WHY-WHY ANALYSIS : COBPP/BATT/MECH/36

RCA:– Quenching Wagon 2, Flap 1 Operating Problem Page-

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Brief Description of Problem & Troubleshooting Executed:

At around 11.50 PM on 26th June’2020, Operation Shift In-charge informed Mechanical & Electrical Shift
In-charges about the problem in Wagon 2, Flap 1 Operation. When the Mechanical Shift In-charge reached to the
location, He found out that the Wagon 2, Flap 1 is neither opening or closing.

Then, following trouble shooting steps were taken to resolve the problem:

1.The Pneumatic Lines & Hoses were checked for any leakages, but no leakage was found – 12 night to 12.30
AM.

2.The 5/2 DC valve was checked for Malfunctioning. The malfunctioning of 5/2 DC valve was confirmed after
checking & was replaced with a new valve- 12.30 AM to 01.30 AM.

3.After replacement of 5/2 Dc valve, Flap1 was again operated and found that the Flap was opening properly but
was not closing fully- 1.30 AM to 2:00 AM

4.Then to find out the reason for Flap closing problem, the cylinder was checked for cross leakage and the cross
leakage of the cylinder was confirmed. It was decided to replace the cylinder – 2:00 AM to 2:45 AM.

5.The cylinder was replaced; flap operation was checked & found Okay. Then the Wagon was handed over to
operation – 2:45 AM to 4:15 AM.
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 WHY-WHY ANALYSIS : COBPP/BATT/MECH/36

RCA:– Quenching Wagon 2, Flap 1 Operating Problem . Page 2

Ref:-
Unit: Phase 1B Section: Mechanical Department: Coke Oven
COBPP/BATT/MECH/36
Break-down Date:26.06.2020 Production Loss: Y Equipment Code: Quenching Wagon
Stoppage Hours: 270 Mins Frequency: 1st time Equipment Name: Quenching Wagon 2
Team:- Mr. Bikash Agrawal & Team
Problem reported: Quenching Wagon 2, Flap 1 was not operating.
Final Action: Flap 1, 5/2 DC Valve & Cylinder replaced .
Problem solving techniques used : Why- Why Analysis

SN WHY ANSWER ACTION REMARKS

1 Why Flap1, 5/2 DC Valve & Cylinder Replaced? 1. 5/2 Dc Valve was malfunctioning.
2. Cylinder had cross leakage.

2 Why? 1. Jamming of spool of DC valve.

1.5/2 Dc Valve was malfunctioning. 2. Piston holding check nut was loose. .
2.Cylinder had cross leakage.

3 Why? 1. Initial filling grease hardening.

1.Jamming of spool of DC valve. 2. Locking of check nut was not proper.
2.Piston holding check nut was loose.

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 WHY-WHY ANALYSIS : COBPP/BATT/MECH/36

RCA:– Quenching Wagon 2, Flap 1 Operating Problem . Page-3

Why-Why analysis must end when any of the following conclusion is reached as a root-cause:
(Please tick the most appropriate option)
Natural Deterioration
Forced Deterioration
Planned Maintenance
Design Weakness
Operational Malfunction
Lack of Knowledge/Skill

Rectification (Activity):
Flap 1, 5/2 DC Valve & Cylinder replaced .

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 WHY-WHY ANALYSIS : COBPP/BATT/MECH/36

RCA:– Quenching Wagon 2, Flap 1 Operating Problem . Page-4

CAPA to Avoid Repetition of the Problem:

Sl No Machine Recommendations Target Date Responsibility

Wagon 1, Flap 1 29.06.2020
Wagon 1, Flap 2 01.07.2020
Siddheswar Nayak
Wagon 2, Flap 1 Wagon Pneumatic cylinders are to be replaced after Piston Check nut 03.07.2020
1 Chandan das
Wagon 2, Flap 2 tightening & welding. 05.07.2020
Kapil Paramanik
Spare Wagon, Flap 1 07.07.2020
Spare Wagon, Flap 2 09.07.2020
Loco 1 27.06.2020
Loco 2 Loco 5/2 DC valves to be overhauled & replaced. 28.06.2020 Chandan Das
2
Spare Loco 29.06.2020
All Locos Replacement of Valves in every 3 months is to be included in PM list 02.07.2020 Gurmeet
3 Spare Loco-Wagon Spare Loco-Wagon Readiness with complete testing. 02.07.2020 Siddheswar Nayak
4 Spare Two sets of wheel assembly to be made ready with casanub. 05.07.2020 Siddheswar Nayak
Loco 1 05.07.2020
Siddheswar Nayak
5 Loco 2 Replacement of existing GI lines with SS lines. 10.07.2020
Chandan Das
Spare Loco 15.07.2020
Weekly Cross leakage checking of cylinders is to be added in PM List.
6 All Wagons Monthly Oiling of cylinders ports to be added in PM List. 02.07.2020 Gurmeet
Monthly greasing of hose fittings to be added in PM List.
Loco 1 30.06.2020
7 Loco 2 Receiver Tanks Tar felt Laying. 05.07.2020 Siddheswar nayak
Spare Loco 10.07.2020
Quarterly Thickness cheking of Receiver tank & Quenching Water tank to be
8 Locos 02.07.2020 Gurmeet
added in PM-Checklist.

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 WHY-WHY ANALYSIS : COBPP/BATT/MECH/26

RCA:– Quenching Wagon 2, Flap 1 Operating Problem . Page-5

Coke Oven Plant Equipment GA

Affected Area: Quenching Wagon 2

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 WHY-WHY ANALYSIS : COBPP/BATT/MECH/26

RCA:– Quenching Wagon 2, Flap 1 Operating Problem . Page-6

Jammed Spool of 5/2 DC Valve

Initial filling Grease Hardening,

Which caused spool Jamming.

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 WHY-WHY ANALYSIS : COBPP/BATT/MECH/26

RCA:– Quenching Wagon 2, Flap 1 Operating Problem Page-

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Cylinder Piston locating Check Nut Grab screw Condition

Damaged Grab screw of the Check Nut

Check Nut used for Holding Cylinder Piston in
Position.