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Why HBD needed

• Hot axle case on 28.03.19 train no CH in stn RDT


Bearing Parts

Cup (1 No.) Backing Ring (1 No.)


Cone Assy (2 Nos.) End Cap (1 No.)
Spacer (1 No.) Locking Plate (1 No.)
Wear Rings (2 Nos.) Cap Screws (3 Nos.)
Grease Seals (2 Nos.) Grease
Why HBD needed

 Hot box occurs when inadequate wheel bearing lubrication or Mechanical


flaws cause an increase in temperature.

 If undetected, the bearing temperature can continue to rise until there is a


bearing “burn-off” which can cause journal breakage resulting in derailment.

 Another problem is brake binding, due to which the temperature of wheel tread
rises. This can lead to skidded wheels, metal deposition on wheel tread causing
wheel irregularity and other safety problems.

 A detection system is therefore required to be developed to sense abnormal


temperatures of axle boxes and wheels on a running train and communicate
with central control for corrective action.
HOT BOX DETECTOR

In Kota division, Hot Box Detector has been installed between ALNI – DDV
station (near ALNI station) on down main line track. The details of HBD are
as under

Year of Sanction - 2016-17


Contract awarded - 09.01.2017
Cost - 52.20 Lakh
Date of commissioning - 11.Aug.2017
HBD System – Features

 Automatic Identification of Hot Axle Box & Hot


Wheel
 Detailed report with axle box and wheel
temperature at two sides of an axle for
complete train
 Automatic Identification of Rolling Stock Types
(Locomotives, Wagons, Coach-ICF,LHB)
 Automatic Transfer of report & analysis to
railway control office through GPRS/Existing
OFC Line. IP55 Outdoor Panel
 Audio Visual Alarm and SMS for given alarm
condition.
HBD Block Diagram
AT REMOTE MONITORING ROOM

AT SITE

GSM Modem/OFC Line

Control &
Switching Circuits Real Time controller

OHE AT Power/
Signal Conditioning Modules Primary Power

Backup Device
Near Axle & Wheel Axle Pyro

Wheel Trigger Sensor Axle Trigger Sensor

Exit Trigger Sensor

Far Axle Pyro


ALNI HBD System
HBD System Architecture

HTTP
Step 4

Step 2 www.railman.in Server

GSM/CDMA/GPRS

HTTP
Examination and Corrective Action
Custom TCP/IP
feedback to C&W Control Room
SFTP/SOAP/Data
Exchange: XML

SMS Notification
for Alarm Condition

HBD-SMS
**
Step 3 RN:12072015
223045
Optional RK:1E,24C
RF/OFC link Axle: 96L
Temp: 125’C
Audio Visual at C&W Control Room
or any Authentic users

HBD Site
Step 1
HBD System – Specifications

Power Requirement : 110V to 230V

Operating Temperature : 0° to 55°C

Alarm Range : Programmable

Measurement Uncertainty : 1°C for measurement <250°C+1°C

Repeatability : 1 °C

Axle Temperature range : 5°C to 350°C

Wheel Temperature range : 5°C to 500°C

Train Speed : Up to 130 kmph

Auto calibration : External


HBD System – Alarm Limits

Alarm Limits are configurable for HBD System and Current Limits are set to
the system

Axle Box:
Critical Alarm >=80’C
Maintenance Alarm >=70’C and <80’C

As per manual axle box temperature:


For freight stock=90’C and above
For coaching stock=80’C and above

Wheel:
Critical Alarm >=200’C
Sample Report – HBD/ALNI
Sample Report – HBD/ALNI
Performance of HBD since Commissioning on 11.08.2017

2017-18
HOT BOX Detector
Sep Oct Nov Dec Jan Feb Mar Total

Nos of Crtical HOT BOX Alarm 255 206 34 8 10 2 54 569


Nos of Wagons Found HOT
0 0 1 1 0 1 3 6
BOX
Nos of Wagons Detached (HOT
0 0 1 1 0 1 3 6
BOX)
Nos of Crtical HOT Wheel Alarm 44 16 17 34 18 25 34 188
Nos of Wagons found defective
0 0 1 2 7 5 10 25
(Brake Binding)
Nos of Wagons Detached
0 0 0 0 0 0 0 0
(Brake Binding)
Performance of HBD since Commissioning on 11.08.2017
2018-19
HOT BOX Detector
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Total

Nos of Crtical HOT BOX 45 105 167 86 6 20 9 4 8 3 3 1 457


Nos of Wagons Found 0 0 0 0 0 1 1 0 2 1 0 0 5
Nos of Wagons detached 0 0 0 0 0 1 1 0 2 1 0 0 5
Nos of Crtical HOT
17 2 84 85 0 19 55 24 8 15 0 0 309
Wheel Alarm
Nos of Wagons found
6 1 8 6 0 5 22 13 2 1 0 0 64
defective (Brake Binding)
Nos of Wagons
Detached 0 0 0 0 0 0 0 0 0 0 0 0 0
(Brake Binding)

Out of order- 12.05.18 to 15.06.18 (34 days) & 01.08.18 to 21.08.18 (20 days)
Analysis of cases detected by HBD
Bearing
Train Bearing
Sr Date Wagon details PR details overhauling Reason of failure Responsibility
No details
shop
P: JHSW:21.02.15
61250830137 BRENCO
1 12.11.17 R/TKD R:TKD: 09.12.16 JHSW: 11/16 CTRB over run ROH depot TKD
BLCA(L) A-06-03
R/Date: 09.19
P: RYPS:12.12.13
BRENCO
2 07.12.17 PRTP 153246 CR BCN(L) R:BZA: 08.04.16 RYPS: 12/13 Grease Seal Failure POH Shop RYPS
A-02-11
R/Date : 01/20
30069233927 SC P:JUDW:12.11.16 BRENCO
3 26.02.18 NTV JUDW:12/16 Cone Bore excess POH Shop JUDW
BCN(L) R/Date:12/22 01-11
62250007642 P: JUDW: 04.07.17 BRENCO
4 05.03.18 R/TKD JUDW:07/16 Nothing is found -
BLCB(L) R/Date: 02/22 06-12
P: JMPW: 18.03.13
30028891021 SR TIMKEN
5 05.03.18 TSG R:BPA: 18.01.17 RYPS:01/17 Cone Failure POH Shop RYPS
BCN(L) 05/2000
R/Date: 04/19
P: KTTW:29.10.14
197436 SE BRENCO
6 15.03.18 HGJ R:DD:09.05.16 RWS: 10/13 Cone Failure POH Shop RWS
BOXN(L) A-04-10
R/Date: 06/19
P: JUDW: 31.12.13
61330700725 BRENCO
7 15.09.18 R/DDL R:MB:09.01.17 JUDW:12/13 Grease Seal Failure POH Shop JUDW
BLCA(L) 08-13
R/Date:08/18
P: JUDW: 26.11.15
21120941035 ECR BRENCO Cone Broken. Case
8 01.10.18 MSTB R:HPT:26.05.17 JUDW:11/15 POH Shop JUDW
BOST(L) A-04-11 is referred to RDSO
R/Date:07/20
P:JHSW:31.03.16
82019660017 CR NBC:
9 20.12.18 PTKC R:MB:05.08.17 JHSW:03/16 Cage Broken POH Shop JHSW
BOMN(L) B-91
R/Date:11/20
Mfr: RCF:21.09.17 Phonic wheel
10 21.12.18 12471 173273 NR LWSCN TIMKEN - PU: RCF
R/Date:09/20 /fastners failure
P: KTTW:17.02.16
12100321275 ECR BRENCO
11 19.01.19 E/BOXN R:BKSC: 21.11.17 BKSC:11/17 Cone Seized ROH depot BKSC
BOXN A-03-06
R/Date:09/20
Analysis of false critical alarms of hot box generated by HBD
during last 4 months.
Temperature Temparature Condition of
Wagon/
Sr Date Train No recorded by Time found at Kota Time bearing axle Action taken
Coach No
HBD (Manually) box
30018766 Wagon was allowed to run
1 5/12/2018 KPRK 216 CR 86.3 15:38 65 16:25 Normal further in service under close
BCN watch in Kota division
Coach was allowed to run
13418
2 5/12/2018 18245 86.7 16:24 60 16:55 Normal further in service under close
SEC LS
watch in Kota division
30020160 Wagon was allowed to run
3 7/12/2018 MOZ 163 ER 80.34 14:27 50 15:30 Normal further in service under close
BCN watch in Kota division
Wagon was allowed ex. GGC
94131258
to run further in service
4 18/12/18 MSTB 478 NCR 130.94 11:53 68 18:25 Normal
under close watch in Kota
BRN
division
Coach was allowed to run
E/CHG 004370
5 20/12/18 116.08 16:53 48 17:50 Normal further in service under close
SPL WR GS
watch in Kota division
Coach was allowed to run
13418 SEC
6 21/12/18 18245 81.76 16:35 52 16:55 Normal further in service under close
LS
watch in Kota division
Coach was allowed to run
13418 SEC
7 1/1/2019 18243 80.04 17:30 52 17:47 Normal further in service under close
LS
watch in Kota division
Coach was allowed to run
13418 SEC
8 16/1/19 18243 80.58 16:49 61 17:10 Normal further in service under close
LS
watch in Kota division
Analysis of false critical alarms of hot box generated by HBD during last 4 months.

Temperature Temparature Condition of


Wagon/
Sr Date Train No recorded by Time found at Kota Time bearing axle Action taken
Coach No
HBD (Manually) box

Coach was allowed to run


13060 SEC
9 10/2/2019 18245 88.96 17:11 45 17:30 Normal further in service under close
LWACCW
watch in Kota division

Wagon was allowed ex. GGC


33101099
to run further in service
10 26/2/19 FZP 840 ECR 81.2 14:01 70 20:30 Normal
under close watch in Kota
BCNHL
division

163366 Coach was checked at AF &


11 28/2/19 12947 WR 80.24 7:08 36 13:15 Normal allowed to run further as
LWSCN temperature found normal.

61401300 Wagon was allowed to run


12 8/3/2019 R/MATP 335 CN 81.04 13:23 52 14:10 Normal further in service under close
BLCA watch in Kota division
Details of cases detected by HBD :
11 critical cases of Hot axle box have been detected by HBD so far and during check
at Kota, in all these cases, the wagons were found unsafe and accordingly these
wagons were detached from the train in Kota yard. Details of these cases are as
under:

1. On 12.11.2017, train no. R/TKD (BLC Load) – at 23:37 hrs message was
received about running of axle no. 144 as hot axle towards right side with
temperature of 113oC. Train was received in Kota yard and during check found
grease oozing out from the axle box and material particles found mixed in
grease. The 05 car unit of affected BLC wagon was detached from the train in
Kota yard. During joint investigation in KTTW, CTRB found over run.

2. On 07.12.2017, train no. PRTP (BCNHL Load) – at 02.08 hrs message was
received about running of hot axle towards left side in 9th wagon from engine
with temperature of 139.15oC. Train was received in Kota yard and during
check found grease oozing out from the axle box and material particles found
contaminated in grease. The affected BCNHL wagon was detached from the
train in Kota yard. During joint investigation in KTTW, grease seal failure was
found.
Details of cases detected by HBD :
3. On 26.02.2018, train no. NTV (BCN Load) – at 01:48 hrs message was
received about running of axle no. 10 as hot axle towards left side with
temperature of 87oC. Train was received at Kota and during check found axle
box temperature 65oC. Due to this, wagon allowed in train under close watch
and during again check by C&W staff at GGC, axle box temperature was
found 101oC with smoke & grease oozing out. The affected BCN wagon was
detached from the train at GGC. During joint investigation in KTTW, found
cone failure.
4. On 05.03.2018, train no. TSG (BCN Load) – at 07.27 hrs message was
received about running of hot axle towards left side in 39th wagon from engine
with temperature of 95oC. Train was checked at Kota and found hot box with
temperature 100oC. The affected BCN wagon was detached from the train in
Kota yard. During joint investigation in KTTW, found cone failure.
5. On 05.03.2018, train no. R/TKD (BLC Load) – at 11.15 hrs message was
received about running of hot axle towards left side in 28th wagon from engine
with temperature of 82.55oC. Train was received in Kota yard & during check
found hot box with temperature 78oC but grease splashing on wheel disc.
Due to this, the affected 5 car unit of BLC wagon was detached from the train
in Kota yard. During joint investigation in KTTW, minor grease oozing from
grease seal lip.
Details of cases detected by HBD :
6. On 15.03.2018, train no. HGJ (BOXN Load) – at 00:25 hrs message was
received about running of hot axle in 54th wagon from engine towards right
side with temperature of 190oC. Train was received in Kota yard & during
check found hot box with temperature 140oC and grease also splashing on
wheel disc. Due to this, the affected BOXN wagon was detached from the
train in Kota yard. During joint investigation in KTTW, found cone failure.
7. On 15.09.2018, train no. R/DDL (BLC Load) – at 14.29 hrs message was
received about running of hot axle towards left side in 6th wagon from engine
with temperature of 97oC. Train was checked at Kota and found hot box with
temperature 100oC. The affected 5 car unit of BLC wagon was detached from
the train in Kota yard. During joint investigation in KTTW, grease seal failure
found.
8. On 01.10.2018, train no. MSTB (BOST/BRN Load) – at 23.46 hrs message was
received about running of hot axle towards left side in 39th wagon from engine
with temperature of 135.87oC. Train was checked at Kota & during check
found hot box with temperature 139oC and grease was also splashing on
wheel disc. The affected BOST wagon was detached from the train in Kota
yard. During joint investigation in KTTW, cone broken found.
Details of cases detected by HBD :
9. On 20.12.2018, train no. PTK/ODC (BOMN Load) – at 09:48 hrs message was
received about running of hot axle in 35th wagon from engine towards left side
with temperature of 240.6oC. Train was received at Kota & during check
found hot box with temperature 240oC and grease also splashing on wheel
disc. Due to this, the affected BOMN wagon was detached from the train in
Kota yard. During joint investigation in KTTW, found cage broken in RB.
10. On 21.12.2018, train no. 12471 BCT-SVDK Express (LHB Rake) – at 23.13 hrs
message was received about running of hot axle towards left side in 9th coach
from engine with temperature of 210.93oC. Train was checked at Kota and
found hot box with temperature 87oC with discoloring of the axle box. The
affected coach was detached from the train at Kota. During primary
investigation, reason of CTRB failure was found failure of either phonic wheel
or shearing off its loosened fasteners.
11. On 19.01.2019, train no. E/BOXN (BOXN Load) – at 07.58 hrs message was
received about running of hot axle towards left side in 14th wagon from engine
with temperature of 147.59oC. Train was checked at DDV by C&W staff &
during check found hot box with temperature 145oC and grease was also
splashing on wheel disc. The affected BOXN wagon was brought to Kota yard
under escorting of C&W staff and the wagon detached from the train in Kota
yard. During joint investigation in KTTW, found cones seized.