 kg/ 250 kg).
- Incorporates a low weight FRP moulded sliding
roof to enable easy, quick bulk loading of
bagged commodities such as loose salt.

- 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.

 Regular production of newly designed 25T open Wagon

Wagon dte, has developed the next version of the


BOXN25 designated as BOXNS incorporating
indigenously developed Light Weight Low Height bogie.
The prototype wagon has been manufactured at M/s
Braithwaite, Kolkata. It has successfully cleared the
Oscillation trial at 110 Kmph in empty condition and at
100 Kmph in loaded condition at Pandrasali -
Dangoaposi section of S.E. Railway. Final speed
certificate of the wagon has been issued at 85kmph
(E)/65 kmph (L). Order has been placed for supply of
2000 wagons. CRS sanction for its oscillation trial on C &M vol 1 track in Central Railway
at 125 kmph (L/E) has been received.

 Design Development of 25T Container Flat Wagon

RDSO have developed the design of container flat


type wagons BLCS (A-Car & B-Car) fit for 25T axle
load operations. The new design has the feature of
Low platform height for enhancing the pay load
capability. The underframe members have been
suitably improved to enable transport of Tank
Container (non-uniform loading) along with existing
dry cargo containers. The design incorporates the
indigenouslydesigned Light Weight Low Height
(LWLH) bogie and twin pipe air brake
arrangements. Board vide letter No. 2014/RS
(B)/971/2 dated 09.07.2015 has placed order for manufacture of 03 nos. prototype

48th Meeting of CBRR 29


Important Activities & Projects undertaken/Completed by RDSO

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.

 Prototype Development of New Design High Capacity Parcel Wagon

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

RDSO has successfully designed and


developed a flat wagon “BFNSM22.9” of
22.9 tons axle load capacity with a
central longitudinal continuous V-
grooved floor to accommodate steel
coils of various sizes. The wagon
prototype has already been
manufactured at Texmaco/ Kolkata. Prototype inspection of this wagon has been
successfully carried out by RDSO. The wagon has special provisions for preventing coil
movement during run. RDSO has filed the application for patent for the wagon design
and its key features with Indian Patent Office. „Examination fees‟ has been deposited
with the patent office. The wagon has successfully passed the stringent squeeze load
test in Jan‟ 2016. Oscillation trials have been completed and it has cleared the speed
110/110 in empty and loaded condition. Final speed certificate is under issue.

 Design & Development of Auto Car Wagon

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

RDSO has successfully designed and developed a flat wagon


“BFNSM22.9” of 22.9 tons axle load capacity with a central
longitudinal continuous V-grooved floor to accommodate steel
coils of various sizes. The wagon prototype has already been
manufactured at Texmaco/ Kolkata. Prototype inspection of
this wagon has been successfully carried out by RDSO. The
wagon has special provisions for preventing coil movement
during run. RDSO has filed the application for patent for the
wagon design and its key features with Indian Patent Office. „Examination fees‟ has
been deposited with the patent office. The wagon has successfully passed the
stringent squeeze load test in Jan‟ 2016.

48th Meeting of CBRR 30


Important Activities & Projects undertaken/Completed by RDSO

 Development of New 25 T axle load bogie (LWLH25) with K class CTRB

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.

48th Meeting of CBRR 31


Important Activities & Projects undertaken/Completed by RDSO

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.

 Development of Double Decker Coach Design

RDSO has developed Double Decker design of


chair cars with increased seating capacity
from 78to 120 (more than 50% increase).
Commercial services of AC Double Decker
commenced on SaraiRohilla-Jaipur, Mumbai
Central-Ahmedabad, Chennai-Bangalore,
Habibganj-Indore, Kacheguda/Guntur-
Tirupati, LokmanyaTilak Terminus-Madgaon
and AnandVihar Terminus-Lucknow Jn.
sections.

For AC Double Decker (3250/3050mm) which


will help in improve passenger comfort
further, design has been released to RCF,
Kapurthala for prototype manufacture for
design analysis, research, trial and testing
purpose of RDSO.

48th Meeting of CBRR 32


Important Activities & Projects undertaken/Completed by RDSO

 Environment Friendly Coach Toilet Discharge System

RDSO in association with DRDE/Gwalior has developed


Bio-toilet having bio-digester filled with “Anaerobic
Bacteria”. Current design does not use either electricity
or pneumatic power. More than 80000 bio-toilets have
been fitted in coaches.

IR aspires to complete the work of retro-fitment of bio


toilets in all variants of coaches by 2019.

 Development of World-class Interiors in ICF type


coaches

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.

Successfully running between New Delhi and Varanasi

 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.

48th Meeting of CBRR 33


Important Activities & Projects undertaken/Completed by RDSO

 Development of Integrated passenger information system (PIS) for mainline and EMU
coaches

Railway Board has directed


RDSO to develop
specification for Passenger
Information System (PIS) for
mainline and EMU coaches.
Accordingly, RDSO has
developed specification for
AC & Non AC mainline coaches and EMU stocks. PIS informs about the late running
status of train, next station name, distance of next station, speed of the train and
welcome & safety messages. Sources of PIS for EMU coaches have been developed. LCD
display type PIS for main line coaches have been working satisfactory in Kalka Shatabdi.

 Design & Development of state-of-the-art air-conditioned rakes for Kolkata Metro

Salient Features of this rake are :


o Microprocessor based brake
system
o Electrically operated door
system
o Efficient Air conditioning
o Air spring suspension
o Stainless steel fittings
o Passenger Information System

Currently 13 rakes have been delivered to Kolkata Metro and are in service.

 Development of first Air-conditioned EMU rake

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).

48th Meeting of CBRR 34


Important Activities & Projects undertaken/Completed by RDSO

 Design of Bow–string arch bridges for long span ROBs:

 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.

 New Bridge Designs:


 Design of 106.7 m span open web girder for railway bridges: This is longest span
developed by RDSO first time.
 Design of 91.4 m span open web girder for railway loading.
 Design of 12.2m and 18.3 m PSC U-type girder: This has resulted in saving of the
cost of new work and applicable for doubling and tripling where the problem of
vertical clearance exist.
 Design of 9.15m PSC U Slab and 12.2m PSC U slabs: These are light weight, less
height, cheaper, without bearings, replaceable with old Steel Plate Girders,
suitable in all seismic zones, up to 4 degree curvature and capable of continuing
LWR.
 Design of 12.2m PSC Girder for DFC loading completed and drawings uploaded on
RDSO railnet website on 19.03.2019: These are light weight, less height, cheaper,
suitable in all seismic zones, up to 4 degree curvature.

 Safety Certification of Metros &completion of Metro activities by RDSO


Nagpur Noida
Lucknow

Kochi Ahmedabad

48th Meeting of CBRR 35


Background of CBRR

3.0

Background of
Central Board for Railway Research
(CBRR)

48th Meeting of CBRR


Background of CBRR

3.0 Background of CBRR

Railway Board vide Letter 2001/ER/3400/15/2 dated 26/02/2002, nominated the


following as the Members of Central Board of 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)

Non-Railways (Regular Members)

1. Director/IIT/Kanpur
2. Director/IIT/Roorkee
3. Director/IIT/Kharagpur
4. Director IIT/Madras

Other Government Departments (Regular Members)

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

Industry Invitee Members

1. Wagon Industry
2. Track Equipment Suppliers
3. Signal/Telecom Equipment Suppliers
4. Electrical Industry

Special Invitee Members

DG/RDSO as Chairman/CBRR may invite any Eminent Engineer/ Technocrat/Scientist/


Associations of Railway related industries as a special invitee to attend any meting
depending upon the specific requirement of RDSO/Railways.

The functions of CBRR in accordance with Board‟s letter 2001/ER/3400/15/2 dated


26/02/2002 are mentioned below :

(i) To consider and recommend the programme of research on Indian Railways.


(ii) To review the research programme from time to time.
(iii) To ensure coordination and assistance from other research laboratories.
(iv) To review the ongoing projects from the technical angle.

48th Meeting of CBRR 36


Background of CBRR

3.1 List of Invitees for current CBRR Meeting

Railway Members:

1. AM(CE), Rly. Bd. Member


2. AM(ME), Rly. Bd. Member
3. AM(Elect.), Rly. Bd. Member
4. AM(Sig.), Rly Bd. Member
5. AM(Telecom) Member
6. AM(Traffic), Member
7. AM (Finance) Member
8. Adviser (Infrastructure)* Member
9. ED(E&R), Rly Bd. Member
10. ED(Plg.), Rly Bd. Member

Non-Railways (Regular Members)

1. Director/IIT/Kanpur
2. Director/IIT/Roorkee
3. Director/IIT/Kharagpur
4. Director IIT/Madras
5. Director IIT/BHU

Other Government Departments

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

Industry Invitee Members

1. Signal & Electrical Industry (M/s. SIEMENS)


2. Track Equipment Industry (M/s. Harscho Track Machines & Service Pvt. LTd.)
3. Electronic Industries (M/s Bharat Electronics Ltd.)

48th Meeting of CBRR 37


Background of CBRR

4.0 Important Projects in Hand

48th Meeting of CBRR


Important Projects in Hand

4.0 Important Projects in Hand

TMM Directorate

1. Provision of Test Track


Brief description: Dedicated test track is an essential requirement on Indian Railways for
conducting oscillation trial of rolling stock, for trial and testing of new
track fittings /track components.
Justification: At present, lot of difficulty is being faced for the above tasks, as being
performed in existing sections of IR already crowded with traffic. As a
result, a number of rolling stocks etc. are pending for clearing such
trials leading to delays in induction of modern rolling stock on IR, DFC.
. At present, no work for construction of the test track is sanctioned.
An exercise had been taken up in NWR and they had earlier identified
stretches near Barmer Town (Rajasthan)
Current status :  Work has been sanctioned at an estimated cost of 353.48 crores on
“Out of Turn” basis in Works Program 2018-19. Tender has been
awarded by NWR and construction work has been started from Km 0
to 5 starting from Gudha.
 Tender for consultancy has been opened on 11-03-2019 and is under
finalization.
 On request of NWR, Team of Geo-tech Officials is regularly visiting
the Proposed Test Track site and witnessing activities associated
with Sub-soil exploration. Few sub soil samples have also been
taken for sample check/test at GE lab/RDSO. Sub soil exploration
and investigation is still in progress.
 Based on the analysis of Sub-soil test results submitted by the
Railways for initial 5.0 Km stretch, Ground Improvement measures
have been suggested to NWR.
 Consultancy for Bridge design for High Speed Loading of 200 Kmph
has been awarded to IIT-Bombay.

2. Measurement of Rail Stresses


Objective: Measurement of longitudinal stress (thermal and total), bending stress
and dynamic augment factor in LWR under dynamic loading using
wayside data acquisition system

Field Trial on Instrumented rail is to be done to conduct study on


stresses at different critical point of rail including the liner biting with
the use of strain gauges. The instrumentation data should also enable
dynamic augments for different type of vehicles on LWR section of
ECoR & NCR.
Justification: Assessment of the values of various track related technical parameters
were determined around 30-40 years back. Presently so many
improvements have taken place in various track components. In the
present scenario it is felt that above track parameters as mentioned in
the objective needs to be determined for the present track structure
which may enhance the higher speed and higher axle loads (25 ton).
Deliverable: 1. Supply Installation and Commissioning of Two 40-Channel Remote
Monitoring Stations.
2. Supply Installation and Commissioning of One 24-Channel Remote
Monitoring Station.
3. Data Acquisition Software with Stress & Temperature
Measurements.
4. Thermal stress in rail due to temperature variation.

48th Meeting of CBRR 38


Important Projects in Hand

5. Bending stress in rails at critical locations.


6. Dynamic Augment for different rolling stock.
Current status: The trial is in progress near Vishakhapatnam (ECoR). On 31th March 2019
commissioning of the system in Kantakapalle (KPL) – Kothavalasa (KTV)
block section of Waltair division has been done. The stream of data
received thereafter from the system is being analyzed.
 Induction of Track Geometry Measurement System (TGMS) with
full Rail profile measurement and acceleration measurement at
axle box level.
a. Speed band of Recording 20 To 180 Kmph
b. Recording of track geometry parameters with curvature
c. Recording of full rail profile and wear parameters
d. Recording of acceleration and Ride Index at axle box level and
on Coach floor at bogie pivot
 Introduction of system for video inspection of Track Components
a. Video recording of Track Components for assessment of their
Condition
b. Acceleration at axle box level and at coach floor on bogie pivot
of TRC
c. Rear window video recording for condition monitoring of track
features
 Introduction of Integrated Track Monitoring Systems for complete
health monitoring of IR Track.
a. Track geometry Parameters including Curvature
b. Rail profile and rail wear parameters including lip flow and rail
inclination
c. Acceleration at axle box level and at coach floor on bogie pivot
of TRC and in test vehicle
d. Rear window video recording of track
e. Recording of obstacle in MMD envelop of IR
f. Condition monitoring of track components
 Introduction of Ground Penetration Radar system for assessment
of condition of Ballast and Formation.
a. Scanning and reporting of 48450 kms of IR track on A,B,C and D-
spl routes.
b. Scanning and reporting of 2400 kms of IR track with formation
related issues for formation rehabilitation works.
 Introduction of Unattended Acceleration Measurement Systems.
a. For frequent subjective assessment health of Track.
b. To be installed on Rajdhani trains.
 Introduction of Turnout Measurement Systems.

Testing Directorate

3. Instrumented Measuring Wheel


Brief description: Instrumented Measuring Wheel (which term includes related hardware
& software for data acquisition and analysis) is equipment for real time
sensing, acquisition, processing and storage of lateral and vertical
forces data at rail-wheel interaction point along with other information
such as time and speed during movement of the rolling stock on-track

48th Meeting of CBRR 39


Important Projects in Hand

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.

4. Switch over to UIC 518/EN 14363


Brief description: The current method of rolling stock oscillation trials by RDSO is a peak
based evaluation method and is quite different from the evaluation
method followed by more advanced rail systems of the world for
assessment of ride behavior, safety and comfort.

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.

In addition, there have been several instructions from Railway Board to


switch over to UIC-518 based method for testing of rolling stock for ride
behaviour, safety and comfort. Railway Board vide AM(PU)‟s DO letter
to DG/RDSO No.2007/Dev Cell/IGRI/1 Vol.IV dated 11/12/2014 stressed

48th Meeting of CBRR 40


Important Projects in Hand

the need to switch over to UIC-518 based criteria for vehicle


assessment. The 31st and 32nd GCM held at RDSO on 17/07/2015 and
06/09/2016 respectively also stressed the need for a switch over to
UIC-518 based method of rolling stock testing.

However, the philosophy and the methods provided in the UIC/EN


based criteria are much different from that followed currently by IR
and there is a considerable knowledge and resources gap which is
resulting in tardy steps being taken for implementation of these
statistical evaluation based criteria by RDSO despite being agreed in
principle by all stake-holders.
Deliverables Scope of Work of the work of switching over to EN 14363/UIC 518
standard
1. To acquire and assimilate knowhow about statistical evaluation
based standards of testing for Rail Vehicles through training and
field experience of Test Track and Test methodologies in use at
international test facilities such as Siemens Bogie Competence
Centre in Europe.
2. Assessment of IR track data for developing criteria for classification
of track as per requirement of UIC-518/EN-14363 and associated
software.
3. To develop competency for carrying out on-track evaluation of rail
vehicles independently using testing methodology in line with
international standards using statistical evaluation methods.
Demonstration using live trials in India for IR stock over IR track for
trial track identification, instrumentation, data acquisition, post
processing and analysis and reporting for acquaintance of RDSO
personnel in the trial protocols as per UIC/EN standards.
4. Acquisition/Development of computerized data analysis software for
statistical evaluation of trial data.
5. Assessment of rolling stock acceptance limits for various parameters
for application over BG track of IR.
6. Development of Instrumented Measuring Wheel for LHB Coach.
7. Development of trial protocols for IR for various operating
conditions and detailed guidance manuals.
Current Status Detailed two weeks inter-directorate Training for switch over to
UIC/EN standard of Validation of Rolling stock got conducted by
CETEST, Spain under consultancy contract from 13th to 24thMay‟2019.
About 60 officers & Supervisors attended this training.

Track Design Directorate

5. Status of New Technologies for Rail Fracture Detection on Indian


Railways
Brief description: Broken rail Detection system based on propagation of ultrasonic waves
in rail
Justification: Timely detection of rail breaks to avoid derailments
Deliverables: Development of a reliable broken rail detection system suitable for
Indian Railway
Current status Trail of Ultrasonic Broken Rail Detection (UBRD) system developed by
ARMSCOR corporation of South Africa is under progress in 22 km length

48th Meeting of CBRR 41


Important Projects in Hand

in ALLD – CNB section of Allahabad division in 60 kg rail. There are


some issues with respect to false alarms and system faults.
Trial started on Moradabad Division, on section with 52 kg rail, has
been discontinued due to a very large number of false alarms. These
issues need to be addressed by the supplier.

6. 25 Ton Axle load operation on DFC/IR


Current Status  Design of Bridges already developed.
 New design for all standard spans for 25T loading completed. Excel
sheet for checking suitability of existing bridge developed as per IRS
Bridge rule.
 “Rationalization of Formation Layer thickness for 25 T & 32.5 T axle
load on Indian Railway Track” has been done and sent to Railway
Board for approval.
 As desired by ME, Letter of Acceptane (LOA) was issued on 18.10.2018
for validation of Railstress calculation done by RDSO. Contract
agreement was signed by M/s Transportation Technology Transfer
(TTT), Inc. USA on 30.10.2018.
After 3 rounds of discussions with RDSO on skype, M/S TTT submitted
draft report on 26.02.19 which was examined and commets were sent
to TTT through mail on 08.03.2019. Subsequently, final report has been
submitted on 14.03.2019 after deliberating the issues raised by RDSO.
The final report is under scrutiny.
 M/S TTTI have recommended use of 60 kg/110 UTS (YS as 800Mpa) rail
for operation of 25T axle load.
 Track structures for 25t axle load has been approved by Railway Board
in 2018. DFC have been authorised to decide their track structure/

7. Raising of speed of 22.9 t axle load wagon to 75 kmph


Current status As per the rail stress calculation, speed of 22.9t axle load is limited to
60 kmph. Determination of dynamic augment using rail instrumentation
and measuring wheel is being taken up. Subsequently, review of rail
stress would be done

8. Drafting of Track & Bridge maintenance standards/codes/manual for


operational speed of above 160kmph
Status Capacity building by knowledge acquisition for high speed tracks is
required.
Railway Board officials have agreed that RDSO should be associated
with National High Speed Rail Corporation (NHSRC) for acquisition of
knowhow on high speed operations. Railway Board is requested to issue
policy guidelines on the issue.

9. Consultancy for rail stress calculation on 25T axle load operation


Brief description: • In view of increased residual stresses reported in rails, there is a
need to revisit the rail stress calculation methodology being
followed by IR.
Current status • Work has been assigned to consortium of professors TTT at
University of Illinois, U.S.A.
• Final Report submitted to RDSO in March 2019.

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Important Projects in Hand

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.

Electric Loco Directorate

11. Up gradation of WAG9 /WAP7 from 6000 HP to 9000 HP


Brief description: To meet enhanced transport requirements in the country and to cater
for higher loadings & passenger volumes, it is required to run trains of
higher capacity with an increased throughput to enhance line capacity
by Up gradation of WAG9 /WAP7 from 6000 HP to 9000 HP with minimal
suitable modifications in propulsion equipment including traction
converter, auxiliary converter, traction motor, transformer & VCU.

Justification: The proposed upgradation shall lead to higher power, increased


continuous power, better acceleration reserve, more reliability and
improved overall performance of the locomotive.

Deliverables: WAG9/WAP7 locomotive of 9000 HP.


Current status CLW had already placed the order for upgradation as under:
i. On M/s Siemens for 5 WAG9 & 5 WAP7
ii. On M/s Medha for 2WAG9 & 2 WAP7
iii. On M/s BHEL for 1 WAG9

All the firms has submitted design documents to CLW which are under
scrutiny and targeted to be completed.

Electric Loco Directorate

12. Development of twin BO-BO Loco of 10000HP capacity for passenger


operation
Brief description: To meet enhanced transport requirements in the country and to cater
for higher passenger volumes, it is required to run trains of higher
capacity with an increased throughput to enhance line capacity and
speed by Up gradation of existing 5440HP WAP5 locomotives by joining
two 5440HP WAP5 locos as „twin Bo-Bo‟ with minimal suitable

48th Meeting of CBRR 43


Important Projects in Hand

modifications in propulsion equipment including traction converter,


auxiliary converter &VCU.

The middle cabs of the locomotive shall be flattened. The mechanical/


outer dimensions of locomotive shall be kept unaltered to the extent
possible, however front shape of the loco may be optimized to suit high
speed operations.
Justification: The proposed upgradation shall lead to higher speed, higher power,
increased continuous power, better acceleration reserve, more
reliability and improved overall performance of the locomotive.
Deliverables: Twin BO-BO Loco of 10000HP capacity for passenger operation
Current status CLW is in process for development of twin Bo-Bo as per RDSO
specification.

Motive Power Directorate

13. Fog Vision


Brief description: Fog vision system is a camera based system that will enhance the
visibility under foggy condition.
Justification: During dense foggy weather conditions, it is very difficult to maintain
the punctuality of trains and train accidents are likely as the vision for
the pilots is not clear enough. In fog, a proportion of the light is
scattered by water droplets present in the atmosphere and thus
deviates from its path. The scattering increases with the distance.

The development of Fog Vision System (FVS) shall be capable of


assisting the locomotive pilot by enhancing visibility under dense fog
conditions for operating the trains and locomotives of Indian Railways.
Deliverables: 1. Development of Specification
2. Procurement of Fog vision system as per RDSO specification for
trials
3. Proving Trials in foggy weather condition and based on the input of
trials further modification if required and proliferation of the
system.
Current status RDSO placed purchase order to M/s Tata Power and M/s BEL (2 loco
sets each) in Dec‟2017. Both the Firms have dispatched the system to
DLW for fitment on Locomotive. System has been fitted on loco no.
40598 & 70873 and dispatched to LDH shed. The field testing of fog
vision system conducted during the period 17.01.2019 to 19.02.2019,
however, testing in extreme dense fog is yet to be done due to non
availability of extreme dense fog in this winter season.

14. Status of ongoing safety related projects

 Ultrasonic broken rail detection system (UBRD):


Trial completed. Evaluation report is under preparation.
 Vehicle mounted broken rail detection system:
The Trails with GE Rail Monitoring system have not been taken
further as decided during 33rd GCM(para 7.4).

 Optical Fiber based distributed Acoustics system for Intrusion


detection:
The work was sanctioned by Railway Board for the year 2017-18.
Vide Railway Board letter No. 2017/Sig/WP/IR/RF& ids/Pt. dated
14.06.2017, it was decided that the Executive authority for the

48th Meeting of CBRR 44


Important Projects in Hand

above mentioned work will be respective Railway and RDSO will


provide technical assistance and remain associated during trials.
Accordingly, the “Functional Requirement Specification” has been
prepared by RDSO in consultation with Industry representatives.
The FRS was issued in September 2017 to North Central Railway.
Tender has been finalized by NCR and work has been awarded. As
per details received, OFC laying work is in progress in the
identified section (MGS-ALD) of NCR. In line with decisions taken
in meeting held at Railway Board on 25.10.18, a team of 2 officers
from NCR and one from RDSO has been nominated to have first-
hand exposure of the system in Austria.

 Consultancy for validation of Rail stress evaluation


methodology:
Letter of Acceptane (LOA) was issued on 18.10.2018. Contract
agreement was signed by M/s Transportation Technology Transfer
(TTT), Inc. USA on 30.10.2018.
After 3 rounds of discussions with RDSO on skype, M/S TTT
submitted draft report on 26.02.19 which was examined and
comments were sent to TTT through mail on 08.03.2019.
Subsequently, final report has been submitted on 14.03.2019 after
deliberating the issues raised by RDSO. The final report is under
scrutiny.
M/S TTTI has recommended use of 60 kg/110 UTS rail for
operation of 25T axle load. Final report has been sent to Railway
Board on 04.05.19.

 Advanced warning system at UMLC for road users


Initial trials were done at 5 nos. of L.C. Gates in ECR. Various
shortcomings of the system were noted and conveyed to ISRO. A
meeting was held at ISRO/Ahmedabad on 08.01.2019 in which
RDSO requested ISRO to conduct final trial in ECR to check
improvements done by ISRO. However ISRO was not willing to
conduct trial in ECR. Matter is being pursued with ISRO for final
views of IRSO. Status of the project has been submitted to
Railway Board vide this office letter No. STT/SAC/794 Dated:
26/29.03.2019 to issue further directives, if any in this regard.

48th Meeting of CBRR 45


5.0

RDSO’s R&D Collaboration


with
Research Institutions of

India

&

Abroad
R&D Collaboration with different Research Institution of India & Abroad

5.0 R&D Collaboration with Different Research Institutions of India

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:

SN Area of Research Nodal CRR

1 Vehicle Dynamics, Heavy Haul & High Speed Technology IIT/Kharagpur

2 Loco Research & Propulsion Technologies, Traction IIT/Kanpur


Installation /OHE

3 Track, Bridges And Structures IIT/Roorkee

4 Signalling & Communication, Condition Monitoring & IIT / Madras


Predictive Maintenance.

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.

Accordingly formation of monitoring bodies was completed in 2016-17 & interaction


meetings of these bodies were also organized in 2016-17 & 2017-18.Initial Grant of
Rupees 2.48 Crore( 1Crore-IIT(Roorkee, Madras) each & 48 lakhs to CRR at IIT Kanpur
was also released in year 2017-18 for setting up CRRs. Regular technical training
programs are being organized under CRRs and research projects from RDSO are under
formulation at IITs.

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.

48th Meeting of CBRR 46


R&D Collaboration with different Research Institution of India & Abroad

5.1 STATUS OF CENTRE FOR RAILWAY RESEARCH (CRRS)


5.1 Centre for Railway Research at IIT (Kharagpur)

1. Year of sanction: 2010-11

2. Memorandum of Understanding:

 Date of MoU signing: 13/2/2010


 Duration of MoU: The MOU will be operative from 13.02.2010 with no fixed
time limit.

3. Areas of R&D:

a) Areas (expertise) as per MOU

i) Heavy Haul Technology


ii) Vehicle Dynamics
iii) High-Speed Technologies
iv) Energy Efficient Traction Power Supply Systems
v) Track Research
vi) Use of Artificial Intelligence for Predictive Maintenance and Management.
vii) Material Sciences for Railway related Composites including Rubbers,
Polymers and Insulation Materials.
viii) Development of Integrated / Embedded Processors for Railway
Applications
ix) Applications for Access Control, Security and Safety including Biometrics
x) Open Platform Propulsion Control Systems for Rail Vehicles
xi) Non-Conventional Drives and Technology including Maglev, Linear
Induction Meter.
xii) Remote Sensing and Measurement of OHE, Track and Signals

4. Monitoring Bodies:

a) Apex Steering Committee (ASC)- Co-chaired by DG/RDSO & Director IIT


b) Programme Advisory Committee (PAC)-Co-chaired by ADG

5. Status of setting up of CRR:

a) Sanction cost: 19.60 Crore


b) Fund Released: 19.60 crore

Status:
Permanent Building is completed & commissioned. Sanctioned cost of the
project i.e. Rs.19.60 Crore has been released to IIT.

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R&D Collaboration with different Research Institution of India & Abroad

5.2 On-Going Research Project:

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

ii) Suspension and Bogies Technology for High Speed Trains-


Status: Project completed/Final report submitted

iii) Assessment of Various Strategies of Seating Arrangements for Indian Rail


Coaches from the Viewpoint of Occupants‟ Safety.
Status: Project completed/Final report submitted

iv) Development of Thermo-mechanically Processed High Strength Bainitic


Steel Rails for Indian Railways.
Status: Final report submitted

v) Development of Composition and Standardization of Properties of


Composite Brake Blocks for Application in Coaches of Indian Railways.
Status: Final report submitted

vi) Scientific Evaluation of High Voltage Insulator Conditions from Predictions


of Residual Life of Composite Insulators.
Status: Project completed/Final report submitted

vii) Design and Development of An On-board Intelligent Embedded Platform for


Detection of Weak Failure Modes and Prognosis of Severe Faults in
Locomotives.

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R&D Collaboration with different Research Institution of India & Abroad

Status: Project completed/Final report submitted

viii) Online monitoring system for OHE Traction Parameters


Status: In progress

ix) Modelling and Validation of Interlocking for Railway Signalling Systems


Status: Project completed/Final report submitted. Phase-2 of project is
under formulation & sanction.

x) Aerodynamic Design of Traction Rolling Stock With Speed Potential of 250


Kmph (Upgradeable to 350 Kmph)
Status: In progress

xi) Development of Provisions for Design of Steel Concrete Composite Railway


Bridges for Normal Speed and Special Provision for High Speed Passenger
Traffic.
Status: Short Closure

xii) Development of Railway Bridge Health Monitoring System With Wireless


Sensor Networks
Status: Short Closure

5.1.2 Centre for Railway Research at IIT (Kanpur)

1. Year of sanction: 2015-16

2. Memorandum of Understanding

 Date of MoU: 22.12.15


 Duration: Three year

3. Areas of R&D:

a) Areas (expertise) as per MOU:

i) Geo- Tech Engineering


ii) Advanced Fuel Efficient Systems
iii) Alternate Engine Propulsion Technologies
iv) Fire Safety Management
v) Wireless Networking Systems
vi) Advanced Electronics
vii) High Speed Track & Rolling Stock Design
viii) Operational Efficiency Measures
ix) Cyber Security Of Railway Communication Systems
x) Material Development & Processing
xi) Smart Power Supply Networks
xii) Advanced Signaling & Fog Vision

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R&D Collaboration with different Research Institution of India & Abroad

xiii) Automatic Rolling –Stock Condition Motoring, Way Side And Onboard

4. Monitoring Bodies:

a) Apex Steering Committee (ASC)-chaired by DG/RDSO &co-chaired by


Director IIT
b) Programme Advisory Committee- Chaired by ADG/RDSO & co-chaired by
Dean(R&D) of IIT

5. Status of setting of setting up of CRR

 Sanction cost: 20 crore


 Fund Released: 48.97 Lakhs

Status

 Space has been identified and being used & expansion/furnishing will be
taken up as per requirement,
 Website of the CRR has been launched.

5.1.3 Centre for Railway Research at IIT (Roorkee)

1. Year of sanction:2015-16

2. Memorandum of Understanding:

 Date of MoU: 22.12.15


 Duration: Three years

3. Areas of R&D:

a) Areas (expertise) as per MOU:

i) Civil Infrastructure of High speed rail


ii) Bridges & Structure
iii) Track Management system
iv) Remote Monitoring of Railway Assets
v) Environmental Engineering
vi) Station Infrastructure
vii) Rail Wheel Dynamics
viii) Engine Noise analysis and management
ix) Electric drives
x) Advance communication systems

4. Monitoring Bodies

i) Apex Steering Committee (ASC):- chaired by DG/RDSO & co-Chaired by


Director IIT

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R&D Collaboration with different Research Institution of India & Abroad

ii) Programme Advisory Committee:- Chaired by ADG/RDSO & co-chaired by


Dean(SRIC) of IIT

5. Status of setting of setting up of CRR

 Sanction cost: 20 Crore


 Fund Released: 1 Crore

Status

 The plan of the building has been finalized


 Electrical & Construction of the space for computation laboratory,
offices (Coordinator, Coordinator and general office), one classroom &
Scholars cabin is in progress.
 Procurement of furniture for the classroom, offices and scholars cabin
has been completed.

5.1.4 Centre for Railway Research at IIT (Madras)

1. Year of sanction: 2015-16

2. Memorandum of Understanding

 Date of MoU: 22.12.15


 Duration: - Three years

3. Areas of R&D:

a) Areas (expertise) as per MOU

i) Structural Health Monitoring of Railways Infrastructure(Rails, Bridges,


Engines, Wagons /Coaches, Electrical, stations) by embedded Intelligence
ii) Intelligent Transportation
iii) Computer Vision & Image Technologies
iv) Advanced techniques for trains control and communication
v) Decision Sciences
vi) Alternate Engine Propulsion techniques
vii) Reliability Engineering
viii) Energy Management
ix) Advanced Materials techniques
x) Advanced Joining Techniques
xi) Non-Destructing testing & Evaluation
xii) Disaster Management

4. Monitoring Bodies:

a) Apex Steering Committee (ASC):- chaired by DG/RDSO & co-Chaired by


Director IIT

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R&D Collaboration with different Research Institution of India & Abroad

b) Programme Advisory Committee:- Chaired by ADG/RDSO & co-chaired by


Dean(IC&SR) of IIT

5. Status of setting of setting up of CRR:

 Sanction cost: 20 Crore


 Fund Released: 1Crore

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.

5.2 RESEARCH & DEVELOPMENTAL ACTIVITIES

5.2.1 Training & Skill development:

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

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R&D Collaboration with different Research Institution of India & Abroad

d) Power semiconductor devices for three phase propulsion


e) DC-DC Converters
f) Introduction to Control Engineering

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

viii) A short course on “Electronic Magnetic Interference/Compatibility” was held at


M/s Bharat Electronics Limited, Bengaluru from 13th to 15th May‟19. Sixteen RDSO
officials from five directorates attended this course. Main topics included in the
course were:

 Introduction to EMI/EMC (Interference, compatibility, sources, receptors, coupling path


etc). How importance EMI/EMC during design, what are the effects if not followed etc
 Filtering
 Grounding
 Shielding
 EMC Standards and EMI/EMC Requirements as per MIL-STD-461E/F/G, How to choose the
applicable tests severities
 EMC Requirements as per MIL-STD-704
 EMI/EMC Requirements as per Commercial Standards FCC, CISPR, IEC61000-4-2,3
 EMC Test facilities, accreditation to NABL
 PCB design (CADDS Requirement)related EMC
 RF Circuit design related EMC
 Power supplies design related EMC
 High speed digital circuit design related EMC
 LAB Visit & practical testing related EMC

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

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R&D Collaboration with different Research Institution of India & Abroad

 Ride Comfort in Rail vehicles


 Dynamic calculations in Vehicle design
 Active Suspension
 Application of MR fluid damper in railway suspension system
 Application of Condition Monitoring Techniques for Railway Vehicles

5.2.2 Research projects

Joint Research Projects under Deliberation with CRRs are as follows:

CRR at IIT Kharagpur

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

iv) Co-relation between Lateral forces on Rolling stocks measured by different


methods

CRR at IIT/Kanpur

i) Improvements in Characteristics/Properties of Weak Soils by using


Chemicals/Additives.

ii) Condition monitoring technique for 25KV solid core porcelain/composite insulators

iii) Engine/Coach/Bogey-mounted Front-End and Drive converter Unit (FEDCU)

CRR at IIT/Roorkee

i) Applications of Geographic Information Systems for delineation of catchments,


dam simulations and profile generation along river courses

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R&D Collaboration with different Research Institution of India & Abroad

ii) Rationalization of existing procedure of rail stress calculation on Indian Railways


and predicting service life of rails on fatigue considerations for various loading
requirements

CRR at IIT/Madras

i) Condition monitoring of Signalling gears and Predictive maintenance of Signalling


gears-yard visit has been done by PI for appraisal

ii) Identification of suitable technology for Integrated on Board Condition Monitoring


System for monitoring the parameters which have implication on train safety,
reliability & availability of coaching stock.

iii) Using Inclinometer and GPS for event marking during oscillation trials.

5.2.3 Interaction Meeting:

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.

5.2.4 Extension of Validity of MoU with IITs

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.

5.2.5 Malaviya Chair at IIT/Banaras Hindu University:

Hon‟ble Minister of Railways announced setting up of „Malaviya Chair‟ for Railway


Technology at IIT-BHU in the Budget Speech 2015-16

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.

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R&D Collaboration with different Research Institution of India & Abroad

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

Projects under Malaviya Chair

1. Development of light weight FRP runner (Impeller) for blower fan assembly of
Roof Mounted Package Unit (RMPU) fitted in AC coaches.

DOC Jan -2016

Cost Rs. 6.25 lakhs

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

Cost Rs. 6.25 lakhs

Status Material based on Poly aryl ether ketone 1%


Polytetrafluoroethylene + 1% antioxidant showed excellent
mechanical performance even at high temperatures up to 300°C
and has passed all the required tests. During last meeting held on
11.01.2019 at RDSO it was mentioned that 10 kg of material was
provided and this was used in samples preparation and testing;
additional lot of 25 kg is awaited from IIT/BHU

3. Project title: Project on “Use of Smart (Alternate) Materials in Design of Rolling


Stock”

DOC April-2016

Cost Rs. 2.5 Crore

Status The technical requirements and manufacturability issues were


discussed in detail in the Chair Core Committee meetings and as
per the decision taken during these meetings; a report on the use
of alternate material in wagon design has been issued by RDSO.
Carriage directorate of RDSO has also been requested to frame

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R&D Collaboration with different Research Institution of India & Abroad

technical feasibility report on possibilities of use of alternate


material in coaches. RDSO report on wagon design has been
forwarded to all members of Chair Core Committee on
27.06.2017 for their comments & firming up the project
deliverables. IIT-BHU has to come up with an R&D proposal for
execution of this project.

5.2.6 Collaboration with National Institute of Design/Ahmedabad:

The National Institute of Design is an autonomous Institute, established in 1961 under


the aegis of the Department of Industrial Policy & Promotion, Ministry of Commerce &
Industry, Government of India for providing world class design education, training and
applied research. NID is an autonomous National Institution for design education at
undergraduate and postgraduate levels, advanced training, design research and
integrated design services. NID has since gained international recognition as one of the
foremost institutions in the field of design and as a catalyst for design intervention and
application in Indian industry at all levels. NID is a multi-campus Institute, having its
main campus in Ahmedabad, PG Campus in Gandhinagar and R&D Campus at Bengaluru.
The Institute is recognized as a Scientific and Industrial Research Organization by the
Department of Science & Technology, Government of India. It also undertakes
outreach, consultancy and industry programmers & projects.

A memorandum of understanding has been signed between Ministry of Railways and


National Institute of Design (NID), Ahmedabad for setting up of “Railway Design
Centre” at NID, Ahmedabad on the 10th April, 2015.

Project proposed with NID, Ahmedabad

Following project have been proposed so far with NID, Ahmedabad

1. Climbing arrangement for middle and upper births in reserved coaches(ICF&LHB)


2. Color scheme ( exterior and interior both) for 200 km/h rake expected to be turned
out from RCF/Kapurthala by December ,2015
3. Improvement in interior of LHB & ICF variants
4. Modular design of seats and berths
5. User –friendly toilet in coaches
6. Collapsible seats for EMUs
7. Double Decker suburban train

5.2.7 Kalpana Chawla Chair

 Memorandum of Understanding has been signed between Ministry of Railways &


PEC University Of Technology on 13th May 2016 for setting up of „Kalpana Chawla
Chair‟ at PEC University of Technology ,Chandigarh

 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.

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R&D Collaboration with different Research Institution of India & Abroad

 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

5.3 COLLABORATION INTERNATIONAL INSTITUTIONS:

5.3.1 Korean Railway Research Institute (KRRI):

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.

5.3.2 Russian Railways:

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.

5.3.3 Railway Technical Research Institute (RTRI)/Japan

 Hon‟ble Minister of Railways had visited RTRI/Japan in September‟15 and was


impressed with their capability. Subsequently, a MOU was signed between Railway
Technical Research Institute (RTRI)/Japan and RDSO on 11th December‟15 to promote
cooperation in Railway Research & Development.
 As a follow up measure, of MoU following interaction have been taken place between
two institutions:

1. A delegation of RTRI led by Dr. Fuminao Okumura/Executive Director visited RDSO


on 15/01/2016.
2. Group of five Eds (Track-1, Carriage, EL, and Finance & Research) visited RTRI in
August‟2016 to ascertain their capabilities & facilities. Five research areas were
shortlisted for further cooperation;

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R&D Collaboration with different Research Institution of India & Abroad

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.

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6.0

„Recently Completed Projects‟ of RDSO

48th Meeting of CBRR


Recently Completed Projects‟ of RDSO

1.0 BRIDGES & STRUCTURES DIRECTORATE


1.1 LWR/CWR over the bridge (Project completed in–house)
1.2 Fatigue Assessment for Steel Bridge(Project completed in –house)
1.3 High Strength Friction Grip Bolts (HSFG)(Project completed in –house)
1.4 Regarding Load Test in Arch Bridges(Project completed in –house)
1.5 Seismic Project (IIT-Kanpur)(Project completed)
1.6 Scour Depth Calculation (IIT-KGP)
Research Project entitled “Bridge scour estimation, Measurement, protection and use of
various real time monitoring systems”
1.7 Criteria For The Dynamic Analysis of Steel Railway Bridges (IIT Roorkee)/ Project
Unsuccessful
2.0 ENGINE DEVELOPMENT DIRECTORATE
2.1 Interim Standards for Exhaust emissions from Diesel locomotives
2.2 Implementation of Bio-diesel 5 % blend in Indian Railways
3.0 GEOTECHNICAL ENGINEERING DIRECTORATE
3.1 Non-Woven Geotextile to be used as separator/filtration layer for railway formation
3.2 Geo-composite Drain to be used behind Bridge abutment/Retaining wall
3.3 Geocomposite Drain to be used at the base of Embankment in Railways
3.4 Rationalization of Formation layer thickness for 25 T and 32.5 T Axle Load on Indian
Railways
3.5 Induction of new technology-Nuclear Moisture Density Gauge
4.0 MOTIVE POWER DIRECTORATE
4.1 Design & development of fabricated Bogie frame for Meter Gauge Locomotive bogie for
export to Myanmar Railways.
4.2 Design of Bogie for rebuilding of WDP1 locomotive.
4.3 Revision of specification & STR of fabricated bogie frame.
4.5 Remote Monitoring and Management of Locomotive and Trains (REMMLOT)
4.6 Preventing continuous blowing of horn in case of horn circuit malfunction
4.7 Reliability improvement in locomotive horn
5.0 POWER SUPPLY & EMU DIRECTORATE
5.1 Development of fully furnished rolling stock with DC propulsion system for Kolkata Metro
5.2 Indigenous design, development, manufacture, supply, testing and commissioning of 25
kV AC 3-phase Air-conditioned EMUs
5.3 Design, Development, Manufacturing, Testing, Supply, Delivery and commissioning of
Light weight fully furnished 750 V DC Metro Rolling stock with 3 phase electric
propulsion along with spare tools
5.4 Design, Development, Manufacturing, Testing, and commissioning of indigenized
electrics with 3 phase propulsion for Kolkata Metro
6.0 PSYCHO TECHNICAL DIRECTORATE
6.1 Development and Implementation of Computer based Aptitude Test Battery for
recruitment of Assistant Loco Pilots by RRBs. Test has been successfully held on
10.05.19 and 21.5.19.
6.2 Development of Computer based Aptitude Test battery for recruitment of Assistant
Station Masters. Test was successfully held on 30.6.17.
6.4 Development of new test of Objective type Group embedded figure test for Metro Staff
(Station Controllers/Train Operators).
6.5 Development of new Memory test, Power of observation test and Form Board test of
intelligence for Metro Staff (Station Controllers/Train Operators).
6.6 Research Study on „Ergonomics Study of Work Place of Train Drivers and its impact on
Job related Attitudes
6.7 Development of Computer based Aptitude test battery for recruitment of candidates to
the post of Assistant Station Master for KRCL.

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Recently Completed Projects‟ of RDSO

7.0 RESEARCH DIRECTORATE


7.1 Wheel Impact Load Detector (WILD)
8.0 SIGNAL DIRECTORATE
8.1 Modelling & validation of interlocking for Railway Signalling System
8.2 Development of Capacity 61inalized61on and Simulation Tool (COST)
9.0 TELECOMMUNICATION DIRECTORATE
9.1 Radio Based Advance Warning System for Unmanned Level Crossing
9.2 Development of VHF Based Approaching Train Warning System For Track Maintainers
(Rakshak).
9.3 Trial of Voice over IP (VoIP) based Train Control Communication System(TCCS)
10.0 TRACTION INSTALLATION DIRECTORATE
10.1 Scientific evaluation of high voltage insulator conditions/predictions of residual life of
composite insulators.
10.2 On-line monitoring system for OHE traction.
10.3 Primary facility for thermal rating of contact lines, load flow capabilities of traction
distribution system etc.
10.4 Mobile instrumentation car for monitoring the health of PSI
10.5 Design and development of 25kV Gas Insulated Switchgear (GIS) and 132/220kV Gas
Insulated Switchgear(GIS) for Traction Sub-Station.
10.6 Development of Copper-Magnesium Catenary Wire.
11.0 TRAFFIC DIRECTORATE
11.1 Passenger Feedback Survey on various services in Double Decker trains
11.2 Passenger Feedback Survey on various services in Humsafar Trains
11.3 Enhancing Passenger and Freight Throughput on existing network.
11.4 Implementation of technological aid at NI-MLC gates.
12.0 TRACK DESIGN DIRECTORATE
12.1 Field Trials of Micro-Alloyed High Yield Strength Niobium & Vanadium Rails
12.2 Development of improved AT Welding Technique with single shot crucible and Auto-
tapping thimble.
13.0 TESTING DIRECTORATE
13.1 Replacement of 02 staff cars with LHB AC staff cars.
14.0 WAGON DIRECTORATE
14.1 Fitment of Bogie mounted Brake system in freight rolling stocks
14.2 Development of High Capacity Parcel Van using Freight Bogies (CASNUB) Wagon type
BCPVN.
14.3 Design Development of 25t axle load BOXNS open wagon
14.4 Development of Class “K” Cartridge Taper Roller Bearing (CTRB) for 25t freight rolling
stocks.
15.0 Carriage Directorate
15.1 Reduction in wheel shelling in LHB Coaches
15.2 Development of Crashworthy Design Of LHB Type Coaches
15.3 Optimizing the design of coupling arrangement and setting up a longitudinal simulation
facility at RDSO.(Completed In-house)
15.4 Development of AC Version of LSCN, LSR and LS
15.5 DEVELOPMENT OF SPECIFICATION (NO. RDSO/CG-18002, Rev-nil) FOR BG LIGHT WEIGHT
ALUMINIUM PASSENGER CARS (LOCO HAULED) WITH OPERATIONAL SPEED OF 200 KMPH
UPGRADABLE TO 250 KMPH. (Completed In-house)
15.6 Foul smell in toilet room (Carriage)

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6.0 ‘RECENTLY COMPLETED‟ PROJECTS OF RDSO

1.0 B&S DIRECTORATE

1.1 LWR/CWR over the bridge (Project completed in–house)


Deliverables:  In-house project has been done for continuation of long welded
rails over bridges with/without ballasted deck. Correction Slip No.
47 and Guidelines under BS 114 has been issued.
 For Rail Structure Interaction Analysis, the software “LUSAS” has
been purchased and more than 100 bridges have been analysed and
cleared for continuation of LWR.

1.2 Fatigue Assessment for Steel Bridge(Project completed in –house)


Deliverables:  Fatigue analysis for steel bridge was discussed in detail in 82nd (Jan-
14), 83rd (May-15), and 84th (Nov-16) BSC meetings & correction slip
No. 21 dated 09-06-2017 was issued for Steel Bridge Code.

1.3 High Strength Friction Grip Bolts (HSFG)(Project completed in –house)


Deliverables:  Guidelines to use of HSFG bolt in bridges for Indian Railways issued
& several revisions (6threvision) incorporated in BS Report No. 111.
 Correction slips for various codes issued:
- A&C Slip No. 20 in Steel Bridge Code
- A&C Slip No. 27 in Bridge Manual
- A&C Slip No.6, 9, 10 & 11 in specification for Fabrication and
Erection of Steel Girder Bridges and Locomotive Turntables.
 All the standard drawings were changed from rivets to HSFG bolts.
Following is the list of drawings revised with HSFG bolts-
- Plate Girders for span 12.2 m and 18.3 m.
- Composite Girders for span 12.2m, 18.3m, 24.4m and 30.5 m.
- Open Web Girders for span 30.5m, 45.7m, 61.0m, 76.2m and
91.4m.
- ROB‟s composite girders 18m, 24m, 30 m and 36 m.

1.4 Regarding Load Test in Arch Bridges(Project completed in –house)


Deliverables:  A&C Slip No. 8 issued.
 BS Report 116 R issued.

1.5 Seismic Project (IIT-Kanpur)(Project completed)


Current Status:  Based upon BSC approved Seismic Parameters, a new IRS Seismic
Code for Railway Bridges has been published and adopted.

1.6 Scour Depth Calculation (IIT-KGP)


Research Project entitled “Bridge scour estimation, Measurement,
protection and use of various real time monitoring systems”
Current Status:  Consolidated report of the project has been submitted by IIT/KGP
in Dec‟2015.
 Training to Railway engineers regarding the scour estimation,
measurement and protection given by IIT/KGP in Feb,2014
 In compliance of the Railway Board Order‟s in 82, 83 & 84th BSC
meetings, RDSO has sent draft A&C slip no. 5 for approval of
Railway Board vide letter no. RBF/BSC/82 dated 13.04.2017.The
project has been completed and item would be discussed in the
next BSC for implementation.

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Recently Completed Projects‟ of RDSO

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.

2.0 ENGINE DEVELOPMENT DIRECTORATE

2.1 Interim Standards for Exhaust emissions from Diesel locomotives


Deliverables:  Emission measurement of 12 nos- GM-EMD Locomotive, 11 nos.-
ALCO Locomotives recorded using Emission Test Car . Interim
Standards for Locomotive Emissions has been issued and sent to
CPCB (Central Pollution Control Board) & MoEF (Ministry of
Environment & Forest) for notification.

2.2 Implementation of Bio-diesel 5 % blend in Indian Railways


Deliverables:  To reduce country‟s dependence on petroleum products
 Reduction in emissions
 Environment friendly
 Non-Toxic
 Bio-degradable

3.0 GEOTECHNICAL ENGINEERING DIRECTORATE

3.1 Non-Woven Geotextile to be used as separator/filtration layer for


railway formation
Deliverables Application of Non-Woven Geotextile in Railway formation

Current status Specification for Non-Woven Geotextile to be used as


separator/filtration layer for railway formation finalized and issued
to Zonal Railways /PSUs for trial on Indian Railways.

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Recently Completed Projects‟ of RDSO

3.2 Geo-composite Drain to be used behind Bridge abutment/Retaining


wall
Deliverables Application of Geo-composite Drain behind Bridge abutment/Retaining
wall
Current status Specification for Geo-composite Drain to be used behind Bridge
abutment/Retaining wall finalized and issued to Zonal Railways /PSUs
for trial on Indian Railways.

3.3 Geocomposite Drain to be used at the base of Embankment in


Railways
Deliverables: Application of Geo-composite Drain at the base of Embankment in
place of sand layer
Current status Specification for Geocomposite Drain to be used at the base of
Embankment for Railway Formation finalized and issued to Zonal
Railways /PSUs for trial on Indian Railways.

3.4 Rationalization of Formation layer thickness for 25 T and 32.5 T


Axle Load on Indian Railways
Deliverables: Optimization of formation layer thickness for different axle loads.
Current status “Rationalization of Formation Layer thickness on Indian Railway Track”
has been done and sent to Railway Board for approval.

3.5 Induction of new technology-Nuclear Moisture Density Gauge


Benefits/  Quick assessment of compaction.
Deliverables  Alternate & Non-destructive measurement of compaction in place
of Sand Replacement/Core Cutter Method.
Current status A detailed and self-contained “Test Procedure” for using Nuclear
Density Moisture Gauge for in-situ measurement of Compaction
issued to Dedicated Freight Corridor (DFCCIL) for Western Corridor.

3.1 Development of Indian Railway Tunnel Manual


Deliverables:  Preparation of Indian Railway Tunnel Manual.
 Training of Railway Officials.
 Capacity building of engineers on Indian Railways for developing a
basic appreciation towards complexity of tunneling projects and
helps them in executing them. The Manual covers all the key
components of a tunneling project including Tunnel planning,
design, construction, safety, inspection & maintenance.
Current status  Indian Railway Tunnel Manual‟ and „Indian Railway Tunnel
Guidelines‟ have been prepared. They are under finalization in
consultation with Railway Board.
 To bring awareness among field officials of Zonal Railways on
various issues related with tunnels, four training courses of one
week duration have been conducted from May-Dec‟ 2016.
 Tunnel Manual submitted to Railway Board for approval

3.2 Economical Construction of Railway embankment in Urban Areas


using Reinforced Earth Wall & Reinforced Steep Slope –
Development of methods
Deliverables:  Checking of RDSO report on “Reinforced Earth Wall & Reinforced
Steep Slope for different heights of embankment.
 RE Wall and Reinforced Steep Slope structures may be adopted in
place of conventional embankment with side slopes where
adequate land is not available for construction of railway

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Recently Completed Projects‟ of RDSO

embankment or where cost of land is high for construction of


embankment
Current status  Project was taken up with IIT Kanpur. Final Report from IIT/Kanpur
was received on 09.01.2015.
 The project has been completed and copy of Guidelines has been
circulated to Zonal Railways for the trial use in railway sidings.

3.3 Development of “Guidelines and Specifications for Use of


Geosynthetics in Railway Formation.
Deliverables:  To cover relevant issues for use of geosynthetics in Railway
embankment,
 To help in achieving economy in construction of new bank and
effective rehabilitation of weak/unstable formations
Current status  Guidelines & Specifications formulated and submitted to Railway
Board for approval.

3.4 Design of Micropiles to Stabilize Railway Embankment


Deliverables:  To carry out state of art review on the analysis and design of
micropiles.
 To develop detailed step by step design methodology for micropile
stabilization considering both geotechnical and structural aspects.
Benefits  Micropilescan be effectively used in many applications of ground
improvement particularly in strengthening the existing foundation.
 Can be used to construct stable Railway embankment over soft soil
and where land constraints are there.

4.0 MOTIVE POWER DIRECTORATE

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

4.2 Preparation of Specifications of TRINETRA (Terrain Imaging for


locomotive drivers- Infrared, Enhanced optical and Range Finder
Assisted)
Deliverables: Will help Loco Pilot in navigation and receive warning of any infringing
object from a reasonable faraway distance
Current status  Specifications developed and issued to Board

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

4.4 Report of failures of Turbo Clutch Assembly


Deliverables:  Carry out analysis and issue action plan for improvement in
reliability

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Recently Completed Projects‟ of RDSO

Current status  Report No MP.Misc-338 (Rev.00) Jan‟19 issued to DLW and Zonal
Railways

4.5 Remote Monitoring and Management of Locomotive and Trains


(REMMLOT)
Deliverables:  To monitor health of the locomotives through web server.
 Higher reliability by reducing down time through remote
monitoring of locomotives.
 Cost effective as the feature is integrated with microprocessor
control.

4.6 Preventing continuous blowing of horn in case of horn circuit


malfunction
Deliverables:  Issue of instructions to Zonal Railways to improve reliability
 Reliability improvement in locomotive horn.
 Reduction in online locomotive failure
 Improvement in safety.
Current status  Modification sheet No. MP.MOD.BK.01.01.17, January‟2017 issued to
all Zonal Railways and Pus for implementation.

4.7 Reliability improvement in locomotive horn


Deliverables:  Issue of instructions to Zonal Railways to improve reliability
 Reliability improvement in locomotive horn.
 Reduction in online locomotive failure
 Improvement in safety.
 Instructions have been issued to Zonal Railways and Pus vide letter
no. SD.DFM.A.4.7 dated 20.10.2016 and 26.10.2016

5.0 POWER SUPPLY & EMU DIRECTORATE

5.1 Development of fully furnished rolling stock with DC propulsion


system for Kolkata Metro
Deliverable:  Air conditioned suburban passenger service
 Passenger comfort, Low maintenance requirement & corrosion free
body
Current Status: All the 13 rakes have been successfully running in Kolkata Metro.

5.2 Indigenous design, development, manufacture, supply, testing and


commissioning of 25 kV AC 3-phase Air-conditioned EMUs
Deliverable:  Indigenous development of 3-phase EMU.
 Energy saving, Passenger comfort
Current Status: I. BHEL: All the submitted designs have been approved, Type tests of
all the equipments have been completed. The static testing of the
rake was completed in Nov. 2016. The Oscillation and EBD trials
have been completed in Central Railway in April 2017. The rake is
undergoing Dynamic performance trials in Western Railway which
are in the final stages. The rake is likely to be inducted in service
by September 2017.
II. Medha: Two EMU rakes have been put into commercial operation in
March, 2017, after the performance trials in Western Railway.

5.3 Design, Development, Manufacturing, Testing, Supply, Delivery and


commissioning of Light weight fully furnished 750 V DC Metro

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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.

5.4 Design, Development, Manufacturing, Testing, and commissioning of


indigenized electrics with 3 phase propulsion for Kolkata Metro
Deliverable:  2 ICF manufactured, indigenous electrics rakes for Kolkata Metro
 Passenger comfort, Low maintenance requirement, Energy
efficient and corrosion free body.
Current Status: Approval of Design has been completed for all the items. Type testing
of all major equipment has been completed. One Train has recently
been flagged off from ICF on 4.7.2017. The rake will be put into
commercial operation after completion of performance trials

6.0 PSYCHO TECHNICAL DIRECTORATE

6.1 Development and Implementation of Computer based Aptitude Test


Battery for recruitment of Assistant Loco Pilots by RRBs. Test has
been successfully held on 10.05.19 and 21.5.19.
Deliverable  Smooth and easy test administration on mass scale with complete
transparency.
 Speedier test administration (1,71,222 number of candidates were
tested in 04 shifts).
 Up-gradation from paper-pencil mode to computer based mode.

6.2 Development of Computer based Aptitude Test battery for


recruitment of Assistant Station Masters. Test was successfully held
on 30.6.17.
Deliverable  Smooth and easy test administration on mass scale with complete
transparency.
 Speedier test administration (34118 number of candidates in a
single day in up to three shifts).
 Up-gradation from paper-pencil mode to computer based mode.

6.3 Development of new test of Power of Observation for ALPS, and


Metro staff (Station Controllers/Train Operators)
Deliverable  Inclusion of a new test in the ALP test battery and Metro test
battery

6.4 Development of new test of Objective type Group embedded figure


test for Metro Staff (Station Controllers/Train Operators).
Deliverable  Inclusion of a new objective type test to replace booklet based
test in the Metro test battery

6.5 Development of new Memory test, Power of observation test and


Form Board test of intelligence for Metro Staff (Station
Controllers/Train Operators).
Deliverable Inclusion of different parallel form tests to replace existing tests in the
Metro test battery

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Recently Completed Projects‟ of RDSO

6.6 Research Study on „Ergonomics Study of Work Place of Train Drivers


and its impact on Job related Attitudes
Deliverable Identification of factors related to performance of Loco Pilots in terms
of ergonomics problems including 68inalized68on68l, Environmental
and work related. Report P.T. 41 issued in March 2019.

6.7 Development of Computer based Aptitude test battery for


recruitment of candidates to the post of Assistant Station Master for
KRCL.
Deliverable Test was successfully conducted on 07.01.19 for the recruitment of
ASMs for KRCL in CBT mode.

7.0 RESEARCH DIRECTORATE

7.1 Wheel Impact Load Detector (WILD)


Deliverables:  WILD (Wheel Impact Load Detector), is an unmanned intelligent
trackside data acquisition system for safety and asset reliability in
train operation. WILD system may be used as a predictive tool for
maintenance of stock.
 WILD is a strategic device for the protection of rail infrastructure
(track and vehicle). In the rare case of excessive track stresses
progressively leading to rail fracture and breakage of rolling stock
components, which are major factors affecting safety as well as
smooth movement of traffic.
 It is a useful „wayside detection system‟ for safety and asset
reliability in train operation.
 The system provides sensor based predictive maintenance inputs.
 The timely detection and detachment of rolling stock with
defective wheels shall help the Indian Railways to improve
passenger comfort, component life and reduce the problem of
damage to rolling stock components.
Current Status:  Deployed systems running and maintained successfully by divisions
through AMC.
 Specification of WILD system has been already developed.
 Fifteen WILD systems have been already installed over IR in two
phases. The First phase in the year 2007-08 (09 Systems) and the
Second Phase in the year 2010-11 (06 Systems).
 Further two more WILD systems have been procured from Australia
and installation of these systems is in progress over IR. These are
based on accelerometer and load bars based technology which was
inspected for the first time by RDSO.
8.0 SIGNAL DIRECTORATE

8.1 Modelling & validation of interlocking for Railway Signalling System.

Date of Start: 2012-13


Deliverables:  Conversion and verification of safety rules for Signalling system
based on yard plan, control table and generic Signalling circuits.
 Generate model for equations for given yard for use of application
data for EI
 Verification of above model to check safety aspect by verifying
parallel, conflicting movement and control of points etc.

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 Later in next phase, use this tool to generate verified


application data for EI
Current Status:  Tool has been submitted by IIT in Feb‟2019 as envisaged in this
phase. Three Zonal Railways have been trained on the tool and
asked to use the same. Separate work is proposed for next phase in
Works programme 2019-20 under DG‟s power.

8.2 Development of Capacity optimization and Simulation Tool (COST)

Date of Start: 2012-13


Deliverable: The tool shall be useful for traffic studies on improvement in existing
& new infrastructure by determining the Line capacity and the effect
of various infrastructure variables like IBS, Automatic Signalling, new
station etc.
Current Status: IIT/ Mumbai has developed the Simulation software and submitted to
RDSO in Feb‟2019. The same has been handed over to Traffic
DTE/RDSO for further utilization.

9.0 TELECOMMUNICATION DIRECTORATE

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.

9.2 Development of VHF Based Approaching Train Warning System For


Track Maintainers (Rakshak).
Deliverable/ Deliverable:
Benefits: With the development of this system we will get a VHF transmitter to
transmit information of an approaching train in the section and a Hand
Held VHF Receiver to provide an audio visual indication with vibration
alert on UP and Down direction track to Track Maintainers.
Benefits:
VHF based Approaching Train Warning System will provide an audio
visual indication with vibration alert of an approaching train on UP and
Down direction track to Track Maintainers, which will help to get rid of
run over cases of trackside maintenance staff (Track Maintainers) &
save precious life of Track Maintainers .

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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.

9.3 Trial of Voice over IP (VoIP) based Train Control Communication


System(TCCS)
Deliverable/ Deliverable:
Benefits:  To provide IP based Train Control Communication System.
 Evaluation of Performance in actual working condition and study of
jitter, delay and Bandwidth requirement of the system.
 Finalization of RDSO specification based on trial results.
Benefits:
 Modern and widely proven Internet Protocol (IP) technology as a
platform.
 Enabling use of common infrastructure for voice and data services.
 Providing feature rich communication system and better user
interface to the controller thereby enhancing their efficiency.
 Future proof technology.
Current Status: System installed in Mau- Shahganj Section (100 Km having 11 stations)
of Varanasi Division of NE Railway Nominated for the Trial & trials
conducted from July‟2017 to Nov‟2017. Overall performance of the
system has been found satisfactory. Report of trials submitted to
Railway Board on 12.01.2018. Based on the experience of the field
trials, the specification for the VoIP based Train Control
Communication System has been revised and Specification No.
RDSO/SPN/TC/99-2012, Revision-2 has been issued in Aug‟2018.
As, the system is an integration scheme of Off-The- Shelf available IP
technology components, the vendor development may not require. It
has been communicated to Railway Board.

10.0 TRACTION INSTALLATION DIRECTORATE

10.1 Scientific evaluation of high voltage insulator conditions/predictions


of residual life of composite insulators.
Date of Start: April 2012
Deliverables:  Report on failure analysis of outdoor insulator to understand the
mechanism of failure.
 Identification of correct testing methods for service life prediction,
and checking of conditions of working insulators in service.
 Improved compound formulations for vendors to produce, insulator
with better performance and extended service life.
 Transfer of Technology to RDSO in the form of technical document
indicating detailed list of equipment along with the procurement
specification, list of probable suppliers for each equipment and
test scheme.
 Revision of RDSO specification for silicone composite insulator i.e.
TI/SPC/OHE/INSCOM/1070 based upon 2& 3 above, so that more
reliable insulators may be procured by IR based upon the revised
specification.

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Current Status: Project completed and Closure report under vetting by Finance.

Proposed Date of June, 2019.


Completion:

10.2 On-line monitoring system for OHE traction.


Date of Start: April 2012
Deliverables: Development of on-line measurement system module of OHE having
features of measurement of contact wire thickness, stagger, height,
slope; identification of exact location of measurement duly
synchronized with GPS positioning system and fully supported
software.
Benefits: On-line monitoring of OHE parameter will greatly help in directive and
preventive maintenance of OHE installations.
Current Status: Analysis of field trails being done including validation.
Refinement of design, identification of partner for manufacturing and
Technology transfer to RDSO are remaining stages.
IIT/KGP conducted field trial on 12.03.2019 in KGP division of SE
Railway, by installing the system on a Tower Wagon. During the
validation field trial problems were encountered with the system
designed by IIT/KGP.
In order to rectify the defects IIT/KGP has requested for extension of
project completion date (PDC) up to 31.08.2019.
The project completion date has been extended up to 31.08.2019

Proposed Date of 31.08.2019.


Completion:

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:

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10.4 Mobile instrumentation car for monitoring the health of PSI


Date of Start: 2016-17
Benefits: Due to increased loading on the line with drastically limited
manpower, degree of desired attention can be given only with modern
diagnostic tools which would also help to Railways plan for directed
maintenance instead of periodic overhauling. The proposed test car
would be carryout detailed diagnostic testing of complete TSS and
Switching Post (SP/SSP).
Current Status: Technical study and specification is under finalization.

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.

10.6 Development of Copper-Magnesium Catenary Wire.


Date of Start: April-2015
Deliverables:  Indian Railways are using Copper- Cadmium Catenary wire in Over
Head Equipment for carrying current. Since Cadmium is a
hazardous material and is being gradually discontinued, the need
was felt to replace the same with an appropriate material.
 TI Directorate developed the specification of Copper-Magnesium
Catenary and after approval by Railway Board, Expression of
Interest was called. A select panel of 13 Vendors was formed and
based on discussions; an amended specification was issued to the
Select Panel. They have been advised The confirmation from the
Vendors is awaited.
 Meanwhile, Railway Board has advised CORE, Allahabad and East
Coast Railway to procure 300 T of the Copper Magnesium Catenary
to RDSO‟s specification
Current Status:  Prototype testing of material developed by two Firms has been
conducted.
 CORE & ECOR has been advised vide letter dated 18.03.2019 to
procure the material for field trial.
Target Date of June, 2020
Completion:

11.0 TRAFFIC DIRECTORATE

11.1 Passenger Feedback Survey on various services in Double Decker


trains
Deliverables: Assessment of on board passenger amenities.

Benefits Enhanced Passenger satisfaction through improvement in services

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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

11.2 Passenger Feedback Survey on various services in Humsafar Trains


Deliverables: Assessment of on-board passenger amenities.
Benefits Enhanced Passenger satisfaction through improvement in services
Current Status: Study has been completed and report No. TFC-95 has been sent to CCM
of SECR Bilaspur, N.E. Railway, and CRM IRCTC for necessary action,
Date of Completion 30-10-2017

11.3 Enhancing Passenger and Freight Throughput on existing network.


Deliverables: Inputs from various technical directorate of RDSO have been collected
and sent to Chairman of the subcommittee.
Benefits Interim report was prepared by expert group for augmenting futuristic
demand of traffic pertaining to Passenger and Freight Throughput
Current Status: Study is completed.
Date of Completion August 2017

11.4 Implementation of technological aid at NI-MLC gates.


Deliverables: Issue of Guidelines for implementation of technological aid at NI-MLC
gates.
Benefits Improving safety at NI-MLC gates.
Current Status: Study is completed. Railway Board has issued instructions to Zonal
Railways as per RDSO‟s recommendations.
Date of Completion May, 2019.

12.0 TRACK DESIGN DIRECTORATE

12.1 Field Trials of Micro-Alloyed High Yield Strength Niobium &


Vanadium Rails
Deliverables: Assessment of field performance of micro-alloyed high yield strength
Niobium and Vanadium rails on heavy axle load routes on IR.
Longer service life due to reduced fatigue defect generation rate and
enhanced yield strength.
Current Status: Field trials of micro-alloyed Niobium and Vanadium rails have been
completed in Kharagpur and Chakradharpur Divisions of South Eastern
Railway, respectively. Minimum Yield strength of Niobium and
Vanadium rails is 540Mpa and 630Mpa respectively against 460Mpa for
880 grade C-Mn rails. During the field trials of about 7 years, total
fatigue defects generated in Vanadium rails have been only 13 against
47 in conventional C-Mn rails. Hence, defect generation rate in
Vanadium rail is much less (About 25%) than that in conventional 880
grade C-Mn rails. Also, extent of gauge corner cracks in Vanadium rails
has been much less as compared to 880 grade C-Mn rails. Based upon
laboratory evaluations and field performance of these rails in field
trials, a report on “Development and Field trials of Niobium and
Vanadium Micro Alloyed Rails” (Report no. CT-27, July 2015) was
submitted to Railway Board on 28.07.2015. Railway Board has
considered the report and agreed that improvement in rail chemistry,

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fracture toughness and corrosion resistance shall be pursued further to


meet the Indian Railways needs. The improvement of rail chemistry is
being pursued through another project.

12.2 Development of improved AT Welding Technique with single shot


crucible and Auto-tapping thimble.
Deliverables: Development of AT Welding Vendors with single shot crucible and
Auto-tapping thimble.
It will ensure consistent quality of AT welds by producing relatively
cleaner welds, free from impurities & voids and reducing dependence
on welder‟s skill.
Current Status: Six firms have been approved for AT welding by single shot crucible
with auto tapping thimble technique.

13.0 TESTING DIRECTORATE

13.1 Replacement of 02 staff cars with LHB AC staff cars.


Deliverables: 02 nos. High speed LHB AC staff cars
Testing directorate is conducting various trials like TM run, COCR etc.,
wherein test specials are required to be run at a speed of upto 180
kmph. These coaches are a part of test specials; In future speed may
go beyond 180 kmph also.
Current Status: 02 nos. High speed LHB staff cars nos. LRDAC-8029NR and LRDAC-
8030NR have been received in May-2016 and Jan-2017 against RD-8027
(RD-84876) and RD-8026 (RD-84877) and these have already been
commissioned.

14.0 WAGON DIRECTORATE

14.1 Fitment of Bogie mounted Brake system in freight rolling stocks


Deliverables: 1. More effective and reliable brake system.
2. Reduction in tare weight due to lighter brake rigging components.
3. Less wear and tear of components
4. Automatic adjustment of brake force in empty & loaded condition
5. Lesser maintenance requirements
6. Reduction in wheel wear as compared to conventional brake
system Possibility of use of space between two bogies
Current Status: Designs submitted by two firms have been approved, Two licensee of
one firm have also been approved. STR verification of two licensees of
second firm have also been done. Type tests at the premises of third
firm are underway.

14.2 Development of High Capacity Parcel Van using Freight Bogies


(CASNUB) Wagon type BCPVN.
Deliverables: 1. New Design of Parcel van, to be operated as dedicated freight
stock.
2. The present Parcel van being coaching stock need to follow
coaching maintenance schedule &are also limited in terms of their
volumetric capacities.
3. Design to cater to requirements of smooth interiors, interior
lighting, and special extra wide door best suited for parcel
loading.

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4. High volumetric capacity along with freight maintenance


schedules would enable lower maintenance & dedicated freight
operations of high earning freight traffic.
5. 23.33% more carrying capacity than carriage parcel van.
Current Status: Design finalized & forwarded to Railway Board. Board (TT Dte) is
evolving a new policy for operations of Freight Parcel Van. Wagon
prototype development requested by Railway Board under PPP mode
with private investment from M/s Gati Logistics.

14.3 Design Development of 25t axle load BOXNS open wagon


Deliverables: 1. Designed with the best ever pay to tare ratio of 4:1
2. Fish Bone Structure i.e. Side Stanchions integrated with Cross
Members.
3. Optimal Material Selection, cost effective design utilizes stainless
steel on surfaces in contact with coal but utilizes HSLA (IS:2062 E
450)carbon steel in under frame.
Current Status: Oscillation trials at 110 kmph €/100 kmph (L) have been successfully
completed. Final speed certificate issued at 85 kmph( E)/ 65 kmph(L)
on 24.08.16. First rake of 59 wagons turned-out from M/s BWT on
15.05.2017. Railway Board has placed an order of 500 wagons each on
M/s Braithwaite & M/s Burnstandard.

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.

15.0 Carriage Directorate

15.1 Reduction in wheel shelling in LHB Coaches


Deliverables: 1. Optimization of dump valve choke sizes for prompt response of
WSP in case of wheel slip.
2. Modification of WSP wiring layout and junction boxes with MIL-
Grade connector with IP67 protection.
3. Standardization of self-lubricating brake caliper bushes to avoid
jamming.
4. Modification of piping layout with reduced joint to avoid leakages.
Current Status: Choke sizes have been optimized after field trials in Zonal Railways.
Self-lubricating bushes are standardized. Revised design of junction
boxes and modified wiring layout has been issued to production units
and Zonal Railways for implementation.
Zonal Railways have reported 60% reduction in wheel shelling after
implementation of above modifications advised by RDSO.

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15.2 Development of Crashworthy Design Of LHB Type Coaches


Date of start: Dec.2007
Deliverables: Crashworthy design of LHB type GS coach & power car.
In the case of accident
No or minimum deformation in passenger occupied areas.
No climbing of coaches one over the other.
Energy absorption in non-passenger areas through controlled collapse.
Low decelerations to avoid injuries to occupants
Current status: The designs have been completed and issued to Production Units.

15.3 Optimizing the design of coupling arrangement and setting up a


longitudinal simulation facility at RDSO.(Completed In-house)
Deliverables:  Study and report on existing design of centre buffer coupler for its
problem of longitudinal jerks through simulations.
 Analysis of test/trial data provided by RDSO and its comparison
with simulation results.
 Provision of software for longitudinal simulation.
Current status : Validation trials for longitudinal behaviour of the train for modelling
and longitudinal comfort criterion development have been conducted
by testing directorate. Data has been sent to the consultant for model
validation and longitudinal comfort criterion finalization. Final report
has been sent by the consultant along with optimised software module
and project has been completed. The project has been completed in
March 2019.

15.4 Development of AC Version of LSCN, LSR and LS


Deliverables: • Presently, Mail/Exp. trains having rake formation of AC as well as
Non AC coaches are restricted to run up to a max. speed of 110
kmph on Indian Railways network due to noise and dust issues in
Non AC coaches.
• Enhancement of speed potential, of Mail/Exp. trains is a basic need
for Indian Railways in todays high speed transport network system.
Current status : • RDSO has developed the layouts of AC Version of LHB design Non AC
Coaches LWSCN, LS (LHB GS) and last vehicle i.e. SLRD with under-
slung power pack coaches and sent to Board for consideration.

15.5 DEVELOPMENT OF SPECIFICATION (NO. RDSO/CG-18002, Rev-nil)


FOR BG LIGHT WEIGHT ALUMINIUM PASSENGER CARS (LOCO HAULED)
WITH OPERATIONAL SPEED OF 200 KMPH UPGRADABLE TO 250
KMPH. (Completed In-house)
Deliverables: This specification describes the requirements for design, development,
manufacture, supply, testing, delivery and commissioning into service
of modern fully furnished and finished BG, integral, lightweight
Aluminium Passenger Cars of EOG/HOG design with transfer of
technology (TOT).
Current status : Specification No. RDSO/CG-18002, Rev-nil has been issued to Railway
Board.

15.6 Foul smell in toilet room (Carriage)


Brief Description 1. Existing coaches was fitted with HDPE lavatory Chute having ventury
effect for air circulation in lavatory area.

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.

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3. Project for study of removal of foul smell by suitable air circulation


method at higher vehicle speed and aerodynamic profile study.
Location of ventilation fan or induced draft ventilation system shall
be defined accordingly.

Study of design aspects of toilets for efficient flushing and surface


finish /materials of floor /lavatory pan, provision of hydrophobic
coating on lavatory floor etc.
Justification: Railway Board has expressed its concern to deal with bad smell from
toilets of Indian Railway Passenger coaches.

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7.0

„On-going Projects‟ of RDSO

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„On -going Projects‟ of RDSO

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)

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11.0 WAGON DIRECTORATE


11.1 Design and Development of 25t axle load wagons for existing IR systems
11.2 Development of new design of 22.9t Axle load Bogie flat wagon BFNSM for
transportation of steel coils
11.3 Development high capacity Draft Gear (71 BD) for higher axle load freight rolling
stocks
11.4 Design of advanced performance Next Generation Freight Bogie Design
11.5 Design Development of 25t axle load BCSA/BCSB container flat wagons
11.6 25t Light Weight Low Height Bogie along with „K” class bearing
11.7 Design and Development of In-Motion Weigh Bridge

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6.0 „On-going Projects‟ of RDSO

1.0 BRIDGES AND STRUCTURES DIRECTORATE

1.1 Development of railway bridge Health Monitoring System with wireless


sensor network (IIT –CRR KGP)
Date of start: March 2012
Deliverables: • Wireless Sensor Network Design for bridge health monitoring and
investigation report of possibility of sensor deployment for early
warning of flood water.
• IIT faculty will conduct a technology dissemination workshop for RDSO
personnel at IRICEN, Pune. The travel and DA cost of IIT faculty will be
borne from the part of IIT Kharagpur official whereas the local
hospitality, TA and DA of the participants of RDSO/Indian Railways will
be borne by RDSO/Indian Railways. If RDSO/India Railways agrees to
bear the TA, boarding and lodging of the RDSO/Indian Railway
participants, then the work shop can be held at IIT Kharagpur
Current status • Procurement of water level sensors also completed. Primary testing of
sensors on Rly. Bridge No. 57 in KGP-HWH section completed.
• Final Report on Flood Water Monitoring System has been submitted to
RDSO on 21-2-2016.
• Draft final Report on “Numerical Modeling of Railway Bridges” has been
submitted by IIT/KGP for scrutiny of RDSO on 30.4.16. After Scrutiny by
RDSO the shortcomings in report has been advised to IIT/KGP on
19.05.16
• Draft report on “Wireless sensor network for Railway Bridge Health
monitoring” was received for first time on 18-08-2016 and after noticing
shortcomings, like deflection, Tilt, Inclination not taken as criteria, no
system of comparing Numerical Modelling Result with Inst. Result,
location of Sensors not reasonable, no criteria limits to decide bridge
healthy or not, issuing of SMS by System etc. and comments on the
software to be used for RBHM were advised vide letter dated 18-10-16.
Positive work done & mentioned in Report was also appreciated like
work on Single Board Computer Rasberry Pi2, Event detection System
along with Algorithm, concept of Master & Child Sensors, Design of
Noise Filters etc. Further progress awaited.
• Shortcomings in Project raised in Video Conferencing on 26.02.16, other
Project Review Meetings held on 08.06.16, 19.07.16 & 20.12.16
• Dir./B&S/T&I visited IIT/KGP from 21-12-2016 – 23-12-2016 and large
shortcomings in Numerical Models, shortcomings in Model Bridge &
RBHM software developed were noticed, same advised to IIT/KGP during
interaction & also letter dated 30-12-2016 was issued.
• In response to 30 day‟s Notice, a report was received from IIT/KGP on
14-6-2017. On scrutiny found none of major issue of RDSO has been
addressed and on account of poor progress, project was terminated on
28.06.17
Proposed date Terminated
of completion

1.2 Evaluation and management of longitudinal force on substructure of


railway bridges. (SERC/CHENNAI)
Date of start: MoU signed on 6th March 17
Deliverables: • Guidelines for design provision for estimation of longitudinal force on
ballast less and ballasted bridges.

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• Guidelines for management of longitudinal forces on bridges.


Current status Testing for longitudinal force evaluation has been completed in 04 bridges
out of 10 bridges. Total payment of Rs. 4.28 Cr. released to SERC.
Proposed date Three years from date of MoU
of completion

1.3 Assessment of efficacy of retrofitment of arch bridges (SERC/ CHENNAI)


Date of start: 2013-14
Deliverables:  Guidelines for assessing the load carrying capacity of existing and
retrofitted arch bridges with detailed commentary.
 Guidelines on selection of retrofitting methods for increasing the load
carrying capacity of existing arch with detailed commentary.
 Report(s) at the end of the identified tasks of the project.
• Training of about 40 Indian Railway Officials on assessment of load
carrying capacity and retrofitment technique to be used for upgrading
the load carrying capacity of arch bridges.
Current status  Detailed estimate Sanctioned. PEC recommendations duly forwarded by
the then DG were submitted to Railway Board during May 2017. Board
has returned with some queries. Fresh PEC minutes have been prepared
and submitted to Railway Board on 18.07.2017.
 Replies to queries of Railway Board have already been submitted to
Railway Board vide this office letter No. CBS/DAB dated 03.11.2018.
 Further queries vide Railway Board E Mail Dated 20.05.2019 have been
replied vide this office E Mail Dated 03.06.2019.
Proposed date Three Years after signing of MOU.
of completion

2.0 CARRIAGE DIRECTORATE

2.3 Environment Friendly Coach Toilet Discharge System


Date of start: Aug.2005
Deliverables:  Development & design of the proposed toilet system for adoption on
new and existing coaches
 Discharge on track and in station will be eliminated. Possibility of
corrosion due to effluents is eliminated
Current status  Cumulative fitment of 195917 IR-DRDO bio toilets in about 53924
coaches till 31.03.2019.
 In the year 2019-20, total 4592 bio toilets installed in about 1347
coaches. On cumulative basis, 200509 bio toilets installed in about
55271 coaches.
 RDSO has issued Retro-fitment design for ICF & LHB stocks including
MEMU, DEMU & OCV‟s.

3.0 GEO-TECHNICAL ENGINEERING DIRECTORATE

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

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existing formation upto 250 Kmph speed.


 Development of design methodology for design of formation, for speed
slab of 160-250 Kmph
 Evaluation of existing formation for use at from 160 Kmph to 250 Kmph.
 Capacity building for design of formation for speed from 160 Kmph to
250 Kmph.
Current Status:  Project awarded to IIT/Roorkee in November 2016.
 A status report of the project was submitted by IIT/Roorkee. Project
objective wise RDSO‟s observations on the same was conveyed to
IIT/Roorkee.
 A meeting to finalize action plan to complete the project is proposed in
3rd week of June.
Proposed Date December 2019
of Completion:

3.2 Use of L.D. Slag as Railway Track Ballast


Deliverables:  The project involve study of technical aspects related to use of L.D.
Slag as railway ballast and conducting of field trials.
 Evaluation of properties of LD slag to ascertain the conformity with
ballast specification
 Use of LD slag as Railway ballast will effectively utilize LD slag which is
an industrial waste by-product..
Current Status:  Trial has been completed at Ispatnagar Yard near Bokaro Steel City in
Adra Division & results are not as per standards for Track Ballast.
Finalized report has been sent to Railway Board for information.
 Field trial for LD slag is proposed at Ghamariya Yard near Tatanagar in
Chakradharpur Division, which is to be conducted by SEC Railway in
association with CRRI.
 CRRI has to submit formal proposal for MOU to Railways in this regard.
Proposed Date March 2021
of Completion:

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
Date of Start: 07.02.2012
Deliverables:  Standardization of composition of composite brake blocks. The effect
of different ingredients on the properties of the brake block may be
elaborated during the course of the project.
 The standards need to be evolved for smokeless and odourless brake
block during brake application.
 Physical Chemical and frictional properties of composite brake blocks.
 Durability of composite brake blocks by ageing studies for longer
service life.
 Thermal conductivity measurements of the brake blocks for better
heat dissipation.
 Moulding / Manufacture of the composite brake blocks.
 Transfer of Technology to RDSO in the form of technical document
indicating detailed design list of equipments along with the
procurement specification, hardware design, schematics, general lay
out drawings, source code for the software, details of test jigs, list of
probable suppliers for each equipment and test scheme.

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 Testing and evaluation of frictional characteristics of Composite Brake


Block on Dynamometer at RDSO.
 Involvement of IIT/KGP in validation/field trial/prototype test and
revision of specification as and when required by IR/RDSO.
 The development of composition and standardization of properties of
composite brake blocks will be helpful to assess the actual
performance of the brake blocks in respect of wear properties. This
will improve the frictional characteristics, dissipation of friction heat,
physical strength and long service life of composite brake block.
Uniformity in the physical properties of different approved
manufacturers will also be achieved through this standardization.

Proposed Date March 2018


of Completion:

4.2 Thermo-mechanically processed high strength bainitic steel rails for


Indian Railway.
Date of Start: 01.09.2012
Deliverables: The bainitic rail steel will be of low carbon low alloy/low carbon micro
alloyed steel which will possess good weldability properties.Expected
metallurgical/mechanical parameters are written below.
Pearlitic rail steel Bainitic rail steel
Tensile strength 880 N/mm2 1000 N/mm2
1/2
Fracture toughness 29MPam 50 MPam1/
Impact toughness --- Twice of pearlitic steel
Wear resistance --- Twice of pearlitic steel
In the present pearlitic steel specification, no such value for Impact
toughness and wear resistance has been made specific. However, in this
project the values of Impact test and wear resistance for pearlitic steel to
be evaluated and accordingly the target of bainitic steel to be fixed at
around twice the value of pearlitic steel
Benefits: i) Benefits likely to accrue – Technical
The Banitic rail steel can be of low carbon low alloy or low carbon micro
alloyed steel which not only have excellent wear resistance but also very
good fracture toughness having low fatigue crack growth rate as
compared to 880 grade or 110 grade pearlitic rail steel. The objective of
the project will be to design specific banitic rail steel grade of rail steel
with superior impact strength, fracture toughness, wear resistance and
weldability properties without compromising with the present axle load
bearing capacity of 32MT axle load. The banitic rail will have lower wear
rate, reduction in rail fracture, effective implementation of ultrasonic
testing ensuring predictive maintenance due to reduced crack growth
rails. Thus the safety and reliability of the rail track can be enhanced
substantially as reduced maintenance cost.
(ii) Benefits likely to accrue- Finance
Indian Railways are having a track net work of 81,215KM. This contains
around1, 24, 94,000 Nos. of 13 meter rail pieces.
a) The use of Bainitic rails instead of Pearlitic rails ( existing practice) is
expected to enhance the life of the rails by at least 90%
b) The cost of Bainitic rails are supposed to be 70% higher than the
existingPearlitic rails.
c) The replacement of rails in Indian railways is done due to wear,
fracture or possible fracture (revealed during NDT Test) of rails during
service.

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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:

5.0 MOTIVE POWERDIRECTORATE

5.1 Design validation of HTSC Fab-II Fabricated Bogie Frame for HHP
Locomotives

Date of Start: 2016-17


Deliverables:  FEA model and 2D manufacturing drawings of the improved bogie
frame including plate drawing specifying edge preparation for weld,
sub-assembly drawings specifying plate weld sequence, weld details,
root gap etc.
 Fatigue test scheme for bogie frame based on mutually agreed test
protocol (Test data from field trials of existing bogie, BS EN
13749:2011, EN 14363:2013 or equivalent International standard) &
infrastructure available in Fatigue test laboratory at RDSO/Lucknow.
 Development of design skills of RDSO officials through training
Current status Under re-tendering (awaiting railway boards‟ clearance)
Proposed date June‟20
of completion

5.2 Design Validation of Fabricated Bogie Frame (Equaliser – less Bogie) for
WDM3D Locomotives.

Date of Start: 2016-17


Deliverables:  FEA model and 2D manufacturing drawings of the improved bogie
frame including plate drawing specifying edge preparation for weld,
sub-assembly drawings specifying plate weld sequence, weld details,
root gap etc.
 Fatigue test scheme for bogie frame based on mutually agreed test
protocol (Test data from field trials of existing bogie, BS EN
13749:2011, EN 14363:2013 or equivalent International standard) &
infrastructure available in Fatigue test laboratory at RDSO/Lucknow.
 Development of design skills of RDSO officials through training
Current status Under re-tendering (awaiting railway boards‟ clearance)
Proposed date June‟20
of completion

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5.3 Development of Bogie for Narrow gauge Railcar to be manufactured at


Parel Workshop.

Date of Start: Apr‟17


Deliverables:  Bogie assembly and part drawings.
 Indigenous development of a bogie for NG Railcar.
Current status  Bogie drawings finalized
 Envelope dimension provided to OEM for transmission and power pack
Proposed date Mar‟20
of completion

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

5.5 Development of energy efficient Multi Genset(WDS6G) shunting


locomotive of 1600 HP
Deliverables:  Development of prototype locomotive with DMW, Patiala.
 Availability of diesel locomotive with reduced emission and fuel
efficiency in switcher services.
Current status  RDSO had issued specification to DMW Patiala in 2016.
 Accordingly, loco manufactured by DMW
 Oscillation trial pending
Proposed date Dec‟19
of completion

5.6 Development of Dual mode locomotive


Deliverables:  Specification of dual mode passenger and goods locomotive
 Development of prototype with DLW.
 Seam less operation in IR without changing of traction
 Reduction of operational journey time.
 Full redundancy
Current status  DLW has awarded contract
 Manufacturing yet to start
Proposed date Mar‟20
of completion

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5.7 Design review and Development of 6000 HP WDG6G locomotive with


M/s GE (PPP project) at Marhowra
Deliverables:  Design review
 Prototype development with trial and testing
 Locomotive with high standard emission norm
 More fuel efficient
 Increased throughput
Current status Two prototype locomotive manufactured at USA received, currently in
South Central Railway for oscillation, rating and performance trial
Proposed date Sept‟19
of completion

5.8 Development of Micro-Processor Based Governor (MPBG) for HHP locos.


Deliverables:  Specification & Performance evaluation by field trials
 Complete flexibility in various adjustments like engine speed, notch-
wise low lube oil shut down pressure, maximum allowable fuel rack as
a function of engine notch position and boost air pressure
 Simple maintenance with modular system and minimum moving parts.
Current status  Specification developed.
 Prototype developed and tested as per Specification.
 04Nos.System underwent field trials for 12 months.
 Performance found satisfactory
 Advised to Board for inclusion in RDSO vendor directory

Proposed date  Sept‟19


of completion

5.9 Development of 9 TBN crankcase oil


Deliverables:  Development of 9 TBN crankcase oil compatible with Low sulfur or
ultra low sulfur HSD
 Reduction in cost of crank case oil due to reduction in additives of
crank case oil.
 Less maintenance is required due to less muck formation.
Current status  Limited trials, considered satisfactory.
 KJM & UBL diesel shed of SWR, PA diesel shed of CR, VTA diesel shed
of WR and TKD diesel shed of NR advised to conduct wider trials.
Proposed Date Mar‟21
of completion

5.10 Vehicle Dynamic Simulation of Standard Gauge Locomotive


Deliverables:  Development of complete vehicle model (System file) including
templates, subsystems and assembly.
 Maximum value of all output results at every speed for all operating
conditions.
 Dynamic simulation analysis report along with Pre-load, linear,
stability and dynamic analysis.
Current status Processed for retendering (Under finance for concurrence for changes in
eligibility criteria)
Proposed Date Dec‟19
of completion

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5.11 Development of Runtrain Simulation Software


Deliverables:  Advanced simulation software
 To facilitate all types of performance related calculation viz.
running time, balancing speed, time lost due speed restrictions,
load factor, fuel consumption and acceleration characteristic etc.
 Of various types of rolling stocks in service over IR under different
combination & conditions up to maximum speed potential of 350 &
150 Km/h for passenger & freight service respectively.
Current status MOU signed with IIT/Delhi for development of Software in May‟19.
Proposed Date Mar‟20
of completion
5.12 Development of Anti Pilferage Management System for Fuel
Deliverables:  Issue of specifications
 To monitor usage of fuel in real time, preventing possibility of
pilferage
 Monitor fuel consumption of locos in real time for identifying badly
performing locos and according take corrective measures
Current status  Specifications issued to DMW in May‟18
 Tendering to be done by DMW

5.13 Introduction of 2000t-m(200T) Capacity Telescopic type Jib crane for
IR & DFC
Deliverables: Development and procurement of Telescopic crane of 2000 t-m capacity
having following features-
 Telescopic boom to provide versatility at breakdown site especially in
cuttings, tunnels & under OHE etc.
 Working radius of the jib/boom upto 23 meters to work in four-line
scenario.
 Can handle loaded wagons of 100 ton capacity.
 Cabin controlled, free adjustable outrigger arms and propping
cylinders stroke, free adjustable counterweight, based on lift
requirements, Remote controlled rigging condition, interlocked with
cabin control.
 Independent slewing of counterweight feature while working in
tunnels, cuttings & other restricted areas.
 Automatic-cant compensation feature & self-levelling of under-frame
on grades & curves without reduction of capacity of crane in Free on
rail condition.
 Additional tunnel fork attachment which can be fixed to main
hook/boom to enable handling of a derailed stock in a tunnel
 Recovery winch with accessories to bring load in range of lifting.
 Set-up time of 40 minutes with all props for operation.
Current status  Specification framed by the Committee, nominated by Board, including
ED/MP, approved by MRS (RB)
 Tender document under preparation by COFMOW for floating Global
Tender.
Proposed Date Dec.‟20
of completion

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5.14 Introduction of 3-coach Diesel –Electric High Speed Self-propelled


Accident Relief Train (HS SPART) with 160 km/h
Deliverables: 3-Coach High Speed Dsl-Electric SPARTwith 160 km/h will have following
features-
 Standard one unit consists of 3-car rake – 1 DPC (supervisor van) +
1TC (Medical Van) + 1 DPC (Tool Van).
 Driving cab at both ends for bi-directional operation
 To reach at accident site upto max. permissible speed of 160 kmph.
 Acceleration 0.8 m/s2
 AC-AC traction system
 Microprocessor controlled & diagnosis system
 Fully Air-conditioned coaches
 Dynamic braking
 Automatic door opening & closing
 Provided with re-railing equipments, rescue devices and medical
facilities.
 Provision for modern kitchen equipment in the supervisory van.
Current status  Specification no. MP-0.24.00.84 (Rev-00) issued to Railway Board in
Oct‟18.
Proposed Date Dec‟20
of completion

6.0 SIGNAL DIRECTORATE

6.1 Development of TCAS


Date of Start: 2011-12
Deliverables:  Development of indigenous Train protection system.
 Development of multiple sources
 Trials in about 250 kms section
 Detection and Prevention of SPAD
 Display of Signal Aspect in Cab.
 Speed Supervision and Control.
 Certain Other Non Signaling Collision Prevention Features.
 Feature of SOS from Loco and Station.
Current Status: Based on successful trials, demonstration to compliance to specification,
interoperability and ISA assessment, the following three developing firms
were approved under developmental orders for speeds up to 110 kmph in
Absolute Block Section.
 M/s. Medha Servo Drives – March 2018
 M/s. HBL Power Systems Ltd. – December 2018
 M/s. Kernex Micro Systems Pvt. Ltd. – April 2019
Now Phase-II trials for speeds upto 160 kmph and trials in Aumatic Block
Section are being planned which are likely to conclude by June 2019 and
November 2019 respectively.
Date of April 2019 (Completed)
Completion for
phase I :

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7.0 TELECOMMUNICATION DIRECTORATE

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.

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 LTE is an efficient technology, which offers high transmission capacity


and low latency. Usage of the network resources – specially the limited
radio resources is optimized in comparison to GSM-R. LTE offers
standardize solution to Indian Railways.
Current Status: Phase –I : IIT Madras along with IIT Hyderabad and CEWiT will analyze LTE
technology vis-à-vis the communication requirements of Indian Railways in
comparison with GSM-R and prepare a detailed report on how LTE
technology can be used in Indian Railways.
Phase –II :, IIT Madras along with IIT Hyderabad and CEWiT will partner
with Indian equipment vendors to develop and demonstrate LTE solution
for Indian Railways in a field setup.

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.

Second Interim report submitted by IIT/M on “Report on Study &


Adaptation of LTE for Indian Railway Requirements” in Dec‟18. Report
has been examined and it is found that report is not as per details given in
MoU activity plan. Observations of RDSO have been submitted to IIT/H for
necessary compliance

Proposed Date Dec‟2019


of Completion:

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

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executed and coordinated by Civil Engineering Dte. in Board and Track


Dte. in RDSO.
In reference to Railway Board‟s directives Vide letter No.
2017/Sig/WP/IR/RF&ids/Pt. dated 14.06.2017, the Executive Authority of
the works has been transferred to respective Railways on IRPSM.
The work of OFC lying is in progress at NC Railway.
Proposed Date Work is being executed by NC Railway.
of Completion:

8.0 TRAFFIC DIRECTORATE

8.1 Revision in specification of LED based battery operated Torchlight cum


flashing H.S. Lamp
Date of Start: 01.01.2018
Deliverables: Improvement in handling and cost effective.
Benefits: Compact size and cost effective product.
Current Status: Based on feed back from zonal Railways, interaction with LPs/Guards/
Station Masters/Gate Men etc, and meeting with vendors, specifications
are under revision in association with Signal Directorate.
Proposed Date June 2019
of Completion:

8.2 Impact of GST on Parcel Traffic Over Indian Railways


Date of Start: 01.01.2018
Deliverables: To study the impact of GST and Parcel E-waybill on Parcel Traffic over
Indian Railways.
Benefits: Assessment of problems in booking of outward parcel traffic after
introduction of GST and parcel E-waybill, so that suitable steps can be
taken to overcome problems leading to attract more parcel traffic.
Current Status: Data has been collected and analysed. Report is under preparation.
Proposed Date July, 2019
of Completion:

9.0 TRACK DESIGN DIRECTORATE

9.1 Ultrasonic Broken Rail Detection System


Date of Start: April-2018
Deliverables: Validating the IR methodology and the requirement of rail for 25t axle
load operation
Benefits/ The project was required to check, if IR methodology is in line with
Justification: international practices.
Brief Validation of rail stress calculation methodology adopted by RDSO by and
Description international expert agency.
Current Status: The consultancy was assigned to a group of facility from University of
Illinois Urbana Champaign (UIUC), USA. The study has been completed and
consultancy report has been accepted.
Proposed Date April-2019
of Completion:

9.2 Improvement in rail quality and review of specification IRST-12:2009


Date of Start: November, 2010

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Deliverables: Development of rail steel with better mechanical and metallurgical


property.
Benefits: Enhancement of service life of rails for IR traffic and environmental
conditions.
Current Status: Rail chemistry has been finalized. Test results have been deliberated and
found satisfactory in the 11th meeting held on 12.05.2017 at Ranchi.
Further tests are in progress for repeatability. Next meeting of the
committee will be held after completion of tests, likely in last week of
July, 2017.
Proposed Date Development part of the project likely to be completed by September,
of Completion: 2017. Subsequently, field trial will be considered for minimum two years
duration

10.0 TESTING DIRECTORATE

10.1 Procurement of 30t Universal Spring Testing Machine


Date of Start: 2016-17
Deliverables:  Actuator +30t capacity.
 Portal frame 2*2 meter,
 Hydraulic Service manifold,
 Hydraulic hose set -1no.
 Conducting load deflection and endurance test of the spring/any
railway components of rolling stocks.
Current Status: Machine likely to be supplied by July‟19 and commissioned by Sep‟19
Proposed Date September, 2019
of Completion:

10.2 Procurement of High inertia and high speed brake dynamometer.


Date of Start: 2017-18
Deliverables:  Test stations with facility of mounting 02 wheels,
 Pneumatic damping system under base frame,
 Static brake test unit,
 Pneumatic and hydraulic brake pressure supply units,
 Torque calibration unit,
 Air conditioning unit for controlling climatic test conditions,
 Video monitoring system,
 Data acquisition system configured with latest hardware and software.
 In view of proposed increase of speed of rolling stock on Indian railway
a high speed and high inertia brake dynamometer is essentially
required for development of improved brake materials in future.
Current Status: Tender has already been floated and is likely to be finalized this year
Proposed Date December 2021
of Completion:

10.3 Procurement of measuring wheel calibration test rig in testing


directorate
Date of Start: 2017-18
Deliverables:  Test Bench and foundation work,
 Load Cell,
 Hydraulic system,
 Controls for hydraulic system,
 Calibration amplifier,
 Software for control system,
 Electrical control system for dynamic as well as static operation load

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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)

Date of Start: 2017-18


Deliverables:  01 no. High speed LHB staff cars against ICF built Staff car RD-
88876/8028 (unit OT-I).
 Testing directorate is conducting oscillation trials, COCR, TM Run etc
in the field. Staff cars are used for accommodation of officers and
staff in the field. During TM run and other trials as per the
requirement staff cars are attached with the test special
Current Status: Included in current year production plan of MCF.
Proposed Date March, 2020
of Completion:

11.0 WAGON DIRECTORATE

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:

i. Physical Load Environment Assessment(LEA) on instrumented


existing BOXN wagon with TTCI covering approx. distance of 16000
Km have been completed to acquire the load Environment data for
design of 25 T axle load open and covered wagons.
ii. Design of open and covered wagon have been finalised and
submitted by the firm.
iii. A prototype open wagon (GONDOLA) manufactured at ARI, USA has

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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:

11.4 Design of advanced performance Next Generation Freight Bogie Design


Deliverables: 1. To evolve a broad based decision matrix with recommendations on the
basis of strength, weaknesses, opportunities and threats for selection
of a Freight bogie design on parameters including (but not limited to):
(i) Fabrication/ casting; (ii) No of axles per bogies; (iii) Articulated/
non articulated design; (iv) Lower lateral forces; (v) Minimizing
adverse impacts of string lining forces in heavy haul operations; (vi)
High speed potential up to 130 Kmph; (vii) Lower weight to achieve a
higher throughput per train and high pay to tare ratio of Wagons; (viii)
Robustness and maintenance friendliness; (ix) evaluation of life cycle
costs and reliability; and, (x) using encumbrance free technologies.
2. Utilize the worst possible hypothetical Wagon superstructure (for
example with maximum CG height and Moment of inertias) to design

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„On -going Projects‟ of RDSO

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:

11.7 Design and Development of In-Motion Weigh Bridge


Deliverables: 1. Indigenous Design as per IR operating condition free from gradient,
curves/ tangent track structure, type of platform under the track etc.
2. Capacity to weigh up to 160 ton per wagon.

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3. Higher Weighing Speeds (Presently Max. 15kmph).


4. Wireless communication system for smooth and uninterrupted.
5. Customized system software able to weigh, receive, display, analyze
and data transfer.
6. The system software should be designed in such a fashion that the
format of the data according to CRIS requirement to connect with
FOIS.
7. Facility for auto calibration or calibration by any nationalized agency.
Current Status: Wagon Directorate has presented the proposal which has been formulated
using WILD platform. It was approved by MICC for execution in a definite
time-frame of six months period. The detailed document as per MMM has
been submitted to MICC by Wagon directorate.

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8.0
New Projects Proposed

48th Meeting of CBRR


New Projects Proposed

8.0 New Projects Proposed

SN Directorate Name of Projects


1.0 Carriage Development of AC Version of LSCN, LSR and LS
2.0 Carriage Foul smell in toilet room
Carriage Design of Self Propelled Bogies for Vehicles on LHB
3.0
Platform
4.0 Carriage Flexi-Coil Spring
Energy Design of Energy efficient lighting system for Railway
5.0
Management Station of Indian Railway.
Energy Standardization of power supply arrangement at Indian
6.0
Management Railway Station premises.
Geo-tech. Engg. Design Methodology and Software Development for
7.0
Railway Formation Design
Geo-Tech. Engg. Development of Design and Construction Methodology
8.0 for Geosynthetic Reinforced Soil (GRS) Retaining Wall
(RW) for Railway Embankment.
9.0 Geo-Tech. Engg. Scanning of Track ballast using GPR
Geo-Tech. Engg. Optimum solution for improvement in characteristics/
10.0 properties of weak locally available soils for use in the
formation.
Geo-Tech. Engg. Design of Railway Embankment on Soil Prone to
11.0 Liquefaction
Geo-Tech. Engg. Effect of Seismic Forces on Railway embankment and its
12.0
remedy.
13.0 Geo-Tech. Engg. Landslide Monitoring System, using Satellite imagery.
Psycho technical Complete computerization of aptitude testing of Metro
14.0
Staff (station controller/train operator)
15.0 Psycho Technical Occupational Stress Survey for Station Masters.
16.0 Psycho Technical Purchase of new computerized psychological tests.
17.0 Psycho Technical Procurement of Global Psychological tests.
18.0 Signal Modelling and validation of interlocking for Railway
Signaling system Phase-II
19.0 Motive Power Upgradation of Hypermesh software package

20.0 Testing Procurement of 4 Staff cars cum Oscillograph Cars


Testing Development of capability for testing of High speed
21.0 Rolling stock

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New Projects Proposed

1.0 Development of AC Version of LSCN, LSR and LS(Carriage)


Brief Description: PROBLEM DEFINITION
• Presently, Mail/Exp. trains having rake formation of AC as well as
Non AC coaches are restricted to run up to a max. Speed of 110
kmph on Indian Railways network due to noise and dust issues in
Non AC coaches.

• Enhancement of speed potential, of Mail/Exp. trains is a basic need


for Indian Railways in todays high speed transport network system.

• In Mail/Exp. trains,there is only a Non-AC compartment in last


vehicle (SLRD) for Passenger with differently-abled (PWDs),
improvement in this area is a also a mandatory requirement in
today‟s scenario for PWDs.

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.

• Development of Air-cooled Version of LHB design Non AC Coaches


LWSCN, LS (LHB GS) and last vehicle i.e. SLRD format coaches that
can be marshalled in Mail/Exp. trains of LHB design platform.

• RDSO has developed the layouts of AC Version of LHB design Non


AC Coaches LWSCN, LS (LHB GS) and last vehicle i.e. SLRD with
under-slung power pack coaches and sent to Board for approval.

• Provision of air-cooling system which provides sufficient cooling in


these proposed coaches is a work of area needs proliferation
referring international practices and norms.

Proposed coaches are as below:


Air Cooled LHB AC EOG Second class GS coach:
• This coach will replace existing LHB Non AC EOG Second class GS
coach.
Air Cooled LHB AC EOG Second class Sleeper LSCN coach:
• This coach will replace existing LHB Non AC EOG Second class
Sleeper LSCN coach.
• Air Cooled LHB AC Second class cum luggage and Brake van with
comptt. For Passenger with differently-abled (PWDs) with Under-
slung power pack.
• This coach will replace existing LHB Non AC Second class cum
luggage and Brake van with comptt. For Passenger with differently-
abled (PWDs)
• Salient features of these proposed 03 coaches are as below:
• Almost no compromise in passenger capacity of these coaches.
• Under-slung power pack has been provided in LHB DSLR coaches.
• Coach proposed in AC-3 Tier profile to avoid reduction in luggage
space with AC duct provision.
• RMPU with AC ducting provided which is to be developed.

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New Projects Proposed

• A new Control panel of smaller size with underslung battery


charger has been provided in GS and SCN coaches to accommodate
AC facilities which are to be developed.
• Bi-directional compartment swing door for other passengers and
sliding door for Passenger with differently-abled for safe
evacuation during accident/ fire emergency, has been provided.
• 450 mm BLDC Fans provided in proposed coaches.
• Air springs on secondary suspension to cater the enhanced load
have been provided.
Justification: • To mitigate dust and noise issues
• Non-requirement of linen
• Suitable development of ducting system and air-conditioning
system

2.0 Foul smell in toilet room (Carriage)


Brief Description 4. Existing coaches was fitted with HDPE lavatory Chute having ventury
effect for air circulation in lavatory area.

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.

6. Project for study of removal of foul smell by suitable air circulation


method at higher vehicle speed and aerodynamic profile study.
Location of ventilation fan or induced draft ventilation system shall
be defined accordingly.

Study of design aspects of toilets for efficient flushing and surface


finish /materials of floor /lavatory pan, provision of hydrophobic
coating on lavatory floor etc.
Justification: Railway Board has expressed its concern to deal with bad smell from
toilets of Indian Railway Passenger coaches.

3.0 Design of Self Propelled Bogies for Vehicles on LHB Platform


(Carriage)
Proposed Cost : Rs.35crores
Brief Description: • Production of coaches on ICF design platform is to be discontinued
from 2018-19
• LHB technology was imported with FIAT bogie for non-powered
vehicles only.
• Powered vehicles like EMU,MEMU,DEMU etc. require Powered bogie
for complete switch over to LHB platform.
• Fitment of traction motor, gear train and associated subassemblies
require major modification in bogie design involving changes in
brake rigging,mounting of discs,shifting of cross members
(tubes),traction lever etc.
• It essentially involves a completely new design bogie for which
required expertise is not available at RDSO.
Constraints in Current Design for Conversion to Powered Bogie
• The space available between two discs is not sufficient for mounting
of motor with gear train and associated cabling along the axle.
• The space required for TM mounting across the axle is not sufficient
and it infringes with tubular structure (cross members) of the bogie.

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New Projects Proposed

• Any shifting of tubular members involves change in design of


traction levers, anti-roll bar assembly , bogie body connection
arrangement.
• The brake arrangement will require change and it may require
conversion to wheel mounted disc brakes or tread brakes.
PROPOSAL
• It is therefore proposed to engage expert agencies having expertise
in bogie design to develop self propelled bogie along with training
of RDSO personnel to acquire bogie design capability together with
required facilities for design including hardware and software
systems.
It may cost around Rupees 35 crores for this project.
Justification: LHB technology imported in the year 1999-2000 did not include Self-
Propelled Bogies. Railway Board has decided that from the year 2018-
19, only LHB type of coaches shall be manufactured on IR. As such, it
is essential to develop self-propelled bogies so that self-propelled
vehicles like EMU/ MEMU etc. may also be manufactured on LHB
platform. Therefore, it is essentially required to acquire bogie design
for self-propelled vehicles. Further, RDSO does not have sufficient
expertise to develop a bogie design for rail vehicles from scratch. The
required facilities and necessary expertise need to be acquired in
consultation with specialized company having sufficient expertise in
bogie design. This with help in development of bogies for vehicles
which may be required in future. Therefore, it is essentially required
to develop the facilities and acquire expertise at RDSO

4.0 Flexi-Coil Spring (Carriage)


Brief Description • The term „Flexi-coil‟ has been used for springs capable of taking
Transverse Loads. The term was coined by General Motors.
• The Flexi-coil effect is used to combine the spring function and the
guidance of Bogie Frame.
• The vehicle body is able to move laterally relative to the Bogie
against the restoring force of the spring.
• This type of spring were introduced with LHB design coaches and
the knowledge base available is very limited.
PROBLEM STATEMENT
• Due to limited knowledge base ,it is not possible to design a new
suspension system or to study the effect of changes in various
parameters of the suspension system.
• Failure analysis is also limited to material composition and other
parameters matching with the laid down limits.
• In depth analysis of failures and proper corrective action will be
possible only after full and proper understanding of various
parameters.
• Clearance to permit coach or otherwise to run upto end terminal
with one broken spring at normal speed or at reduced speed and its
effects.
• Such studies need a clear understanding of this type of springs.
Proposed actions
• It is therefore proposed to engage expert agencies having expertise
in Flexi-Coil spring design to develop expertise for design of
suspension system with Flexi-coil spring among RDSO personnel
together with required facilities for design including hardware and

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New Projects Proposed

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.

5.0 Design of Energy efficient lighting system for Railway Station of


Indian Railway.(Energy Management)
Brief Description: As various type of activities are undertaken at railway stations the
illumination requirements at Railway Stations are quite complex.
Presently no standard lighting system design is being followed.
Lighting scheme of each Railway Station has evolved gradually from
the immediate illumination requirements. Due to lack of standard
lighting design the existing illumination system at Railway stations is
not only energy inefficient but it poses serious constraints in meeting
the operational requirements. Hence it is proposed to take up a
project under TMIR for design of lighting scheme catering to the needs
of illumination requirements of various functional areas available at
Railway Station .
Justification: The existing lighting system not only provides an opportunity for
energy saving but also to improve aesthetics and operational efficiency
at Railway Station. The recent development in lighting industry has
made it possible to achieve significant energy saving through the use
of energy efficient luminaire , optimum lighting design and advanced
light control system.
Deliverable: The project will provide detailed design of lighting scheme duly
identifying type of luminaires, their mounting arrangement and control
scheme to achieve optimum illumination level with minimum energy
consumption at various functional areas of Railway Station.

6.0 Standardization of power supply arrangement at Indian Railway


Station premises.(Energy Management)
Brief Description: Existing power supply system at Railway Stations has evolved gradually
based on immediate local power requirements. as such there is no
standard scheme being followed for power supply arrangement at
different Railway Stations. Hence it is proposed to evolve a standard
power supply arrangement complying with various National /
International standard and using equipments of latest technology.
Improving safety, reliability and operational flexibility of power supply
system at Indian Railway Station will be an important aspect of
suggested scheme.
Justification: The power supply requirement at important Railway Stations is a
complex issue due to presence of many passenger amenities and other
important utilities. The non-availability of power supply even for small
duration can cause serious inconvenience to the passenger and hamper

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New Projects Proposed

the operation of many important services. Standardization of power


supply arrangement with adequate spare capacity and possibility of
operational flexibility can avoid/ minimize the possibility of power
supply outage.
Deliverable: The project will identify standard design of power supply system to
improve reliability and availability of power supply at Indian Railway
Stations.

7.0 Design Methodology and Software Development for Railway


Formation Design.(Geotechnical Engineering)
Deliverables: • Design of formation for axle load of 25t, 30t and 32.5t for various
soil groups with and without use of geo-synthetics. The design will
include thickness of various layers i.e. Ballast, Blanket layer upper
subgrade, lower subgrade, side slope and berms etc.
• Development of user friendly optimum design of formation with
variable input data of subsoil, fill material, axle load, speed and
properties of Geosynthetics. Manual Design as well as software for
the same will be developed.
• Training to Railway officials on the Design of Formation.
Benefits: Capacity Building for design of formation in Indian railways and
software development.
Current Status: Project is formulated in consultation with IIT/Roorkee has been
&approved under TMIR. Project team has been constituted with
IIT/Roorkee& RDSO representatives. Further progress can be made
after issue of letter of Acceptance letter and release of funds.

8.0 Development of Design and Construction Methodology for


Geosynthetic Reinforced Soil (GRS) Retaining Wall (RW) for Railway
Embankment. (Geotechnical Engineering)
Deliverables: • Training/Visit of Indian Railway officials (from RDSO & Zonal
Railways) to actual GRS RW embankment sites in Japan and
RTRI/Japan
• Visit of RTRI experts to India, including discussion with Indian
Railway officials (from RDSO and Zonal Railways) and field visits.
• Testing of input materials (soils, geosynthetics etc.) of India
• Finalization of Design of GRS GW embankment for Indian Railway
condition, separately for carrying Heavy Axle Loads and for Semi
High Speed.
• Training of Zonal Railway officials, by RDSO.
Benefits: • Capacity Building Design and Construction methodology for GRS
Retaining wall for Railway embankment.
• With adoption of this technology, reduction in land requirement is
possible for construction of embankment especially in urban areas
where cost of land is high, and adequate land is not available.
Current Status: • In December 2015, an MOU was signed between RDSO & RTRI,
Japan for technical cooperation in following fields:
i) Safety in train operations
ii) Advanced techniques of maintenance
iii) Use of environment friendly technologies
iv) Throughput enhancement measures; and any other area jointly
agreed upon by the parties.
• The project was envisaged for taking up with RTRI, Japan as per
the MOU.
• RTRI, Japan in principle agreed vide email dated 30.04.2017 for
collaborating on the project as per the MOU between RDSO and

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New Projects Proposed

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.

9.0 Scanning of Track ballast using GPR(Geotechnical Engineering)


Deliverables: • Scanning of track ballast using Ground penetration Radar (GPR)
mounted on Track Recording Car (TRC) and submission of
customized output report after necessary post-processing of data
• To determine the extent of ballast fouling & penetration.
Benefits: • Data obtained will be used in decision making on ballast
cleaning/recoupment.
• Identifying stretches for formation rehabilitation.
• Segregating track geometry deterioration due to ballast
contamination as compared to other reasons for better and quick
appreciation of track deterioration.
Current Status: • Inputs on the Functional Specifications & Technical Requirements
and Special Tender conditions of tender document for GPR with
respect to Geotechnical aspects, have been provided to TMM
directorate for fixing consultancy.
After finalization of Tender for Ground Penetration Radar (GPR) by
TMM Dte., execution of ballast survey & related aspects will be
carried out.

10.0 Optimum solution for improvement in characteristics/ properties


of weak locally available soils for use in the formation.(Geotechnical
Engineering)
Deliverables: • Study of use of various additives/ chemicals as a possible option to
strengthen the local weak soil so as to use it for construction of
formation.
• Identification/ Characterization of various additives/ chemicals
based on their type, mechanism of of action, extent of
improvement in soil properties/ characteristics, durability,
environmental friendliness, etc.
• Suitability for various types of additives/ chemicals for different
types of weak soils, and likely quantum of improvement in soil
properties,
• Issue of guidelines for use, assurance tests for achieved
properties, etc.
Benefits: In Indian Railway, the soil with requisite properties is brought from
some other source away from the site of work. Transportation of large
quantity of materials increases the cost of project. Improvement in
characteristics of locally available soil for use in Railway formation
will significantly reduce the cost.
Current Status: The project is under formulation with IIT Kanpur. Draft Project
Proposal was submitted by IIT/Kanpur. Proposal has been discussed in
the meeting held at RDSO with Professor, IIT/Kanpur & revised
proposal will be accordingly submitted by him.

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New Projects Proposed

11.0 Design of Railway Embankment on Soil Prone to


Liquefaction.(Geotechnical Engineering)
Brief Description: • To conduct numerical analysis of Railway embankment resting on
liquefiable soil along with experimental investigation.
• To develop designing criteria for Railway embankment
constructed with soil having uniformity coefficient (Cu)< 2
Deliverables: Railway embankments situated in seismic regions are also susceptible
to liquefaction induced damages. The project will be helpful in
understanding the phenomenon so that counter measures can be
adopted to reduce the effect of this phenomenon.
Current Status: Draft MOU has been signed by concerned faculty members of
IIT/Kanpur, for taking up under Rail technology Cell (RTC) at
IIT/Kanpur. The MOU between Ministry of Railways & IIT Kanpur and
RDSO for Railway Technology Cell (RTC) at IIT Kanpur needs to be
extended from 04.01.2016 to suitable date.

12.0 Effect of Seismic Forces on Railway embankment and its


remedy.(Geotechnical Engineering)
Brief Description: • To evaluate the seismic force and displacement demands of the
embankment
• To evaluate possible damage or failure modes including extent of
damage under significant earthquake events.
• To explore possible remedial measures if the existing formation
does not meet the adequate requirement
Deliverables: Railway embankments in a seismic region may be highly susceptible to
earthquake induced damages. The project will investigate the seismic
demands of railway embankments under significant earthquake
events.
Current Status: Draft MOU has been signed by concerned faculty members of
IIT/Kanpur, for taking up under Rail technology Cell (RTC) at
IIT/Kanpur. The MOU between Ministry of Railways & IIT Kanpur and
RDSO for Railway Technology Cell (RTC) at IIT Kanpur needs to be
extended from 04.01.2016 to suitable date.

13.0 Landslide Monitoring System, using Satellite imagery.(Geotechnical


Engineering)
Deliverables: • Traditional tools for Land Slide Monitoring, using point-based local
monitoring equipment, are labour intensive, costly to deploy and
identification of specific vulnerable locations for monitoring, out
of a large area, is a difficult task.
• Remote sensing, using satellite imaging can be used for
demarcating the areas prone to future landslide occurrences.
• Thus, an Early Warning System can be developed for providing
probabilities and intensities of pending landslide hazard.
Benefits: The project proposes use of satellite imagery and advance sensors for
producing landslide inventory mapping, and development of Early
Warning System, which will ultimately lead to safe train running
operations in the landslide prone hilly areas.
Current Status: It was proposed to take up this project with IIT/Roorkee, under MOU
signed with them as Centre for Railway Research (CRR). The project is
under formulation based on the response received from IIT Roorkee.
The project may be proposed in TMIR in view of the importance of the
project.

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New Projects Proposed

14.0 Complete computerization of aptitude testing of Metro Staff (Station


Controller/Train Operator)
Brief Description: Computerized aptitude testing of Metro staff

Justification:  Aptitude testing with Precision in dynamic mode of computerized


Aptitude tests
 Elimination of Manual interface

15.0 Occupational Stress Survey for Station Masters


To study the level of occupational stress among Station Master
Brief Description: is required to suggest remedial measures for optimum performance
Justification: Periodic assessment, of occupational stress .of Station Masters is
required to suggest remedial measures for optimum performance.

16.0 Purchase of new computerized psychological tests.


Brief Description: Computerized version of NEO Big five personality test and Rorschach
tests are being procured for research studies.
Justification: Computerized personality tests.to be used for research studies and
case studies of accident involved safety category staff .

17.0 Procurement of Global Psychological tests


Brief Description: Two licenses of internationally acclaimed Vienna .Test System (VTS)
for research studies are being procured
Justification: Tests of VTS to be used for research purposes and its efficacy in the
Indian context.

18.0 Modelling and validation of interlocking for Railway Signaling system


Phase-II (Signal)
Justification : Manual Development of Interlocking Circuits and Data for every Station
is a cumbersome and time taking work. For automation, a project on
Modelling and validation of interlocking for Railway Signaling system
was taken up with IIT/Kharagpur in WP 2012-13. The IIT has developed
the basic tool for proof of concept and requirement as per Phase-I for
the work are over. The outcome of project is positive and it is
proposed to go for the Phase-II of the work as also defined in MoU with
IIT/KGP.
Brief Description: The goal of the project is to fine tune the tool for use on all Zonal
Railways and making it suitable as one stop solution to automatically
generate Interlocking Design (RCC, Circuits) so as to reduce the design
time for Interlocking works. Automation in tool together with adoption
of standardized circuits over Indian Railways will help in Indian
Railways Policy of Self reliance on Electronic Interlocking for reducing
dependency on vendors.

19.0 Upgradation of Hypermesh Software Package (Motive Power)


Brief Description:  License of latest version of softwares.
 DVD of latest version of Softwares.
 Training of upgraded version of softwares.
Justification  The upgradation of software package is required for FEA Analysis.

48th Meeting of CBRR 105


New Projects Proposed

20.0 Procurement of 4 Staff cars cum Oscillograph Cars (Testing Dte)


Justification :
Brief Description:
21.0 Development of capability for testing of High speed Rolling stock
(Testing Dte)
Development of capability for testing of High speed Rolling stock
Consultancy to study, Seminar/Workshops and visits to related labs
and and centres to understand: a) Benchmarking standard practices
with regard to Testing procedure world over, b) To understand various
additional on track tests, c) Bench/Factory Tests for Rolling stock
design validation
Justification :
Brief Description:

48th Meeting of CBRR 106

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