2.4 road map for implementation of benefits derived out of ... · road map for implementation of...

Road Map for Implementation of Benefits Derived out of TMRS Project

29th Meeting of Governing Council – 10/9/10 93

2.4 Road Map For Implementation Of Benefits Derived Out Of TMRS Project

Technology Mission for Railway Safety(TMRS)

As per Mission Management Manual, anticipated TMRS duration was 3 years and an additional six months period was allotted for transfer of technology to Railways. Since these projects were started Feb -2005 –Aug 2005, TMRS was due to close by Sep2008 with Transfer of Technology upto March 2009. Ultimately Mission was declared closed on 30th Sept 2009 by Mission Implementation and Coordination Committee (MICC)

MICC consisted of-

• Director IITK as Chair- Dr S.G.Dhande

• DG RDSO as Co-chair

• Prof N.S.Vyas Mission Coordinator

• Other industry invitees

• Permanent special invitees –ED/F, ED/R, Dean R&D IITK, Dy Director IITK

Out of 12 projects –

• 9 projects – Objectives achieved

1. Track Side Bogie Monitoring System

2. Sensors for Detecting Hotboxes, Hot Wheels

3. Wheels and Axles of Improved Metallurgy

4. Corrosion Prevention Of Rails

5. Derailment Detection Devices

6. On Board Diagnostics

7. Measuring Wheel Technology

8. Environmental Friendly Coach Toilet Discharge System

9. Satellite Imaging for Rail Navigation (SIMRAN)

• In rest 3 projects- Objectives not achieved

1. Improved Fastenings

2. Rail Flaw Detection Instrumentation

3. Fog-Vision Instrumentation

1. Satellite Imaging for Rail Navigation (SIMRAN) The project had been undertaken under the Signals & communication mission

area. The major objectives of SIMRAN project were:

• Develop technology to continuously track every train in a given geographical boundary for its location, speed and direction of movement.


• Develop techniques to dynamically disserunning to passengers and to the general public.

Following concerted efforts, installation & commissioning of Prototype Train Equipment has been completed & the system validated. The current status of the project is that a total of 43 Rakes which include Rajdhani, Shatabdi, Duranto, Pushpak and MEMU trains have been fitted with the developed systems.

New Knowledge Creation The developed system is capable o(1) Disseminating information

regarding the train arrival time (at the station), train departure time (from the station), train passing time from a station, the current position of a train between two stations and speed of train.

(2) The web based interface, shmeet functional requirements of internet users and passengers.

(3) Dissipating realthe next station or next stoppages and current running status of the train.

(4) At the station, the same realshared with passengers through a display device (LCD/PLASMA).

Knowledge Spillovers (Effect):

The developed technology platform of SIMRAN can prove to be a foundation for wide ranging application areas. Some of the applications, which can be built on the SIMRAN, infrastructure could be:

1. WCD + Water Level Indicator + Announcement2. Coach Diagnostic Data Transmission3. LC Gate Warning System4. Integration with IR

Management) 5. Integration with IR

Information Hub for IR)6. Gang man Safety Device7. Wagon-Coach Tracking using RFID


Develop techniques to dynamically disseminate information about train running to passengers and to the

Following concerted efforts, installation & commissioning of Prototype Train Equipment has been completed & the system validated. The

of the project is that a total of 43 Rakes which include Rajdhani, Shatabdi, Duranto, Pushpak and MEMU trains have been fitted with the developed systems.

Screen Snapshot of SIMRAN Train

New Knowledge Creation The developed system is capable of

Disseminating information regarding the train arrival time (at the station), train departure time (from the station), train passing time from a station, the current position of a train between two stations and speed

The web based interface, shall meet functional requirements of internet users and passengers. Dissipating real-time information to passengers inside the train about the next station or next stoppages and current running status of the

At the station, the same real-time train-running information could be shared with passengers through a display device (LCD/PLASMA).

Knowledge Spillovers (Ripple

The developed technology can prove

to be a foundation for wide ranging application areas. Some of the applications, which can be built on the SIMRAN, infrastructure could

WCD + Water Level Indicator + Announcement Coach Diagnostic Data Transmission LC Gate Warning System Integration with IR-GIS (Asset & Operation

Integration with IR-RIS (Central Information Hub for IR) Gang man Safety Device

Coach Tracking using RFID


minate information about train

Screen Snapshot of SIMRAN Train-Tracking

time information to passengers inside the train about the next station or next stoppages and current running status of the

unning information could be shared with passengers through a display device (LCD/PLASMA).



8. Driver Lobby Automation 9. OBD Communication 10. SafeRun + End of Telemetry 11. Wireless Braking System 12. Real-Time Station Announcement 13. Coach Location Display System at Platforms 14. Loco shed Automation (Maintenance Schedules & Inventory) 15. Car Shed Automation (Maintenance Schedules & Inventory) 16. Traffic Analysis, Time Table Optimization, New Trains 17. Optimized Resource utilization (Locomotive, Rake, Coach, Wagon)

Objectives of this R&D project have been met. A proposal for All India

implementation of SIMRAN at an estimated cost of Rs. 83.24 Cr, duly

vetted by RDSO Finance has been sent to Railway Board on 16.12.2009

for inclusion in Works Program 2010-11. The proposal is under

consideration in Railway Board.

2. Track Side Bogie Monitoring System The project, envisaged, development of a way-side detection system for

enabling Preventive maintenance of the Rolling stock. Reprofiling and replacing worn wheel sets constitutes a significant portion of

rolling stock maintenance costs. Misaligned wheel sets are also responsible for increased fuel consumption and accelerated track deterioration. Typically about 5% of wheel sets have abnormal behavior. The misaligned wheel sets represent a serious safety risk and hence earliest detection of misaligned wheel sets is essential.

Detailed objectives of this project include (i) development of an automated

system to be installed along the track for detecting faults in bogies of rolling stock (on-line monitoring of the condition of bogies), (ii) measurement of lateral and vertical rail forces, , (iii) development of instrumentation for detection of components of the rolling stock which may cause derailment.

The system developed uses a laser rangefinder to measure the angle-of-attack

(AOA), and tracking position (TP) of every passing wheel from which the inter-axle misalignment (IAM) and tracking error (TE) of wheel sets is determined. A separate sub-system included in the design also provides the vertical and horizontal rail forces using strain gages.

Project Status: The prototype system has been developed. The system measures and reports the data through the internet. System also has the capability to send critical messages to the nominated person through SMS in case of critical readings. Data is also available for integration into the communication network of the Indian Railways. Knowledge Creation: • Measurement of lateral load • Measurement of Angle of attack • Instantaneous L/V ratio can be calculated



• New method of predictive maintenance • RFID detection of Rolling stock

Knowledge Spillovers:

• LabVIEW platform capability developed at RDSO • Capability of integration with SIMRAN Platform for data transmission • IIT K developed as Centre of Excellence for Way side monitoring technology • Exposure to High speed State of Art DAS of different types and capabilities

Objectives of this R&D project have been met. Now a separate project has been undertaken under the powers of DG for detailed field trial which will be completed in Oct 2011.

3. Development of Derailment Detection Devices For the first time in the History of World Railways, Indian Railways have

developed this indigenous technology for detection of derailment and preventing/minimizing its ill effects.

Development of on – board equipment for sensing derailment of rolling stock has been completed. It measures the acceleration along the 3 axis using tri-axial sensors, analyzes the acceleration in time and frequency domain and thereafter trains the neural network. The threshold limits for the accelerations have been fixed. If the threshold limits are exceeded, an alarm is generated which in turn is communicated to the driver through wireless communication. Simultaneously, a pneumatic valve, vents out the brake pipe pressure thereby actuating the brakes.

Objectives of this R&D project have been met. The concept has been developed with IIT Kanpur by manufacturing and conducting limited field trials. With the available deliverables received from IIT Kanpur, Testing Directorate is making 1 coach set of derailment detection device to undertake extended field trials on running trains during the financial year. After successful field trials, specification will be prepared and handed over to Design Directorate for Adoption over Indian Railways.

4. Sensors for Detecting Hot Box, Hot Wheels This Project also added one more way side detection system for Indian

Railways for detecting unsafe condition of Rolling stock wheels, axle boxes including cold Braking.


Most derailments can be traced to either the failure of wheel bearings or bbinding. Both conditions lead to overheating followed by seizure which in turn can cause wheel flats, track damage and derailment. Hot Axle and Hot Wheel Detection (HAHW) systems are used globally for the purpose. These rely on remote measurement of tbearing boxes and the wheels. These systems have to be capable of measuring the temperatures very fast (at 200 kmph the measurement of a minimum of 10 points has to be made within 0.004 second). Any system to be used in India has to be designed to cope with extremes.

In this project two prototype systems have been developed. The system uses state of the art technology to measure the axle box and the wheel tread temperature of the axles passing the site and report the data through the internet website. System also has the capability to send critical messages to the nominated person through SMS in case of critical readings. Data is also available for integration into the communication network of the Indian Railways. Knowledge creation: • Detection of braking efficiency• Effect of climatic condition on wheel temperatures • Portable Hot wheel detectors Knowledge Spillovers:• RFID detection of wagons • Capability of integration with SIMRA• IIT K developed as Centre of Excellence for Way side monitoring technology • Use of pyrometers in unmanned modes for accurate data recording• LabVIEW platform capability developed at RDSO

Objectives of this R&D project have been methas been undertaken under the powers of DG for detailed field trial which will be completed in Oct 2011.

5. On Board Diagnostics on Diesel and Electric Loco: Presently the data for the preventive maintenance for Locos is not available on

line. The owner shed has no information on working parameters of the asset, while it is running over the Indian Railways and has to wait till loco returns back, to the shed.

By the help of this Project a parameters governing the health of a locomotivebased control system was developed. Mounting and functional monitoring of sensors viz. FTMB/RTMB /Expressor(viwater(temperatures), Water pump/L.Oil Housing(pressures), Axle Boxes / Sus. Brg. (vib. & temp.), TA(Voltage& current) and Aux. Gen. voltage along with Monitoring and analysis of data received has been completed. Knowledge Creation: The project has introduced a new concept of predictive maintenance and broughtamalgamation with periodic maintenance to avoid break down maintenance, thereby improving reliability, availability and safety.


Most derailments can be traced to either the failure of wheel bearings or bbinding. Both conditions lead to overheating followed by seizure which in turn can cause wheel flats, track damage and derailment. Hot Axle and Hot Wheel Detection (HAHW) systems are used globally for the purpose. These rely on remote measurement of temperatures of the bearing boxes and the wheels. These systems have to be capable of measuring the temperatures very fast (at 200 kmph the measurement of a minimum of 10 points has to be made within 0.004 second). Any system to be used in India has

esigned to cope with climatic

In this project two prototype systems have been developed. The system uses state of the art technology to measure the axle box and the wheel tread temperature of the axles passing the site and

through the internet website. System also has the capability to send critical messages to the nominated person through SMS in case of critical readings. Data is also available for integration into the communication network of the Indian Railways.

ge creation: Detection of braking efficiency- Running of Cold wheels /Brake binding Effect of climatic condition on wheel temperatures Portable Hot wheel detectors

Knowledge Spillovers: RFID detection of wagons Capability of integration with SIMRAN for data transmission IIT K developed as Centre of Excellence for Way side monitoring technology Use of pyrometers in unmanned modes for accurate data recordingLabVIEW platform capability developed at RDSO

R&D project have been met. Now a separate project has been undertaken under the powers of DG for detailed field trial which will be completed in Oct 2011.

On Board Diagnostics on Diesel and Electric Loco: Presently the data for the preventive maintenance for Locos is not available on line. The owner shed has no information on working parameters of the asset, while it is running over the Indian Railways and has to wait till loco returns

By the help of this Project a system for online, monitoring of various parameters governing the health of a locomotive through a microprocessor based control system was developed. Mounting and functional monitoring of sensors viz. FTMB/RTMB /Expressor(vibrations), Exhaust gas/ Cooling water(temperatures), Water pump/L.Oil Housing(pressures), Axle Boxes / Sus. Brg. (vib. & temp.), TA(Voltage& current) and Aux. Gen. voltage along with Monitoring and analysis of data received has been completed.

The project has introduced a new concept of predictive maintenance and brought-about an amalgamation with periodic maintenance to avoid break down maintenance, thereby improving reliability, availability and safety.


Most derailments can be traced to either the failure of wheel bearings or brake binding. Both conditions lead to overheating followed by seizure which in turn can cause wheel flats, track damage and derailment. Hot Axle and Hot Wheel Detection (HAHW) systems are used globally for the purpose. These rely on

been developed. The system uses state of the art technology to measure the axle box and the wheel tread temperature of the axles passing the site and

through the internet website. System also has the capability to send critical messages to the nominated person through SMS in case of critical readings. Data is also available for integration into the communication network

Running of Cold wheels /Brake binding

IIT K developed as Centre of Excellence for Way side monitoring technology Use of pyrometers in unmanned modes for accurate data recording

. Now a separate project

has been undertaken under the powers of DG for detailed field trial

Presently the data for the preventive maintenance for Locos is not available on line. The owner shed has no information on working parameters of the asset, while it is running over the Indian Railways and has to wait till loco returns

system for online, monitoring of various through a microprocessor

based control system was developed. Mounting and functional monitoring of brations), Exhaust gas/ Cooling

water(temperatures), Water pump/L.Oil Housing(pressures), Axle Boxes / Sus. Brg. (vib. & temp.), TA(Voltage& current) and Aux. Gen. voltage along with



Knowledge Spillover:

• On-board diagnostic system can be extended to all families of locomotives.

• The diagnostic system developed is capable of on-line monitoring of various parameters viz. vibration, temperature, pressure, TM current, TM voltage. This can help Railways to monitor the healthiness of different on-board equipments at any given time.

• The system developed will be of great help in reducing the downtime of locos & graduate to predictive maintenance from the currently practiced, breakdown maintenance.

Objectives of R&D project have been met. Through this project, RDSO has acquired the know-how for designing system for remote diagnostic of locomotive parameter/faults. The project was undertaken in 2006, since then advancement of technology has been done on the ALCO locomotives and the E-type excitation system was replaced with microprocessor control. At present, over 1000 nos. of locomotives are working with microprocessor control. These locomotives have several sensors that monitor over the 100 different locomotives parameters in real time.

These microprocessor locomotives have the capability of transmission of data to a remote server with little additional input. On the other hand, implementation of on board diagnostic would cost upto Rs. 10 Lakh per locomotive, considering the cost of sensors and other hardware.

This microprocessor control locomotives however, do not have sensors to monitor vibration and temperature of bearings. This in any case, is needed for high-speed operations and not for diesel locomotive operation to upto 120 kmph. In view of the above, it is planned to merge On board diagnostic project with the remote locomotive monitoring system (REMLOT). This would not only ensure speedy implementation but would also reduce the cost of implementation.

6. Wheel & Axles of Improved Metallurgy

This project envisaged development of steel of improved metallurgy for wheels and axles for achieving reduced in-service failures, to withstand higher axle loads without sacrificing safety and achieving overall improvement in reliability. � Forged wheel

After finalizing the Composition and heat treatment process at IIT K, DSP has manufactured forged wheels as per improved metallurgy. Objectives of this R&D project have been met. 112 Nos of Forged wheels in the form of 56 wheel set (with conventional axle) have been sent to RCF. These are to be put in field trial. After getting the feed back from the field, specification will be finalised.

� Cast wheel

After finalizing Composition and heat treatment process at IITK, RWF has already casted wheels of improved metallurgy and heat treatment as per the plan. The mechanical properties have been tested in RWF and



results are encouraging. � Forged axle

Composition and heat treatment process has been finalized and prototype axle have already been forged at DSP

Objectives of this R&D project have been met. 50 Nos of forged axles 50 nos of cast wheels have been manufactured in DSP & RWF. It is planned that they will also be put under field trial and specification will be finalized after getting feed back from the field.

7. Development of Measuring Wheel Technology

The project envisaged Design & development of Measuring Wheel Sets for measuring the dynamic forces at the rail-wheel level for : 1) locomotive 2) coach & 3) wagon

Measuring wheel for Wagon has been developed successfully and now the technology can be extended to Loco and coaching wheels also.

Objectives of this R&D project have been met. Under this project RDSO has developed the capability to make measuring wheel for Freight Stock. The cost of indigenously manufactured Measuring Wheel is about Rs. 2 crores as compared to imported measuring wheel set of 3.9 crores. It may further reduce during manufacture of measuring wheel for coaching stock which is under development at RDSO.

8. Environment Friendly Coach Toilet Discharge System The objective of the project

was to conceptualize design and indigenously develop a working/ready to install Environment Friendly Coach Toilet System for Indian Railways Passenger Trains. This toilet has been successfully developed and the prototype has been running successfully on field trials in Southern Railway since Feb 2009. This design of toilets is with Zero discharge to the outside system.



Objectives of this R&D project have been met. At present the prototype field trial has been done on one coach only but for formulating the IR manual, extended trials on at least one complete rake is required. Now Open tender has been floated for full rake trial and the tender is due for opening on 31.8.2010

9. Corrosion Prevention of Rails The project was envisaged 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.

(a) Objectives of this R&D project have been met. (b) In this project corrosion resistant rails i.e. Ni, Cr,Cu (NCC) has been

developed and the same has been included in Indian Railway Specification for Rails i.e. IRST-12-2009.

(c) On finding the satisfactory performance of NCC rails in initial trials, Railway Board has ordered rolling of 10000MT of NCC rails out of which 7,895MT rails have been rolled and sent to zonal railways for laying in corrosion prone areas for extensive trials. Further, as a result of the extensive trial and on finding their performance satisfactory, rail renewal in corrosion prone areas can be done with NCC rails to prevent corrosion of rails and increase service life of rails.

(d) In the second deliverable, as a result of TMRS project, corrosion protection by cold galvanizing (zinga coating) was recommended whose procedure for application was approved by Railway Board. Railway Board desired further information regarding cost comparison monitoring parameter etc., which have been submitted to Railway Board. On approval from the Railway Board, some of the zonal railways may conduct trial of cold galvanizing (Zinga Coating) for prevention of corrosion of rails.

10. Improved Rail Fastenings The main objective of Project was the selection and

development of improved rail fastening system and components complete in all respect having Toe load in the range of 1200-1500 Kg with loss of toe load of maximum up to 15% in service, Anti sabotage/anti theft features and Anti jamming properties by suitable coating or improved metallurgy of the material. Objectives of this R&D project have not been met. Since technology could not be developed, hence TOT not completed as deliverables were not achieved. A new work is being sanctioned separately under DG power undertake the work further.



11. Rail Flaw Detection Instrumentation

The objective of the project was the development of state of the art rail / weld testers using most appropriate non destructive technology in order to maximize scan area of rail / weld with event logging facility for post processing of data.

Objectives of this R&D project have not been met. Since technology could not be developed, hence TOT not completed as deliverables were not achieved.

12. Fog Vision Instrumentation

The project envisages development of instrumentation for improving the visibility during foggy weather, night and bad weather conditions by developing Fog vision system.

Experiments with Thermal Imager & 1.55 µm laser have not been successful. CO2 laser experiments in for Fog attenuation & Scattering loss have been done in IIT Kanpur laboratory. Reduced fog attenuation with CO2 laser observed during initial lab experiments. Laser detector has been received and Lab trails completed. Prototype Loco model could not be made by IIT Kanpur.

Knowledge creation

• Measurements of Attenuation of very dense fog (visibility < 10m) at several wavelengths [0.633mm (visible), ~1.55mm (near IR, and 10.6mm (far IR)]

• Measurement of Scattering properties of several Rail Track objects at 10.6mm

Objectives of this R&D project have not been met. Since technology could not be developed, hence TOT not completed as deliverables were not achieved. Further discussions are being held with IIT/K and also BEL for developing a proto type and it is also proposed to invite Expression of Interest (EOI) for developing the proto type on the proof of concept given by IIT/K

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