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TelejFax: 0522-2452581E-mail:[email protected]
Government of IndiaMinistry of RailwaysResearch, Designs &
Standards Organization,LUCKNOW-226011
No. EL/3.2.19/3-Phase/i Dated 26.07.2018
Principal Chief Electrical Engineer,1. Central Railway, Mumbai CST-400 001.2. Northern Railway, Baroda House, New Delhi-110001.3. North Central Railway, Subedarganj, Allahabad- 211001
4. North Eastern Railway, Gorakhpur-273 001
5. Eastern Railway, Fairlie Place, Kolkata -700001.
6. East Central Railway, Hazipur-844101.
7. East Coast Railway, Chandrashekharpur, Bhubaneshwar-751016.
8. Southern Railway, Park Town, Chennai-600 003.
9. South Central Railway, Secunderabad-500 371.
10. South Eastern Railway, Garden Reach, Kolkata -700043.
11. South East Central Railway, Bilaspur-495004 .
12. Western Railway, Churchgate, Mumbai-400 020.
13. West Central Railway, Jabalpur-482001.
14. Chittaranjan Locomotive Works, Chittaranjan-713331 (WB)
Sub: Technical Audit Report of ELS/GZB/NCR for maintenance practices of E-70 Brake System for3-Phase Electric Locomotives.
Vide subject above, Technical audit of ELS/GZB/NCR was carried out on17.07.18 & 18.07.18 on
maintenance practices of E-70 Brake System (M/s FTRTIL) of 3-phase Electric Locomotives. Please find
Technical Audit Report on RDSO's website under following link.
http://www.rdso.indianrailways.gov.in/view section.jsp?lang=0&id=O,2,344,5213
Encl: Nil ~~'<lo(Aseem Kumar)
For Director General/Elect.Copy to:
Secretary (Electrical), Railway Board, Rail Bhawan, New Delhi-llOOO1(Kind attn.: Shri A. K. Goswami, DEE/RS/RB) for kind information please.
M/s. Faiveley Transport Rail Technologies India Limited,P.B. No. 69, Harita, HOSUR,Tamil Nadu- 635 109
(Aseem Kumar)For Director General/Elect.
End: Nil
I Page 1 of 10 I Issued on: 26.07.2018 I Report No. RDSO/2018/ELITARl0019 Rev. '0'
IGOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
Technical Audit Report Of Electric Loco Shed, GHAZIABAD,Northern Railway, For Maintenance Of E-70 Brake System Of
. Three Phase Electric Locomotives.
Report No.: RDSO/2018IELITARl0019 Rev. '0'
Issue Date: 26.07.2018
Approved by Signature.Principal Exe. Director Standard Electrical ,
~~I~ 2.b·7·1f
Issued byElectrical Directorate
Research Designs and Standards OrganizationManak Nagar, Lucknow-226011
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Status of Revision
SN. Date of Page No. Revision Reason for RevisionRevision
1. All 0 First Issue
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Technical Audit (TA) Report ofELS/GZB
1. Technical audit of Electric Loco Shed, Ghaziabad for maintenance practices ofE-70 brakesystem of MIs FTRTIL for three phase locomotives has been carried out on 17.07.2018 &18.07.2018. Observations are given as under:
2. MAINTENANCE PRACTICES:
2.1 OBSERVATIONS:
2.1.1 Three new test benches for various components for testing of E-70 system suppliedby Mis FTRTIL in April'2015 were found commissioned on 09.11.2017. The oldtest bench wherein some of the pressure gauges, isolating cocks, fixers etc. are inbroken condition and not being used on regular basis is planned to be sent toELS/LDH.
2.1.2 Work benches for dismantling, overhauling & assembling of various pneumaticvalves, pressure switches, cocks etc were not found in proper condition. Generalhousekeeping of the section was found in shabby condition.
2.1.3 Test bench for Air Dryer and Dew point measurement arrangement as per TC-0139are not available in Shed.
2.1.4 An assurancel counseling register created for the various instructions, precautionsetc with effect from 23.01.2018. Apart from this there is a Drive register to keep thestatus of various drives or modifications.
2.1.5 Shed reported the failures of MIs Eaton make Pressure switches due to stuck upcases. However they could not find root cause of the problem. Four no.'s pressureswitches are under investigation with the firm.
2.1.6 The extant maintenance practice followed by shed is to carry out lCO schedule ofthe locos received after POH. Thereafter, they use to send the report of shortcomings to HQ/POH shop. However, POH shop send a compiled exception reportas Annexure-C after a longer period like 5-6 months containing the detailswork/items not carriedl replaced during POH of a locomotive. But this report wasbeing simply kept in the record with SSE/PPIO and not circulated to concernedsections.
2.1.7 The exception sheet from POHIBSL of Loco no. 30020/WAP5 was checked. It isnoticed that overhauling of A9(DBC), SA9, Air Dryer & horn switches are notdone by POH shop.
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2.1.8 Apart from above Provision of Trap chamber, Over hauling of some valve is notdone such as Double check valve, Parking brake unit, DBC etc.Refurbishment of Electronic cards ofE70 is also not taken by POHIShop.The check sheets of inspection schedules available in the section were studied andfound that it is not in line with the SMI-0298.Shed has proposed inclusion of Overhauling ofunloader valve and non-return valveduring IC schedule instead ofIOH/POH.
2.1.92.1.10
2.1.11
OLD Test Bench New Test Benches
Fig.1 Work benches and Test Benches available at ELS/GZB
2.2 RECOMMENDATIONS:
2.2.1 The staff involved in maintenance should be properly trained to test various
components of E70 system with technical representatives of Mis FTRTIL atELS/GZB. Mis FTIL should arrange to impart training.
2.2.2 Test bench for Air Dryer along with Dew point measurement is to be arranged.
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2.2.3 Proper work benches are to be arranged for overhauling and maintenance ofpneumatic equipments by staff.
2.2.4 Proper housekeeping of overhauled equipments as well as new spares is required.2.2.5 Mis FTRTIL is advised to Impart training of setting of pressure switches and also
advise methodology, facilities and precautions required for the same. ELS/GZB isrequested to investigate pressure switch stuck up cases jointly with the firm andprovide feedback to RDSO.
2.2.6 Apart from the shortcomings found during ICO, the shed should also plan theworks and materials which were not carried out/replaced by POH shop duringPOR schedule.
2.2.7 The check sheets should be made in line with the SMI 0298 and system should bemade such that these check sheets should be reviewed quarterly with inclusion!deletion as per latest instructions issued from time to time.
2.2.8 Shed is requested to send the proposal of the changes required in overhaulingperiodicity of items to RDSO and the firm based on their experience, so thatsuitable amendment/ revision of SMI-0298 may be issued after taking feedbackfrom other Railways.
3. Electronic cards maintenance:
3.1 OBSERVATIONS:3.1.1 There is an electronics lab in ELS/GZB, wherein defective cards are being tested.
Defective cards of E-70 found in lab are as follows: (i) PS cards (ii) Main controlcards (iii) LPO cards (iv) Blender cards and (v) VCD cards. It is noticed that onlyfailed cards were tested. Testing of cards started during major schedules as perSMI-0298 from April'2018. After taking out the electronics cards during majorschedules, the procedure followed by staff to clean the card was found not as perOEM's recommendations.
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Fig.2 Electronic Card Test Rig available at ELS/GZB
3.1.2 Staff was using antistatic brush for cleaning electronic cards instead of cleaningthem by blowing dry air. Moreover, for PSU card the staff was not opening thecover plate and was doing cleaning over the cover only, it has been now started.There was confusion among the staff regarding indigenous and imported cards andrack and the modification carried by firm to overcome the problem of loose fitmentof card in the rack. RDSO has issued letter No. EL/3.2.19/3-phase dated15.10.2012, wherein it is mentioned in item no. 1 that a spacer in indigenous cardand insulation strip in indigenous rack were provided to address the problem. Adrive has been started by shed for checking of spacer and tightness since10.07.2018during every schedule.
3.1.3 Shed reported that during testing of cards, they are found to be normal but inlocomotive they are showing Brake Electronics Failure massage. Five nos. suchcards were tested again during technical audit. Two no. PSU cards and one Controlcard were found defective during testing. Another two PSU cards were foundnormal during testing. One of them was placed in Loco/30220 and found workingnormal.
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.H"-U",,''-'U~'U'" card card Provision of SpacersFig.3 Cleaning and provision of spacers
3.2 RECOMMENDATIONS:
3.2.1 Electronic cards testing W.r.t. OEM recommended format and standard values ofparameters are necessary on test jig during major schedules as specified in SMI-0298.Concerned staff should be trained for this.
3.2.2 It was noticed that voltage value at point no 20 of the check sheet of Control card for BPpressure being observed by control card was considered normal as 7.17±0.25 volt insteadof 7.17+0.25-0.00 volt. Suitable correction is to be made in the check sheet.
3.2.3 For point no. 19 of the check sheet of Control card, the voltage was being measurebetween terminal no.20 & 30 instead of 22 & 30. Suitable correction is to be made in thecheck sheet.
3.2.4 Mis FTRTIL was advised to carry out investigations of failed cards before taking up therepair, rehabilitation or replacement of these cards and submit the report with root causeanalysis. The firm is also requested to make component wise details of the refurbishmentdone for all the electronic cards. Mis FTRTIL is also advised to submit summarized reportof investigation done for failed Electronic cards of at least last three years.
3.2.5 Based on experience of nature of failures of Electronic cards, Mis FTRTIL is advised totake measures for improvement of test jig if required.
3.2.6 Shed is requested to investigate cases where cards are found defective in locomotive butfound normal on test jig jointly with the firm's representative and provide feedback toRDSO.
4 STORAGE OF SPARES, OVERHAULED EQUIPMENTS AND RUBBER KITS:
4.1 OBSERVATIONS:4.1.1 Overhauled components of E-70 are found dusty and kept open without wrapped
with polythene covers.
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4.1.2 Proper storage facility for spares and rubber component is not available in thesection.
Fig.4 Storage of overhauled equipments
4.2 RECOMMENDATIONS:
4.2.1 Storage space is required to be arranged and the identification of components of variousequipment of E-70 which should be clearly segregated so that they can be picked upconveniently as per requirement.
4.2.2 Storage of rubber component in section should be in a dry and temperature controlledenvironment.
4.2.3 First In First Out (FIFO) system should be followed to avoid prolonged storage of rubbercomponents and use of rubber items will be within shelf-life period.
5 AVAILABILITY OF OVERHAULING KITS:
5.1 Shed informed that a list of 11 critical non-supply items (Table-I ) has been given to MisFTRTIL for which POs already exist and DP of many items have expired. Because of this,many valves are being overhauled without replacing the must change items. The presentspares availability position ofPL items is mentioned in Table-I.
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5.2 It was also found that ELS/GZB has developed DBC Cam kit and is procuring and replacingin DBCs which have completed nine years of service life.
5.3 Shed also pointed out that the constituents of the various kits may be reviewed based on theexperience gained in maintenance of E-70 brake system.
5.4 RECOMMENDATIONS:
5.4.1 Mis FTRTIL has to comply status of supply of critical items and rubber kits to ELS IGZB asmentioned in Table-I. Mis FTRTIL has to include DBC Cam kit in their maintenance kit.
5.4.2 ELS/GZB is requested to send their proposal of review of various overhauling kits to RDSOand the firm so that further decision can be taken after taking feedback from other Railways.
6 COMPLIANCE OF SMI, MS &. TC ISSUED BY RDSO:
6.1 Status of TC-124 (RAP) compliance of some items is as below:
6.1.1 Replacement of metal seated NRV by Teflon seated NRV is under progress andbalance in 20 locos.
6.1.2 Replacement of old PVC pipe in pneumatic gauges in those 3-phase locos whichhave completed more than 6 years of service is not yet started. Material in underprocurement.
6.1.3 MS-0465 (Provision of trap chamber)-is being planned.6.1.4 SMI-313 (Pneumatic pipe connection with double ferrule fitting)-single ferrule
fitting is being adopted. As per shed they are not facing any failure / problem.6.1.5 Rehabilitation of E-70 Tri-plate panel (completed 9 years of service)- case of
20nos. is under progress at HQ level.
7 Other Recommendations:
7.1 There should be a dedicated investigation cell to analyze the abnormalities and failures inlocomotives. This practice is available in most of the sheds. Presently this work is done bysection supervisors themselves and this practice may lead to hiding of actual facts. Shedhighlighted that there is acute shortage of supervisors. 33 out of 87 sanctioned posts ofsupervisors are vacant. Shed could not provide failure /performance records of E70 brakesystem during technical audit other than those based on punctuality.
7.2 General ambience, housekeeping and upkeep needs to be improved. Overhauled items canbe kept wrapped in polyethylene covers or bubble wraps. Storage facility for rubber itemsand various kits in section should be made.
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Sr. PlNo. Description of Item Actual Supply in last two ShortfallNo Me years
2016-17 2017-18
1 29160029 Kit for compressor check valve 30 20 10 30
2 29160030 Kit for unloader exhaust valve 200 102 70 228
3 29160091 Maintenance repair Kit for 75 28 35 87Emergency exhaust valve
4 29160145 Maintenance repair Kit for 23 2 2 42Venturi Valve
5 29160285 Kit for D2 Relay Valve 80 2 42 116
6 29160340 Set of Kit for pressure control 50 13 1 86Valve
7 29160364 Kit for Direct Exhaust valve 75 18 43 89
8 29160510 Maintenance repair Kit for 100 12 60 128(Pressure) limiting valve
9 29160595 Maintenance repair kit for 60 8 2 110Parking Brake Cylinder
10 29510107 Safety valve 1/4" BSP(12.5 BAR) 15 5 14 11
11 29510119 Safety valve 1/4" BSP(3.6 Bar) 30 2 13 45
Table 1***************************
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