rdso/hhp demu/15/06 director / motive power - indian · pdf filerdso/hhp demu/15/06 dated...

RDSO/HHP DEMU/15/06 Dated 21.12.2015 Director / Motive Power Motive Power Directorate Research Design Standards Organization Manak Nagar Lucknow- 226011 Kind Attn : Mr Abhijit Singh Ref : Minutes of DEMU and SPART coordination Meeting held on 3rd June 15 Subject : Action taken report on DEMU and SPART coordination meeting held at ICF Chennai on 3rd June 2015 Dear Sir, This is based on the DEMU coordination meeting held on 3rd June 15 at ICF Chennai and the action points decided there on, we are herewith attaching the update on the improvement actions as per the change advice instruction format as required by RDSO / ICF. We would request you to please accord approval for proceeding with the modifications wherever approval is requested from RDSO. Thanking You, Yours sincerely, for Cummins India Limited

Janamjay Singh Executive Manger- Rail Business Cc : CME / CDE Mech - Design, ICF - for kind information Cc : ED,, Motive Power , RDSO for kind information Cc : Director M Traction , Railway Board for kind information Cc : ED Traction, Railway Board, for kind information Annexures: 1. Point No 3, SOP for Pulley alignment ( Annexure I) 2. Point No Details with photographs on corrections carried out refer Annexure II.

1. Oil Leakage from Exhaust manifold slip joints and Turbocharger joints (Slobbering issue)

i. Description of change:

a) Implementation of Multilayered gasket in the exhaust manifold and Turbocharger joints.

b) New Cylinder – with inclusion Valve stem seal in the cylinder head.

Note : As the issue is being addressed in the root (in combustion) No need for

Implementation of bellow joints in the exhaust system.

II. Reason for change:

Oil slobbering - Oil leakage was observed from exhaust ports in cyl heads and turbo joints where

engine idling operation was noticed for longer hours.

Changes Adopted:

a) Addition of valve stem seals which will prevent the entry of oil inside combustion

chamber, which eventually reduces slobber effect.

b) Multilayered gasket t to prevent the external leakage of oil/ gas.

iii Implemented from:

a) Multilayered gasket .Modifications carried out at Plant for all new Engine supplies to

ICF. First ESN: 25391819 Effective Date: 31st July, 2013 and New Cylinder Head with Valve

Stem seal is introduced on all engines supplied to ICF effective July 2014. First ESN:

25399995.

iv. Part Numbers involved in change:

a) Cylinder Head without valve stem seal - P/N: 3646323 changed to Cylinder with head

stem seal: P/N: 3811989.

v. Implication of engines in Service:

• Number of engines identified with this issue – 46

• Lateral deployment planned in six engines, Field actions for all balance engines will be

done after validation confirmation from RDSO.

Action Progress:

Job completed on 8 engines, Idle run test & load trial carried out in all locations. Final

performance sign off done at WR & Konkan Railway.

Status Update

S/N Railway ESN Hours Clocked After Head Replacement

Performance Status

1 Western Railway

25382422 5431 on 04-Oct-15 Satisfactory

2 Konkan Railway

25384087 5978 on 13-Dec-15 Satisfactory

3 South Central 25364017 5452 on 01-Oct-15

Leakage observed at one exhaust port # LB 7. Replaced same Cylinder Head with new one on 21-Jan-15 Failed cylinder head was sent to engineering for analysis. Analysis done by cutting cylinder head. Damage to seal and abrasive wear observed on valve stem.

On 22-Mar-2015, Oil leakage again observed near exhaust port # LB 6&8. This time we have decided to replace Injectors also on affected cylinder heads # LB 6,7 & 8

Cylinder heads & #1 & #4 Injectors are replaced. Till no complaint received post replacement.

4 Western Railway

25362116 1720 on 08-Dec-2015 Satisfactory

5 Western Railway

25328577 1390 on 08-Dec-2015

Slobbering observed from all exhaust joints.

All injectors were replaced with new one. Slight slobbering observed. Bellow joint type exhaust manifold and fuel pump to be replaced. Parts have been arranged, awaiting railways to spare the engine.

6 Southern Railways

25268383 310 on 03-Nov-2015 Satisfactory

7 South Central Railways

25373822

130 Hrs on 15-Sep-2015 Slobbering observed, Bellow Type Exhaust manifold and Injectors have been replaced & commissioned on 16-10-15

8 South Eastern Railways 25368994 900 Hrs on 11-Dec-2015 Satisfactory

� South Central Railways- 16 Nos cylinder heads and other parts required to complete the job on another engines,

parts have been handed-over to Maula Ali Shed. Awaiting DPC to be spared for the job.

� North Central Railways- 16 Nos Cylinder heads and other parts required to complete the job on one engine are ready with dealer at Agra. Awaiting DPC to be spared for the job. NCR have decided to dispatch DPC for POH at Charbagh Workshop Lucknow and wants us to complete the job of Cylinder head replacement at Lucknow

� South Eastern Railway- 16 Nos Cylinder Heads and other parts have been ordered by dealer for replacement on engine due for D Check.

� Northern Railways Burgam- 16 Nos Cylinder Heads and other parts have been ordered by dealer for replacement on engine under D Check.

All the new engines supplied by ICF to Zonal Railways eff Aug 2014 are supplied with

modified cylinder heads (with stem seals) and are operating with various Zonal Railways.

Railways Number of Engines with Modified

Cylinder Head Max of Hours Status

CR 6 3744 Satisfactory

ECR 4 3158 Satisfactory

NR Jalandhar 4 3080 Satisfactory

NWR, Ajmer 5 3096 Satisfactory

SER, Kharagpur 8 1748 Satisfactory

WR 6 996 Satisfactory

NER 1 5250 Satisfactory

Grand Total 34

2. Grade of Lube oil:

Cummins stated that grade of lube oil to be changed from 15W40 - CF4 to CH4.It has been

decided that RDSO shall advice necessary guidelines in this regard.

RDSO has advised for the grade of oil to be used for Cummins engines to CH 4 to all Zonal

Railways with the oil change period as 1000 hours which is not in line with the manufacturer’s

recommendation, we request RDSO / ICF to revisit on the same and issue guidelines for 500

hours oil change period for Cummins engines.

3. Air Compressor V-belt failure / dropping (1400 HP DEMU)


The air compressor pulley has been modified.

ii. Reason for change:

Grooves in the V-pulley fitted to air compressor were not matching with those on

engine drive pulley, Dimension variation in Air compressor and sub base caused the

compressor alignment on the end of slot due to which V-belts were failing frequently.

iii. Implemented on all new KTA 50 L engines supplied by Cummins plant to ICF from:

First ESN: 25392062 with effective date - 23rd Aug, 2013.


Air Compressor Pulley P/N: 4344089.


DEMUs compressor end pulley shall be replaced with new belts on the existing DEMU running

with problems.

Action plan:

1. Dimension correction has been implemented on new supplies.

2. Air compressor in stock at ICF were also corrected with modified pulley.

3. Alignment procedure of air compressor V belt followed as attached SOP.

4. Based on the observation belt size corrected from size C114 to C113.

5. Number of engines running with this issue identified = 34

Action Progress:

Pulley Modification completed on 38 Nos Engines at various Zonal Railways. We are

undertaking job of pulley conversion on failure report from user railways. (SOP for

alignment procedure attached in the Annexure I)

Current Status Report on the modification carried out in various Zonal Railways is as below.

S/N ESN Railways Date Completed Remarks

1 25296053 NR Jalandhar Done in Sep_2014 Satisfactory

2 25296054 NR Jalandhar Done in Oct_2014 Satisfactory 3 25301618 NR Jalandhar Done in Sep_2014 Satisfactory 4 25279590 NR Jalandhar Done in Sep_2014 Satisfactory 5 25292954 NR Jalandhar Done in Sep_2014 Satisfactory 6 25301646 NR Jalandhar Done in Sep_2014 Satisfactory 7 25306555 NR Jalandhar Done in Sep_2014 Satisfactory 8 25394648 NR Jalandhar Done in Dec_2014 Satisfactory 9 25394649 NR Jalandhar Done in Dec_2014 Satisfactory

10 25320236 NR Jalandhar Done in Sep_2014 Satisfactory 11 25364010 NR Jalandhar Done in Sep_2014 Satisfactory 12 25366373 NR Jalandhar Done in Sep_2014 Satisfactory 13 25374944 NR Jalandhar Done in Oct_2014 Satisfactory 14 25377026 NR Jalandhar Done in Oct_2014 Satisfactory 15 25271378 NR Jalandhar Done in Sep_2014 Satisfactory 16 25340645 NR Jalandhar Done in Sep_2014 Satisfactory 17 25392062 NR Jalandhar Done in Sep_2014 Satisfactory 18 25364016 NR Jalandhar Done in Oct_2014 Satisfactory 19 25387269 NR Jalandhar Done in Oct_2014 Satisfactory 20 25382996 NR Jalandhar Done in Sep_2014 Satisfactory 21 25382997 NR Jalandhar Done in Oct_2014 Satisfactory 22 25394647 NWR, Ajmer Done in Nov-2014 Satisfactory 23 25395324 NWR, Ajmer Done in Dec-2014 Satisfactory 24 25404241 SER, Kharagpur Done in Jul-2015 Satisfactory 25 25403461 SER, Kharagpur Done in Jul-2015 Satisfactory 26 25347629 ER, BURDWAN Done in Jul-2015 Satisfactory

27 25378243 ER, ANDAL Done in Jul-2015 Satisfactory 28 25378244 ER, ANDAL Done in Jul-2015 Satisfactory 29 25387334 ER Patna Done in Jul-2015 Satisfactory 30 25384000 ER Patna Done in Jul-2015 Satisfactory 31 25383999 ER Patna Done in Jul-2015 Satisfactory 32 25387333 ER Patna Done in Jul-2015 Satisfactory 33 25323079 NR Burgam Done in 23-09-2015 Satisfactory 34 25329417 NR Burgam Done in 14-09-2015 Satisfactory 35 25361080 NR Burgam Done in 19-09-2015 Satisfactory 36 25314807 NR Burgam Done in 28-09-2015 Satisfactory 37 25363307 NR Burgam Done in 10-09-2015 Satisfactory 38 25379104 NR Burgam Done in 11-09-2015 Satisfactory

4 .Failures of level indicator of cooling water:

a. Coolant level indicator material improved. For P/N 5276959 with effect from April 2012.

Field engines were replaced case to case basis.

1. Description of change:

The below improvements were implemented Failures of level indicator of cooling water:

Action Taken

• Thread size for bolts corrected.

• Improved glass material implemented suitable for High temp.

• All necessary process documents like process flow diagram / Control Plan revised

• Testing procedure improved at supplier end. Pressure testing of float level switch after

stem fusion welding at 50 PSI introduced wet testing of the indicator.

• Supplier has introduced the pressure testing of stem at air pressure of 50 psi. and

pressure testing of float at 30 psi hydraulic.

2. Reason for change:

The level indicator gauge had fitment issue and the material was not suitable for very high

temperature leading to breakage.

3. Implemented from:

The actions have already taken from FESN: - 25374943 effective date: April 2012

4. Part Numbers involved in change: P/N: 5276959. No change in part number. Product is improved with the same.

5. Implication of engines in Service: Nil

Feedback awaited from Zonal Railways on the current performance.

5. D Check and E Check Rate Contracts.

Decision:

a) Railways to consume allotted quantities before the end of contract by Dec.2015.

b) CIL to expedite and complete order placed by Railways.

c) 6 nos D-check available with SWR will be transferred to SR.

a) RDSO confirmed that E-check period is 54 months or 18000 hrs, whichever is earlier for

1400hp engine.

D check - 1400 HP DEMU

SL NO Railways Zone Zone 2014 2015 TOTAL

1 Eastern Railways EAST 3 2 5

2 North Central Railway NORTH 0 3 3

3

North Eastern Frontier

Railways EAST 5 4 9

4 Northern Railways NORTH 15 13 28

5 South Central Railways SOUTH 5 0 5

6 South Eastern Railways EAST 4 0 4

7 South Western Railways SOUTH 2 4 6

8 Western Railway WEST/NORTH 3 8 11

9 South East Central Railways WEST 5 0 5

10 East Central Railways EAST 3 3 6

11 North Eastern Rly 0 2 2

12 North Western Rly 0 2 2

Total 45 41 86

E check - 1400 HP DEMU

SL NO Railways Zone Zone 2014 2015 Total

1 Eastern Railways EAST 3 4 7

2 North Central Railway NORTH 1 1 2

3 Northern Railways NORTH 13 11 24

4 South Central Railways SOUTH 3 2 5

5 South Eastern Railways EAST 3 3 6

6 South Western Railways SOUTH 4 0 4

7 Western Railway WEST/NORTH 2 2 4

8

South East Central

Railways WEST 0 3 3

9 Southern Railways South 4 2 6

10 North Western Railways North

11 North Frontier Railways EAST 0 4 4

Total 33 32 65

6. PT (Pressure-Time) Pump failures:

CIL confirmed that reconditioned PT pumps are only used and dealers are not servicing PT pumps.

Reconditioned PT pump is included in the D-check. NCR requested to provide gauge to check fuel

pressure in the PT pump in order to identify the health of PT pump.

During review meeting held at Vijaywada DEMU Diesel shed / SCR on 26.09.2014 with M/s

Cummins & user railways, it was decided that PT pumps are low pressure pump, hence,

pressure gauge is not required.

Decision: RDSO to study the feasibility of providing gauge in PT pump

Description of change: No Action from CIL

7. LCC (Locomotive Control Console) B-part Failure:

SWR reported that CLCC make is performing satisfactorily. CIL has not implemented CLCC and

stated that the firm is sourcing LCC as well as Actuator from M/S GAC. NR stated that connector

in B-part of LCC is modified to avoid failure of LCC, which is giving good result at NR.

Decision:

a) M/s United Industries Erode has developed the computerized LCC (CLCC) with same functional

requirement of LCC and has also added the facility of data logging and user settable parameters.

RDSO has included CLCC developed by M/s United Industries as Part ll source in the approved

vendor directory against Governer/LCC Engine for DEMU.

Railways should use CLCC in view of obvious advantages and satisfactory performance.

b) Based on SWR suggestions and study of NR modification of LCC, Mod Sheet No.

MP.MOD.EC 02.04.15 dated 01.06.2015 has been issued by RDSO. Railway may

implement the same.

8. Abnormal sound and failure of ventilation fans:

CIL is sourcing vent fans from Southern Magnetics, Chennai. CIL has implemented high temp

grease and sealed cover bearings from June 2013. However, NR reported problems in new

DPCs.

Decision:

a) CIL to study the issues with Southern Magnetics to avoid abnormal sound and failure of

Vent fans.

b) CIL to replace vent fans at NR before the end of July 2015.

Root cause: Dust in grease and grease drying causing overheating.

Action Progress:

High temp. Grease and sealed cover bearing introduced from June 2013 Implemented in all

new supplies of engines to ICF Production engine sr.no. 25390658 It is reviewed by Cummins

Technical Team and it is Double Bearings.

9. Radiator and Hydraulic Pipe leakages;

NCR reported poor quality of radiator tubes (less thickness) and leakage of oil in hydraulic system.

They have replaced with WDM2 loco radiators, which are found satisfactory.

One case of coolant leakage from after cooler outlet hose clamp was reported in Oct 14.

Root cause:

1. Leakage was due to clamp loose, causing coolant leakage. Problem was rectified by tightening

the same clamp.

2. Based on analysis identified hose clamp torque loss could be probable reason.

Action:

1. Portable Auto shut off gun implemented on assembly for this hose clamp from Dec 14.

2. Leak testing of radiator before assembly at ICF being done by CIL

3. Packaging improvement of rubber pad below the radiator has been implemented to avoid any

stress during handling

Radiator leakage are old cases and no occurrence in current and last year.

10 Air Compressor base frame Improvement


The air compressor bracket design is part of the frame rests on the base rail which is now

separated from the base frame and separately mounted.


It was found that air compressor is one of the prime sources of vibration in the DEMU power

pack. Newly developed air compressor base frame which is sturdy and separated from engine

alternator base which will reduce the vibrations.

iii. Implemented from:

Modified air compressor bracket is fitted on new DMU at ICF awaiting load trials.


Air Compressor Bracket P/N: 4105974 will be changed to P/N: 4345205.

5. Implication of engines in Service: Not yet

• Coach allotted and fitment trial in progress at ICF

• Will approach RDSO for approval once the trials are completed for new supplies.

Action Progress:

Set of Modified brackets sent to ICF for implementation, fitment trials completed at ICF.

Performance will be monitored in Zonal Railways.

DPC# 237 having ESN 25401555 KTA50L has been commissioned at Rourkela and has run @

1320 Hrs on 25-Sep-2015. No issue reported in the bracket.

11. Deficiencies in new Cummins engines

New engines supplied to ICF have various quality defects such as poor clamping of hydraulic lines,

vibration of fuel hand pump, unsupported pneumatic lines connecting between unloader in

compressor, defective pulley alignment & adjusting screws, poor clamping of cables and non

provision of proper clamps, improper termination of sensor cables, etc. CIL stated that the points

raised by ICF are taken care and addressed in the newly supplied engines from Sep.2014.

Decision:

a) This issue will be discussed between ICF and CIL. CIL should give action taken on all points

raised by ICF.

Action Progress:

Improvements carried out on the newly supplied Engines in terms of proper clamping , routing of

harness and alignment checking has been adopted at ICF for all new DEMUs supplied since October

14.( Details with photographs is attached as per Annexure II )

12. Cladding of exhaust pipe:

Removable cladding of exhaust pipe is necessary for removal and re-fitment during maintenance.

SCR (BZA) and SR (LW) implemented re-useable cladding. CIL is yet to implement in the new

engines and shall give action plan for implementation.

Decision:

a) CIL to cut-in removable cladding for exhaust pipe immediately.

b) RDSO to issue guidelines to zonal Railways based on re-useable cladding implemented by

SCR and SR.

RDSO guidelines awaited for the materials to be used for the cladding for implementation in

future.

13. Poor life of cam shaft in 700hp Engine

SCR (BZA) reported the cam shafts of 700hp engines last for 1.5 years only due to profile getting

worn out. At least it should last for E-check period. CIL stated that cam shaft has been improved.

Decision:

a) CIL to spell out improvements done in the cam shaft and give details of part no. to zonal

Railways.

Cummins Response

1. The cam lobe failure may be due to Oil degradation / High soot contain / overloaded valve train.

Cummins will analyse for future cases for above points along with machining process & material.

Future incidences will be closely monitored & investigated for similar failure mode.

14. Failure of vibration damper bolts in VTA28L – 700 HP DEMU engine.


Four groove vibration damper pulley has been replaced with two groove vibration damper pulley

in VTA28L (700 HP DEMU) engine.


Due to recent failures observed in zonal railways, the vibration damper pulley mounting bolts

were breaking due to bending stresses. Hence modified vibration damper pulley of two groove

was replaced to reduce stresses on the mounting bolts.


As agreed in the meeting with railways, the modified damper pulley with will be replaced during

D/E check which will be carried out at our service center or at some of the Railways base

workshop carrying out during POH. New pulleys to be shipped.


S/N Old Part No New Part No Description Qty

01 213358 4347216 Crank Flange 01 02 3015585 Same Crank shaft flange mounting bolts 06 03 216701 Same Vibration Damper mounting bolts 06 04 148916 Same Vibration damper mounting bolts washers 06

05 140218 Same Crank Shaft flange mounting bolts washers 12

06 4959045 5279650 Two groove pulley 01

5. Implication of engines in Service:

Action Progress:

Two groove pulley replacement done on 52 engines, listed as under

S/N ESN Railways Area Office Date Status

1 25213861 WR Vadodara Dec-14 >1500 Hrs

2 25219645 WR Vadodara Mar-15 >1500 Hrs

3 25222289 WR Vadodara Nov-14 >1500 Hrs

4 25225310 NR Jalandhar Chandigarh Jun-15 Yet to be commissioned

5 25242387 WR Vadodara Dec-14 >1500 Hrs


7 25245256 NR Jalandhar Chandigarh 2014 >7000 Hrs


9 25305796 WR Vadodara Niv-14 >1500 Hrs


11 25222809 NR Jalandhar Chandigarh 2013 >8000 Hrs

12 25228615 NR Jalandhar Chandigarh Jan-15 >1500 Hrs

13 25264479 NR Jalandhar Chandigarh Oct-14 >2000 Hrs

14 25266885 NR Jalandhar Chandigarh Oct-14 >2000 Hrs

15 25285982 SCR Hyderabad Dec-14 >1000 Hrs

16 25244418 WR Vadodara Mar-15 >1500 Hrs

17 25245689 WR Vadodara Nov014 >1500 Hrs

18 25249645 WR Vadodara Apr-15 >1500 Hrs

19 25370233 WR Vadodara Jun-15 >1500 Hrs

20 25314133 SR Trichi Jan-15 > 2000 Hrs

21 25266482 SR Trichi Mar-15 > 2000 Hrs

22 25262441 SR Trichi Dec-14 > 2000 Hrs

23 25274819 SR Trichi Dec-14 > 2000 Hrs

24 25291697 KRC Pune Dec-14 >1000


26 25233738 SCR Hyderabad Aug-14 >1000 Hrs

27 25265541 SR Trichi Dec-14 > 2000 Hrs

28 25242784 SR Trichi Dec-14 > 2000 Hrs

29 25364372 SR Trichi Feb-15 > 2000 Hrs

30 25377311 SR Trichi Jan-15 > 2000 Hrs

31 25221531 SR Trichi Jan-15 > 2000 Hrs

32 25320999 SR Trichi Jan-15 > 2000 Hrs

33 25261841 SR Trichi Feb-15 > 2000 Hrs

34 25230327 ECR Ranchi Mar-15 Yet to be commissioned

35 25364373 ECR Ranchi Mar-15 Yet to be commissioned

36 25380671 SECR Nagpur Jun-15 >1000 Hrs

37 25218766 SECR Nagpur Jun-15 >1000 Hrs


39 25212245 NR Jalandhar Chandigarh >4000 Hrs

40 25222288 NR Jalandhar Chandigarh >4000 Hrs

41 25444417 NR Jalandhar Chandigarh Apr-15 >500 Hrs

42 25327960 WR Vadodara Mar-15

43 25244479 NR Jalandhar Chandigarh >1817

44 25261847

SR Chennai Jun-15 Yet to be commissioned

45 25203666 NR Jalandhar Chandigarh Jul-15 Yet to be commissioned

46 25244417 NR Jalandhar Chandigarh Jul-15 Yet to be commissioned

47 25224722 NR Jalandhar Chandigarh Sep-15

48 25221142 NR Jalandhar Chandigarh Jun-15

49 25225311 NR Jalandhar Chandigarh

50 25283494 NR Jalandhar Chandigarh Aug-15

51 25231697 NR Jalandhar Chandigarh Sep-15

52 25245257 NR Jalandhar Chandigarh Aug-15

Two failures observed after conversion to 2-Groove pulley conversion. Both failures are on

salvaged crank nose threads and suspecting uneven crank nose face and damaged threads are

the root cause of failure.

15. Diesel oil dilution issue in VTA28L in 700HP DEMU


The injection timing of the fuel is advanced using a new camshaft woodruff key.


The unburnt fuel was mixed in the oil sump because of excessive idling of engine as per the

operating conditions. The new camshaft key will increase the timing and therefore resolve

the issue.


As agreed in DEMU coordination meeting these modifications will be carried out in the

identified engines as and when they are received for E check.


Old Camshaft woodruff Key P/N: 3021600 will be changed to new Camshaft Woodruff Key -

P/N: 3065975.


Number of engines running with this issue identified 14 numbers, the injection timing to be

set between 0.049”and 0.054” by using of above key P/n: 3065975 will be replaced during E

check (engine overhauling).

Action Progress:

1. As agreed in the DEMU Coordination meeting, Camshaft Key is being replaced on all V-

28 engines (700 HP DEMU) at Cummins rebuild center on all engines arriving for E

check.

2. List of engines where we have revised timing at rebuild centers is as follows-

Performance of these engines is being closely monitored by Cummins field network.

S/N

ESN Dealer Railways Area Office Date Service Centre

Status

1

25228615 SSS Ludiana NR Jalandhar

Chandigarh Jan-14 Phaltan 4819 hrs, dated: 10.12.15

2

25264479 SSS Ludhiana NR Jalandhar

Chandigarh Oct-14 Jaipur 5000 hrs, dated: 10.12.15

3

25266885 SSS Ludhiana NR Jalandhar

Chandigarh Sep-14 Phaltan 4450 hrs, dated: 10.12.15

4

25370233 SSS, Ahmedabad WR Vadodara Jun-15 Phaltan Yet to be commissioned

5 25314133 JN Machinery SR Trichy Sep-14 Phaltan 4241 hrs, dated:

11.12.15

6 25266482 JN Machinery SR Trichy Sep-14 Phaltan

7

25291697 Trnity Mahalsa Durga,Goa

KRC Pune Dec-14 Phaltan 2436 hrs, dated 30.07.15

8

25242785 SSS, Ahemdabad WR Vadodara Nov-14 Phaltan Yet to be commissioned

9

25233738 Srinivasa Vijaywada

SCR Hyderabad Aug-14 Phaltan Yet to be commissioned

10

25242784 JN Machinery SR Trichi Mar-15 Phaltan Yet to be commissioned

11

25230327 JTPL ECR Ranchi Mar-15 Phaltan Yet to be commissioned

12

25364373 JTPL ECR Ranchi Mar-15 Phaltan Yet to be commissioned

13

25261847 Powerica Chennai

SR

Chennai Mar-15 Phaltan Yet to be commissioned

14

25203666 SSS Ludiana Northern Railways

Chandigarh Jul-15 Jaipur Work in progress at Jaipur, Jul-15

15

25244417 SSS Ludhiana Northern Railways

Chandigarh Jul-15 Jaipur 108 hrs, dated: 10.12.15

2. Failure of radiator motors: SPART

After rampant failures of radiator fan motor due to water ingress, M/s SAN Engineering,

Bangalore (Prime contractor for SPART DPC equipment) has investigated the issue with the

engine supplier CIL. Decision was taken in Sept.2014 to replace the motors with better protection

class. SAN started replacing the existing ABB make motor (IP55) with IEC make (IP56). The firm

has so far replaced 8 motors in two rakes, while replacement is required in the first 22 rakes. It

is seen that abnormal time is taken for replacement.

Action Progress:

As agreed in the DEMU Coordination meeting the Status update on the Fan motor

replacement is attached. 79 out of total 88 Motors have been replaced.

Repeat failure of IEC motors observed at SECR Gondia and ER Jamalpur. Motor replacement

and Step-3 containment action completed at SECR Gondia. Same is to be done on all motors

after validation.

ESN Model Railway no User Railways Motor Replacement Status

25375741 NTA 14 R SEC 13892 South East Central, Raigarh Completed

25375740 NTA 14 R SEC 13893 South East Central, Raigarh Completed

25376425 NTA 14 R NC 13933 North Central Railways, Gwalior Completed

25376426 NTA 14 R NC 13934 North Central Railways, Gwalior Completed 25381323 NTA 14 R SEC 13895 South East Central, Nagpur Completed

25381324 NTA 14 R SEC 13896 South East Central, Nagpur Completed

25381243 NTA 14 R NC 13936 North Central Railways, Agra Reached

25381244 NTA 14 R NC 13937 North Central Railways, Agra Completed

25386760 NTA 14 R NE 13921 North Eastern Nainital, Uttarakhand Completed

25386759 NTA 14 R NE 13922 North Eastern Nainital, Uttarakhand Completed

25381325 NTA 14 R NR 8154 Northern Railways New Delhi Completed

25382670 NTA 14 R NR 8155 Northern Railways New Delhi Completed

25382672 NTA 14 R NR 8157 Northern Railways Lucknow Completed

25382671 NTA 14 R NR 8158 Northern Railways Lucknow Completed

25389887 NTA 14 R EC 13901 East Central Railways , Varanasi Completed

25389888 NTA 14 R EC 13902 East Central Railways, Varanasi Completed

25388727 NTA 14 R ER 13901 Eastern Railways Asansol Completed

25388728 NTA 14 R ER 13903 Eastern Railways Asansol Completed

25387163 NTA 14 R SWR 13876 South Western Railways, Hubli Completed

25387162 NTA 14 R SWR 13876 South Western Railways, Hubli Completed

25390330 NTA 14 R EC 13904 East Central Railawys Sonpur Completed

25390329 NTA 14 R EC 13905 East Central Railawys Sonpur Completed

25392034 NTA 14 R SC 13911 Southern Railways Erod Completed

25392033 NTA 14 R SC 13911 Southern Railways Erod Completed

25393034 NTA 14 R NFR 13876 North Frontier Railways Guwahati Completed

25393033 NTA 14 R NFR 13877 North Frontier Railways Guwahati Completed

25393036 NTA 14 R NR 8160 Northern Railawys Moradabad Completed

25393035 NTA 14 R NR 8161 Northern Railawys Moradabad Completed

25394393 NTA 14 R CR 13882 Central Railways Sholapur Completed

25394391 NTA 14 R CR 13883 Central Railways Sholapur Completed

25394833 NTA 14 R CR 13885 Central Railways , Pune Completed




25394394 NTA 14 R SER 138961 South Eastern Chakradharpur Completed

25394392 NTA 14 R SER 138941 South Eastern Chakradharpur Completed

25398512 NTA 14 R NFR 13879 North Frontier Railways, Alipurduar Completed

25398513 NTA 14 R NFR 13880 North Frontier Railways, Alipurduar Completed

25399264 NTA 14 R ER 13902 Eastern Railway Malda Town Completed

25399265 NTA 14 R ER 13904 Eastern Railway Malda Town Completed

25400287 NTA 14 R WR 138784 Western Railway, Ahmedabad Reached

25399815 NTA 14 R WR 138785 Western Railway, Ahmedabad Reached

25400545 NTA 14 R SC 13911 South Central Railway, Hyderabad Completed

25399814 NTA 14 R SC 13911 South Central Railway, Hyderabad Completed

Standard Operating Procedure (SOP) :

DEMU Air compressor belt alignment procedure – SO38301 and SO38302

5/6/2015 Cummins Confidential1

Purpose of SOP: To assemble air compressor#4021195

and align the pulley with crank pulley using laser tool, and adjust belt tension


Air compressor

V Belt

Air compressor

pulley

Crank pulley Sub base Air compressor bracket

Standard Operating Procedure

1. Purpose

To align air compressor and crank pulley for belt and adjust belt tension

2. Scope

SOP Applicable only for DEMU application SO38301 and SO38302

3.Procedure :

1. Mark to air compressor position in belt tight condition

2. Loosen air compressor mounting bolt – 4 nos.

3. Loosen two front side bolts, ensure to keep back side bolts in intact condition

4. Slide compressor towards engine by loose and tighten the opposite side bolt for belt tension

3. Remove belt

4. Take compressor back to original belt tight position, match the confirmation mark

5. Tighten all mounting bolt and give torque


Side bolt belt tension

– 2 nos

Side bolt belt minor

alignment - 4 nos

Compressor

mounting bolt – 4nos

6. Align the laser tool with correct mount for V groove pulley.

7. Put laser tool on crank pulley and check alignment on compressor pulley, Allowable mis-alignment

(crank pulley to air compressor pulley): upto 2mm

8. If required adjust the compressor bracket position

9. Check alignment at top and bottom of the compressor pulley

10. Adjust the alignment using side bolts or shim as required

Note# Final alignment check has to be done with all bolts properly tightened

11. Repeat step 2 and 3

12. Assemble new belt, ensure C113 belt is used with matching pair


Laser alignment tool

#3163524

13. Ensure hardware sizes as per below list:

14. Follow step 4 and 5

Note# Tighten torque as per below specification:


Hardware parts P/No Qty

BOLT S144 2 nos SCREW DIAMETER - THREADS PER INCH

5/8-11, Length 2.50 inch, grade 5



BOLT S192A 6 nos SCREW DIAMETER - THREADS PER INCH

5/8-11, Length 4 inch, grade 5

NUT 6 S201 12 nos

WASHER 6 146177 24 nos

lock washer 6 S603 12 nos

Bolt 3089328 2 nos Dia/pitch M16x2, Length 70mm class 9.8 (8.8)

Bolt 3916071 4 nos Dia/pitch M16x2, Length 50mm class 9.8 (8.8)

Hardware parts P/No Qty Torque



180 Nm



180 Nm

BOLT S192A 6 nos SCREW DIAMETER - THREADS PER INCH

5/8-11, Length 4 inch, grade 5

180 Nm

Bolt 3089328 2 nos Dia/pitch M16x2, Length 70mm class 9.8 (8.8) 195 Nm

Bolt 3916071 4 nos Dia/pitch M16x2, Length 50mm class 9.8 (8.8) 195 Nm

15. Check belt tension with tool , adjust if required (Spec 200lb for new belt)

16. Mark the position with paint marker as shown below

Take trial for 1 hour and check for any damage on side wall and heating of belt


Belt tension tool

P/N ST-1138


Status of issues


Inserted a metal gland at the

outlet as shown in photo

Cable outlet was not provided

proper support at pressure

switch.

Issue 1 - Cable outlet was not provided proper support pressure switch

Before After


Cable outlet was not provided proper

support for temperature switches.

Inserted a metal gland at the outlet as

shown in photo

Before After

Issue 2 - Cable outlet was not provided proper support for temperature

switches.


Sensor cable from engine sump

not supported and not coveredCovered by conduit and

supported by P-clamp

Issue 3 Sensor cable from engine sump not supported and not covered


Every single cable is covered with

conduit and supported by P-clamps

Cables hanging without any

support

Issue 4 - Cables hanging without any support


Magnetic pick up cables not

properly terminated

The connections done properly

and conduit provided till end to

support

Issue 5 - Magnetic pick up cables not properly terminated


Conduit in T joint is not fitted

properlyCorrect fitment of conduit in T joint

Issue 6 Conduit in T joint is not fitted properly


Wires are tied with plastic tagsAll cables are covered with conduit

and they clamp with metal hose

camp / P clamps

Issue 7 - Wires are tied with plastic tags


Wiring not supported resulting in

vibrations

Wiring covered with conduit

and supported by clamp

Issue 8 - Wiring not supported resulting in vibrations

rdso/hhp demu/15/06 director / motive power - indian · pdf filerdso/hhp demu/15/06 dated...

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