PENDING ISSUES /ASSISTANCE REQUIRED FOR IMPROVING HHP LOCO MAINTENANCE/RELIABILITY 1.

RAILWAY BOARD : (i) Instructions for repair/overhauling of Traction Alternator, Traction Motor & Turbo Super charger Requested to nominate nodal agency for repair /overhauling of Traction Alternator, Traction Motor and Turbo supercharger. AMC of Control system (TCC & LCC) by OEMs. (a) Though, the rates for AMC of control system (TCC & LCC) is mentioned in the purchase order of DLW, zonal Railways are to separately process for AMC on single tender basis, which require substantial time in finalization. It is desired that since the rates of AMC are already finalized by DLW at the time of issuing of purchase order. Instructions may be issued to zonal Railways to directly execute the AMC on those finalized rates without going for tendering procedure. (b) Terms for AMC of LCC of M/s. EMD make control systems may also be finalized, as not mentioned in the purchase orders. (iii) Dead loco movement on schedule account & change of status/ service by Controllers SBI shed is suffering outage loss of about 2 locos per day due to dead loco movement on traffic account and frequent changes in loco service/status by divisional Power Controllers. It is requested that zonal Railways should be advised to closely monitor the overdue schedule locos and for timely diversion towards home shed /HHP loco shed. Suitable modification in the software of FOIS is also required so that once the loco is made dead, the status should not be changed till, the loco is attended by shed.

(ii)

2. (i)

DLW : Power assembly failures and cases of high lube oil consumption 111 Power assemblies have been taken up out of course in SBI shed due to liner crack, cylinder head crack, valve guttering and head to liner gasket failures. 53 HHP locos having LOC more than 4.0 and LOFR more than 0.6 are running with 15 days oiling schedule. DLW may investigate and suitably advise for improvement in reliability. Assistance of engine block (2 Nos. for 12485 & 12405 WDG4) 2 Nos. of Engine block complete are urgently required for stabled loco no. 12485 & 12405 WDG4.

(ii)

(iii)

Problem of ovality/crack in the opening in block for water outlet elbow 2 blocks of Loco no. 12373 & 12378 having problem of ovality and crack in the opening in block for water outlet elbow are lying in SBI shed. Though, an attachment is being developed by shed for in position boring, DLW may investigate the failure in that area and advise the procedure/tooling required for attention by the sheds.

(iv)

Frequent attention to gear case due to oil leakages. Gear case of HHP locos require frequent attention due to gear case oil leakages. This is inspite of the shed using recommended sealant and procedure as advised by RDSO. The issue require thorough investigation as resulting in lot of out of course work.

(v)

Failure of Fuel tanks 16 failures of Fuel tanks have taken place till date. Though, DLW has issued advisory and recommended for replacement of defective fuel tanks with modified design. However, fuel tank replacement in all the locos require substantial expenditure and staff. Therefore, possibility of in position reinforcement may be explored.

3.

DLW & RDSO : (i) Premature failures of Relays, Governor solenoid & wiring issues contactors and

There are large number of failures are of GP Relay of M/s. Vapour Bus, Contactors of Cuttler Hammer and Governor solenoid coil resistance abnormal. The issue require to be taken up with the OEMs for improved reliability. (ii) Premature failures of radiators There have been 25 failures of Radiators, out of which 16 failures are of M/s. Banco (failure per 100 loco holding 16.32) and 5 failures are of M/s. Perfect (failure per 100 loco holding 11.90). In some cases, Radiators have failed within months of loco commissioning. The issue require to be taken up with the suppliers of radiators. (iii) Failure of Fuel pump motors There have been 36 failures of Fuel pump motors. Recently, DLW has carried out detailed investigation and recommended for relocating the fuel pump motors to reduce suction head. However, the modifications in shed in all the locos require considerable time and man power.

(iv)

Non inter-changeability issues in air driers causing difficulty in procurement & maintenance There are 5 different makes of Air driers having issues of inter-changeability (both as unit/spares), causing difficulty in maintenance and procurement. The performance of M/s. Parag Polymers & M/s. Trident make Air driers particularly is not satisfactory.

4.

RDSO : (i) Failures of M/s. Siemens make TMs due to stator coil There have been 15 cases of Traction Motor failures due to stator coil failures. The problem is mainly in M/s. Siemens make Traction Motors. (ii) Failures of M/s. KPC make pinions There have been 13 Nos. of failures of Traction Motors pinions of M/s. KPC make. In this reference, RDSO has advised sr. no. of Traction Motors, in which defective pinions are to be replaced by removing the Traction Motors. However, in some cases, the failures are also taking place in the pinions outside the RDSO list. (iii) Cases were nothing found wrong and loco put right by recycling There are large number of electrical failures/irregularities on line, in which nothing was found wrong on arrival of loco in shed and the loco was put right by the drivers after recycling. In most of the cases, irregularity also not reflecting in fault archive. The issue require thorough investigation with the control system suppliers. The problem is mainly in M/s. Siemens & M/s EMD make control systems.