Inside the locomotive assembly line

Audit of following Work Instructions was done in Shop # 19. Report is as follows:-

Manufacturer of BA panel ( W 19.005):-

Points noticed:-

• BA panel frames ( Mostly of M/S Modern) were rusted at many places. This was either due to inferior paint or due to outdoor storage in CLW

• Busbar to earth clearances of 60 mm as prescribed in para 3.9 of this WI are  to be strictly maintained.

• Para 3.6 of this WI needs modification. QD and Q20 have gone into CPU nowadays and SHAA has become SHTM.

• Arc chute bolt and nuts material should be same.
• Gas welding quality needs improvement.
• Line contactors of M/S Stesalit  make had spring washers whereas CLW make don’t have spring washers. This needs to be addressed by design.

Three Phase Locomotive Assembly

Audit of following 3 Work Instructions was done in Shop # 19. Report is as follows:-

Fabrication of AC2 panel ( W 19.006):-

Observations:-

• Drilling as mentioned in the para # 3.2 of this WI is irrelevant. Same should be modified.

• VS diodes fixing plates have 4 corner holes but are fixed on 2 mid holes. Same should be procured accordingly.

Arc welding of joints ( W 19.007):-

Observations:-

• Pre-heating of electrodes as mentioned in para 34.1 of this WI should be ensured.

Prepartion of Cable of various size ( W 19.008):-

Observations:-

• Cables of this section not being sent for ‘pull-out’ test, were sent for same.

Other Observations:-

• HSBC contactors are lying on the floor since long in zero bay of shop #19. This is making them dusted all around. They should be stored properly.

Locomotive Assembly in CLW

Audit of following 2 Work Instructions was done in Shop # 19. Report is as follows:-

Assembly of transformer ( W 19.017):-

Observations:-

• 
  Quality of welding ( of bend plate , brackets ) was discussed for scope of improvements. It was found there is shortage of welder in the shop.

Other inspections:-

• LMS was inspected for pin manufacturing process. Same will be further continued.

How Locomotives are assembled?

Audit of following 3 Work Instructions was done in Shop # 19. Report is as follows:-

Calibration of Pantograph ( W 19.018):-

Observations:-

• 
  Calibration being done in test shed on AM-12 was observed . Practical method being adopted by using a kind of jig is entirely different from the one given in WI.

• WI should be modified accordingly.

• Measurement of Panto lock down force of 17 kg as mentioned in para 3.8 of this WI is to be ensured.

Oxy fuel welding of pipes ( W 19.019):-

Observations:-

• This WI has become obsolete since pipes these days come with bellows.

Transformer oil filtration ( W 19.020):-

Observations:-

• This WI has not been revised since 1996, as new types of filtration plants have come after that.

• Floor are near oil-filtration plant was found very dirty and slippery, same attended.

Bushing fitment in locomotive

Audit of following 2 Work Instructions was done in Shop # 19. Report is as follows:-

Fitment of condenser type main bush ( W 19.021):-

Observations:-

• Use of dummy condensor bushing as mentioned in para 3.3 to para 3.7 of this WI is  difficult practically.

• These days gel filled bushing are in use for 3-phase locomotives, Hence the WI mentioning use of oil in para 3.12 and 3.13  needs modification.

Fitment of condenser type main bush ( W 19.021):-

Observations:-

• Flange bolts being used on the roof of LPS make looked rusty, same attended.

• This WI is incomplete and needs to be re-issued as it does not mention the adhesive tape used in the process of fitment.