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Mechanical Department - Kalyan Diesel Shed

Diesel Loco Shed, Kalyan 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:
**ViewPOSITION**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: 17-05-2018