Inspection Notes of Shri Vivek Kumar, EDME/Tr./Rly. Board during his visit to el Loco Shed Moula- Ali/South Central Railway on 06.12.2013 | performance: : 7 a) The shed is headed by a Sr. DME, assisted by a DME, 02 ADMEs and one AMM : = 8) | Diesel Loco Shed/MLY commissioned in 1984, was originally an MG shed, later on converted into BG, after conversion of MG line to BG Initially, Diese! Hydraulic Shunting Locos were homed (in 1980) and subsequently Main Line Locos: WDM2 (in 2002), WDM3A (in 2010) and WDG3A (in_2012) were homed. ] SrDME/DSLIMLY gave a presentation on shed basic data and | ©) In the year 1997 & 2000, 9 DHMUs (in consists of three: DPC, TC & DTC) were homed in this shed (only shed on Indian Railways to hold these diesel hydraulic multiple units). However, in view of the various design constraints resulting in frequent problems on line and | | incidences of fire, these were gradually withdrawn from passenger | service between 2011 to 2013. With the permission of Board, these | | withdrawn DHMU rakes are being converted into SPARTS by | Lallaguda workshop. Already two numbers have been converted, two | are under conversion and remaining three will be taken up subsequently (two DHMU rakes were damaged in fire incidents and condemned) 9) In the year 2010, one rake of DEMU was homed in the she ®)| Currently, the shed is having a holding of 78 diesel locos (14 WDM2, 31 WOM3A and 33 WDG3A), 10 aerodynamic 1400 HP DEMU rakes (total 20+1 Spare OPCs, 60 TCs}. Maintenance of one original | SPART and one ARMV (commissioned in year 2000) and one 140 | ton crane of SC division is also being done by the shed. 1)/ Examination and repair of power cars is done at Moula Ali Shed, Whereas for carriage side is being done at Kachiguda Coaching Depot. For this purpose, rake links are such that each rake is maintained twice a week at KCG and once a week at MLY. | 9) The shed has only one line for the DEMU inspection. There are two | | pits provided on the line to suit DHMU configuration. Examination of DPCs is being done by bringing the first power car over the pit and then moving the rake to get the second power car on pit, which is | | time consuming and infruct 1) [It is noticed that over 02 years period there is good improvement in| the shed performance: outage, reliability, punctuality and Lube oil | CMEC! consumption. It should be kept up. ') | Sr.DME brought out problems of acute shortage of Man power, the | | MPR is 3.2 which is lowest on IR and informed that proposal _ creation of 217 posts is pending with FA8CAOISC. It is vital for shed | ME" | to have adequate staff as it otherwise will adversely affect safety and | “ reliability of locos. 2 [Reviewed the maintenance practices of DEMUs. Following modifications have been carried out by the shed for better reliability a) ICF has started fitment of BLDC fans in DEMU coaches. These require less maintenance and are also better from safety point of view cuence (chances of grounding are much less as compared to DC fans). | CMEs/AN | However, ICF is providing DC fans in driving cab and engine) 28 compartments of DPCs. BLDC fans may be provided in these areas | Page 1 of 6[ also. In this regard, it was further informed that all DEMUs of MLY | | shed have been fitted with BLDC fans and in BZA shed 70% DEMUs | have been fitted with BLOC fans and remaining are planned to be | | covered by March'14. It is a good step to improve safety of DEMUs. | | Other Railways may also take similar action TAs a safely measure an Emergency shutdown switch has been | CVETIGE provided in all DPCs | 4 @ | Modified DEMU Tail LampiCiassification Lights circuit to enable them | CMEC) | to work even after switching off Battery Knife Switc Modified Control circuit to isolate from Train Lighting circuit. Provided Control Air Pressure Gauge in the LP Cab to detect failu __| inthe System 1) Provided Chimney for Muffler tank to prevent spreading of smoke on | CME/CE the roof @) | Alarm Bells are frequently failing. Shed has started replacing with | cmencr Electronic type for increasing reliability. | 3._| St.DME informed following problems are being faced with DEMUs: 8) | Seats provided in the DEMUs are inconvenient to the LPs as they experience heavy vibration on run. Also, these seats are breaking | cweicr | quite frequently. In this regard it was suggested to provide latest | CMPE(Oy | | design LP seats, as are now being provided by DLW in WDP4D| SOR locos. ») | Earlier, DEMUs were being provided with FRP nose cones. These | | | nose cones are developing cracks during service, are prone to heavy | | damage even with slightest obstruction and in case of any damage, it | is not possible to carry out repair. The doors and hinges of these cones also got loosened. It was requested to permit the conversion of | CMENICF FRP nose cones to steel ones, as is now being provided in the new | DEMUs. ICF should make out a procedure for replacement of FRP with steel cone, so that Zonal Railways requiring such replacement can get it done by a works contract or in shops. | Horn foot pedal is inconvenient to operate in BHEL make Control | CVEICF stand. Loco Pilots are requesting to replace with CGL design. @| CGL Make Dead man handle is very hard and it is difficult to operate | CVENC for which Loco Pilots frequently complain ®|In 1400 HP Cummins engine, after some period of idling, lube oil | starts leaking from cylinder head and Exhaust Manifold joint and drips | eoqupy | | on to the nearby hot surfaces, which is a fire hazard. This problem | | R0SO | has not been attended to even after repeatedly raising the matter by | CMEICF SCRwith OEM. | BHEL make Altemator V block (Separating main poles) dropping due | EO(PY [owencr | re | CMENCE _ | to bolts sheared off onense_| ‘9) | Water entering into Head Codes and MU Jumper Cables | CMENICE ') | Water enters through Single Look Out Glass (due to vibrations). CMEICF 4. | Following other issues related to DEMUs were highlighted by South Central Railway: - | 3) | ICF has issued drawing for separation of positive and negative wires of 700 HP DEMUs. However, as per this drawing extra cable, junction box and sockets are required to be provided, which is a major Work. | ayer) South Central Railway has given an alternative suggestion for this separation to ICF which has been agreed to by ICF. However, for carrying out this modification, as per the alternative suggestion, an Page 2 of 6r boy} © ms e) @ —T expenditure of approx. Rs.10 lac per coach will be incurre | are 85 coaches, based at BZA shed, to be covered. It was requested | to permit carrying out this modification in revenue keeping in view the | _| safety aspect | Adequate unit exchange spares of DEMUs are not being sancioned | | in RSP. it was requested to convey the sanction of folowing DEMU } | ites in RSP \ | i. Traction Motors CGL type for 1400 HP DEMU i | ii. Motorized wheel sets for 1400 HP DEMU | il. Power Rectifier for 1400 HP DEMU iv. Traction Altemator TA 7003CW (BHEL) for 1400 HP BEM jOMeCTe) |} v. Lec | vi, Actuators vii. Radiators | vil. Crank shafts for Cummins and Caterpillar ix. Engine blocks for Caterpillar Cylinder heads for Cummins and Caterpillar Jin the RD RDSO schedule of standard examination electrical tems ih the I coaches to be attended during various schedules have not been fully , covered. A reference in this regard has been made by South Central | "eee! Railway to RDSO, vide letter No.M.92/DSL/DEMU-DHMU/185 t:07.09.12. These may be ‘included at the earliest. | Difficulty is being faced in procurement of good quality spare parts of | DEMUs, as very few items are having RDSO/ICF approved vendors. To overcome this constraint, it was requested to issue centralized Rate contract of DEMU spares In BZA shed, DEMUs are homed since 1996. As on date itis having) 26 Nos. 700 HP DPCs (18 having Caterpillar 3412 engine and 8 with | Cummins 17101 engine), five 1400 HP DPCs and two 1600 HP DPCs | (three phase). The age profile of 26 700 HP DPCs of DLS/BZA is as | under: _ = | [ StZyears [7 OPCs } cMencr | | S16 years | 12DPCs | P15 years | 2DPCs [S12 years [a DPCs . “Sttyears | 1DPCs ee | | Midlife rehabiltation of these DPCs has to be planned where | electrical controls, power pack (codal life of 16 years already completed/completing shortly), etc., to be renewed. MLR of six nos. | DPCs have been sanctioned in RSP 2013-14. It was requested to assign this work to some DEMU POH shop. Also, it was requested to allot MLR of more DPCs in the current year RSP, to cover all 26 old | DPCs of SC Railway. Both CiL 1710L KTA and CAT 3412 DITA powerpacks of 700 HP OPCs design are quite old (more than 35 years). The maintenance | cowpy and operation cost of these engines is also high. It was suggested to, R0SO go for alternative and more efficient power pack suitable for the existing alternator as part of midlife rehabilitation Issues related to design and manufacturing of 1600 HP 3 phase | owe DEMU rake have been intimated by SCR to ICF and RDSO. These | Eby | May be considered and accordingly necessary action taken. | ROso | Page 3 of 66. | It was ‘suggested fo provide AESS in DEMUs to save fuel during | EOIMEY ] idling | 6. | Reviewed Progress of the new DEMU project “Facilities for Homing 6 | | | DEMU rakes” under Sanction No. 458 of 2010-11. St DME explained | | that 50% of work has been completed and the further progress is | stopped because of non-availability of funds. A proposal for re- | | | appropriation of Rs.1.9 crores to this work has been submitted BY) oy. | | L | | SCR to Board vide Lr.No.B.111/Pig./PH 4200/(WS)/456/13-14 dt: | (PU) | 19.11.2013. Early re-appropriation was requested, Once this shed is completed, integrated maintenance of power cars and trailer cars can | | be done here. This will result in increased availability as well as | reduction in inter-yard movement of DEMU rakes. Hence, it is important to complete this work at the earliest | 7. | Reviewed Progress of the Loco project “Additional Infrastructure: facilities for holding 100 locos" under Sanction No. 344 of 2007-08. Sr DME DME explained that 90% of work in the 1st phase has been) “Ply | | completed. For the femaining work, estimate is under revision. | | | Approx. 3.5 Crore funds will be required for completing the work. ~~’ St DME informed that proposal for “Augmentation of DEMU Car Shed | |for homing 10 Rakes" was sanctioned during last year but] oi. | subsequently dropped. It has been submitted again in PWP 2014-15. , “Pty | Requested to consider the present proposal in view of the increasing | _|DEMU holding. ____| 9. | Inspected the modifications carried out and problems faced on the available DEMU Rake 15050-15057, which was undergoing trip - |e echedulotssacauenume : pa) 10. | There are three makes of parking brakes: FTIL, SIL and Escorts There are some design and operational constrains in parking brakes of SIL and Escorts, causing frequent problems on line. Problem of | | reapplication of brakes automatically, after manual disengagement in | ED(Cany/ | one Parking Brake of Escorts make was seen. RDSO has already | 80SO had a meeting with all manufacturers to sort out these issues. Early implementation of the decisions taken in the meeting may be, |__| ensured. _ _ _ 44. | ‘Checked Schaku coupler system of DEMUs. Sr.DME informed that it | | is a cumbersome process for coupling and uncoupling of DEMUs that | | requires expertise and trained personnel. Itis difficult to uncouple the | | coaches during emergencies. Further he suggested that the above | "oie" | aspects have been taken care in the latest design of couplers | proposed to be used on LHB coaches and same may be considered for DEMUs also. _ 12./SrDME explained that the conventional Cartridge type Fire | Extinguishers have been replaced with Stored Pressure type on all) cmesiali the DEMUs in view of their advantage of ease of the operation and | Zora Ris facility to check their good condition through a pressure gauge 13. | Store was well-stocked with day-to-day maintenance spares like =| filters, gaskets, electrical switches, gauges etc. : Following issues related to diesel locos were highlighted by South | |__| Central Railway: _ a) | Practically no loco spares are being sanctioned in itemized RSP. Last | OME(Tr) | year (2013-14) only four items, out of 47 items proposed were | sanctioned. It will have adverse effect on maintenance of locos. Requested for sanction in the current year to the maximum extent Page 4 of 6| possible. KZJ shed is now homing 33 WDG4 locos and it is likely to increase |) OMECTE} *| further. Requested for allotment of major UE spares like Power Pack, | TMs, TAs, TSC, Turbo Clutch Assembly, Motorized Truck Assembly, | | etc. of HHP locos from bulk RSP ©) | The condition of Co-Co bogie frames is not good. Requested it to be | PME(Tr) made a bulk RSP item and allotment of 20 nos. to SCR. Shortage of powers packs of Alco locos, requested allotment of 5 | OEIT?) nos. Shortage of TSCs of Alco locos, requested allotment of 15 nos. | MET) | All the eligible CO locos of SCR will be fitted with MEP by | OME(Tr.) March'14. However, for putting goods service locos on 30 day schedule, in 64 locos roller suspension bearing wheels are required | However, allotment in the current year to South Central Railway is only 8 locos. It was requested to allot additional wheels for 56 locos._| 9) A proposal for giving VCD reset control only to LP has been £DIMPY | submitted by SCR to RDSO. It is important for ensuring alertness of "°S° LP. Early implementation of this modification may be done. h) SCR is facing problem of breakage of centre pivot block retaining | EDIMPY plate bolts. There are three designs of the centre pivot: 2- bolt, 3-bolt R°S° and 4-bolt. RDSO has issues instructions for preventing breakage of | bolts of 3-bolt and 4-bolt design. But, 2-bolt design has not been covered. A reference inthis regard has been made by SCR to RDSO._ tt may be looked into early, keeping in view the safety implication ') | Serious problem of breakage of intermediate side buffers of HHP ERY | locos, when they work in MUs is being faced by SCR. Now, SCR has | 8°S° | started removing the intermediate buffers, as suggested by ROSA | } However, solution to this issue needs to be found at the earliest. } i) Board has issues instructions regarding approved vendors for child | ED(MPY | parts for assemblies vide letter no. 2043/m(L)/466/8(402) dated | °°S° | 04/09/2013. However, there are cases in which there are more than ‘one vendor for one particular item and child parts of the assemblies of } different vendors are not interchangeable like air dryer. In such cases. PAC is required to be given by the consignee for procurement of child | parts. Hence, SCR requested to specify whether child parts are | Jinterchangeable or not. It is already being done by RDSO for | compressor items. Same can be done for other assemblies also, so | that need of PAC by consignee is obviated No. 2013/M(Ly6ag/22 New Delhi, dated 20" December 2013 ABN (Vivek Kumar) Exec. Dir Mech.Engg (Traction) Railway Board) Chief Mechanical Engineers/All Indian Railways Chief mechanical Engineer/ICF/Chennai CMPE(Diesel)/South Central Railway/Secunderabad ED(MP)/RDSO/Lucknow ED(Carriage)/RDSO/Lucknow EDME(PU)/Railway Board DME(Traction)/Raiiway Board NOaeenae Page $ of 6