Page 73 - GM's Annual Inspection Booklet DEC- 2022

Fabrication & Cost:

 The Mobile single car test rig was developed completely in house by the shed for the
testing of the air brake parameters of the DEMU coaches.
 An electric driven compressor unit available with the shed is being used for supply of
compressed air to the test rig.
 All the valves, compressed air tanks and gauges were sourced from spare materials
available in the shed.
 The wheels and materials required for the fabrication of the test rig have been
purchased outside costing INR 6,000/-.
 It would cost about INR 5,00,000/- if the test rig were to be procured from an outside
agency.

Purpose & Advantage:

 Shed was in the practice of utilizing the DEMU Power cars for compressed air and
brake valves of the cab in order to test the brake system involving switching ON the
DPC and placing it in idle condition for about 3 hours per rake thereby, consuming
about 12 lts of HSD oil for testing of one rake.
 Thus, to save the precious fuel oil, DLS/MLY team has come up with an innovation for
testing the DEMU coaches without utilizing the DEMU power cars.
 The following checks can be performed by use of this Test rig:
 Performance and functioning of Application and Holding magnet valves.
 Performance and functioning of all the electro pneumatic air brake valves.
 Parameters that can be checked by use of this indigenously developed test rig:
 Application and release timing of the EP brake.
 Application and release timing of the Auto brake.
 Application and release pressures of the valves.
 With the use of this test rig the shed is now able to perform the complete testing of the
Air brake parameters and check the real time performance of the valves without having
to depend on a power car saving HSD oil.
 Previously the entire DEMU coach rake was being tested and troubleshooting was
quite tedious as any problem/trouble in a particular coach could not be identified
immediately but was done only through trial and error.
 With this test rig the shed staff can now test the individual coach and can find and
troubleshoot any defect in no time, increasing the efficiency of the team.

Savings: Annual savings of INR 4,80,000/- can be achieved utilizing this test rig.

2. Developed Scrap exhibits for Children’s Park:

Scrap exhibits were fabricated by DLS/MLY and were placed at newly inaugurated
Children’s Park at South Lalaguda. They were well appreciated by GM, PCME and
other PHODs

71