Feedback from Tata loco shed

More failure reports sent by TATA shed were analyzed in the sop:

Failure of carbon brushes:-

Pigtails were reported to have come out.

These carbon brushes are of Assam Carbon Make.

Pigtails are moulded inside the brushes and there is no means of testing their grip

Other failures:-

PCB Card failure, CG Module failure that were reported by TATA shed had card failures from M/S BT and M/S CGL.

Failure of M/S Anup Malleable Bogie frame as reportede by SER was discussed with the production and inspection staff .

Staff has been booked to Bondamunda shed for investigating the FAG and NBC make Axle boxes.

Report from WR regarding WAP-5 TM power cables rubbing with lifting hook was verified in the shop. This is a known problem ( WAP-5 excess length power cable) which has already been reported to production.

 RB’s letter regarding failure of ABB make transformer oil in DGA test was discussed with production staff on shop floor. All three transformers were having BDV > 60 KV. DGA facility is being made available in CLW.

Tata and Bondamumnda Loco Shed feedbacks

Defects pointed out by TATA shed in newly commissioned WAG9H locos were studied in the shop.

• MCB-100 which being provided in better location nowadays:

Earlier inaccessible location:-

This modification has been regularly cut in now.

• Bellow modification in TM fitment

.

• 
  ‘A” Panel cables rubbing with U clamp of the frame:

This is a known problem ,and slution has been found.

• 
  Filter block door not closing properly:-

This will also be solved.

Bondamunda shed has sent the snaps of axle box failures in WAG7 locos:

DyCME/Mfg has taken up the problem.

WAG9 loco manufacturing

Defects list sent by TATA shed was studies in the shop recently.

• Problem of vertical clearance in WAG9H

Vertical clearances were measured again in TG-294 ( loco returned from Gomoh Shed). They are to be attended if found more than prescribed 35 mm. 

Camber measurement with theodolite instrument was observed on TP long beam in the shop .

 

Inspection staff was asked to be very strict in camber measurements and to raise deficiencies in welding as this was highlighted during recent GM’s inspection.

TM tests and WAP-5 bogie

One day  BHEL’s TM failure was analysed with BHEL representative in the shop #18 .

Heavy abnormal sound was observed hence motor was declared unfit for service.

WAP-5 bogie new checksheet’s locations were have been finalised

Deviations are generated regularly for dimensions.

Holes in the brackets were not in the exact centre of the brackets.

In view of these deviations, RDSO has concluded that Gear Case breakage is taking place.

Since exact tolerances are to be  maintained in WAP-5 bogie it is machined on CNC.

WAG-7,WAG-9 & WAP-5 Bogie Fabrication

( W 25.010):-

What to be ensured:-

• Spheriblocks being used in WAP-5 Bogies ( 8 in each bogie) should not be of expiry date. Being rubber item, it may not be desirable from residual life point of view.

• Fixtures for bogie fabrication should be calibrated

Welding by GMAW process ( W 25.002):-

What to ensure:-

• 
  Lots of spatter which appear after each welding should be avoided.

• The anti-spatter spray should beused  by staff without fear of flashing. Anti-spatter spray being used should not be of expiry date.

• WAP-5 bogie fabrication work is to be done on  CNC machine, otherwise Holes are off-centre, dimensions are out of tolerance.

How we check crimping?

Evry 6 months, lugged cable is sent for pull out test.

Tests we do Hitachi Traction Motors

Production Target for 2012-2013

Here is the JPO for current year

Loco Maintenance

cee_rs

GTOs in Loco

Reliability of GTO Ver1

Metallurgy and loco

Metallurgy for Engineers-IRIEEN at Nasikh

Traction Motor

Some Name plate details and the costs.