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Minutes of 4th Bulk Indent Meeting held

at DMW on 18th March 2016

Address by CME/DMW

CME welcomed AM/ME and other officers from Board, RDSO, DLW and Zonal Railways. He further expressed that BIM is useful for Zonal Railways and will meet their expectations. DMW has taken aggressive approach to procure critical spares and assemblies for WDP1, WDS6 locomotives. Four WDS6 locomotives have already been rolled out in last month by Parel Workshop and hopefully 10 nos. of WDP1 locomotives will be rolled out in 2016-17.

Address by COS/DMW

COS mentioned that DMW is clearing the demand of Zonal Railways for Ann ’N’ & BIM items and approx. Rs. 270 crores worth cases have been finalised in this year. He further expressed that timely submission of indents will help DMW to supply adequate spares. Regarding rate contracts he stated that Zonal Railways to send their requirements for optimum utilization of funds and Zonal Railways should avoid separate Purchase Orders at their end for those items for which rate contract has been placed by DMW.

Address by CAO(R)/DMW

CAO(R)/DMW warmly welcomed AM/ME and other officers from Board, RDSO,

DLW and Zonal Railways. He stated that in his opinion, this meeting is a

customer meet which provides not only an excellent forum for the planning for

the supply of Spares of ALCO Locomotives, but also to exchange views on the

problems being faced by Zonal Railways related to supply, quality, warranty and

other technical aspects. He further informed that although presently DMW is

dealing mainly with ALCO loco materials, we are gearing up for HHP locos as

advised by Railway Board. He assured the house that DMW was commited to

meet all the spare parts requirements of Zonal Railways, and will continuously

address their demands. He requested that apart from feedback about warranty

failures, DMW would be happy if ZRs shared their analysis of performance of

DMW supplied materials and their suggestions regularly.

Address by EDME (Traction)

EDME (Traction) stated that reliability of Locomotives is the biggest concern. We

need to drastically improve reliability. Task force on condition monitoring has

already submitted their report. All failures need to be analysed to establish their

linkage to REMMLOT monitored data. CMPEs should look into this and REMMLOT

should be used as a tool to prevent failures.

Sheds should take immediate action on this aspect in co-ordination with PUs. He

further informed that RDSO has opened an Innovation Forum and all CMPEs are

advised to use it. Safety modifications are invariably to be done.

APU utilisation needs to be monitored and improved. Drivers’ training is to be

improved. For fuel savings overaged locos are to be condemned, Railway Board

has a target to improve fuel efficiency by 1% in SFC every year. While expressing

his deepest appreciation to DMW’s positive response for compliance of RSP,

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Ann ’N” and BIM items, and new projects, he stated that DMW should initiate

action for more upgraded Cabs, should not use block after 3rd reclamation (DMW

and GOC) , implement 100% PU painting, and enhance AC Traction Motor

overhauling/ rehabilitation in 2016-17.

Address by AM (ME)

While complementing DMW for holding this meeting, he asked all CMPEs to do

intro - inspection as almost 260 Locos are failing in a month. There is a need to

bring about large scale improvement in loco maintenance. He felt there is a

serious need to induct more Engine blocks and all rehabilitated locos should be

fitted with new Engine blocks. He further desired that sub assembly

performance issues such as Cylinder liner, SUCS, Cam Gear, Split Gear, Water

Pump failures are to be looked into. He further stated that Traction Motor Shop

of DMW has done good job for ALCO Motor/TA overhauling and would like that

DMW set up best facilities for AC Motors also. It is to be examined whether we

can go back to using cast bogies in view the poor performance of fabricated

bogies.

This year, our fuel bill is going to be more than Rs. 17,000 crores. Zonal Railways

and PUs have to ensure plugging leakages/wastage of fuel in locomotives, and

fitment of APUs as the fuel budget for 2016-17 has been restricted to Rs. 15,000

crores.

Multigen Set was produced by DMW for fuel saving. Based on service

performance on WCR, DMW to ensure that further production of these

locomotives is expedited.

Warranty complaints should be looked into in a professional way. Vendors

should be treated as partners and healthy relations maintained with them, so

that Zonal Railways and PUs can ensure and deliver good quality in whatever they

produce.

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Minutes of General Agenda items

Item No.1 Hub for ALCO loco and its spares:

Deliberation DMW and DLW have entered into an MOU for supply of ALCO loco and spares to NRC customers from DMW. Under this MOU, DLW will take orders for NRC lo-cos and spares, and will pass these orders to DMW for execution. DLW will share part of D&G fund to DMW for marketing activities at DMW. First NRC Loco will be rolled out by DMW on 31st Mach’ 16. ZRs brought out the issue of vendor approval process for ALCO items. Railway Board has already directed DMW to take over vendor approval process of ALCO items.

Decision DMW to take over Vendor Directory of DLW controlled items for ALCO loco at

the earliest.

Item No.2 Rebuilding of WDP1 Locomotive

Deliberation DMW has placed PO for various uncommon items required for rebuilding of WDP1 locomotive. Crankshaft, which is an imported item has arrived and Bogie frame is expected by June,2016. DMW should ensure availability of all material required for WDP1 locomotive by June,2016.

Decision DMW to rebuild 10 nos. of WDP1 locomotive during 2016-17.

Item No.3 Rebuilding of WDP3A Locomotive

Deliberation DMW presented issue of bogie, wheel set and other items for WDP3A for which RDSO has to provide details.

Decision RDSO to resolve issue of various drawings and other details by 30-APR-2016 so that some

of locomotive can be taken for rebuilding in 2017-18.

Item No.4 Manufacturing of WDS6 Locomotive

Deliberation In current financial year 8 WDS6 locos will be manufactured. DMW has arranged material

for 40 nos. of WDS6 locos in 2016-17 and Parel has confirmed capacity. Engine Block will be

critical as DLW has given commitment for only 24 Engine Blocks during 2016-17. DMW has

already floated for 25 Nos of Engine Block from trade, however, as an iterim measure re-

build Engine Block from GOC may be considered by Railway Board. Reference for the same

has already made to Board.

Decision 1. DLW to ensure supply of 36 nos.. Of 6 cylinder engine block during 2016-17.

2. Development of WDS6 Engine Block from trade should be done in time bound

manner.

3. Permission of using 15 rebuild, 6 Cylinder Engine blocks is given. DMW to coor-

dinate with GOC and arrange dispatch of old 6 Cylinder Block from GOC.

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Item No.5 Retrofitment of APU on ZR

Deliberation DMW has supplied 28 loose APUs to ZR, out of which 14 nos. have been fitted and remain-

ing are waiting fitment. DMW has to supply material to MLY, VSKP,BKSC, GD sheds and at

ED, NKJ,ERS,PTRU - where material is available - ZR to provide locos for fitment of APUs.

Issue of compatibility of different make APU with MEP was discussed and RDSO need to

examine the issue.

DMW has further opened tender for fitment of 500 nos. of APU on ZR.

ZR to expedite fitment after PO is placed by DMW.

Decision 1. DMW to coordinate for fitment of 14 nos. of loose APU which were supplied earlier, by July,2016.

2. Issue of compatibility of different make APU with MEP was discussed and RDSO need to examine the issue and provide a solution within 2 months.

3. ZRs to expedite fitment of available APUs, and further plan fitment of additional al-lotted quantity after PO is placed by DMW.

Item No.6 Fitment of new items

Deliberation CRDeI :

DMW has placed PO for 15 nos. of CReDI kit on M/ Medha and 1 no. on M/S RITES. M/S

Medha has tie up with M/S Ganser of Switzerland and M/S RITES has tie up with M/S

DUAP of Switzerland.

2 nos. of CReDI from M/S Medha are expected in April,2016. DMW has plan to fit 15 nos.

of CReDI kit during 2016-17. The locos fitted with CRDeI be sent to GY-5 Nos., Kazipet- 5

Nos. and Maulai-6 Nos. These locos be closely monitored by RDSO, DMW and respective

sheds.

Loco Cab Voice Recorder (LCVR) and Cab AC

DMW has floated tender for 25 nos. of LCVR and 25 nos. of Cab AC.

Variable Turbine Geometry (VTG) Turbo

DMW has floated tender for 10 nos. of VTG.

Miller Cycle Turbo

This is under testing at RDSO. RDSO test bed is out of order and need to be attended on

priority by RDSO.

Decision 1. CRDeI project be closely monitored by RDSO. 2. Development of VTG be closely monitored by RDSO and development of Miller Cycle

turbo be expedited by RDSO. 3. Loco Cab AC and fitment of LCVR need to be expedited by DMW.

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Minutes of Supply Agenda items

1. Submission of Indents: Zonal Railways were requested to submit vetted indents for 2017-18 by 30.09.15. It was decided in last meeting that Railways to submit their vetted indents positively by target date. It is mentioned that vetted indents from all Zonal Railways have been received. Sheds and workshops should provide sufficient number of Road Permits (wherever appli-cable) enabling DMW to supply Ann’N’, BIM, RSP and other items to Zonal Rlys intime.

Details of Summary of Indents

Railway Date of Indent

Receipt at DMW Ann-N BIM CB Total Remarks

WCR 08.01.16 20.01.16 34 73 3 110 Late by 4 months

WCR 28.12.15 02.02.16 30 52 5 87 Late by 5 months

NCR 01.10.15 16.10.15 9 16 5 30 Late by 1 month

NCR 03.11.15 30.11.15 15 40 2 57 Late by 2 months

NCR 12.11.15 07.01.16 9 1 0 10 Late by 4 months

NCR 02.12.15 12.01.16 2 7 1 10 Late by 3 months

SER 30.09.15 27.11.15 52 94 13 159 Late by 2 months

SER 12.01.16 10.02.16 46 63 0 109 Late by 5 months

NER 06.11.15 09.11.15 63 108 5 176 Late by 2 months

ECR 12.11.15 14.11.15 74 129 12 215 Late by 2 months

ER 11.11.15 30.11.15 77 149 7 233 Late by 2 months

SCR 26.05.15 29.09.15 56 78 0 134 Within Time Frame

SCR 16.10.15 03.11.15 0 56 0 56 Late by 2 months

SCR 30.09.15 03.11.15 28 0 12 40 Late by 2 months

NWR 26.11.15 28.11.15 51 0 0 51 Late by 2 months

NWR 28.12.15 11.01.16 0 93 0 93 Late by 4 months

SECR 09.07.15 20.08.15 0 0 3 3 Within Time Frame

SECR 08.07.15 28.09.15 14 52 0 66 Within Time Frame

SECR 01.10.15 16.12.15 32 52 4 88 Late by 3 months

NR 29.09.15 01.10.15 0 0 13 13 Late by 1 month

NR 09.10.15 03.11.15 81 103 0 184 Late by 2 months

NR 09.11.15 02.02.16 4 2 0 6 Late by 5 months

NR 11.02.16 18.02.16 18 10 2 30 Late by 5 months

Zonal Railways are requested to sent vetted indents for 2018-19 by 30.09.2015 as only 11% of total indents were received by 30.09.2015.

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2. Outstanding Dues:

Outstanding dues would be carried forward to the next year regularly as a policy. DMW

has already uploaded the latest status of net indents and supplies for 2015-16 (upto 18th

March’2016) on DMW website. Zonal Rlys may check status of indents & supply.

Railways are advised to provide additional demand, if any, for 2015-16 latest by 15th

Apr’16. Railways should make adequate fund provision for catering to carried forward

quantities.

3. Compliance of Ann’N’, BIM and Carbon Brush items: DMW has despatched Ann’N’ items worth Rs.76.25 cr. and BIM items worth Rs.191.86 and

Carbon Brushes worth Rs.10.97 Cr. cr. till 18th March’2016. DMW has complied more

than 100% in most of the items. DMW promised to further improve the compliance rate of

items such as extension shaft gear, Cam gear, Stiffer Camshaft.

DMW should make action plan for less compliance items of Annexure-N and BIM items.

4. Review of demand of High Value items:

The demands of high value items was analysed taking into account 03 years i.e. 2014-15,

2015-16 & 2016-17 average demand per 100 locomotives (or cylinders) holdings of Zonal

Railways. There was a wide variation in demands across Railways in reference to average

demand.

a. Five types of Critical Gears

In order to deal with variation in demand of five types of gears ( Gear CrankShaft,

Cam Gear, Driver Gears LOP (Modified), Gear Ext. Shaft (Modified), Gear Water

Pump (Modified), DMW has decided to process for fixed qty demand based on last

revision of 2015-16 demand. In addition DMW has decided to go for procurement of

some quantities of finished gears from trade ( Cam Gear, Driver Gears LOP

(Modified), Gear Ext. Shaft (Modified). This will improve availability of these gears in

2016-17.

DMW has also taken action for Case Carburised Cam Gear and Crankshaft Gears (

100 Sets) which will be proved out during 2016-17.

b. Cylinder Liner -

Yearwise demand

Year 3RV 5RV

2017-18 (R0) 5031 19342

2016-17 (R1) 3454 20485

2015-16 (R3) 4360 ( All from DMW)

21555 ( DMW-13555 & GOC-8000)

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DETAILS OF CYLINDER LINDER (10989535/10880495) FOR INDENTS AND SUPPLIES TRANFERRED TO SR/GOC

YEAR

INDENTS CR ECO EC ER NR SC SEC SE SW WC All Rlys

15-16 TRANSFERRED 500 700 1000 1500 600 1000 200 1800 300 400 8000

SUPPLIED 570 800 350 710 0 350 0 1400 0 0 4180

14-15

TRANSFERRED 1200 700 1400 1200 0 1400 300 1800 0 0 8000

SUPPLIED 1420 1000 250 1120 0 960 400 2000 320 320 7790

13-14 TRANSFERRED 1000 500 1333 1000 0 1200 300 1400 1267 0 8000

SUPPLIED 1240 1000 0 1058 0 900 300 1650 878 0 7026

Note: SCR, ECR, SWR, NR & WCR have not/only partially collected against their

respective allotment.

Decision:

AM/ME directed that :

i. Railways should examine their consumption pattern before submitting their vetted

indents.

ii. Railways have to assess their requirement meticulously for their maintenance need.

Railways should also share information for the Spares lying in excess with them so

that these can be used by the Railways to meet their maintenance requirement.

iii. Zonal Railways are directed to collect their portion of 5 RV Cylinder Liner from

GOC. Since Zonal Railways are facing problems for collecting the material for this,

S.Rly has to enter into Road Transport Contract so that 5 RV Cylinder liners could be

despatched to concerned Rly.

iv. Zonal Railways to review their demand from 5 RV to 3 RV Cylinder Liners upto 15th

April’16 and advise accordingly.

5. Deletion of BIM and Annexure ‘N’ ITEMS:

Some of the items procured under Annexure ‘N’ are low value and are indented by only two or three Railways. Besides, some of these items are of MG locomotive or pertaining to the unmodified design.

SN.

PL No. Desc. Indents 15-16 Rlys Indenting Rlys

1 10124317 OUT BOARD BRG. HOUSING (WDM2)

6 1 SER-6

2 10140827 SHAFT ROTOR 720A1 TURBO (WDP1 & WDM2)

19 4 ER-3, NER-8, SR-4, SER-4

3 10120427 FP SUPPORT (WDM2) 71 2 SR-9, ECR-62

4 10141042 SHAFT ROTOR 350C (YDM4)

19 4 ER-3, NER-8, SR-4, SER-4

5 10211585 FUEL CONTROL SHAFT (YDM4)

14 2 WR-4, SECR-10

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6 10211639 CONTROL CABLE END (YDM4)

48 2 ER-4, SR-44

7 10216248 GEN. END SHAFT R-9 (WDM2)

44 3 NER-16, ECR-4, WCR-24

AM/ME asked these ZR to review their requirement being of MG & WDM2 loco and advise DMW accordingly. DMW to initiate procurement only after reconfirmation by respective ZR.

6. Addition of BIM items:

The dampers for WDG3A/WDM3D are procured from RDSO approved sources and some

of sources are of foreign origin and ZR are approaching DMW for assistance. Due to

import and inspection issue arising out of small quantities it is proposed to make

Hydraulic Dampers as BIM item :-

SN Item Per Bogie

1 Lateral Hydraulic Damper 11665671 for WDM3D 2

2 Vertical Hydraulic Damper 11665660 for WDM3D 6

3 Lateral Hydraulic Damper 11666857 for WDG3A 2

4 Vertical Hydraulic Damper 11459037 for WDG3A 4

5 Vertical Hydraulic Damper for ATHS Bogie for WDS6 and WDM3A

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Railways send to sent their vetted indents to DMW by 30-APR-2016.

7. Standardization of indents:

DMW had proposed following:- In view of failure of Lube Oil assembly and Water Pump assembly, it has been decided to supply components of these assemblies against the vetted indents of assemblies. Details of components for these assemblies are as under:- a) Water Pump Assly:

S.No Description Part No. No. Off

1 Impeller Sleeve 10210866 01

2 Castellatged nut 15380166 01

3 Water Seal 10170844 01

4 Oil Seal 10175880 01

5 Seal Plate 10120208 01

6 Sleeve (Bearing) 10212693 01

7 Slinger 10240263 01

8 Slinger hub 10170728 01

9 Bearing SKF 6312 10150171 01

10 Bearing SKF 6311 10150262 01

11 Modified Driver Gear 10142873 01

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b) Lube Oil Pump Assly:

S.No. Description Part No. No. Off

1. Drive Gear 10142861 01

2. Flanged bearing bushing 10130070 01

3. Flanged bearing bushing 10130081 01

4. Flanged bearing bushing 101317800 01

5. Flanged bearing bushing 10131711 01

6. Straight dowel 15292174 01

7. Key 15315034 01

Note : In case of additional components for assemblies, ZRs to submit individual demand.

AM/ME has directed that in case DMW is supplying any Assly of Water Pump for a interim period, the same is to be tested before dispatch. Assly requirement of Zonal Railways is to be converted into individual component demand for supply by DMW.

8.0 Feed back on modifications:

09 important Modifications were implemented in manufacturing/rebuilding of

locomotives suggested by RDSO & Railway Board from time to time. Details of

modifications given below .

SN. Description Fitted in

Rebuilt Locos since No. of locos fitted as

on 01.03.16 1 ATHS Bogie Frames Jan’14 103

2 FRP Interior in Driver Cab Feb’13 35

3 Auxiliary Power unit April’12 185

4 REMMLOT(Remote monitoring of Lo-comotive & Trains)

July’11 259

5 Roof mounted DBR (RMDBR) May’10 623

6 3 RV Piston Kit April’10 875

7 18 mm Fuel Injection Pump April’10 570

9 Microprocessor Control System April’07 1033

12 Key 153111090 01

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Following decisions were taken during meeting.

FRP Interior in Driver’s Cab:

Zonal Railways to send feedback for further decision on FRP.

ATHS Bogie : Cracks in ATHS bogies be investigated by RDSO.

Remaining modification should continue.

9.0 Feed back on developmental items

Items fitted against Developmental Purchase Orders being advised to Railways from time

to time. System of monitoring and reporting to be streamlined at shed level to ensure

feedback timely. DMW has uploaded list of developmental items on its website for ready

reference.

10.0 Rate contract of spares:

Rate contract of 14 items have been undertaken by DMW. Latest status has been placed at Annexure-I.

AM/ME directed that :

i) RDSO to look for inter-changeability of Air Dryers ii) RC for overhauling of PTLOC is to be executed with OEM

10.1 Proposal for New Rate Contracts for Spares:

Rate contracts for additional items have been proposed by Zonal Railways as under:-

SN. Description Proposed by Railway

Decision

1 Overhauling of VTC 214 NR New Item, need to be covered.

2 Overhauling of VTC 304 DMW is already procuring spares for

VTC 304 against RC 3 CCB SCR Railways to follow procedure being

followed for HHP loco CCB. 4 GE Single Discharge

Turbo

SCR DMW is already procuring overhauling

kit A and D for GE turbochargers. 5 Overhauling for Air

Dryers

SCR DMW is already procuring spares for

air dryers against RC

DMW to enter into new Rate contracts for Overhauling of VTC 214 .

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11.0 REHABILITATION & RC for spares OF TURBO SUPER CHARGERS:

Rehabilitation

DMW is rehabilitating Turbo Super Charger of ABB and GE make received from Zonal

Railways.

DESC Loco Prod. Plan 2015-16

Supply Status Till 15.03.2016

Under repair with firm

Lying with DMW for repair

Dispatched to Rlys/Remarks

PO Status

ABB-TPR-61

3100 HP

200 141 (dis-patched) 21 (awaiting dispatch)

13 NIL MGS-6, LDH-10, NKJ-12, PR-11, JMP-06, JHS-14, ABR-06, KYN-06, KGP-19, KZJ-12, GOC-26,MLDT-06, VTA-05, GY-02.

Ordered Qty – 424

Balance Qty - 253

ABB-VTC-304

3100 HP

50 25 (dispatched) 06 (awaiting dispatch)

2 NIL JMP-02,TKD-02,VSKP-06.KZJ-02, PR-02,KGP-02, JHS-05,GOC-04.

Ordered Qty – 29

Balance - 8

ABB-VTC-304

2300 HP

NIL NIL NIL 26 NIL NIL

GE-Single Discharge

3100 HP

45 Nil Nil 100 NIL Case for 100 nos. is to be floated.

GE-Double Discharge

3100 HP

NIL NIL NIL 49 Rehabilitation is financially not viable.

Not Required by ZR

RC for Turbo Spares

DESC HP Price Agreement No. Valid upto Remarks Order Qty

ABB-TPR-61 Turbocharger overhauling

3100 HP

20/15/5001/1/314637 03.11.17 PO Qty – 519

ABB-VTC-304 Spares

3100 HP

20/15/5005/1/314764 23.12.17

GE-Single Dis-charge

3100 HP

-- -- Spare kit-A and kit-D are supply to Zonal Railways against BIM de-mand

KIT-A

Ordered Qty – 253

Balance Qty – 198

KT-D

Ordered Qty-75

Balance Qty-29

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TECHNICAL AGENDA ITEMS:

Following items were discussed:

Item No.

Detail Item No.

Detail

1 3RV/5RV Cylinder Liner 19 Equalizer less type breakage

2 Engine Block Failure 20 FAILURES OF FPM OF ALCO LOCOS

3 Implementation of FEV recommendation 21 Corrective and preventive action plan against repeated failure of MCBG:

4 Piston Failures 22 Crack & Vibration in Underframe

5 Reclamation of Crank Shaft 23 NU 330 Bearing

6 Indigenous CrankShaft – Make in India Effort

24 LWS failure

7 Stiffer Cam Shaft Performance 25 Excessive buffer gap in H-Type Coupler

8 Cam Gear and Split Gear Breakages 26 Failure of AEC make radiator fan bearing

9 Failure of Connecting Rod Bush 27 Failure of Piston Pin

10 Water Pump Failure 28 Overhauling of IRAB Panel

11 Performance of Fuel Injection Nozzle 29 Insulation Scheme of HHP Loco Traction Alternator

12 Performance of PTLOC 30 Approved sourced for child parts of assemblies

13 Exhaust Manifold 31 Interchangeability of Air Dryers

14 Carbon Brush CB-21RF 32 Repair and Overhauling of DEMU TM and TA

15 Failure of NADI make RTTM Blower 33 Rate Contract for maintenance spares & AMC of Cummins Engine for Multi Gen Set Locomotive

16 Auxiliary Power Unit (APU) 34 Tooling Items supplied by DMW

17 Utilisation of REMMLOT towards predictive maintenance

35 Constant pressure brush holder for TM-4907 and AG 3101

18 REMMLOT ISSUES 36 Provision of Extra Happy Pads in APU fitted Locos

37 Failures of MEP cards

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Item No.1 3RV/5RV Cylinder Liner

Deliberation There has been large no. of cases of 3RV liner breakages during 2014-15. In fact 3RV liners were found broken during loco testing at DMW itself in 14-15. RDSO has addressed these issues and audited manufacturing process of M/S Cooper. Further RDSO also various technical bulletins to address the issue of fitment and manufacturing process. Now failure of 3RV liners have reduced, comparative position of 3 RV/5RV liner failure is as under

Type of Liner

No. of Liners Supplied by DMW during 2015-16

No. of Liner Failed % failure

5RV 18174 100 0.55

3RV 6351 14 0.22

Although issue has been addressed, there has been still cases of liner breakages in both i.e. 3RV and 5RV liners. These need to be logically investigated. All sheds to follow proper maintenance practices and implement them including latest IB issued by RDSO in this re-gards. Machining of Cylinder Liner and Liner Sleeve by Diesel Shed (for which instructions were issued long back and have been reiterated by RDSO recently). WR has suggested that as failure issue of 3RV liners have been addressed and there are added advantages of reduced lube oil consumption rate with 3RV Liners, there is need to switch over from 5 RV to 3 RV. WR has suggested they are planning to convert 50 nos. of Locos to 3 RV Liner Design for which DMW should arrange necessary 3RV Kits.

Decision 1. Diesel Sheds to implement cylinder liner and engine block related instruction including

latest IBs issued by RDSO.

2. Additional quality parameters like flatness on various surfaces of Engine Block issued

by RDSO need to be finally implemented by DMW and DLW. It is to be ensured that

these are achieved during block manufacturing.

3. Breakages of Cylinder Liners need to investigated in detail and taken to logical conclu-

sion.

4. Extended trials for Laser Hardened Liner need to undertaken. RDSO to issue sources for

Laser Hardened Liner and DMW to initiate for procurement of 1000 Nos. of Laser Hard-

ened Liners during 2016-17.

Item No.2 Engine Block Failures

Deliberation Premature failures of Engine Block are occurring in both i.e. New as well as Rebuilt Engine Block, which is a cause of concern. The following issues were deliberated during BIM :- Reclaimed Engine Block : DMW has done study of Engine Block life and summary is given below :-

1. 25 % of Blocks received for first salvage i.e. New Engine Block at DMW are of less than 8 year life.

2. 50% of Blocks received for second salvage i.e. Life after First Salvage at DMW are of less than 8 year of life.

3. 60% of Blocks received for third salvage i.e. Life after Second Salvage at DMW are of less than 8 year of life.

4. 85 % of Blocks received for fourth salvage i.e. Life after third Salvage at DMW are of less than 8 year of life.

Currently DMW has stopped fourth Salvage but above data indicates that even third Sal-vage need to be stopped. As per DMW data approx. 17% of blocks rebuild at DMW are giv-en third salvage. This will be possible only after sufficient induction of new blocks.

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DMW also presented that they have also tightened the repair criteria so that Engine Block after rebuild gives good life. Failures of Rebuilt Engine Blocks are on account of water leakages which are taking place between 6 to 24 months. Further, large scale L9/R9 Cam Bearing bush work need to be in-vestigated. There is need to address proper welding technique for arresting water leakages and for Cam Bearing there is need to strengthen Cam Bearing area. Although FEV report has addressed the issue of strengthening of Cam Bearing but fabrication issues have not been taken to logical conclusion. DMW, DLW and RDSO to work on the issue of strengthen-ing of Cam Bearing area, if need, a consultancy may also be considered. New Engine Blocks :

New Engine blocks are mainly failing on account of water leakages. Vendors audit and im-provement in welding need to be addressed on priority. DMW has advised that in new pro-curement in-process inspection by RITES has been mandated, which is expected to improve Engine Block quality. Field trial of first Cast Block have shown positive result. Cast blocks are suitable for 4000 HP and as such are expected to perform better on existing 3300 HP requirement. They are also lower in price and absorb vibrations. There is need to expedite proliferation of cast blocks.

Decision 1. DMW and GOC to plan for restricting third salvage of Engine Blocks and for this cov-

erage of new engine blocks be planned and expedited.

2. Cam bearing strengthening of ALCO blocks need to addressed by DLW, DMW, RDSO.

3. Welding practices at DMW and GOC during rebuilding need to be improved so as to

address possible future leakages by stricter quality checks and rejection criteria.

4. Cast Block proliferation needs to expedited.

Item No. 3 Implementation of FEV recommendation

Deliberation Status of various modification on Engine Blocks are given below :-

SN Modification description Implementation status

1. Increased height of MB cap (Inter).

Implemented from April’ 2013

2. MB Stud inter increased height with stretch value 50 thou Grade 12.9 Nut and Wing Nut of grade 12.9

a) Implemented in 122 Engine Blocks till date.

b) Due to breakage of cotter pin and very high torque required by Die-sel Sheds in opening and tighten-ing of MB bolts in Engine Block upside position, RDSO vide letter No. SD.Recl EB dated 15.06.2015 has advised DMW to switch over to 40 thou elongation, till issue is resolved.

3. Chamfering of MB cap inter Implemented from April’ 2013

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4. Crush height of the MB shell These are under field trial for one year ( 11461 ET and 11469 MLDT). Advice for regular implementation of this modification shall be issued separately by RDSO after successful trials duly taking issues involved in 50 thou elongation.

5. EB Mounting points This modification is applicable for 3300 HP New Locos and not for re-built locos. However, this need to be explored for rebuild locos also by DMW.

6. Chamfering of MB cap inter Implemented from April’ 2013

7 Strenghtening of Cam Bear-ing

DLW has not implemented. This need to further deliberated by DLW,DMW and RDSO.

Decision RDSO, DLW and DMW to jointly address the issue of strengthening of cam bearing area

alongwith consultancy, if required, may also be looked into.

Item No. 4 Piston Failures

Deliberation There has been failures of piston on locos leading to extensive power pack damages. Failures of

piston within warranty failures are given as below :-

FIRM || YEAR 09-10 10-11 11-12 12-13 13-14 14-15 15-16

FMGIL 06 10 10 02 - 10 06

PIONEER - 01 - - - 01 -

INDIA PISTON - 01 - 01 -

HALLON - - - - 02 - 01

Decision RDSO to audit both vendors for addressing quality issues and incorporate important check points

in QAP.

Item No.5 Reclaimed Crankshaft

Deliberation DMW has fitted approx. 151 nos. of reclaimed crankshaft during rebuilding and 14 nos. i.e. 14% have failed. It may be further noted that 10 nos. out of these have failed within 12 months of fitment. The failures are taking place from the same place from where reclama-tion were done at Crank Pin. It was decided in the meeting that crankpin repair should not be undertaken.

Decision DMW should send only those crankshafts in which crank pin condition is OK. Repair of

crank pin be generally avoided.

17

Item No.6 Development of Indigenous New Crankshaft

Deliberation As a part of “Make in India” effort, DMW has placed PO for 65 nos. of 16 Cylinder Crank-shaft on M/S Bharat Forge Limited. Firm has supplied 43 nos. of Crankshaft and out of the-se 23 nos. have been fitted till Feb,2016. In Nov,2016, 4 nos. of these crankshaft will be completing 2 years. There has been recently failure of one crankshaft at SPJ diesel shed which need to be investigated by RDSO.

Decision RDSO and DMW to closely monitor development of 16 Cylinder Crankshaft.

Item No.7 Performance of Stiffer Unit Cam Shaft

Deliberation There are following issues related to SUCS : 1. Breakage of SUCS Flange –As per details presented large no. of SUCS flange breakage

were specific to R8/L8 location.

2. Life of Cam Shaft – SUCS is designed to give 4 year life, however, there is wide varia-tion in yearly % change of SUCS , which varies from 4% at GD to 15% at RTM diesel shed and the same need to be studied. It is important that good maintenance practices of good diesel shed are followed by other sheds. ZR to take action.

3. Less Lift of FIP- The issue of less fuel pump lift has not been resolved. Further 6.5 mm dimension as recommended by M/S Bosch is not being obtained. There is need to re-look into SUCS component design as cases of SUCS components are reported by ZR. DMW has floated tender for 5 locos set of Fuel Pump Support, Push Rod Lifter, Cross Head Lifter with closer tolerance which will be used for study of lift at DMW.

Decision 1. DMW to switch over to larger radius at least for R8/L8 location which should be fur-

ther proliferated to other segments in a time bound manner.

2. Sheds where yearly % changes are high to adopt better practices of other sheds.

3. RDSO to study de-novo the components drawings of SUCS and related components as

the issue of less lift is still not addressed.

4. DMW and RDSO to jointly study effect of closer tolerances of FIP Lifters for taking

decision.

Item No.8 Cam Gear and Split Gear failure

Deliberation Failures of Cam Gear and Split Gear teeth breakages within one year after fitment are tabu-lated below:-

Type of Gear 13-14 14-15 15-16

Cam Gear 4 3 7

Split Gear 1 7 20

From the analysis of failures it is concluded that fatigue failures of gears need to addressed apart from proper backlash between Cam Gear and Split Gear. Action for switching to Case Carburising need to taken on priority for which DMW has floated tenders for 96 sets of Case Carburised Cam and Split Gears. There is need to go for Cam Gear with lower PD for addressing the issue of lower back lash clearance. Diesel Shed should know locos with less backlash and should advise DMW to

18

supply such gears. Camgear with less PD be suitably punched to easily identify.

Decision 1. Manufacturing process for Camgear and Split Gear at DMW, including vendor for raw

material be audited by RDSO.

2. Some quantities of Step Size Camgear be supplied by DMW to ZR as per specific need

of ZR.

Item No.9 Connecting Rod Bush Small End

Deliberation Premature peeling off white metal of the bushes has led to failures of four power packs, out of which two blocks were also damaged. In addition large nos. of Benara make bushes were found loose at RTM and it was established that quality of small end bushing supplied by M/S Benara was poor. As such DLW delisted M/S Benara from DLW vendor directory. Currently this item is DLW controlled. Connecting Rod Bush is a critical item and similar to other plain bearing this should be made RDSO item.

Decision 1. Connecting Rod Bush Small end be made RDSO Controlled item.

2. Quality control on Connecting Rod Bush small end be constantly checked and feed-

back communicated by ZR to DMW and RDSO.

Item No.10 Water Pump Failures

Deliberation There has been large no. of out of course water pump gear failures. Following actions have been taken by DMW :-

1. Lubrication of Water Pump Gear as per RDSO IB MP. IB. ES.09.81.09, November 2009 has been ensured by DMW in all locos turned out since Aug,2015.

2. DLW has revised drawing of impeller which has incorporated casting by CO2/NO bake shell moulding process, in addition static and dynamic balancing has also been incorporated in drawing. DMW has placed PO for 230 nos. of such Water Pump Impellers. This need to be expedited.

3. 100 % checking of hardness of water pump gear. 4. Maintaining proper backlash as per MI-11026 E. 5. Control vendor quality on water pump gear

GD diesel shed has implemented lubrication in all locos after Aug,2015 and there has been reduction in Water Pump Failures during period Aug-2015 to Feb,2016 (3 nos. of failures dur-ing Sep ,2015 to Feb,2016 as compared to 7 nos. during April,2015 to Aug,2015), as such it is im-portant that this modification be completed by various diesel sheds and compliance sent to RDSO and Railway Board. Gonda Diesel Shed is checking backlash at four points and proper dowelling of guide ring is ensured.

Decision 1. All Diesel Shed to reinstate lubrication of water pump gear as per RDSO IB MP. IB. ES.09.81.09 dated Nov,2009.

2. Backlash to be checked as per MI-11026 E at four points alongwith proper dowelling of guide ring.

3. DMW to expedite procurement of improved impeller. 4. Stricter manufacturing control to be ensured at DMW and by Water Pump Forging ven-

dors.

Item No. 11 Performance of Fuel Injection Nozzle

Deliberation Complaints of M/s Bosch make fuel injection nozzle getting crack in Alco locomotives have been received from various sheds of Indian Railways. These failures are causing fuel dilution in lubricant oil.

19

S. No. Cause Nos.

1 Control rack jam. 7

2 Base crack/broken 7

3 Collar damage/broken 5

4 Plunger and barrel crack. 1

5 FIP damage 1

6 Leakage 1

7 Nozzle body crack. 1

Zonal Railways have conveyed that majority of failures are due to vertical crack. WR has reported vide their letter no. M233/148/7 dated 22.07.2014 that the firm M/s Bosch vide letter no. AA/SAI-KAM/WC dated 24.06.2014 has conveyed that the failures are taking place due to high fuel line pressure (1500 bar) than the specified (1200 bar), for which nozzles have been designed. However, as per the results available of engine test bed of 3100/ 3300/ 3600 HP locos, the fuel line pressure is well below (maximum 1164 bar observed with 18 mm FIP in 3600 HP loco) the specified pressure i.e. 1200 bar. To resolve quality issues, a meeting has been held at RDSO on 13.10.2014 with the firm i.e. M/s Bosch and DMW/Patiala. Following actions were decided to be taken by M/s. Bosch to resolve the quality issues: • To collect failed samples from KZM, ED, VTA shed & DMW Patiala and submit inves-

tigation report. • To conduct joint audit at KZM&VTA sheds for investigation of failures and review the

maintenance practices being followed and report submitted to DMW & RDSO. • To update the DOs and DONTs to be followed by the shed for educating the mainte-

nance staff. • To conduct workshop to have technical interaction about reliability measure taken by

the firm after conducting the joint quality audit. Decisions: (i) RDSO to conduct joint audit in presence of M/s Bosch at Vatva Shed. (ii) Railways to send performance report data to RDSO for further study.

RDSO Comments:

Meeting with RDSO & M/s Bosch on 24.09.2015 at RDSO , M/s Bosch informed that the failed samples of nozzles have been collected from ED & KJM sheds and the same is under analysis.. Also,

Team from RDSO & M/s Bosch visited AMV shed on 24.09.2015 regarding reported failures of injector nozzles.

From M/s Bosch, RDSO received 04 nos. display charts (regarding Exploded view of FIP and Injector, Tightening torque and other settings, Centring of nozzle and true running & Functional test of nozzle on nozzle tester) for FIP room in Loco sheds and Workshops for improving the maintenance practices. Same have been supplied by Bosch to all workshops and sheds.

M/s Bosch advised to Sr. DME/AMV that AMV should get the pump of the nozzle tester checked and calibrated as frequently as the pressure gauge. As per Bosch, the wear element of the tester is the main cause for the pressure dropping drastically not through the injector.

20

After repeated persuasion, BOSCH conducted audit of vatva shed on 03/02/16.

M/ Bosch vide letter no. AA/KAM/RDSO/16 dated 02.03.2016 has attributed failures vertical crack to inadequacy of design of injector as these were originally were for 2600 HP. This issue need to be addressed by RDSO.

Decision RDSO to further finalise the issue of design inadequacy as referred by M/s Bosch and other issues on priority.

Item No.12 PTLOC maintenance

Deliberation ZR has deliberated the issue of overhaul periodicity of PTLOC. RDSO has already docu-

mented study of temperature drop across PTLOC over the period of use. The issue of perio-

dicity of overhaul needs to be examined by RDSO.

Further, overhauling contract need to be in place by DMW, as ZR have brought the issue of

non-availability of RC of these PTLOC.

As per BIM 2006 meetings, overhauling of PTLOC was to be done with OEM and accord-

ingly DMW has processed for its overhauling. This need to expedited.

Decision 1. DMW to expedite overhauling contract on OEM on priority.

2. RDSO to address periodicity issue of PTLOC.

Item No.13 Exhaust Manifold Failures

Deliberation There has been 34 nos. of warranty failures during 2015-16 ( till feb,2016) of which 12 nos.

were of location no. 7. The following issues have been addressed so far :-

1. Specification :

a) Increase in thickness of sheet from 1.6mm to 2mm.

b) Annealing of Exhaust Manifold after fusion welding & radiographic inspection of

welding joint for better quality.

c) Ferrule to be made in single piece by extrusion/deep drawn (without welding).

d) Exhaust manifold with revised specifications are being fitted.

2. Alignment of Cylinder Head to be ensured before final assembly of cylinder head with

engine block.

3. Fitment of Exhaust Manifold is being done as per MI.

4. Testing of Power Pack is being done with brace assembly.

5. DLW has downgraded M/S Paul Auto to Part-II.

Large nos. of failures at location no. 7 need to be further investigated by RDSO and DMW.

Decision 1. Procurement of exhaust manifold by ZRs need to be done as per latest drawing.

2. Audit of vendors need to be done afresh by RDSO for confirmation of adherence to re-

quirement.

3. RDSO and DMW to investigate exhaust manifold at location no. 7.

Item No.14 Carbon Brush CB-21RF

Deliberation DMW presented action taken to improve performance of Carbon Brush. It should be en-

sured that these are properly documents and adhered on regular basis. RDSO has suggest-

ed following additional items :-

21

1. All Cu wires in flexible 7x58x40SWG may be fitted on trial

2. Alternately shunt size 7x76(65Cu+11SS) as per IS13466 or nearer to that may be tried.

3. Provision of individual sleeve on all four pigtails.

4. Sharp corners and edges of existing spring need to be rounded off

Decision a) RDSO to audit various steps taken by DMW on Carbon Brush.

b) DMW to expedite trial as suggested by RDSO and RDSO to monitor the performance.

Item No. 15 Failure of NADI make RTTM Blower

Deliberation Performance of RTTM Blower supplied by M/s NADI fitted in newly received ALCO locos is poor and this issue was also discussed in BIM 2015. A joint meeting between RDSO, DLW & M/s Nadi ,was held at DLW on 12/05/15 regarding railures reported by various Zonal Railways. In MOM,- firm stated that corrective actions .i.e. proper assembly of brgs on the shaft & housings, reduction on temp. rise on brg housings etc. shall be taken to minimise the premature failures. DLW has already acted on ZR complaints and M/S Nandi has been downgraded.

Decision Railways to send feed-back of RTTM Blower to DLW and DMW.

Item No. 16 Auxiliary Power Unit (APU)

Deliberation More than 185 ALCO locos fitted with APU are working in the field. In general, it is observed that around 55% of APU favourable hours (hours which are favourable for APU to cut in) are wasted due to various reasons. RDSO has identified the failure prone areas based on the field performance of APUs and along with M/s Medha identified the corrective and preventive action(CA&PA) vide MOM dt 20.1.2015. RDSO vide letter no. SD.DEV.APU dt 16.02.15 has informed all Zonal Railways vide. The CA&PA drive has been completed by M/s Medha. Railways to furnish the feedback on its effectiveness.

Decision 1. ZR to regularly advise RDSO on field performance issue.

2. RDSO to compile all issues of APU and put it on website so that ZR is kept

regularly updated.

Item No.17 REMMLOT towards predictive maintenance & REMMLOT Issues

Deliberation Board have already approved policy for condition monitoring of Diesel Loco, which need

to be implemented by ZR.

Decision 1. ZR and DMW to implement decision of condition monitoring of Diesel Loco as ad-

vised by Railway Board vide letter no. 2007/M(L)/466/19(84) Vol.IV dated 18.01.2016.

2. DMW to immediate take action for fitment of additional sensors as per Condition

Monitoring report.

3. REMMLOT issues be addressed by RDSO.

4. RDSO to compile all issues of REMMLOT and put it on website so that ZRs are kept

regularly updated.

22

Item No.18 REMMLOT ISSUES

Deliberation ZR has mentioned that reports through REMMLOT are not available in different version of

MEP.

DMW also mentioned that ZR should process for Data Charges for REMMLOT as men-

tioned in Purchase Order.

RDSO is regularly holding meeting for REMMLOT and issues referred by ZR will be ad-

dressed.

Decision 1. REMMLOT issues be addressed by RDSO on priority.

2. RDSO to compile all issues of REMMLOT and put it on website so that ZR is kept reg-

ularly updated.

Item No.19 Equaliser less type bogie frame failure

Deliberation Railways are facing problem due to bogie frame cracks in Equaliser Less Type design bogies

in WDM3D locos. Although further proliferation of these bogies have been put on hold.

There is an immediate need to take both short term and long term measures for addressing

the problem. RDSO has conducted meeting with vendors and issued action plan for repair

of bogies on 16-Feb-2016.

SR has also advised during BIM that crack in ATHS ( fabricated version of Cast Bogie for

WDM3A loco) bogie has also been observed recently within one year.

Decision Short term

1. DMW to procure Strengthening Kit for supply to ZR so that these can be used for strengthening existing bogies.

2. DMW to dispatch locos with duly strengthening bogies only. 3. As an immediate help DMW has floated a tender (TOD 10-03-2016) for 24 Nos. of bo-

gies for Conversion of Equaliser Type to Equaliser Less Type bogie. PO has been placed by DMW. The supplies to be expedited.

4. DMW to procure 67 nos. of Equalizer Less Bogie ( duly strengthened) under RSP to meet the current requirement.

Long term

1. RDSO to quickly get the design analysis of not only of WDM3D fabricated bogies

but also of ATHS as cracks has been reported by SR.

Item No. 20 FAILURES OF FPM OF ALCO LOCOS

Deliberation The issue was discussed in July-2013 and DMW has already switched over to HHP de-sign of fuel pump motor and as per discussion the failures are controlled. However, actions already taken on existing fuel pump motors like relocation of FPM in-verter in nose compartment, providing a separate back up inverter for FPM/CCEM in the driver cab /nose compartment or DBM inverter as a backup may continue to be done in existing design of FPM.

Decision 1. Improvement taken on existing old design of fuel pump motor should continue on ZR so as to mitigate failures.

2. DMW to continue to use HHP design of fuel pump motor. Zonal Railways to give

performance to RDSO who should compile and send reports to Railway Board by

23

31-05-16.

Item No. 21 Corrective and preventive action plan against repeated failure of MCBG:

Deliberation RDSO vide letter no. SD.DEV.MCBG.ALCo (Medha) dated 08.01.2015 has advised Railways for implementation of corrective action plan against repeated failure cases of M/s Medha make MCBG.

Decision RDSO to advise ZR on various improvement made, so that they can assess the efficacy of action taken by M/S Medha. ZRs to submit performance report to RDSO.

Item No. 22 Crack & Vibration in Underframe

Deliberation WR: Over the last few years cracks have been detected on the chassis of large number of ALCO

locos of WR (Currently 18 locos). These locos are running in service after reclamation by

sheds. Further some of the locos are running with multiple cracks reclaimed. Currently, except one

loco, remaining are with 30+ age profile.

CR: CR has reported vibration on WDM3D locos resulting in compressor chair and pipe broken.

DLW has advised modification to be done by ZR way back in 2011.

DMW has incorporated this modification in almost all WDM3D (except initial 8 to 10 WDM3D).

Decision RDSO to examine the issue. Locos with cracked underframe be processed for condemnation, as per existing instructions.

Item No. 23 NU 330 Bearing

Deliberation NWR has reported online failures of 17 nos. of NU 330 Pinion End bearing which has taken place from April 2014 to November 2015, out of which 16 cases were of NBC make bearings and 01 case was of FAG India. RDSO to address the issue and take remedial measures

Decision RDSO to audit vendor manufacturing practices and product quality.

Item No. 24 LWS failure

Deliberation NWR and ECoR have reported failure of LWS switch of HEMCO and Meno-Tech.

Decision DMW to address the issue and quality of LWS switch be improved by framing improved

specification and proper vendor.

Item No. 25 Excessive buffer gap in H-Type Coupler

Deliberation NR and SWR has reported the issue of excessive buffer gap in H-Type Coupler and the same will be discussed in meeting.

Decision The problem of excessive buffer gap in H-Type Coupler is already under deliberation at RDSO the same nees to be addressed on priority by RDSO.

Item No. 26 Failure of AEC make radiator fan bearing

Deliberation SR has reported failure of AEC make radiator fan bearing. DMW has advised DLW who is vendor

approving authority.

Decision DLW to examine failures of AEC make radiator fan bearing.

24

Item No.27 Piston Pin Failures

Deliberation ZR have reported cracks in Piston Pin and as per failure analysis the cases broadly are account of following reasons :-

Piston Pin Worked out.

Waviness/lobbing effect on outer surface of piston pin.

Cracks on outer surface of piston pins.

Piston pin sleeve loose and hydraulic leakage.

Poor surface finish( surface roughness more than 20rms)

Low or High Hardness (Required Hardness 56-62 HRC).

DMW has taken actions to address above issues. Although finish recommended as per drawing ( 20 micro-inches) has been achieved, improvement in finish should be further looked into for which super-finishing operation be included in process sheet. DMW should also procure 20% quantities from trade from vendors who have requisite infrastructure.

Decision 1. DMW should procure polishing machine and start using it. Surface finish of piston

pin be achieved of order of HHP piston pin.

2. 20% Piston Pin be procured as finished from trade who have having requisite

infrastructure.

Item No. 28 Overhauling of IRAB Panel

Deliberation SR has requested overhauling periodicity of IRAB panel and its Rate Contract.

Decision RDSO to examine the issue.

Item No. 29 Insulation Scheme of HHP Loco Traction Alternator

Deliberation Regarding indigenization of EMD traction Alternator, Railway Board has circulated minutes vide letter no. 2000/M(L)466/2703 dated 09-06-2010 to DMW, DLW, RDSO and COFMOW and advised DMW/PTA to source coils, insulations, varnish and other compo-nents from OEM for manufacturing of first 100 sets of Traction alternators for HHP Loco-motives. Referring to Board’s directives, RDSO has also advised DMW/PTA to source es-sential materials from OEM vide RDSO letter dated 02-06-11, 01-06-12, 03-09-13, 24-10-13, 22-01-14 and 24-01-14. Recently problem of non-participation of vendors in DMW/PTA tenders for spares of HHP TA has also been resolved by RDSO by impressing BHEL to have meeting with DMW/PTA. A MOM dated 19-01-2016 in this regard was drawn up between BHEL and DMW for tender participation and supply of spares.

The approved Part–I vendors of RDSO – M/s EMD and M./s BHEL and Part-II vendor M/s Yongji have been using Silicone Rubber based insulation scheme in manufacture of Traction Alternators for HHP Locomotives and now this insulation scheme is well established and proven in the field. Developmental vendors have also been impressed to follow Silicone Rubber based insulation scheme in manufacturing of Traction Alternators for HHP Loco-motives.

Hence, RDSO is of opinion that DMW should plan for original insulation scheme on priori-ty. However, RDSO will associate in testing of alternator as and when required. DMW/PTA has offered one traction alternator for HHP locomotive with Kapton Mica Based Insulation Scheme to RDSO for type testing at its newly established test bed vide letter no. DMW/M/TMS/RDSO dated 14-01-16.

25

Decision DMW to plan overhauling of HHP TA with original insulation scheme on priority. However, till receipt of required infrastructure, Kapton Insulation scheme is permitted and complete testing of repaired TA be ensured with testing approval by RDSO on newly commissioned HHP TA test bed.

Item No. 30 Approved sourced for child parts of assemblies

Deliberation SCR has raised the issue of child parts of assemblies of two vendors which are not interchangeable.

Decision Wherever child parts of assemblies are not interchangeable and ZR is in need to such components, provisions exists under stores code for procurement through PAC.

Item No. 31 Interchangeability of Air Dryers

Deliberation ER has brought out the issue of Interchangebility of Air Dryers of different makes.

Decision RDSO to examine and resolve the issue by 15-04-2015.

Item No.32 Repair and Overhauling of DEMU TM/TA

Deliberation The issues was discussed in detail and in past DMW has placed PO on non OEM firms for repair of TM and TA and these firms have taken excessive time in development of rehabilita-tion of these items. On IR there are different type of TM/TA from different vendors for which drawings and de-tails are not available with DMW are used on DEMU. As such it is important that DMW should either rehabilitate these TM/TA at their end after developing child parts as done for TM-4907 or get the work done from OEM for new type of TM/TA which are currently not covered under contract. TM/TA for DEMU are also due overhauling for which DMW should enter RC for compo-nents required for overhauling and Diesel POH shop should gear-up for overhauling of TM/TA for DEMU.

Decision 1. DMW should enter into RC for repair-kit on OEM for overhauling of TM/TA as per rec-

ommendation of OEM and respective Diesel Shed/Workshop should gear up for over-

hauling of DEMU TM/TA.

2. DMW should enter in contract for overhauling of TM/TA from OEM.

Item No. 33 Rate Contract for maintenance spares & AMC of Cummins Engine for Multi Gen Set

Locomotive

Deliberation WCR has advised DMW to enter Rate Contract for maintenance spares & AMC for Cummins Engine.

Decision AMC of Multi Gen Set Locomotive has been already dealt in RDSO specification for Multi Gen Set

Locomotive. Accordingly, DMW should process for AMC for Multi Gen Set Locomotive.

Item No. 34 Tooling Items supplied by DMW

Deliberation NWR, ECoR have brought the quality issue of Pinion Pullers, Pressure Gauges etc. DMW has presented that quality issue of pinion puller was referred to DLW ( being DLW drg item) and specification has been revised by DLW and tender with revised specification is under consideration at DMW.

DMW also advised that they have procured 5 nos. of M/S Bosch Fuel Pump Test bench and these have been supplied one each to GD, KYN,ED,ABR and TKD. Performance report of these be sent to DMW for further action.

26

Decision DMW should address quality issue of tooling items and take the issue to logical conclusion.

Item No.35 Constant pressure brush holder for TM-4907 and AG 3101

Deliberation The project was started by RDSO about two year back and extended trials has yet not started. DMW brought out the issue of verification of constant pressure due to which supplies were rejected at DMW. While constant pressure may be one of features of improved carbon brush holder. It would be desirable to go for extended trials with improved carbon brush holder.

Decision 1. Trial for constant pressure brush holder be discontinued.

2. RDSO should work on improved carbon brush holder which should improve on mainte-

nance requirement of existing carbon brushes.

Item No.36 Provision of Extra Happy Pads in APU fitted Locos

Deliberation NCR has reported the issue of less buffer height in Loco No. 11525 which was transferred from KJM Shed. DMW presented that extra Happy Pad in Short Hood side bogie was required on WDM3D locos fitted with APU.

Decision RDSO to study and issue IB.

Item No. 37 Failures of MEP cards

Deliberation NCR has reported that there has been increase in MEP cards failures

Decision RDSO examine cards failures and hold meeting with M/S Medha to give action plan.

27

Annexure-I

Details of RC for Spares

SN. Item Firm M/s

Price Agreement No. PA Valid up to

Present Status

1 Spares for ABB

VTC-304 TSC ABB

20/15/5005/1/314764

dt. 24.12.2015 23.12.2017

No action to be taken at

present.

2 TPR-61

TSC(overhauling) ABB

20/15/5001/1/314637

dt. 04.11.2015 03.11.17

No action to be taken at

present.

3 Air drier

Knorr

Bremse

20/15/5007/314830

dt. 14.01.2016 13.01.2018

No action to be taken at

present.

4 Air drier Faiveley

20/14/5015/1/314148

dt 07.07.15 06.07.2017

No action to be taken at

present.

5 Air drier

Stone In-

dia

20/14/5001/1/313874

dt. 30.04.15

30.04.2017 No action to be taken at

present.

6 Upgraded Com-

pressor ELGI

20/15/5011

20/12/5100/1/310382

Dt.03.11.12

30.04.16 Fresh PO also placed.

7 Upgraded Com-

pressor KPC

20/15/5011

20/12/5100/1/310381

Dt.03.11.12

30.04.16 Fresh case under TC

8 Paper less speed

recorder & Indi-

cator

Autome-

ter

21/15/5003/314884

dt. 02.02.2016

31.03.2017 No action to be taken at

present.

9 Paper less speed

recorder & Indi-

cator

Medha 21/15/5001/314881

dt. 01.02.2016

31.01.2018 No action to be taken at

present.

10 Paper less speed

recorder & Indi-

cator

LAXVEN 21/15/5002/314876

dt. 29.01.2016

28.01.2018 No action to be taken at

present.

11 Wood-ward

Governor Woodward

21/15/5008 Under TC

12 MEP Medha

21/11/5004/310364

dt.31.10.12 30.10.16

NR,NWR,NFR,WCR,ECoR

and SR to give require-

ment for fresh RC as old

RC will be expiring short-

ly.

13 AMC for MCBG Medha

21/13/5000/1/312809

dt.09.07.14 08.07.16

No action to be taken at

present.

14 Overhauling of

PTLOC

Tranter 20/15/5012 Case under process for

floating tender.

Alfa Laval TOD for 836 nos. opened

on 15.03.2016