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DIESEL LOCOMOTIVE vl'ORKS
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VARANASI.22 1 OO4. INDIA
Fax: 0542- 2642586. email : dycdeene@email.com

No. DL W/D &D IEL&HH P/Gen/B I MlPt-2

Office of the: CDE
Date:23.04.2019
AII CMPE/DSL
Indian Railways
&
EDS/MP/RDSO

Sub: Technical agenda for HHP Bulk Indent Meeting (BIM)'

Reft CME/SE/DLW's letter no. 2017lMCOllLl33 dated 01.04.2019

Vide above reference, HHP-BIM meeting is going be held at DLW, on 24th and 25ft May 2019'
Technical agenda for discussiorfduring Hrtp-gtl\rl meeting is enclosed herewith for kind information
please.

All the ZonalRailways and RDSO are requested to kindly send feedback on these technical agenda
points, by 6* May 2019 through email at cdedlw@gmail'com

Encl/: As above

Chief Design Engineer/Dl

Copy to:

EDME/Tr./Railway Board- for kind information please'

 {y
Sub: Technical agenda for HHP Bulk Indent Meeting (BIM) to be held at DLW on24th & 25th
May'2019.
Ref: CME/SE letter no.2017lMCO/lll33 dated 0l .04.2019

On the basis of increasing trend in failures reported through SIG warranty portal &
communication/letter from differenl Zonal Railways, following items have been decided for discussion
in the above BIM meeting.
l. Power Assemblies (Cyl. Liner, Piston ring, Piston, Head to liner gasket)
2. Turbo Supercharger
3. Mechanical Unit Injector (MUI)
4. Water Pump
5. Clutch Drive Asm
6. Radiator Asm
7. Lube Oil Cooler
8. APU (Siemens make)

Additional Agenda items related to above failures are as under:

9. Ensuring proper maintenance practices in HHP Loco Diesel Sheds
10. Poor quality of indigenous Baggie filter
I l. Bad performance of Coolant ISC 7537
12. Power Assemblies failure and Turbo surging due to High Ca content in Lube oil
13. Availability of proper Maintenance infrastructure in HHP Loco Diesel Sheds.
14. Skill set in application of basic tools

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 Annexure-I

SN Agenda Items

1 Failure of Power Assemblies (Cyl. Liner, Piston Ring, Piston, head to liner
gasket)

i. Cylinder Liner:
As per DLW’s warranty portal, warranty failures of Cylinder Liner is as below:
2017-18 (Upto Feb) : 190
2018-19 (Upto Feb) : 331

Action taken:
 GE make cylinder liner fitment stopped since June16.
 Total 3590 nos GE Liners rejected.
 M/s EMD has taken corrective action and rectified the sharp edges at air
inlet port.
 Engine testing schedule enhanced from 3 hr 35 min to 8 hrs 20 min,
including 2 hrs 35 min at 8th Notch with full /overload.
 More indigenous sources are under development. 50 loco set of M/s Cooper
make liner is fitted and 36 loco dispatched to Zonal Rly/ sheds.
 Total 80 nos. (5 L/S) HL/China make fitted in Engines & 5 loco dispatched to
Zonal Rly/ shed. One no. was rejected due to oil throw during engine testing.
 DLW carried out detailed analysis of failures of M/s CAPL make liners and
undertook following corrective actions at firms’ end:

Leakage from brazing joint:

 Additional cleaning of brazing joint surface with acetone introduced in place
of existing washing process.
 100% checking introduced for cleaning process since 20th Feb’ 2018.
 After improvement, firm supplied around 5623 number liners (SNo-
CA18B0500) up to 28 Feb ’19.

Leakage from welding joint:

 Weldment fillet (4 mm size) introduced since 20th Feb’ 2018.
 100% throat size checking since 20th Feb’ 2018.
 Welder qualified to ASME standard only to be allowed to weld.
 MIG welding introduced since 28th April 2018 instead of TIG welding done
earlier.
 Around 4199 nos. received with MIG welding.
 After improvement firm supplied around 5655 number liners (SNo-
CA18B0500) up to 28 Feb’19.

Liner crack/broken at inner wall and air inlet port:

 Destructive testing in 1 out of 16 liners at air inlet port from Jan’18.
Thereafter, Firm has supplied around 6277 liners up to 28 Feb ’19.
 Air inlet port sharp edge is removed using fabric abrasive in place of grinder
since 06 March’18. After fabric abrasive introduction, firm supplied around
5024 number liners up to 28 Feb ’19.
 DLW team during visit to SBI Shed on 19.06.18- 21.06.18 observed DP test
of all new Liners and pistons by SBI shed. DPT allows penetrant to deposit
 on liner honing pattern and air inlet port edge, on piston tin plating, lube oil
holes of oil scraper ring in piston, in ring grooves. Penetrant from these
areas cannot be removed completely, which in service may block lube oil
passages and further affect cooling rate of piston and ring.
 All CMPEs have been advised vide DLW letter dtd.-17.07.18 to do Liner and
Piston inspection as per ETI -204 and ETI-051.

ii. Piston Ring:

As per DLW’s warranty portal, warranty failures of Cylinder Liner is as below:
2017-18 (Upto Feb) : 43
2018-19 (Upto Feb) : 116

Action taken:
 169 loco sets of EMD supplied Piston ring sets rejected.
 Show cause notice issued to M/s EMD/USA on 07.08.17. Reply against
show cause is received to this office on 01.12.2018.
 1329 Loco sets M/s Mahle/Mexico make Piston ring supplied by M/s New
Tech Imports New Delhi to DLW.
 Quality issue in Low lube oil piston ring has been highlighted by
CMPE/ECR, during the CMPE video conference on 22.03.18. Hence
fitment of low lube oil piston ring stopped from 23.03.18, pending
investigation and advice by RDSO, as decided by Bd.
 Joint inspection done at FMGIL along with RDSO team on 08-09th June’18.
 Joint discussion held at DLW on 10.07.18 with FMGIL/Germany and
Bangalore team regarding Design feature of FMGIL ring and failure report.

iii. Piston:
As per DLW’s warranty portal, warranty failures of Cylinder Liner is as below:
2017-18 (Upto Feb) : 53
2018-19 (Upto Feb) : 154

Action taken:
EMD: 100% dimensional check during manufacturing.
CRRC:
• Firm introduced 100% checking during core assembly and rough machining
to maintain concentricity.
• Firm introduced strict control on tin plating process ensuring proper cleaning
& bonding/adhesion testing of tin plating.
HL:
• Joint inspection done at DLW with firm-M/s Dalian/China on 18-19.07.18.
• No metallurgical and Dimensional deviation observed in failed sample at
DLW due to crown crack.
• 02 nos. failed at UBL shed during commissioning due to tin plating peel- off.
Plating also changed from mat to glossy in those patches.
• Tin plating thickness measured at MGR, plating thickness found within
specified limit.
• Firm has been advised during joint inspection to introduce Blister test in
QAP for further supply to check the soundness of tin plating bonding.
Cooper: M/s Cooper has supplied 535 nos piston after improved tin plating July’
2018 onward.
CAPL: Prototype lot of Piston fitted and tested in Engine No.2429 and dispatch
 to HWH diesel shed on 29.09.18 as Power Pack. Pilot lot 96 nos.Piston
is under fitment in engine.

iv. Head to Liner Gasket:

As per DLW’s warranty portal, warranty failures of Cylinder Liner is as below:
2017-18 (Upto Feb) : Nil
2018-19 (Upto Feb) : Nil

Action taken:
• Introduced improved design gasket (having Viton grommet in place of Teflon
& silicon).
• Fitment started from May’2016 at DLW.
• No report of failure in new design gasket.

2 Failure of Turbo Supercharger

As per DLW’s warranty portal, warranty failures of TSC is as below:
2017-18 (Upto Feb) : 65
2018-19 (Upto Feb) : 77

Action taken:
Jumper Bolt Breakage :
• Squareness checking of threaded holes of Idler gear support asm introduced
at DLW & at vendors end since 26/08/15 to arrest jumper bolt breakage. Now
problem has been completely resolved.

Turbo Inlet Scroll Asm:

M/s Mazdoor/NDLS:
• Firm visited DLW on 19.07.18 for joint inspection and corrective action plan.
• As per DLW Lab report chemistry and micro structure found OK.
• Lack of fusion in welding observed.
• Firm advised to do root filling by 1 mm filler wire to achieve better penetration
of welding.
• Verification of heat-treatment and weld penetration has been done on
30/11/18 .Weld penetration & microstructure found satisfactory at DLW Lab.
Clearance given on 08/12/18 for supply.
• 56 nos. Improved heat-treatment supply has been received at DLW and
fitted.

M/s Hind/FBD:
• Joint inspection done with firm at DLW on 29.06.18.
• Firm has submitted action plan on 11.07.18.
• Current parameter increased from 90Amp to 105 Amp.
• Hydraulic test pressure increased from 10 PSI to 30 PSI.
• Verification of heat-treatment and weld penetration has been done on
18/11/19. Weld penetration & microstructure found satisfactory at DLW Lab.
Clearance given on 23/11/18 for supply.
• 120 nos. Improved heat-treatment supply has been received at DLW and is
under fitment.
 M/s Avibha/FBD:
• RI rejection of 13 nos. M/s Avibha/FBD make on 22.06.18 due to wrong
heating rate during heat treatment. However further firm supplied 79 nos. to
DLW, which have been accepted by CQAM.
• Verification of heat-treatment and weld penetration has been done jointly by
Design & Lab on 23/12/18. Clearance given on 4th Jan’2019 for supply.
• Weld penetration & microstructure at DLW found satisfactory.
• 145 nos. Improved heat-treatment supply has been received at DLW and is
under fitment.
• Heat treatment specified in the OEM’s drawing was inadequate for upgraded
material AISI: 321.
• Specification has been revised on 21/11/18. Incorporated Heat-treatment
cycle of stage-I & stage-II should be done after complete fabrication of Turbo
Inlet Scroll Asm for upgraded material AISI: 321.
• Stress relieving temperature for upgraded material AISI: 321 increased from
640°C to 925°C.
• It is the temperature at which titanium combines with carbon to form
harmless titanium carbides. The chromium is restored to solid solution and
carbon is forced into combination with titanium as harmless carbides.

Set Gear Planet and Shaft Carrier:

• Quality audit has been conducted at M/s Supreme/Mumbai’s premises on
08/10/2017.
• During quality audit, deviations noticed are as Chattering, rough surface,
Ovalty & Taper in the pin holes, MOP less, lack of concentricity of planet gear
holes.
• Firm has taken corrective action and supplied 62 nos. to DLW. Last supply
received on 04/04/18.

Turbo surging:
• Design Bulletin no. DB/01/2017/01,dt.13/05/17 has been issued to all Zonal
Railways to conduct Rice blasting for cleaning the nozzle ring and turbine
blades.

Warpage of Exhaust Diffuser:

• Exhaust diffuser Vanes will appear to be “WAVY”, if turbocharger becomes
overheated, thermal expansion forces thin metal vanes to distort
permanently. A warped diffuser is always an indication of excessive engine
exhaust gas temperatures.

Planetary Gear Train failure:

• Failure is due to misalignment of turbocharger during mounting on engine by
diesel sheds.
• Issued Design Bulletin no. DB/01/2015/26,dt.11/05/15 to ensure mounting of
turbocharger on locomotive by diesel shed and check Impeller eye clearance
at different locations such as 12 O’clock, 3 & 9 O’clock and 6 O’clock during
mounting.

Abnormal/Unusual Sound:
• Abnormal/Unusual Sound is due to misalignment of turbo, Rotor damage /
 unbalance and Clutch failure/malfunctioning of clutch.
• Issued Design Bulletin no. DB/01/2015/26,dt.11/05/15 to ensure proper
mounting of turbocharger on locomotive by diesel shed.
• DLW is doing Rotor balancing on 100% basis before assembly since Jan’18.

3 Failure of Mechanical Unit Injector (MUI)

As per DLW’s warranty portal, warranty failures of MUI is as below:
2017-18 (Upto Feb) : 77
2018-19 (Upto Feb) : 87

Action Taken:
• DLW has started air blowing of Fuel Oil Headers and Fuel Oil Line
assemblies.
• DLW started calibration of all 16 nos MUI/Engine at test bench since March
2018.
• DLW has started replacement of 16 MUIs of tested Engine with calibrated
new ones since March 2018.
• MUI removed from tested Engine are again fitted on a new Engine and
removed after testing. This eliminates any possibility of loco turnout with
dust/rust ingress in MUIs from fuel oil line.

4 Failure of Water Pump

As per DLW’s warranty portal, warranty failures of Water Pump is as below:
2017-18 (Upto Feb) : 40
2018-19 (Upto Feb) : 43

Action Taken:
• Audit of manufacturing process of M/s Shakthi Tech by design in Nov’ 18.
• During audit, it has been noticed that bought out items is being procured from
un-approved vendors. Parallelism of spring also found beyond prescribed
limit i.e. 107 & 86 thou as against specified 39 thou.
• Firm has been advised to purchase bought items from OEM or DLW
approved vendors.
• Firm has assured that bearings will be purchased from DLW approved
vendor (dated 23.02.2019).
• Show cause notice issued to M/s Shakthi Tech on 11.03.2019.
• Firm’s reply received on 12.03.2019, assured to supply SKF make bearings.
5 Failure of Clutch drive Asm:
As per DLW’s warranty portal, warranty failures of Clutch Drive Asm is as
below:
2017-18 (Upto Feb) : 26
2018-19 (Upto Feb) : 17

Action taken:
 Hardness checking of rollers has been introduced since June’2016.
 Clutch drive assembly design modified.
 Spring: Wire dia. & spring OD increased to improve strength
 Cup has been changed to Pin with a head to improve strength.
 Plate Cam: Stepped hole has been changed to uniform and higher dia.
hole.
  PO (dtd.09.09.17, qty: 415 nos.) placed on M/s Avtec/Hosur for modified
design clutch drive assembly. Complete lot received. 281 nos. dispatched to
zonal railways. 134 no. rejected by CQAM.
 Firm’s representative visited DLW for segregation of rejected clutch drive
asm.
 Further, DLW advised firm on 17/11/18 to visit other sheds and do similar
exercise as done at UBL diesel shed.
 DLW started manufacturing of modified clutch drive assembly from dt.
08/08/18 and manufactured 93 nos. new clutch and 380 nos. overhauled
clutches as on 28/02/19 (total 473 nos.) and marked as “MOD” on clutches.
 No failure of modified clutch reported by diesel shed till date.

6 Failure of Radiator:
As per DLW’s warranty portal, warranty failures of Radiator is as below:
2017-18 (Upto Feb) : 101
2018-19 (Upto Feb) : 44

Action taken:
 Closing of all end tubes implemented & modified the side frame.
 In order to avoid hitting of tie rod (Dia increased from 10mm to 12mm)
with core tubes lifted the Tie Rod in up-ward direction.
 Modified the side frame design i.e bolting given on both side.
 In new radiators supplied since June’14 onwards the side frame design is
changed from “L” type to “Z” type. This will avoid buckling of side frame
consequently will improve reliability of radiator.
 The mounting bolts (used by DLW of Thread length 25mm) replaced by
mounting bolts of Thread length 40mm to reduce the failure in Radiator. By
replacing the bolt, the reduction in failure has been observed.
 Dresser coupling in place of rigid pipe connection has already been
implemented by DLW, since July’2013 and onwards. Relevant Drawing no. of
this effect is 17066440.

Action taken in case of M/s Leel:

 Joint meeting held on 18.06.2019 to discuss & resolve the issue of increased
failure rate of MBR.
 Firm was directed to visit all the diesel shed along with the BGKT/ NWR shed
for joint inspection for resolving all the pending issues.
 Firm’s manufacturing processes were audited on 25.06.2018 by DLW
representative and found to be under control.
 Firm was directed to forward the failed tubes to OEM (M/s Arzon / Canada) to
investigate the reason behind failure of HF welding of failed tube.
 As per Investigation Report received at DLW in Dec’ 2018, radiator tube
found muddy internally & leaked from tube welding area due to excess
vibration.
 To authenticate the Quality of HF welding of culprit/ failed tube, OEM has
assured for an improvement in Eddy current process.
 Quality of HF welding, and chemical analysis of Sample Tube material, also
conducted at CMT Lab/ DLW and was found to be satisfactory.
7 Failure of Lube Oil Cooler
As per DLW’s warranty portal, warranty failures of Cylinder Liner is as below:
2017-18 (Upto Feb) : 33
2018-19 (Upto Feb) : 21

Acton taken:
Standard Radiator :
 Heat dissipation problem observed.
 Quality audit has been conducted.
 Change in bypass valve setting as per OEM setting.
 Failure reduced drastically after modification in bypass valve setting.

Saaswad:
 Following corrective actions implemented:
 100 % inspection of casting to ensure oil pockets as per drg.
 Checking of bulleting ball size twice in one core with 100% visual check to
ensure proper bonding of tube to fin.
 100 % checking of by-pass valve setting introduced with immediate effect.
 Inspection by CQAM at firm premises introduced in current PO. Firm has
supplied 54 nos under CQAM inspection so far.

8 Failure of Auxiliary Power Unit(APU), (RDSO controlled):

As per DLW warranty data, the failures reported are as under from period Apr’18
to Feb’19:

AC-AC Failures
TCS Make Population Warranty Shed wise failure
Failure
Siemens 62 19 Raipur-17, BNDM-2
EMD 38 2 Kazipet-2
Medha 69 2 Raipur-2
Total 169 23

Action taken:
M/s Siemens has been advised to rectify the issues related to their APU vide
this office letter no. DLW/D&D/ HHP/EM/ AC-AC/Siemens part-III dt.
01.11.2018. In response to DLW letter, M/s Siemens has communicated that
out of 54 Locos; only 5 locos have been left for APU commissioning and also
informed that there are some technical issue of non functioning of APU.

1. Koel make APU:-

 Communication break between APU & LCC- Modification in
microcontroller required and will take 1 hour per loco to complete above
modification.
 Coupling breaks between Alternator & Fan of APU- Completed in 12
locos out of 34. Material available at all shed and will take 8-10 hours for
replacement.
 Fuel solenoid failure of APU- Failures is due to foreign particles in fuel line.
Modification will take 1 hour for each loco.
 2. Cooper make APU:-
 Communication break between APU & LCC- Modification in
microcontroller required and will take 1 hour per loco to complete above
modification.
 Fuel solenoid failure of APU- Failures is due to foreign particles in fuel
line. Modification will take 1 hour for each loco.
Note:
I. M/s Siemens has requested for availability of Locomotives for at least 10-12
hours for doing the above mentioned modifications
II. Zonal Railways to ensure the availability of locos to M/s Siemens for above
modifications.

9 Ensuring proper maintenance practices in HHP Loco Diesel Sheds:

Following practices have been observed at some HHP Diesel Sheds:

SN Maintenance practices
1 No preventive & corrective action taken on Spectrometer report
of crankcase oil
2 Use of old power assembly parts without qualification
3 Non availability of critical toolings.
4 Air box cleaning not done
5 Use of old hardware during assembly of power assembly
6 Use of head to liner gasket procured from un-approved vendor
7 Use of DPT on new liner bore & piston OD for checking of
surface crack
8 Improper torquing Head to Liner nut
9 Use of governor oil during assembly of Power assembly in place
of Crankcase oil.
10 Masking of inlet & exhaust port of power assembly not done,
after assembly
11 Dirty environment in Power assembly area

10 Issues related to clogged baggie filter and quality of indigenous approved

vendors:

Investigation:
 Clogged Filter is due to tapping & changing not being done as per schedule -
30 and 90 days respectively.
 Sheds are not having proper stock of Baggy Filter. Due to unavailability of
Filters, sheds are not changing in specified schedule period.
 Dirty baggy filter leads to PA failure because of fine sand particles entering
inside and causing scouring of PA & finally leading to seizure.
 During joint investigation on 21.04.2018, at BGKT shed, Baggy filters found
clogged with lot of dust, oil and muck in a short span of only 1 month due to
dusty environment of NWR.
 Clogged Baggy filters also noticed in failed Locos of SBI, SPJ and HWH
sheds during joint investigations.
 Crisis of baggy filter observed by Diesel Mitra in Pune and Kalyan sheds
during visit on 06-08.2018.
  Vide letter dated 12/03/2019, BGKT shed raised the issue of poor quality of
indigenous Baggie filter i.e. dust gets passed through fiber glass bag of filter
element & accumulated in air box chamber.

Type of Consequential Failure:

 Liner-Piston scoring
 Liner crack
 Liner Seizure
 Piston Ring wear
 Valve Guttering
 Excessive heating of Power Assembly
 Turbo surging
 Less power

Action taken:
 DLW referred BGKT request to RDSO vide letter dtd-12.05.2018.
 RDSO vide letter dtd-17.05.2018 has agreed that BGKT as a special case,
may change the baggy filters on condition basis/ reduce the periodicity to
change the filter.
 BGKT stated that reducing periodicity has also not resulted in any relief. To
address the issue, DLW requested RDSO on 14.03.2019 to examine the
case and to issue necessary guidelines. RDSO reply is awaited.

11 Bad performance of Coolant ISC 7537

Investigation:
 SBI shed reported failure due to bad performance of ISC 7537 coolant to
RDSO vide letter dtd.-21.03.18.
 Water coolant is RDSO controlled item.
 SBI shed noticed deposition of muck having magnetic properties in Water
Pump.
 Coolant –ISC 7537 is not serving its purpose as corrosion inhibitor.
 Muck deposition/erosion reduces cooling efficiency of heat exchangers
resulting into increase of thermal load on Power asm.
 Muck in cooling water also reduces heat transfer in Liner and Cyl. Head.
 Since the inception of ISC 7537 by SBI shed in 2013, failure of Liner, Head,
Radiator, after cooler increased multiple times.

Type of Consequential Failures:

 Radiator failure
 After cooler failure
 Lube oil cooler failure
 Liner failure
 Head failure
  Water pump failure
 Excessive heating of Power Assembly

Action Taken:
 DLW requested RDSO on 19.06.2018 to examine the problem on priority and
issue necessary guidelines at the earliest.
 RDSO vide letter dtd.-23.07.2018, decided to discontinue use of boron based
coolants (ISC 7537 & Nalco) from Jan’19.
 RDSO vide letter dated 23.01.2019 issued revised guidelines for use of
boron free coolants (HP power Kool).
 Zonal Railways is yet to provide compliance of using new coolant
recommended by RDSO.

12 Power Assemblies failure and Turbo surging due to High Ca content in

Lube Oil

Investigations
 Vide letter dated 26.06.18, UBL shed reported
 hard calcium (CaCO3) deposits over TSC Nozzle ring blades,
 This restricts the passages of exhaust gas in nozzle, resulting into Turbo
surging.
 UBL shed observed such phenomena in about 33 locos since 2015-16.
 Turbo surging at UBL shed has increased from 2015-16 onwards, after
introduction of Lube oil RR817, RR813 and RR606.
 DLW team, during visit to SBI Shed on 19-21.06.18, observed similar calcium
deposits over-
 Exhaust valve stem
 Cylinder head fire face
 piston ring groove of piston
 piston crown
 Calcium deposit on exhaust valve causes poor heat transfer, leading to valve
guttering due to melting/crack of exhaust valves.
 Deposition of hard calcium also causes poor seating of valves on head
seating area, causing exhaust gas leakage, which further develop into
guttering.

 Calcium deposits on fire face of cylinder head causes poor heat transfer from
cylinder head fire face resulting into cylinder head crack and overheating of
power assembly.
 Hard calcium deposits on compression ring grooves causes piston ring
jamming, resulting into scouring in liner/piston/seizure.
  This problem has also been observed by Dy.CME/Eng, during his visit to SBI
shed on 18.08.2018.
 Recently many cases of CaCO3 deposition found in exhaust valves at SBI
shed.

Action taken:
 DLW referred these issues of UBL and SBI sheds to RDSO, vide letter dtd-
23.06.18 and reminder dtd- 04.07.18, 05.10.18, 04.01.19 and 08.03.2019.
 DLW again requested RDSO on 12.03.2019 to examine the issue. Final reply
awaited from RDSO.

13 Availability of proper Maintenance infrastructure in HHP Loco Diesel sheds

 Some Diesel Sheds are not carrying out prescribed schedule maintenance
due to unavailability of some basic tools and equipments viz.
 Pneumatic Crank Over tool
 Fuel Rack Setting tool
 Injector timing setting gauge
 Compression Pressure Gauge
 After Cooler Housing Tackle
 Deflection gauge for alternator alignment
 Basket Torque Wrench.
14 Skill set in application of basic tools
.
 All machine operators must be thoroughly trained before operating a
machine tool.
 Keep equipment well maintained.
 Always wear Personal Protective Equipment (PPE).
 Timely calibration of tools.
 Proper marking of capacity /range on tools.
 Suggestion for new tools requirement