QHM

SECTION

AUDIT REPORT
2017-18

UPDATED ON March 2017

Proposed by Certified by
SSE/QHM/DSL/KZJ DME/DSL/KZJ

Approved
Sr.DME/DSL/KZJ

No Description Page No 1. Reliability improvement action plan . Staff competency level 5. Stocked item position 9. Action plan ALCO 4. Non stocked item position 10. Modifications under progress/ to be carried out 13. Make wise population and failures 8. MESSAGES AND SHED FINDINGS 6. INDEX S. Tools 12. Action plan HHP 3. Shed messages 7. OCCURRENCES. M&P 11. Various jobs in section 2. ANALYSIS OF FAILURES.

Knuckle DPT 2) FRC. Removal and refitting After coolers after blowing with dry compressed air i. Under truck schedule attention l. Load Box& Releasing . UST of axles m. IRC b. VARIOUS JOBS IN WDG4 (HHP) LOCOMOTIVES 1) Yearly Schedule Attention (Y1. Tappet clearance adjustment f. Changing of Fuel primary& secondary spin-on filters. Torqueing of all bolts in Under truck as per their Torque values n. Y2. Y4. turbo filters. Torqueing of all bolts in Power pack as per their Torque values h. lube oil filters. soak back filters and air maze filters Under truck: j. Compression Test c. Lead wire test e. IRC& RSB greasing k. Rack Adjustment g. One revolution test d. Y5& Commissioning of New locos) Power pack: a.

M20& Commissioning of Re-build/ OFF POH Locos) Power pack: 2) IRC 3) Blow bye& Tappet Clearance adjustment 4) Changing of Fuel Injectors and Checking alignment of HP tubes 5) Trouble shooting 6) Changing of Fuel oil primary& secondary filters. lube oil filters and air maze filters. VARIOUS JOBS DONE IN ALCO LOCOMOTIVES 1) Medium Schedules i. M16.Qly (M4.e. Annealing and Re-fitting of all copper pipelines of the fuel oil system 5) Changing of RTTM belts and Rubber Rollers of the flexible coupling 6) Blowing and cleaning of Radiators Under truck: 7) Changing all Brake Blocks . Overhauling and Re-fitting of sleeve type water pump 3) Changing U-shaft of radiator fan 4) Removing. if due Under truck: 7) IRC& RSB greasing 8) Knuckle DPT 9) Axle box greasing and UST for every 8 months (one for every 4 months alternatively) 10) Schedule attention in UT Half Yearly Schedule Attention (M12): 1) All the jobs that are carried out in M4/ M8/ M16/ M20 Schedules Power pack: 2) Removing.. M8.

15-16 16-17 Actual till Description 2015-16 2016-17 2017-18 No. SRINIVASA RAO Section Officer S. CAPA to improve Reliability 2017-18 Sl. Total Qty. now 01 TPs 0 0 0 01 Fuel Rack struck up 2 0 02 OTPs 1 1 1 02 Piston& Connecting Rod 0 0 03 SFs 23 22 20 03 Spin on filter 0 0 04 Test valve 0 0 05 After cooler 0 0 06 Water pump 7 2 07 Power assembly 7 17 08 Cyl. All Locos 76 Ensure DPT of all water inlet tubes 02 Ensure after cooler outlet pipelines are All Locos 76 aligned properly 03 Decanting of fuel oil and cleaning of fuel oil All Locos 76 tank 04 Checking of fuel oil tank supporting legs in All Locos 76 bottom tank for cracks in the vicinity of supporting leg . Failure Target No. Population Target now 01 Check adjustment of water inlet tubes. Type of Sl.Head 1 0 09 Radiator 2 0 10 Water inlet tubes 1 0 11 Cam shafts 1 1 12 Vertical damper bolts 0 0 13 Buffers. CBC coupler body 3 2 TOTAL 24 22 03. Failure Analysis 17-18 Sl./ Description Actual till No. ACTION PLAN FOR 2017-18 (HHP) Section QHM Section Supervisor D. Performance Review 02. DAKSHINA MURTHY ADME-III 01.

Submitting Gear case oil sample to Lab for All Locos 76 Spectro analysis .05 CBC knuckle DPT All Locos 76 06.

now 01 TPs 1 0 1 01 Lube oil cooler/ lube oil filter drum/ lube oil 4 2 pump 02 OTPs 1 0 1 02 After cooler leaking/ chocked 4 2 03 SFs 172 243 190 03 Water pump/radiator fan attention 3 3 04 Cylinder head changing 71 109 05 Piston/ Liner attention 27 74 06 FIP Supports attention 15 22 07 EMF attention 2 6 08 Split gear/ cam gear attention 3 0 09 Cam shaft changing 2 3 10 RTTM/FTTM Blower attention 2 2 11 Extension shaft/ECC/RAGB attention 10 3 12 CBC Draft gear/ knuckle/ gear case/ 15 13 Suspension bearing/ buffert& nose&end cap attention 13 Fuel oil system 0 0 14 Pressure cap/ water level glow rod gauge 1 0 15 Lube oil pump/ lube oil pipe line leaking 2 2 16 Radiators 2 2 17 CCEM oil throwing 1 0 TOTAL 164 243 03. 15-16 16-17 Actual till Description 2015-16 2016-17 2017-18 No. Performance Review 02. CAPA to improve Reliability 2017-18 Sl./ Description Actual till No. ACTION PLAN FOR 2017-18 (ALCO) 01. Total Qty. Type of Sl. Failure Target No. Failure Analysis 17-18 Sl. Population Target now 01 Cleaning of radiators by applying wire brush All Locos 46 and external cleaning agent for Hly locos 02 Ensure blowing of radiators with air for all All Locos 245 Qly& Hly locos .

POH/Commissioning . axle box at that location is to be changed. Check piston&liner change if necessary. If rings are inline. Annealing of copper pipes during Hly All Locos 245 schedules 07 Removal of all copper pipelines whenever All Locos 245 heavy repairs are attended to avoid accidental damage 08 Topping up grease for axle boxes through All Locos 245 grease nipples only 09 Check for extension shaft wobbling. All Locos 245 conduct blow bye test. submit grease All Locos 245 sample to Lab for debris analysis. 05 During Axle box greasing. change rings. Remove head and piston at poor blow bye locations. All Locos 245 brashbush clearance should be less than 0. If ferrous content exceeds 2500PPM at any location. 06.03 Check rack mechanism for free movement. Hly. All Locos 245 Adjust dead rack and ensure rack position ‘0’ when OSTA tripped.oil 16 HP tubes to be checked on gadjet and All Locos 245 ensure proper alignment during Qly. must clean with either K. 04 As per blotter test if high soot comes.oi/F.040” 10 Ensure blue matching between FIP supports All Locos 245 crosshead and FIP during POH Commissioning 11 All cam lobes checking at 16 locations and All Locos 245 attend if required 12 Check fuel connectors both male and All Locos 245 female adaptors during Hly schedule 13 Checking of stabilizing temperature during All Locos 46 Hly Schedule 14 Checking of CC vacuum and EMT (Min CCV All Locos 245 should be 10mm oh Hg&EMT<520˚C) 15 Cleaning of Axle box cover with wire brush All Locos 245 and dust to be removed.

17 During Injector changing Blue match to be All Locos 245 done and proper alignment of Injector .

PUSHPA RAJU Tech-I 112 01-06-1961 12-05-1982 All Rounder in UT Very Good 4. THIRUPATHI Tech-II 265 20-06-1971 06-09-1997 All Rounder in PP Very Good 12. 1. SOLOMON RAJ Sr Tech . 05-01-1964 26-05-1988 All Rounder in PP Very Good 3. G. J. N. BHIKSHAPATHI Tech-III 320 12-05-1966 27-09-2003 Schedules in UT Good 18. LAKHAN LAL MEENA Tech-II 285 06-05-1987 03-05-2014 All Rounder in PP Very Good 13. P. SURENDAR Tech-I 157 04-04-1966 13-02-1985 All Rounder in PP Very Good 8. RAMBABU Tech-III 340 14-05-1984 03-05-2014 Schedules in PP Very Good . V. T. SRINIVASA RAO Tech-III 299 13-06-1972 01-03-2003 Fuel Injectors changing& Powerpack Good Schedules 16. SUBBA RAO Tech-I 210 01-06-1977 04-08-2005 All Rounder in PP Very Good 11. DOB DOA DORC Expertise in Grading Remarks No No. NAGESWAR RAO Tech-I 189 05-10-1967 12-06-1983 All Rounder in PP Very Good 10. D. NARSING RAO Tech-I 174 10-10-1973 12-04-1996 All Rounder in PP Very Good 9. RAVINDAR Tech-III 314 20-02-1976 13-01-2007 All Rounder in UT Very Good 17. 06-06-1968 19-10-1994 All Rounder in PP Good 2. K. Staff competency level SL. SUDHAKAR RAO Tech-I 134 01-01-1963 13-07-1984 All Rounder in UT Very Good 5. A. IYLAIAH Tech-I 141 09-12-1964 03-09-1994 Fuel Injectors changing& IRC&FRC Good 6. KRISHNA Tech-III 293 10-10-1976 19-08-2010 All Rounder in PP Very Good 14. A. ABDUL ZAHEED Tech-III 296 16-01-1984 10-10-2010 Fuel Injectors changing& IRC&FRC. CH. G. K. SRINIVAS Tech-I 142 08-04-1965 19-09-1997 All Rounder in PP Very Good 7. M. G. Name Token Desg. Very Powerpack Schedules Good 15. T. S. VENKATA SWAMY Sr Tech .

RAMESH HELPER 575 21-01-1988 01-01-2016 Schedules in PP Very Good 25.19. PARAMESH Tech-III 386 14-01-1994 31-07-2013 Schedules in PP Good 22. K. SAI PRASAD 390 12-12-1962 29-01-1987 All Rounder in UT Very Good 23. M. AMEER MIA HELPER 579 05-08-1988 01-01-2016 Schedules in PP Good . SURESH CHAND Tech-III 344 10-12-1989 20-05-2014 Schedules in PP&UT Very MEENA Good 21. K. P. RAJ KUMAR HELPER 559 18-09-1996 06-08-2015 Schedules in UT Good 24. N. SIVAIAH HELPER 576 14-04-1985 01-01-2016 Schedules in PP Very Good 26. PEMA RAM MEENA Tech-III 343 10-07-1988 03-05-2014 Schedules in PP&UT Very Good 20. B.

I. Component 2014-15 2015-16 2016-17 2017-18 No.Head 0 0 4 4 0 0 1 1 0 0 0 0 9 Radiator 0 0 5 5 0 0 2 2 0 0 0 0 10 E 0 0 3 3 0 0 0 0 0 0 0 0 . ANALYSIS OF FAILURES. TP OTP SF TOT TP OTP SF TOT TP OTP SF TOT TP OTP SF TOT 1 Fuel Rack struck up 1 0 0 1 0 0 2 2 0 0 0 0 2 Piston& Connecting Rod 0 1 0 1 0 0 0 0 0 0 0 0 3 Spin on filter 0 1 0 1 0 0 0 0 0 0 0 0 4 Test valve 0 1 0 1 0 0 0 0 0 0 0 0 5 After cooler 0 0 0 0 0 0 0 0 0 0 0 0 6 Water pump 0 0 5 5 0 1 6 7 0 0 2 2 7 Power assembly 0 0 2 2 0 0 7 7 0 0 17 17 8 Cyl. Component 2014-15 2015-16 2016-17 2017-18 No. MESSAGES AND SHED FINDINGS a) ALCO: Sl. TP OTP SF TOT TP OTP SF TOT TP OTP SF TOT TP OTP SF TOT 1 Lube oil cooler/ lube oil 0 1 2 3 0 0 4 4 0 0 2 2 filter drum/ lube oil pump 2 After cooler leaking/ 0 1 9 10 0 0 4 4 0 0 2 2 chocked 3 Water pump/radiator fan 0 0 5 5 0 0 3 3 0 0 3 3 attention 4 Cylinder head changing 0 0 83 83 0 0 71 71 0 0 109 109 5 Piston/ Liner attention 1 0 82 83 0 0 27 27 0 0 74 74 6 FIP Supports attention 0 0 39 39 0 0 15 15 0 0 22 22 7 EMF attention 0 0 2 2 0 0 2 2 0 0 6 6 8 Split gear/ cam gear 0 0 1 1 0 0 3 3 0 0 0 0 attention 9 Cam shaft changing 0 0 8 8 0 0 2 2 0 0 3 3 10 RTTM/FTTM Blower 0 1 24 25 0 0 2 2 0 0 2 2 attention 11 Extension shaft/ECC/RAGB 0 0 16 16 0 0 10 10 0 0 3 3 attention 12 CBC Draft gear/ knuckle/ gear case/ Suspension bearing/ 0 0 26 26 0 0 15 15 0 0 13 13 buffert& nose&end cap attention 13 Fuel oil system 1 0 0 1 0 0 0 0 0 0 0 0 14 Pressure cap/ water 1 0 0 1 1 0 0 1 0 0 0 0 level glow rod gauge 15 Lube oil pump/ lube oil 0 0 0 0 1 1 0 2 0 0 2 2 pipe line leaking 16 Radiators 0 0 0 0 0 0 2 2 0 0 2 2 17 CCEM oil throwing 0 0 0 0 0 1 0 1 0 0 0 0 3 3 297 303 2 2 160 164 0 0 243 243 TOTAL b) HHP: Sl.OCCURRENCES.

Sl. TP OTP SF TOT TP OTP SF TOT TP OTP SF TOT TP OTP SF TOT M F p i e c e 11 Water inlet tubes 0 0 5 5 0 0 1 1 0 0 0 0 12 Cam shafts 0 0 1 1 0 0 1 1 0 0 1 1 13 Vertical damper bolts 0 0 2 2 0 0 0 0 0 0 0 0 14 Buffers. Shed message for the year 2017-18 a) TP S No Loco No Date of Actual message Shed findings Corrective action failure taken b) OTP S No Loco No Date of Actual message Shed findings Corrective action failure taken c) Shed findings S No Loco No Date of Actual message Shed findings Corrective action failure taken III. Sl. STOCKED ITEM POSITION: Items are supplied by components sections. Component 2014-15 2015-16 2016-17 2017-18 No. yearly power pack and shift stores. SOH PL. CBC coupler 0 0 0 0 0 0 3 3 0 0 2 2 body 1 3 27 31 0 1 23 24 0 0 22 22 TOTAL II. Make wise population and failures: Maintained by Respective Components’ Sections IV.NO DESCRIPTION AAC Remarks No Section Stores 01 02 03 .

¾”X7/8” DE RING 01 4. 04 V. no Description Available Remarks Requirement 1. Non STOCKED ITEM POSITION: Sl. SOH PL. 1 1/8”X15/16” DE RING 01 2. 9/16”X1” DE RING 01 6. 1 ½”X15/16” DE OPEN 01 7 15/16”X1” DE OPEN 01 8 ¾”X7/8” DE OPEN 01 9 ¾”X5/8” DE OPEN 01 10 9/16”X1/2” DE OPEN 01 11 9/16” ALLEN KEY 01 12 3/8” ALLEN KEY 01 13 5/16” ALLEN KEY 01 14 7/32” ALLEN KEY 01 15 SCREW SPANNER-10” 01 16 PIPE WRENCH-14” 01 17 TORQUE WRENCH-50 Lb-Fts 01 -100 Lb-Fts 01 18 BOXES-9/16”.Modifications under progress/ to be carried out Sl. Status Description Reference Remarks No Completed Balance 1. Reliability improvement action plan for year 2017-18 of Alco locos .NO DESCRIPTION AAC Remarks No Section Stores 01 02 03 VI. 15/16”X1” DE RING 01 3.3/4”.15/16” 01 each 19 EXTENSION PIPES-5” 01 -10” 01 VIII. Tools Additional Sl. Provision of De-airators 54 37 instead of Bubble collectors in Alco Locos IX. ¾”X5/8” DE RING 01 5. M&P : On Run Centrifugal Machine VII.

Ensure blue matching between FIP All Locos 240 245 supports crosshead and FIP during 18 POH Commissioning 11. 4. Cleaning of Axle box cover with wire All Locos 240 245 brush and dust to be removed. 18 POH/Commissioning 17. 6. Annealing of copper pipes during Hly All Locos 240 245 44 schedules 7. If 163 rings are inline. Topping up grease for axle boxes All Locos 240 245 163 through grease nipples only 9. All cam lobes checking at 16 locations All Locos 240 245 163 and attend if required 12. submit All Locos 240 245 grease sample to Lab for debris analysis. During Injector changing Blue match to All Locos 240 245 be done and proper alignment of 163 Injector X. Checking of stabilizing temperature All Locos 240 46 44 during Hly Schedule 14.oil 16. Check fuel connectors both male and All Locos 240 245 44 female adaptors during Hly schedule 13.oi/F. must 163 clean with either K. 2016-17 2017-18 Sl. axle box at that location is to be changed. Check for extension shaft wobbling. change rings.040” 10. As per blotter test if high soot comes. If ferrous content exceeds 163 2500PPM at any location. Check rack mechanism for free All Locos 240 245 movement. Checking of CC vacuum and EMT (Min All Locos 240 245 CCV should be 10mm oh 163 Hg&EMT<520˚C) 15. Cleaning of radiators by applying wire All Locos 240 46 brush and external cleaning agent for 44 Hly locos 2. HP tubes to be checked on gadjet and All Locos 240 245 ensure proper alignment during Qly. All Locos 240 245 conduct blow bye test. Ensure blowing of radiators with air for All Locos 240 245 163 all Qly& Hly locos 3. Check piston&liner change if necessary. During Axle box greasing. Hly. All Locos 240 245 brashbush clearance should be less 163 than 0. Adjust dead rack and ensure 163 rack position ‘0’ when OSTA tripped. 5. Removal of all copper pipelines All Locos 240 245 whenever heavy repairs are attended to 44 avoid accidental damage 8. Total Qty/ Description Actual Actual No Population Target Target now now 1. Remove head and piston at poor blow bye locations. Reliability improvement action plan for year 2017-18 of HHP locos .

No Total 2016-17 2017-18 Description Populatio Target Actual Target Actual n now now 01 Check adjustment of water inlet tubes. Submitting Gear case oil sample to Lab All Locos 50 61 76 for Spectro analysis .S. All Locos 50 61 76 Ensure DPT of all water inlet tubes 02 Ensure after cooler outlet pipelines are All Locos 50 61 76 aligned properly 03 Decanting of fuel oil and cleaning of All Locos 50 61 76 fuel oil tank 04 Checking of fuel oil tank supporting All Locos 50 61 76 legs in bottom tank for cracks in the vicinity of supporting leg 05 CBC knuckle DPT All Locos 50 61 76 06.