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  Mechanical Department - Kalyan Diesel Shed

 

Diesel Loco ShedKalyan was inaugurated on 31st January 1987. It was initially planned to home WDS6 Diesel Electric locos only in this shed. During the year 1993-94, the pattern of holding changed with the inclusion of 2 WDM2 locomotives. Later more WDM2 locomotives were introduced, The shed has progressed a lot since then and it now holds technologically advanced high horsepower locomotives. 

At present 95 locos are homed in the shed with majority of 37 WDG3A locomotives. In addition shed also homes 21 WDM3D, 12 WDG4, 11 WDG4D and 14 WDP4D locomotives. The types of locomotives and their horsepower and other technical features are tabulated below:

Loco type

Holding

 Horse Power

WDG3A

37

3100

WDM3D

21

3300

WDG4

12

4500

WDG4D

11

4500

WDP4D

14

4500

 
 

 
 

IMPORTANT TRAINS AND SECTIONS COVERED:

 
 

The shed has mail link of 47 locomotives at present and provides locomotives for important trains like:

12223/12224 LTT-ERS DURANTO Express,
11019/11020 Konark Express,
11043/11044 LTT-MDU Express,
18520/18519 LTT-VSKP Express. etc.

Kalyan Diesel Shed also provide maximum locos for working holiday specials or special mail-express trains running towards Konkan Railway & other parts also. 

Following important mail links are operated by Kalyan diesel shed locomotives:

SN.

Train no.

Train Name

From-To

1

12071/12072

Janshatabdi

DR-AWB

2

11043/11044

LTT-Madurai Exp.

LTT-MDU

3

18520/18519

LTT-VSKP Exp.

LTT-KZJ

4

17318/17317

LTT-Hubli Exp.

LTT-UBL

5

12131/12132

DR-SNSI Exp.

DR-SNSI

6

12223/12224

LTT-ERS Duronto

LTT-ERS

7

22113/22114

LTT-KCVL

LTT-KCVL

8

11019/11020

Konark Exp.

CST-BZA

9

22105/22106

Indrayni Exp.

CST-PA

10

12701/12702

HUSSAINSAGAR Exp.

CST-HYB

 
 

 
 

Kalyan Diesel shed has achieved the distinction of being one of very few diesel sheds homing 100% population of locomotives fitted with microprocessor control system. 

TECHNOLOGICAL DEVELOPMENTS
 
 

Many technological inputs are being provided to improve the reliability and availability of diesel locomotives. These include Microprocessor based control systems (MEP), microprocessor based governors (MCBG), vigilance control device (VCD) and remote sensing (REMMLOT).

All 95 locomotives have been provided with Microprocessor Controlled Systems (MEP) and 75 locomotives have also been provided with REMMLOT, which enables access to microprocessor control system data of locomotive through internet by GSM/CDMA/GPS.




Microprocessor Based Loco Control System (MEP 660) 
 

This system has been fitted in 100% (95 out of 95) of locomotives in Diesel shed, Kalyan. Microprocessor system is designed to eliminate the drawbacks in conventional E type excitation and propulsion control system. It is built with an on line fault diagnostic system, which continuously monitors operating levels of parameters of various equipment on locomotive and identifies any abnormal conditions of working of any equipment, indicating a fault in that equipment

 
 

Vigilance Control Device (VCD) 
 

100% of Diesel Locomotives (95 out of 95) are equipped with vigilance control to enhance the safety of the locomotive operation. The vigilance control device acts very smart and recognizes the normal loco operation performed by the driver. If no such operations are performed within set time limit, it then applies the emergency penalty brakes and brings the loco to idle position.

 
   
 


Remote Monitoring & Management of Locomotives and Trains (REMMLOT) 
 

REMMLOT system has in-built GPS capability. This system wirelessly transfers the fault diagnostic and locomotive health monitoring data at regular intervals to a secure password protected web server accessible to IR personnel. An interface is also provided to acquire the GPS location data of locomotives / trains. Diesel Loco Shed, Kalyan has 75 loco with this feature.

 
   
 IMPORTANT FACILITIES  
 

Various advanced facilities for maintenance, testing and shed management have been arranged for effective working of the shed. Details of some of the important facilities are given below:

NAME OF FACILITY

MAKE

COMMISSIONING DATE

USE OF FACILITY

Microprocessor based FIP calibrating test stand

SLVMR fuel injection Equipment Haryana

17.03.09

For testing of Fuel Injection Pumps used in 266 HP and 3100 HP locomotives.

Dynamic rotor Balancing Machine

M/s ABRO balancing M/C pvt LTD

25.08.06

For balancing of all type TSC rotors

Test bench for testing of speed recorder.

Medha servo Drives Pvt Ltd.

15.03.05

For testing and calibration of speed recorder and indicator.

Computerized SFC recorder

United Industries Erode.

23.04.03

For calculating SFC and automatically measuring the fuel consumption of the locomotive.

Centrifugal Separator Machine

WESTFALIA SEPERATOR INDIA PVT LTD

24.03.03

For separation of sludge, impurities, carbon contents etc and filtration/purification of engine lube oil.

Computerized Load Box testing equipment

AG Measurematics Pvt Ltd., Roorkee.

22.05.07

For automatically calculating of Load Box testing parameter and plotting HP Curve.

Effluent Treatment Plant with Incinerator.

Suyash Equipment Pvt Ltd Pune

30.03.07

For recycling of Water having capacity of 3KL/Hour.

Lube Oil Spectro Machine

MAO II Plus

USA

13.09.10

Spectrographic analysis of used crank case oil for predicting abnormal wear of components that may lead to major breakdowns.

Water Load Box

Central workshop Golden Rock Tiruchirapalli (Southern Railway)

19.11.90

For load box testing of all type of locomotive.

HSD oil Centrifuge machine

Pranav Ind.

20.12.16

For cleaning of HSD oil sample brought in Lab.

Spring load deflection testing machine

D.M. Associates, Thane

19.09.08

For checking of Spring height of Under truck.

Stationery magnetic particle testing machine

K. Electronics, Mumbai

11.09.14

For checking of cracks in Ferrous components.

Under floor Wheel lathe machine

HYT, Pune

23.08.11

For Wheel profiling of loco.

Digital Ultrasonic flaw detector

EEC, Mumbai

19.10.13

For checking internal crack in Axle.

Nozzle test master for Injector testing

Sahyadri, Pune

18.03.14

For checking of Injector nozzle.

Variable DC power supply machine

DESWETCH, Thane

03.12.14

For Run test of Traction motor.

Electric Operator screw jack- 25 ton

Marwah, New Delhi

17.12.14

For lifting of Loco.

Electric Operator screw jack- 35 ton

Marwah, New Delhi

06.01.16

For lifting of Loco.

FIP test bench EPS 625

BOSCH

10.03.16

For testing of overhauled FIP.

Shot blasting equipment

MEC, Jodhpur

29.09.05

For cleaning (de-carbonization) of Cylinder head valves face.

Cylinder head valve face grinding machine

SIOUX

15.05.02

For grinding of Cylinder head valve face.

Hydraulic torque wrench

HTORC, Mumbai

24.03.09

For main bearing stud elongation.

Pinion Extractor (WDG4/WDP4)

Chindalia, Navi mumbai

11.03.13

For removal of Traction motor pinion.

 
  
   
 FUTURE INFRASTRUCTURE DEVELOPMENT PLANS 
 

Major infrastructure inputs are being provided in the shed to handle the current level of workload and also to increase loco holding in the future. Following major works are under way:

Brief Description of Work

Current Status ( 01/03/2017)

Augmentation of facilities for maintenance of heavy assemblies and improvement to pit lines

Sanctioned year : 2011-12

Sanctioned cost :- 3.5 Cr

Pink Book No :- 584 (16-17)

Civil  : Completed

Elect : Completed

Mech:

1.Set of Tools of EMD Locos (TOD-25.11.16, under TC at COS, File No.25.16.3464 )

2.Condition Analyzing kit for EMD locos (Under TS)

3.Steel Shelving Cabinet ( RT -13.02.2017)

Extension  of  Bogie  pit  by 14m  and  Extension  of  Gantry  Girder  in  Heavy Repairs  bay.

Sanctioned year : 2009-10

Sanctioned cost :- 40.9 Lakhs

Law Book No :- 580 (2015-16)

Civil: Extension of Pit of Bogie Section by14mtrs.  Towards PA end inside  the covered  Shed. Pit casting done. Finishing to be done. Angles on both end top edges of pit to be fixed. Tiles on both side walls to be provided. Leveling of pit flooring and channel at the bottom of both side of pit for drainage of water to be provided to avoid stagnancy of water in the pit.

          Extension of Gantry Girder Heavy Repair  Bay  by  13mtrs.  at PA end. Chequered plates for Catwalk to be provided. Painting of Girders at the bottom side to be done.

Mech: Set of Hydraulic workbenches of different size –Out of 4 indents, material against 2 indents received on 20/02/7. 02 Indents with SR.DFM, BB for vetting.

Modification/Up gradation of Washing Pit for Fuel Pad/Servicing and  Maintenance Facilities for WDP4/WDG4 /WDM3D/WDM3A/WDG3A Diesel Locos

Sanctioned year : 2012-13

Sanctioned cost :- 62.42 Lakhs

Law Book No :- 590 (2015-16)

Civil :

Rooms completed.

Pit work, Strengthening of Superstructure, Repairs of Drainage System of Washing Pit - Yet to start.

Mech: Out of 09 items-01recd & 01dropped. 07items at different stage with COS/SR.DMM/AMM(D)KYN.

Elect: Lighting arrangement in the pit -Yet to start

 
 
 
 




Source : Central Railway / Indian Railways Portal CMS Team Last Reviewed on: 07-03-2017  


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