RDSO TRANSFORMING RAILWAYS

RDSO has been playing an important role in the development of designs and
systems covering various facets of Railway infrastructure and operations. With
technology updating, it has been possible to run heavier, faster, safer, cost effective
and more passenger friendly trains. RDSO has been in the forefront in the endeavors
of development of new technologies and adaptation of the state of the art technology. H.S. Pannu
The activity of RDSO covers various aspects related to infrastructural requirements Director General,
and all types of rolling stock for the Indian Railways. RDSO in its role as R&D RDSO
organization of Indian Railways and also as technical advisor to Railway Board, Zonal
Railways and Production Units is committed towards absorption, adoption and development of new
technologies. It will leave no stone unturned to make Indian Railways to world class standard.

The primary objective of R&D is to make rail travel safer, more comfortable, reliable and economical.
Efforts are also made to achieve the maximum throughput with the least investment in infrastructure and
rolling stock. The project taken up by RDSO in the recent past have a direct bearing on these aspects of
railway operation and the results in most of these projects have already borne fruit for the Indian Railways. For
enhancing safety in train operation and for better passenger comforts, RDSO is closely interacting with the
centers of excellence, eminent educational & research institutions like IITs & industries etc., so that cutting
edge technology with broad vision may be developed and the knowledge of latest technological developments
may be incorporated on Indian Railway system at a reasonable cost.

The Indian Railways has registered a growth of 9 percent, Railways during 2007-08 loaded 794 million
tonnes, which was 66 million tonnes more than the loading in 2006-07. Freight and passenger earnings grew
at 14 and 15 percent respectively. To sustain this growth, continuous technical inputs are required to meet the
growing demand of passenger and freight traffic. RDSO is working for improvement in quality of service both in
passenger and freight traffic.

RDSO also offers international consultancy for design, testing and inspection of railway equipments.
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. Some of these are:-

Air Brake Laboratory

Brake Dynamometer Laboratory
Bridge & Structure Laboratory
Diesel Engine Development Laboratory
Fatigue Testing Laboratory
Geo-Technical Engineering Laboratory
Metallurgical & Chemical Laboratory
Psycho -Ergonomics Laboratory
Signal Testing Laboratory
Track Laboratory
Electrical Laboratory
Instrumented Mobile Facilities
Centre for Advanced Maintenance Technology at Gwalior

Some of the important activities & projects carried out by RDSO for improving freight operations,
passenger services, safety & throughput for Indian Railways are explained as:-
TECHNOLOGICAL INPUT FOR IMPROVING THROUGHPUT

Development of 22.9 t Axle Load Open Wagon type BOXNHL

Special Features of this wagon are:-

Pay to tare ratio - 3.45 (v/s 2.50 of existing BOXN)

Brake block K type
Body and under frame of stainless steel to IRS M-44
Rake throughput increase of 22.25 % over rake of BOXN (CC)
Additional earning of Rs.3.84 Crores per rake per year over
rake of BOXN (CC)

Development of 22.9 t Axle Load Covered Wagon Type BCNHL

Special features of this wagon are:-

Pay to tare ratio - 3.40 (v/s 2.30 for existing BCNA with
20.32 t axle load)
Brake block K type
Body and underframe of stainless steel to IRS M-44
Wagon length reduced to 10.963 m from existing 14.45m for
BCNA wagon
Number of wagons per rake increased from 44 (of BCNA) to 58.
Rake throughput increase of 4.7-39.5% for different commodities, over rake of BCNA [Cement 39.5% (in
comparison to CC+8), Food grain 12.9 % & Fertilizer 4.7 % (in comparison to CC+6)]
Additional earning of Rs. 8.81 Crores per rake per year, for cement, over rake of BCNA(CC).
Increase in Speed of Existing Wagons

To permit faster turnaround & higher throughput, speed of following wagons has been increased:-
Speed of BOSTHS wagon in empty condition increased to 100 Kmph
Speed of BOXNHSM1, BCNAHSM1 & BCNM1 wagons in loaded condition increased from 60 to 75
Kmph at CC+6+2 t loading

Introduction of Modern Track Friendly Bogie for Higher Axle Load Wagons

IR has entered into an Agreement with Amsted Rail, USA to design a track friendly bogie for IR. Special
features of this bogie are:-

Swing Motion Bogie Designed for 25 tonnes Axle load

Same bogie can be used for 32.5 tonnes axle load in future by addition of suspension springs
Speed potential of 110 KMPH at 25 tonnes as well as 32.5 tonnes axle load
Weight of bogie is same as that of present CASNUB bogies viz. 5.3 tonnes per bogie
At 25 tonnes axle load, Maximum lateral force (at Rail-wheel level) of 4 tonnes at 125 KMPH
against present lateral force of 7 tonnes at 70 KMPH (22.82 tonnes axle load)

Design of Ro-Ro Wagon for Universal Operation

Roll On- Roll Off (Ro-Ro) wagons are designed to carry fully loaded truck which at the starting station
get on the wagon, secured and at the destination station get off the wagon. This helps the truck operators as
well as the Railways. Such wagons are already in operation in Konkan Railway. New Ro-Ro wagons with
lower floor height and for universal application are being designed with new bogie being developed for auto
carrier wagons. Also, the possibility is being explored to develop a bogie with wheel diameter of 355 mm. This
will help in attracting new traffic and result in national saving in fuel expenditure
Increased throughput on wagons designed by RDSO:

A) New Wagons Designs- Manufacturing started in year 2008-

Wagon Throughput increase Pay to tare increase from Additional earning

(in tonnes) per rake per year (in
From To From To Rs. Crores)
BOXNHL 3369 4118 2.50 3.45 3.84 Crore
(of (22.25%) (of BOXN)
BOXN)
*BCNHL 2496 4106 2.30 3.40 8.81 Crore
(of (40%) (of BCNA)
BCNA)
* No. of wagons per rake increased from 44 to 58

B) New Wagons Designs- Manufacturing yet to be commence-

Wagon Throughput increase Pay to tare Remarks Addl. earning

(in tonnes) increase from per rake per
From To From To year (in Rs.
Crores)
BOY25 3686 4582 3.42 3.76 Design 6.24 Crores
(of BOY) (24.3 %) (of BOY) completed
(no. of wagons
per rake
increased from
52 to 58)
BOXN25 3369 4466 2.50 3.35 Design 5.62 Crores
(of BOXN) (32.6 %) (of BOXN) completed

BRN25 2425 3210 2.45 3.25 Design 4.90 Crores

(of BRN) (32.3 %) (of BRN) completed

BOBRN25 3229 4385 2.17 3.10 Design 5.92 Crores

(of (35.8 %) (of completed
BOBRN) BOBRN)
BOBSN25 3305 4292 2.01 2.85 Design 6.87 Crores
(of (32.3 %) (of completed
BOBSN) BOBSN) (no. of wagons
per rake
increased from
54 to 58)

Manufacturing of Aluminium Wagons

RDSO has designed two types of Aluminium Wagons: BOXNAL and BOBRNAL. These wagons are
very light weight and pay to tare ratio is higher, 3.45 for BOXNAL and 2.62 for BOBRNAL, as compared to
BOXN (2.50) and BOBRN (2.17). Purchase Orders for 240 nos. BOXNAL and 60 Nos. BOBRNAL placed by
Rly. Board. Pay to tare ratio of these wagons is still less than the World Standards (5-6 for BOXNAL and 4-5
for BOBRNAL). Efforts are being made by RDSO to enter into collaboration with foreign
manufacturers/designers to improve Pay to Tare ratio

New Locomotive Designs and Major Equipment / Component Developed to Improve the Performance
of Locomotives

RDSO has done excellent for new locomotive design as well as development of retrofitable features to
improve the performance of diesel locomotives in respect of facilitating heavier loads, improved fuel efficiency,
enhanced reliability and availability:
4000 hp EMD locomotives upgraded to 4500 hp; five locomotives turned out.
4500/4000 hp EMD locomotives converted to more reliable and efficient IGBT-based invertors, design fully
developed by end 07 and complete switch over achieved in 08-09
 4500/4000 hp EMD locomotives with fully indigenous three-
phase electrics turned out; a path-braking effort for the first
time outside the developed world
Microprocessor-based comprehensive excitation, wheel slip
and propulsion controls as per RDSO specification (and
development effort), which not only enhances starting an
hauling capability of locomotives but also results in higher
reliability, locomotives serialized at DLW, & DMW earlier;
retrofitment on more than 200 locomotives done in sheds in
08-09, based on scheme prepared by RDSO.
Development of High adhesive wt. 1400 hp WDS6 variant WDG4 locomotive with indigenous IGBT-based
with high performance ATHS bogie 3-phase drive

Development 4500 hp six-motors version passenger locomotive with hotel load capability
Development 2300 hp Cape Gauge locomotive on WDM7 platform
Standardization of Brake and Auxiliary Pneumatic Equipment based on study of the systems on various
diesel & electric locomotives
Development of EP Assisted brake system

Development of High Reach Pantograph

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 7.6 meter
under all weather conditions, at operating speeds up to 160 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 pantograph
will be suitable for working on DFC as well as under the existing OHE.
RDSO is also developing more sources of the pantograph using the state
of the art technology for conventional as well as three phase electric
locomotives also.

Development of the 12000 HP High Horse Power Locomotives

In order to meet the challenge of ever increasing originating

freight loading, it has been decided to procure 800 nos. new
generation electric locomotive during next 8 years through a
new electric locomotive.
Manufacturing unit being set up under joint venture at
Madhepura, Bihar. RDSO has finalized the specification for the
12000 HP high horse power new generation electric locomotive for
the proposed dedicated freight corridor, to be procured from reputed
manufacturers of the state of the art locomotive.

Development and Upgradation of Track Formation for Heavy Axle Loads

Design Methodology for Railway Formation : A rational design methodology for design of track
formation need to be developed for operating heavy axle load/high speed trains to construct economical
railway track with reduced cost of maintenance. This will be beneficial for introducing heavier axle load on
Indian Railways as well as for Dedicated Freight Corridor (DFC).
Strength Assessment of Railway Formation: A methodology is required to be developed for
assessment of condition of existing formations to determine its axle load carrying capacity to decide
inputs/strengthening measures required for running of heavy axle loads. This is particularly relevant for feeder
routes of Dedicated Freight Corridors. To meet out the above challenge, a project is proposed to be taken up
with TTCI as a part of Track Design Dte.s project on Development and upgrade of Track for Heavy Axle
Loads with TTCI.
Assessment & Development of Bridge Approaches Transition System

With the existing system & guidelines, track settlements have been observed frequently at many
locations of bridge approaches. In view of Heavy Axle Load and future High-Speed Trains, improvement in
transition system on bridge approach is essential over existing provision. Studies are required to be carried out
in field to lay down provisions of different type of transition systems, specifications of backfill materials, length
of transition system etc. for different heights of embankment, different types of bridges & various types of
routes etc. to avoid differential settlement of track at bridge approaches.

To meet out the above challenge, a project on Assessment & Development of Bridge Approaches
Transition System is proposed to be taken up as part of the Pilot Project of B &S Directorate with TTCI titled
as, Capability Assessment & Condition Monitoring of Bridges.

PSC Sleeper Suitable For 32.5t Axle Load

RDSO has designed and developed a new

PSC sleeper for 32.5t Axle Load. All the laboratory
investigation of this sleeper including fatigue tests
has been completed and the sleeper has passed the
tests successfully. A comprehensive report on the
same was submitted to Railway Board vide this office
letter No. CT/SRC/3/2 dated 26.6.2008. Field trial of
this new PSC sleeper has been approved by Railway
Board on South Eastern, East Coast, South Central
& South Western Railway on Iron ore / Feeder
routes. Drawings for the same has already been PSC SLEEPER FOR 32.5T AXLE LOAD
issued to concerned Zonal Railways.

Rail Seat Assembly For PSC Sleeper Fit For 32.5t Axle Load

Railway Board has advised for field trial of PSC sleeper fit for 32.5 t axle load on SER, E.Co.R, SCR
and SWR on 10 km of track on iron ore and feeder route to judge the performance of PSC sleeper under field
condition. Drawings of fastening system i.e. rail seat assembly, SGCI insert, ERC, rubber pad and liner have
been developed for 32.5t and issued to these four railways. In new drawings, eye of insert has been provided
in oval shape to avoid jamming of ERC in addition to other improvement over the existing fastening system.

IMPROVEMENT IN PASSENGER SERVICES

Introduction of Air Springs at Secondary Suspension of Mainline Coaches

The existing IR coaches are operated at speeds of upto 105 kmph on other than Rajdhani standard
track and 130 kmph over Rajdhani standard track, with FIAT coaches being cleared for 160 kmph speeds. To
further improve the ride, pneumatic suspension (also called air springs) have been designed and subjected to
detailed field trials for evaluation of passenger comfort and safety. Similar springs have been in service on
Suburban sections for about eight years with good results.
Upgradation of WAP5 Locomotives for Service Speed of 225 kmph

RDSO has taken up high speed as mission 24. In this regard

test trial of WAP5 locomotive along with LHB coaches on the
upgraded track of Delhi-Mathura section at 225 Kmph is envisaged.
For increasing service speed of WAP5 loco from 160 Kmph to 200
Kmph the transmission system of the locomotive is required to be
changed as per design detail submitted by M/s. BT in the TOT. Rly.
Board has approved for manufacturing of two WAP5 locomotives by
CLW with modified transmission system. CLW has been advised in
this regard.

Concept of World Class Station

Works Directorate has taken up a study project on World Class Stations. Conceptual plans and 3D
views of various elements in a World Class Station have been developed considering Lucknow Station. It is
further proposed that officers of Works Directorate should visit advanced countries for further studies.

Standardization of Flooring and Roofing on Railway Stations

Standardization of flooring & roofing material for various categories of stations at different locations has
been taken up by a committee comprising of ED/Works, RDSO, CE/Works, N. Railway and S.C. Railway.
Standardization of floorings at station premises i.e. platform, concourse, portico, circulating area, FOB, waiting
halls, retiring rooms, cloak room, toilets etc. has been prepared. The material for covered shed roofing over
Railway platforms has also been prepared. The draft recommendations have been circulated to Zonal
Railways.

Manual of Standardization and specifications of Passenger Amenities

RDSO has taken up work of Manual of standardization & specification of passenger amenities at
Railway Stations. A committee of ED/Carriage, ED/Tele, ED/Works, ED/Traffic and ED/EEM has been
formed in RDSO for preparation of station manual. The work is in progress and is expected to be completed
by 30.06.09.

Development of Nano Coating Paints for Coaches

BENEFITS:
i) Outstanding adhesion the paint becomes embedded in the
walls surface.
ii) High resistance to weathering (UV, fungus, water dirt etc.) and
any blistering.
iii) Elastomeric matrix (Stretchable paint that covers cracks) for a
smooth clean finish.
iv) Highly robust finished surface due to inorganic nano-particles.
v) Easy to apply with high coverage and non sticking application
The trial with nanotechnology paint in RDSO/M&C/Paint Lab for performance evaluation is under progress.

Improving Aesthetics of Coach Interior

From aesthetic viewpoint pleasing colour shades with proper colour

matching have been chosen and the colour, shade and pattern of
the fire retardant vinyl coated fabric have been standardised and
revised specification have also been issued. Use of improved
material has improved the aesthetics of interior of coaches.
Use of Bio-Toilets in Indian Railway Coaches

Very soon the dirty sight of railway tracks on platforms and

elsewhere created by primitive toilet discharge systems in Indian Railway
Coaches which throw Human Waste on the track will end by deployment
of Bio-Toilets.

Bio-Toilets use bacteria to Bio-Degrade Human Waste into gas

and water which may be released into environment without degrading it.

One rake of Delhi-Rewa Express has been running with Aerobic

Bio Toilets based on technology from Microphor , USA for past one year
and results are encouraging.

Defence Research and Design Establishment, Gwalior has also

developed Anaerobic Bio-Toilets for stationary use. The technology is
being tried out for its suitability in mobile use. It has been planned to fit
forty more rakes with bio-toilets in the year 2009-10.

Apart from these IIT-Kanpur has also designed a toilet system

which works on solid liquid separation. The water is recycled for flushing
purpose and solid is taken out from toilet tanks periodically for IIT- Kanpur Designed Zero-Discharge
composting in pits. Two prototype toilets have been installed in Coach No Toilet
SR 08224 and are running in train no. 6093/6094 (Chennai- Lucknow
Exp.) since 2-2-09.

Integrated Passenger Information System

consisting of Train Indication, Coach Guidance
and PC Based Announcement System

RDSO has developed Integrated Passenger

Information System consisting of train indication
board, coach guidance board and PC based
announcement system as per Railway Board's
guidelines on priority for passenger business under
touch and feel items. Integrated Passenger
Information System consists of two control console
unit in redundancy mode loaded with software for
announcement, display board of different sizes, at
a glance display board, coach guidance display
board, CCTV, main and platform data
communication hub.

The various type of display boards are LED based.

Integrated Passenger Information System consists of two control console unit
in redundancy mode loaded with software for announcement, display board
of different sizes, at a glance display board, coach guidance display board,
CCTV, main and platform data communication hub.The various type of
display boards are LED based.

True Colour Video-cum-Train Information System

RDSO has developed specification No.

RDSO/SPN/TC/67/2007 of true colour video-cum-train information
display system used for giving train arrival / departure in stations
and any other videos to passengers. These consist of PC based
announcement system and true colour display boards, namely
electronic display board, coach guidance display board, indoor
video display board and outdoor video display board to be
provided at various places of the stations with the features of networking and operation from a centralized
location. The system mainly consists of Central Controller Unit (CPU) with standby for redundancy, loaded
with required software for user interface and announcement, different sizes of true colour display board,
central data switch, platform data controller, video display controller, CCTV.
Satellite Imaging for Rail Navigation (SIMRAN) SIMRAN
Global Positioning System (GPS)

The project on Satellite Imaging for Rail

Navigation (SIMRAN) has been taken under GPS
Satellite

technology mission for railway safety. The pilot

project on Satellite Imaging for Rail Navigation User

(SIMRAN) is being executed by IIT/Kanpur in

Display Board
coordination with RDSO, Lucknow, which involves Inside
World
Display Board Loco
Real Time Train Tracking System using Global Inside
S
Wide Web
RF modem
Wired
Comm.
Train Display Board
Coach R communicaion
GP
Positioning System (GPS) and Global System for SMS
At
Station

Mobile (GSM) technologies. The project envisages Train

Navigation
dissemination of Real Time Train Running Hardware

Information through Internet, SMS and Display Server

Moving Train
Boards at the stations. The system designed under
the project is capable of integrating with IVRS and
Call Centers also. Necessary hardware and software have already been developed.
Extensive field trials of this project are under progress. Cumulatively train equipments have so far been
installed in thirty six rakes of Rajdhani Express, seven rakes of Shatabdi Express originating from New Delhi,
two rakes of Gomti Express, fourteen rakes of MEMUs running between Lucknow Kanpur New Delhi
Section, twelve rakes of Patna bound Mail Express trains & two nos. each of locomotives of Kanpur Electric
Loco Shed and Guwahati of N.F. Railway and are running under trial.
These equipments are equipped with key pad and display for LOG-ON facility and will permit assigning
/ deassigning of train number to SIMRAN train equipment. These trains, MEMUs & locomotives are being
monitored continuously and data collected are being analyzed at IIT/Kanpur for further improvement in the
software and GIS map.
Develop technology using GPS and GSM to

Continuously track every train for its location, speed and direction of movement.

Dynamically disseminate information so gathered to passengers and to the general public.

Transfer data from running train to central server regarding the health of the locomotive and other
vehicles in the train.
Current Status:

Hardware and software have been developed.

System field trial in 7 Shatabdi Express and 36 Rajdhani Express trains and 2 locomotive of kanpur
(ELS) and 14 Rakes of MEMU which is going on since Dec 08 is also successful. Trasnsfer of
technology is underway.
Improvement in Suburban Services
 20 Coach MEMU services: Capacity of MEMU rake is increased from 16 car rake to 20 car rake to cater
more passengers traffic on high density roots. Speed certificate for running of 20 coach MEMUs at 100
kmph have been issued to Railways.
 15 Coach AC-DC EMU Services for Mumbai area: Design approvals including layout for manufacturing
of prototype rake at ICF have been completed. Final speed certificate for operation of 15 car AC-DC EMUs
has been issued on 09.02.2009.
 Ventilation System in EMU / MEMU: Based on the RDSOs specification, the prototype has been
developed for 3-phase AC-DC EMUs in Mumbai. This gives fresh air of 14535 CMH per coach. Thus, adds
to passenger comfort during the peak loading of EMUs (SDCL Loading). CO2 level inside the coach is
reduced to 50% to 60% from existing level. 35 rakes with this scheme have been manufactured so far.
This is widely appreciated by daily commuters. Railway Board has furter given directives for 100% cut-in
by ICF/RCF in MEMU/EMU.
 Air Conditioning of Driving Cab: RDSO has prepared a scheme and specification for air-conditioning of
driving cab of MEMUs/AC EMUs to increase the comfort level and efficiency of driver. and issued to
ICF/RCF. ICF has turned out first rake on 9th Feb. 2009 and being operated in Mumbai.
 Development of Air Conditioned EMUs: The specification no. RDSO/2008/CG-05 (1st issue) for AC
EMU rolling stock with 25 kV AC, 50 Hz traction system having roof mounted air conditioning units and
conventional electrics has been issued. Railway Boards advice is awaited for number of air-conditioned
AC EMU rakes to be manufactured.
TECHNOLOGICAL INPUT FOR IMPROVING SAFETY

Introduction of End of Train Telemetry (EOTT) on IR

EOTT is a device by which it is possible to monitor in the drivers cab of the loco, the brake pipe pressure
in the last vehicle of the train.

 Main Functions of the EOTT is:-

i) Brake System monitoring including continuity checking
ii) Train integrity checking
iii) Simultaneous Emergency & Service Brake Application from last vehicle
iv) Provide light sensitive Marker Light
v) Monitors movement status of train
vi) Data logging

Advantages of Using EOTT:

i) One extra wagon can be accommodated in the same length of train, resulting in increase in revenue.
(Implementation of EOTT on all the good trains running on IR shall result in annual saving of approx.
Rs. 1370/- Crore.)
ii) Detention of rake on account of shunting of brake van can be avoided
iii) Procurement & maintenance cost and haulage charges of brake van are saved
iv) Resources required for shunting of brake van in terms of loco, shunting crew, shunting line etc are not
required.

Laboratory tests of EOTT equipment of three firms have been completed. Six trips of field trial of two
firms on TKD- JNPT route have also been completed. Some minor problems have been faced in equipments.
After completion of one more trip of successful field trial, Phase-II shall be started, after issue of necessary
instructions by Railway Board.

Bipolar Concrete Penetrating Corrosion Inhibiting Admixture

RDSO has developed a product named Bipolar Concrete Penetrating Corrosion Inhibiting Admixture
which will reduce the corrosion of steel reinforcement bar embedded in concrete significantly based on the
principle of inhibition mechanism. It also protects steel reinforcement of RCC structures even in the presence
of Chloride Salt.

500T Universal Spring /Structure Fatigue Testing System

With the growing freight demand of the country, it has become necessary for Indian Railways to launch
High Axle load wagons to haul more capacity of Payload. Towards the processes of development of High axle
load wagons Indian Railway has signed a MOU with TTCI/AAR/USA for transfer of technology of design and
development of high axle load wagons and its testing facility in Indian Railways.
A new project has been sanctioned by the Railway Board at a cost of Rs. 20.74 crores in works
programme 2008-09 for Augmentation of 500T Universal Spring /Structure Fatigue Testing System for
conduction of accelerated fatigue testing of high axle load bogie frames and bolsters as per the AAR test
parameters.

Improving Fire Safety on Trains

All coach furnishing material specifications have been upgraded to UIC norms with respect to following
fire retardancy features:
Resistance to spread of flame
Deterioration of visibility due to
Limiting oxygen index,
Toxicity Index

Fire simulation facility with M/s SNCF International Computer aided simulation on the coaches
under varying operating and coach design & layout conditions to assess the behaviour of the spread of
 fire, movement of smoke and toxic gases and heat. Work is under progress and simulation facility will
be installed in RDSO by March 2009.

Fire Testing Lab: The Lab is being planned in consultation with M/S Interscience Communications,
UK .

Modifications to make the doorway and gangway area fire resistant under way.
Auto Resetting Multi Orifice Passenger Alarm Device (Armopad)

RDSO in collaboration of M/s Recon Engineering Co. (P) ltd, Kolkata

has developed an Auto Resetting Multi Orifice Passenger Alarm Device
(ARMOPAD) which is completely based on pneumatics and provides audio-
visual indication and auto resetting feature and can be used in passenger
alarm system by eliminating passenger emergency alarm signal device
(PEASD) and passenger emergency alarm valve (PEAV). Passenger alarm
system will be automatically reset after 3-5 minute of ACP.
Development of Cordless Train Speed logger

Train Speed Recorder is an approved Small Track Machine which is

used to record the speed of running trains by using transducer/sensors (fitted
to the track) and connected to the recorder through cables. It can record speed of train on both up and Dn
lines simultaneously in a double line track. Cordless train speed logger is a very handy lightweight speed
logging device used to record the speed of a train on a track by directly fitting the logger at the rail web without
infringing the normal traffic. The transducer / sensors are inbuilt for which no cable connections are required.
This cordless train speed logger is under the process of approval.
Off Track Tamper (Engine Mounted Version and Power Pack version)
The engine-mounted version of Off-track tamper is a portable, users
friendly hand held track tamping equipment requiring no external power source.
The off track tampers are intended to be used as a regular means of packing
for spot attention/picking up slacks in between two successive tamping by
heavy on track tamping machine on concrete sleeper track on Indian Railways.
The power pack version of off track tampers are intended to be used as a
regular means of packing for spot attention/picking up slacks in between two
successive tamping with heavy on track tamping machine on concrete sleeper
track in Railway yards and midsections where machine could be carried out on
rail/road transportation or any other suitable arrangement. The power packs
can also be used for driving other electrical small track machines.
Development of LED Based Route Indicator

Present design of direction type route indicator has a limitation of providing

indication for only three diversions on either side. To overcome the above limitation
development of LED based route indicator has been taken in hand. The design
provides indication for total of nineteen lines without any restriction on number of
routes on either side of main line. Draft technical specification for LED based route
indicator has been issued. A prototype sample has been developed and is under
evaluation.
Development of Battery Operated LED Based Torch Cum Hand Signal
Lamp

Display of Red/ Green light by various category of Railway staff is

required in the normal course of discharge of their duties related with train
running. A Hand signal (HS) lamp is provided so as to give either red or green
indication to train crew. Hand signal lamp is also used as a torch at night.
Existing HS lamps suffer from poor illumination, low visibility and low battery life
besides other quality related problems. Hence, development of battery operated
LED based torch cum hand signal lamp was taken up. Based on new RDSO
Specification, prototype samples have been developed and evaluated by RDSO.

The developed Battery operated LED Based Torch Light-cum-Hand Signal Lamp is lightweight, rugged,
maintenance-free and user-friendly. This is powered by commercially available dry cell batteries and complies
the specified illumination, battery life and visibility criteria. After successful passing of type tests, one vendor
has been cleared for field trial.

Block Proving By Axle Counter (BPAC)

The development of BPAC is expected to reduce block

operation time and, therefore, will increase section capacity. The
existing design of BPAC with Analogue axle counter and MUX is not
so reliable and therefore Block Proving by Axle Counter using
UFSBI & SSDAC for single line & double line has been developed
for field trails. Field trials are under progress.
Block Panel of BPAC

In addition, Solid State Block Proving by Axle Counter (SSBPAC) is also being
developed by M/s Efftronics/ Vijayawada. In this system, the relay logic has been
replaced by solid state logic thereby reducing the total number of relays from about 40 to UFSBI & Relay rack
20 which is expected to improve the reliability. Field trials of prototype equipments, one of BPAC
each in double line & single line section, are in progress on Vijayawada division of
S.C.Rly. Hardware validation of the system is in progress.

Train Protection & Warning System

Train Protection & Warning System (TPWS) provides a safety aid

to train drivers by dynamically controlling speed of the train within
specified limits & prevents Signal Passing at Danger (SPAD). The speed
limits are specified dynamically based on signal aspect, route to be
followed, sectional speed limits, speed restrictions etc. By use of this
system, required train speed can be maintained in all weather conditions
while visibility of line side signal is hampered adversely due to fog. Use of
this system will facilitate running of trains safely in all weather conditions.
The system has been commissioned on 51.75 route kilometers of
Chennai-Gumudipundi section of SR. The system is under installation on New Delhi-Agra section of NR &
NCR. The existing specification of TPWS has been revised incorporating the experience of commissioned
system of SR & trials on part of New Delhi-Agra section.

In-Situ Reconditioning of CMS Crossing By Robotic Welder

After evaluation of technology of in-situ

reconditioning of CMS crossing by RW-20
translamatic Robotic Welder of M/s Stanley at
RDSO, it was advised to NR, NER & NCR to
conduct in-situ reconditioning of 10 nos. of
CMS crossing using this technology for the
purpose of field trial.

Railway Board desired that trial of in-situ

reconditioning of CMS crossing, 30 crossings
each on all Zonal Railways, may be carried out
from the open market to benchmark various
technologies available world over. In this
regard, required Performa for the reconditioning particulars of the CMS crossing along with the performa for
periodical field monitoring of the reconditioned crossing have been circulated to Zonal Railways by RDSO.

NR, NER & SCR have carried out in-situ reconditioning of CMS crossing by using Translamtic Robotic Welder.
RDSO team inspected the reconditioned crossing on NER during the month. It has been observed that
around 35 GMT traffic has passed on the reconditioned crossing and the performance is satisfactory.
Trackside Bogie Monitoring System

The condition of the bogie is monitored by measuring lateral force, vertical

force with the help of strain gauges and Bogie parameters viz angle of
attack (AOA) and tracking error using a laser range finder.
This Equipment also incorporates Dragging equipment detector for
detecting loosely hanging parts. It is capable of automatic vehicle
identification using RFID system.

SCXI system & Instrumented Rail

Current Status:
Technology has been developed using Laser Range Finder for
measurement of AOA and Tracking position.

SCXI based stress measurement system has been

developed for measuring lateral & vertical rail forces.

Detection of dragging equipment of the rolling stock is being
done using proximity sensors.

Field trials of prototype with more sensitive Laser Range
Finder are underway.

Derailment Detection Devices

Laser Range Finder

Development of on-board equipment for sensing derailment
conditions of rolling stock by Monitoring acceleration values.

Apply emergency brakes automatically when threshold values are
exceeded and Informing driver through wireless communication
about derailment condition.

Current Status:

Extensive field trials conducted with various stocks for

ascertaining acceleration values.

Electronic as well as mechanical derailment detector developed
for coaches & wagons.

Lab trials on above detectors conducted & design modified.

Electronic type Derailment detection device was tested with brake actuation mechanism on BOX n
bogies & found successfully working .

Field trails with prototype designed are underways.

Sensors for Detecting Hot Boxes, Hot Wheels

Development of a wayside detection system using Infrared

sensors for identifying axle-boxes running hot due to bearing
failure and Wheels having abnormally high temperatures due to
brake-binding. MCT Sensor
Pyrometer

Current Status:

Developed systems for detecting Hot wheel / box using

pyrometers and Indigenized the hardware.

Field trials with prototype developed are underway.

On-Board Diagnostics

Developing a system for online, monitoring of various

parameters governing the health of a locomotive.

To introduce predictive maintenance and amalgamate with
periodic maintenance to avoid break down maintenance, Front panel template for aiding trouble
thereby Improving reliability, availability and safety. shooting at shed level
Current Status

Phase - I comprising of placement of identified sensors and field trials completed.

Fitment of the sensors for the second phase of the project is now being done at DSL/SHED/AMV.

Installation of Axle box bearing temperature and vibration sensors on axle boxes of diesel electric loco
is under taken and is under fitment for electric as well as for diesel loco

Wheels and Axles of Improved Metallurgy

Alloys of improved metallurgy and corresponding heat treatments for forged wheels, cast wheels and
axles have been developed in Lab scale.

With this improved metallurgy, the wheels and axles will be able to withstand higher pay load upto
32MT without change in design and will have better wear, life & safety factor with existing pay load.

The cast carriage wheels may be used upto a speed of 130 Kmph against existing speed limitation of
cast wheels of 110 Kmph.

Forge Wheel - DSP & RITES have been advised to dispatch these wheels to Jagadhari workshop.
After getting them assembled in wheels sets, Jagadhari Workshop will send them to RCF for fitment in
coaches.

Cast wheel RB has placed order on RWF Banglore for Manufacturing 25 Nos.

Axle order for manufacturing to DSP yet to be issued from RB. Meanwhile DSP has been requested
to produce axles through existing orders.

Measuring Wheel Technology

RDSO has designed & developed measuring Wheel Sets for measuring the dynamic forces at the rail-
wheel level for

locomotive

coach &

wagon.

Current Status:

Wagon Wheel developed & strain gauging done.

Static calibration & data analysis of wagon wheel done.

Dynamic calibration of wagon wheel completed.

Algorithm for force computation has been developed.

Field trails yet to commence.

ENERGY CONSERVATION MEASURES

RDSO has issued following specification:-

 Grid Connect Solar Generating System of 10 KWp, 25 KWp, 30 kWp, 50 KWp & 100 KWp
Capacity.
 LED Based Street Lighting System powered by Solar cells.
 Solar based Water Heating System
 Energy saving system for installation in workshops, sub-stations etc.
 T5 florescent light fittings.

 LED Based Lighting Luminaire for Coaches: For improving the efficiency of coach lighting and reduce
the burden on Alternator and batteries of the coach, energy efficiency eco friendly LED based coach lights
are being developed and is being provided on 50 coaches by RCF. LED based Luminaire are more
efficient, compact, quick light up in micro seconds, ideal for use in applications that are subject to frequent
ON & OFF cycle, dimming feature, cool, long life i.e. more than 50 thousand hours, shock resistant,
maintenance free and having no toxicity. There will be reduction of power consumption by 30-35% on
account of implementation of LED based coach lighting scheme.
 Head On Generation System for Power Supply in Coaches: Scheme for head-on-generation system
has been developed by RDSO and is under implementation. This is energy efficient and pollution free
system of power supply for trainload with considerable saving in energy and maintenance cost. Due to
energy efficiency, annual saving of Rs. 31.6 lakh will result in 19 coach Rajdhani with HOG system in
comparison to existing Rajdhani Express with power car.

Saptgiri Express, running between Chennai and Tirupati, is first train on Indian Railway with HOG system
is working satisfactorily since Nov. 2007. Railway Board has directed RCF to equip 10 rakes of
Rajdhani/Shatabdi and 15 SG type trains with HOG scheme and individual coach converters. Open tender
has been invited by Railway Board. Work on development of traction independent HOG scheme, an
alternate scheme, in by using bulk inverter for supplying 3 phase power supply from locomotive to the
coaches is in progress.

Aero-Dynamic Profile of High Horse Power DMU and MEMU Coaches

RDSO has developed aero-dynamic front of high horse power DMU and MEMU coaches to reduce the
air drag thereby reducing the consumption of energy and also giving train an aesthetically pleasing look.

Use of Bio-Diesel

The characterization of ALCO and EMD Engine with Waste Fish Oil and Waste Cotton Oil based Bio-
Diesel has been carried out in the Directorate with B10, B20, B50 and B100 Blends of Bio-Diesel. Further
Tests with Non-Edible Mahua and Karanja based Bio-Diesel are being planned. Electronic Fuel Injection (EFI)
System has been procured for Testing on 3100/3300/3600 HP ALCO Engine.

This Electronic Fuel Injection (EFI) System is Microprocessor controlled Device which offers flexibility
to vary Injection Timing in dynamic manner while Engine is in operation, thereby, resulting in Fuel Saving.
Projects on Reduction of Exhaust Emission from Diesel Locomotives and CNG based DEMU and ALCO
Locomotive have also been planned.

Development of Electric Locomotives with Hotel Load

Based on the guidelines issued by Railway Board for development of locomotives with hotel load
facilities in their transformers, RDSO has finalized the details for implementation of HOG scheme including
specification for centralized inverter, coach inverter, under slung DG set for coaches of trains hauled by
WAP4, WAP5 and WAP7 locomotives and the same has been approved by Railway Board. RCF has been
advised for procurement action as per these approved specifications.

OTHER TECHNOLOGICAL IMPROVEMENTS

Design Improvements on Traction Motor

Three phase traction motors were a part of

the three phase propulsion system of three phase
electric locomotives procured from then M/s. ABB
during the nineties. At the time of procurement,
three phase traction motor due to its robust
design were considered to be more reliable
option. However, in actual service these traction
motors started giving serious trouble affecting the reliability of the locomotive. While the stators failed due to
failures of the brazed joints of the overhangs, rotors also failed due to breakage of the rotor bars. Other
Railway systems overseas have had similar experiences with axle hung nose suspended three phase traction
motors including diesel locos on Indian Railways.

A detailed study was carried out to analyse these failures, based on the trial data, study of literatures.
Excessive shock and vibration was singled out as the main cause of the failures of the traction motor. The
design was suitably modified and validated by Finite Element Analysis for the first time on IR. The modified
traction motors have already been put in service on the IR.

It is expected that this will fetch a saving of approximately Rs. 57 Crore annually to the Indian Railway.

Corrosion Prevention of Rails

To tackle the problem of corrosion of rails, especially under the liner location on rail foot and at weld
collars and to prevent jamming of leg of elastic rail clips inside the insert through:

Material Characterization of ERC, insert, liner and rail.

Analysis of rust samples of existing rail.

Trial crevice corrosion experiments (between C-Mn rail steel and metal & GFN liners) by immersion
method in 3 different solutions, namely FeCl3 solution, artificial urine solution and 3.5% NaCl solution.

Use of alternate alloying elements for improved corrosion behavior.

Study effectiveness of different coating methods.
Status

After detailed literature survey and deliberations with experts five alternative metallurgies were selected
for lab scale evaluation of corrosion resistant properties. The best metallurgy with Ni, Cr & Cu micro-
alloying elements was recommended to Railway Board for field trial.

Railway board approved the trial and 570 MT of these rails have been supplied to SCR and are under
laying.

One coating system comprising of Zinc as major element has been recommended by this project to
Rly Board and approved by Rly Board for trial.

Improved Rail Fastenings

Design and develop suitable fastening system with:

Higher Toe load in the range of 1200-1500 Kg with
maximum loss of toe load, upto 15%, in service.

Fastening components such as clips, liners & pads
to have almost equal service life, compatible with
life of Rail & Sleeper (Approx. 20 Years).

Minimum Fastening components with easy maintainability.

Anti-Jamming Properties either by suitable coating or by Improved Metallurgy.

Anti Sabotage Features.

High Fatigue Life.

Design of components i.e. ERC,GFN Liner, Rubber pad and Metal liner has been completed. New ERC
is having higher toe load 1200-1500 kg retaining the existing bar dia. The ERC will have sufficient
scope to take care of accidental increased stresses. Other components are also having design
advantages over existing products.

Theoretical Modeling of New ERC ,Rubber PAD and GFN is completed.

Mathematical model completed and results generated.
ERC die is under manufacturing. Rubber pad samples are under lab testing and orders has been placed for
making liners.

Use of New Materials

a) Development of Hytrel Material for use in Coaching Components
Advantages:

Gives longer life up to two POH.

Excellent resistance to oil and chemicals.
Better creep resistance.
Lighter in weight, Lower in cost.
 Status:

Upper & Lower Washers for Mainline coaches Developed and implemented
Axle Box Front Cover Developed and spec. issued
Upper & Lower Washers for EMU Coaches under development
Hytrel Ring for Axle Box Rear Coverunder development

b) Development of Self Lubricating Polyester Resin Based Composite material for use in Coaching
components-

Advantage:
Low rate of wear i.e. longer life.
Self lubricating property i.e. easy fitment.
Lower life cycle cost.

Status:
Self Lubricating Polyester Resin Based Composite Brake Gear Bushes Under development
Self-lubricating Polyester Resin Composites Wearing Piece Under development

Oil Free Compressor

Lubricated type compressors are currently being used on Electric Locomotives. RDSO is developing oil free
compressors for electric locomotives owing to its superiority over the conventional lubricated type
compressors, which include reduced maintenance cost and down time of Locos, eco-friendly due to oil free
air, longer service life of air dryer and other pneumatic valves/components, low vibration and low noise,
reduced start up energy requirement, low life cycle cost, no fire hazard.

Development of Numerical Type Microprocessor

Development of numerical type microprocessor based protection relays and control and relay panels having all
digital meters was undertaken by RDSO. The specification has been finalized and issued to all approved relay
manufacturers for development. The prototype control and relay panel developed is under testing at the works of
manufacturer.

Specification for Improved Rail Pad For Longer Service Life

Specification for improved rail pad for placing beneath rail (Provisional 2008) for service life of 300 of GMT are
8 years have been prepared and issued to Zonal Railways for trial in 25 Km stretch on each Railway as per
directives of Railway Board. Trial scheme and drawing have been issued to Zonal Railways.

Design of 1 In 10 Movable Switch Diamond Crossing 52 Kg. With Double Slips (Curved Switch) Bg
(1673mm) On PSC Sleepers

The diamond crossings with acute angle of crossing more than 1:8 (especially with non-standard designs)
are observed to be more prone to derailment. To overcome the problem Railway Board desired that RDSO
should develop standard design of 1:10 switch diamond crossing with single and double slips on PSC
sleepers, highlighting the case of derailment on NC Rly. The issue was further reiterated by Railway Board. In
compliance to above instructions of Railway Board, RDSO has evolved the following three designs, the use of
which would enhance the safety on diamond crossings:

i) Design of 1:10 movable switch diamond without slips BG, 52 Kg. on PSC Sleepers and
standard drawings No. RDSO/T-6644 to RDSO/T-6696 have been issued to NC Railway.

ii) Design of 1:10 movable switch diamond with single slips BG, 52 Kg. (curved Switch) on PSC
Sleepers and standard drawings No. RDSO/T-6877 to RDSO/T-6887/1 have been issued to NC
Railway.

iii) Design of 1:10 movable switch diamond with double slips BG, 52 Kg. (curved Switch) on PSC
Sleepers and standard drawings No. RDSO/T-6889 to RDSO/T-6895/1 have been issued to NC
Railway.

With this, RDSO has completed action on this safety related item.
DESIGN OF FAN-SHAPED PSC LAYOUT FOR TURNOUTS ON SHARP CURVES

S.W. Railway had asked RDSO to develop design of fan-shaped layout taking off from main line having
curvature of 7.1o. A design of contrary flexure fan-shaped layout taking off from main line has been evolved
by adjusting the spacing of sleepers and details have been advised to S.W. Railways.

Extending the exercise carried out to prepare drawing for laying a contrary flexure, 1 in 12 turnout in
7.1o curve, RDSO has developed a general drawing. The drawing incorporates sleeper spacing for laying a
contrary flexure, 1 in 12 turnout, on PSC sleepers in curves of 1o, 2o, 3o, 4o and 5o. The details have been
advised to Zonal Railways. Further, PSC sleeper spacing for turnouts to be laid on a similar flexure curve
having curvature from 1o to 4o were also advised to Zonal Railways for trial purpose.

Design And Development of Movable Switch Diamond For 1:8 , B.G. (1673mm), 60kg (UIC) On PSC
Sleepers

In reference to Railway Boards letter No. Track/21/2006/0401/7 Diamond Crossing dated 25.08.2008,
the work of development of new design of 1:8.5 movable switch diamond crossing (without slips) BG
(1673mm) for 60kg (UIC) on PSC sleepers has been completed. The drawings have been issued to Northern
Railway for trial.

Design of 1:12 And 1:8 Turnouts With Zu-1-60 Thick Web Tongue Rail Bg For 60 Kg (UIC) On PSC
Sleepers

For better riding comfort, enhanced life and permitting higher

speed, design of ZU-1-60 thick web switch for 1 : 12 and 1:8.5
turnouts has been developed and drawings have been issued to
Zonal Railways. Subsequently, the drawing has been modified to
incorporate elastic fastening system, to make continuation of LWR
through points & crossing possible. Railway Board has decided that
these thick web switches would be provided on entire A route and
other high-density routes having annual density of 20 GMT and
above. Tender for procurement of the same is being finalised by
Railway Board.

Development of Drawing And Specifications Of Weldable CMS Crossing

As per instruction of Railway Board, RDSO have developed the drawing for 1:12 and 1 in 8.5 weldable
CMS crossing using intermediate piece and vertical stiffeners and Drawings have been sent to Railway Board
vide this office letter No. CT/PTX/Inspection/MT dated 27.10.2004 and dated 31.01.2005 respectively. The
specifications of weldable CMS crossing has been prepared and sent to Railway Board. Typical sketches are
given below :
1200 mm NORMAL RAIL

SPECIAL ALLOY WELD METAL

WELDABLE 1 :12 C.M.S. CROSSING

Railway Board asked RDSO to firm up the drawings of LWR through Points & Crossing. Study has
been carried out about possibility of taking LWR through Points & Crossing. Based upon study, detailed report
on continuation of LWR through Points & Crossing (RDSO Report No. CT-11) has been sent to Railway
Board. Tender for procurement of weldable CMS is being finalised by Railway Board.

1200 m m N O R M A L R A IL

S P E C IA L A L L O Y W E L D M E T A L

W E L D A B L E 1 :8 .5 C .M .S . C R O S S IN G
Composite Sleeper
As an alternative of wooden sleeper, a
project of development of composite sleeper
was taken in hand by RDSO. Railway Board
instructed RDSO to prepare technical
specifications for the extended trial of Tietek
design and to draw complete scheme of trial
for development of composite sleeper. The
technical specifications and trial scheme for
development of composite sleepers have
been prepared and sent to Railway Board.
Railway Board approved the extended trial of Tietek design of sleepers in all Zonal Railways. All Zonal
Railways have been advised to carry out trials as per Railway Boards instructions vide this office letter No.
CT/FRPS/Tietek design dated 11.11.05.

UIC Project On Optimization Of Design Of PSC Sleeper

UIC has entrusted RDSO a project on optimization of design of PSC sleeper specially for Asian
countries. In this regard, a draft scope of the project was submitted for discussion among the UIC member for
finalizing the scope of the project. Recently, a design literature has been received from Swedish Railway for
discussing some of the design parameters for optimization. Consultant from Sweden is likely to visit India for
discussion on design parameter with RDSO. Thereafter a technical visit is planned to Sweden by Indian
Railway Officials.

Trial Of PSC Sleeper For Curve Upto 10o

Railway Board vide letter dated 12.12.08 asked RDSO to take up the design of PSC sleepers suitable
for curve upto 10o. RDSO vide letter No. CT/SRC/3/2/Curve dated 01.01.2009 advised that PSC sleeper to
Drg. No. RDSO/T-4183-86 is suitable upto 10o curve and trials can be conducted by Zonal Railways. This
PSC sleeper has the provision of slack gauge upto 1682 mm which is 9mm slack to nominal gauge of 1673.
Section modulus as well as cross-sectional area is more as compared to normal sleeper in use for 22.5t.

G Clip Report

Railway Board vide letter no. 97/TK II/22/1/4(Vol-II) dated 19-9-2008 communicated not to peruse
further implementation of G-Clip may till the shortcomings like early permanent set and lesser torsional
resistance are properly addressed by RDSO. In this connection a study on static permanent set of G clip &
ERC Mk-V has been carried out at RDSO laboratory. Further Railway Board vide letter no. 2001/ TK-II/ 22/ 1/
4/ 111 dated 27.11.2008 advised to observe behavior/ performance of G clip already under trial on Northern
Railway under incidental forces during machine tamping etc. in presence of Director/ Track, RDSO & sectional
Sr. DEN. Joint inspection has been carried out on 23.12.2008.