GZB PPT for railways analytics report.pptx

Gzb railways ppt

1. Provision of Old Magnet Coils in EP Units Action Taken by CBW : PL No. 31395510 AAC for 2024-25 has been increased to 138 from existing 118 Nos. in FY 23-24. One time demand for 240 Nos. has been placed in Feb-24. Demand No. 1524020662 dt 21.02.24, Tender No. 07241399 New material will be provided as soon as it is received.

2. Replacement of Defective Wheel Sets Action Taken by CBW :

3. Defects/Failures observed in brake cylinders in MEMU Coaches Action Taken by CBW : The cause of a jammed brake cylinder is the flexible hose pipe choking owing to the deformation of the nylon washer employed in it. All of the outgoing bogies currently have new nylon washers installed because CBW has acquired new flexible washers . Also to improve BMBC reliability a new 04 point computerized BMBC test bench PO has been pl.aced

4. Broken Nose Pads of TMs Action Taken by CBW : Material Failure This material was procured in NS through PO No. 56215561100015 dt 04.01.22 by M/s Venus Enterprises GZB. This item is not a controlled supply item, does not have RDSO spec and is procured using BHEL drawing. Not possible to test this item in lab and no approved vendors on UVAM. Warranty claim was raised on UDM and replacement material has been received. Failed material is required from GZB for lifting this item from CB store.

5. Permanent Earth Fault in MEMU MC 30140 Action Taken by CBW : Earth fault: 02 cases were reported in FY2023-24 in which 01 case pertains to earthing of choke tank. There is a design issue for which letter no. Train Set/CTA/CB/24 dated 15-03-2024 has been send to BHEL . Following works and practices have been started to improve reliability of Transformers and connected equipment which could be responsible for earth faults: 1. Complete oil leakage testing. 2. Cork Sheet Gaskets sheets have been procured. 3. T/Oil Flange Joint Gaskets have been purchased. 4. PRV for Transformer 27 Nos. has been procured. 5. Complete Transformer Rehabilitation Works Contract for 09 Nos. Transformers LOA issued on 04.03.2024. 6. 05 Nos. Transformer Radiators have been overhauled through outsourcing and open tender for complete overhauling of radiators for 02 years has opened. 7. Choke tank overhauling has been started for 01 no. choke tank on trial basis. 8. 08 Nos. Transformers are available at CBW for overhauling and rehabilitation .

6. Difficulty to operate MR angle cock Action Taken by CBW :

7. Provision of unapproved ROTEX make Magnet coils Action Taken by CBW : Matter was referred to RDSO for clarification. Vide letter no. MC/EMU/KBS dt 28.11.2023 RDSO, Magent valve of EP brake system in EMU/MEMU is a part of Electro Pneumatic Brake system to RDSO Spec. RDS0/2013/CG-03. The approved suppliers of EP brake system are listed on UVAM. M/s Rotex , Vadodra is listed as as source for Magnet valve QAP of M/s Escorts for EP brake system.

8. Huge cases of RTL Smoke/Burning Practices to ensure no failure in future : LT testing at 110V has been started on berth so that all and every assembly is checked before lowering of coach on bogie Tap changers are being thoroughly checked on endurance test bench in section and then also after fitment on coaches during LT testing

9. Failure of Brake Controller in MC 304113 Action Taken by CBW : Material failure, Warranty claim has been raised on UDM with Advice Note No. 99521-23-28485 dated 23.02.2024 It is a part of 69 part kit of Brake controller under PL 31352200 Practices to ensure no failure in future: Staff has been counselled and Special attention shall be given to sealing washer fitment while overhauling of brake Controller with above mentioned Brake Controller POH Kit to Escort make from now on

10. Smoked PG Cable in MC 304102 & Missing Centering Coupler Devices in coaches Action Taken by CBW : In regard to smoked PG cable, staff of welding and body repair have been counseled to secure any and all cables before performing gas cutting or welding. Centering coupler devices are being provided in 100% MEMU coaches since Jan-2024.

11. Failure of Reversor K2 in MEMU MC 304087 Action Taken by CBW :

12. Failure of Brake Cylinders in Coaches Action Taken by CBW : Computerised BMBC test bench has been installed in section to test the BMBCs and a new machine demand has been generated to test 4 brake cylinders at a time to increase the cycle time. PO is under vetting. Detailed analysis is attached.

13. Failure of Brake Cylinders in Coaches Case 1 & 2 Case-3 Rake No. 393-380-30121 304089-358-304116 Coach No. 31186 31421 304089 Failed equipment Brake cylinder Brake cylinder Brake cylinder Date of observation of failure During schedule inspection on 08.12.2023 During schedule inspection on 10.12.2023 Type of failure Brake cylinder no.1 ratchet is free Brake cylinder no.2 giving air leakage from housing Brake cylinder no.1 pin jam and cannot be operated for gap adjustment Remarks of CBW and suggestions for EMU/GZB for action to be taken Ratchet has 18 teeth which is a part of adjusting screw, If ratchet is free, there may be possibility, that one or more teeth may have worn out after POH because of which locking pawl might have lost the grip. All 18 teeth of ratchet were intact during POH schedule at CBW. It is requested that ratchet may be changed at EMU/GZB. It is also requested that adjustment of adjusting tube with adjusting screw may be carried out at EMU/GZB. Since there is air leakage from housing, according to RDSO SMI-37, during IA schedule, in under frame, check and ensure securing of brake cylinder and intactness of all fasteners. Housing is joint to dome of cylinder to 4 nos. Hex T-bolt with nylon lock nut. According to RDSO SMI-37, during IA schedule,, Check and ensure proper securing of brake cylinder and intactness of all fasteners With the passage of time, dust must have crept in which may have jammed the pin and sometimes it is required to be cleaned with oil and make some adjustment manually which may be carried out at EMU/GZB.

14. Failure of Main Compressor in MEMU MC 304088 Action Taken by CBW : During Joint Inspection, Main compressor motor dismantled and checked Connection lead was found burnt and pit marks were observed on commutator . New lead was provided and pit marks were removed by CBW. After drop test, meggering and testing on test bench it was found suitable and fit for service. CB staff counseled and contractor penalized.

15. Smoke emission from MCP of MEMU MC 314111 Action Taken by CBW: During joint inspection, Motor stator was checked and found overheated on upper side pole of stator. Replacement MCP provided to GZB. CBW staff counseled.

16. Huge number of MCP failures in MEMU MCs Action Taken by CBW : Primary reason for failure of MCPs is overage MCPs in service. AAC for MCPs in FY 2024-25 has been increased from 05 Nos. to 12 Nos. One time demand of 10 nos. MCPs have been raised on UDM. 10nos. MCPs have been proposed in bulk RSP for FY2024-25. Case wise detailed investigations of MCP failures in FY 2023-24 are listed in Annexure attached. Total 05 failures in 100 days of all reported failures.

17. Huge number of MCP failures in MEMU MCs S. No MC No. MCP Sr. No. Date of POH Date of removal of compressor Days to Failure DOC of MCP Remarks 1 30052 ELGI-1188 12-10-23 17-11-23 36 Mentioned compressor is different from MCP installed at RSW-CB in POH-Schedule. RSW-CB staff reached EMU Car shed GZB for failure inspection of MCP after reported to workshop, but it was not shown to them. 2 30112 ELGI-1332 26-06-23 24-08-23 59 08/2004 RSW-CB staff found okay after joint inspection done with EMU Car shed staff. Report of the same is being attached. 3 30083 REC-003473 21-08-22 20-10-23 425 02/2017 Failure occurred after 425 days from POH. During IC schedule, head stripping and valve cleaning should be done. 4 30123 REC-003463 18-07-23 25-10-23 99 02/017 RSW-CB staffs were sent for failure investigation. MCP found seize after joint inspection with GZB Shed staff. Warranty replacement is being planned from RSW-CB. 5 30105 ELGI-1288 08-04-22 25-11-23 596 Identification Plate Missing Failure happened 596 days after the previous POH, which is even longer than the duration of two POH schedules in a row. During IC schedule, head stripping and valve cleaning should be done. 6 30108 AA- 1350 11-03-23 16-11-23 250 Identification Plate Missing Failure occurred after 250 days from POH. Frame intactness/ crackness should be checked in each Trip schedule. 7 30049 EUS050451 14-06-22 23-11-23 527 New 2022 Failure occurred after 527 days from POH. During IC schedule, head stripping and valve cleaning should be done. 8 30156 ELGI- 1488 10-01-23 12-01-23 2 Mentioned compressor is different from MCP installed at RSW-CB in POH-Schedule. Mentioned compressor is different from MCP installed at RSW-CB in POH-Schedule. However, it is related to air dryer issue, which was also overhauled at RSW-CB. 9 30133 EUBS050046 30-11-22 07-12-23 372 2008 Failure occurred after 372 days from POH. During IC schedule, head stripping and valve cleaning should be done. 10 304088 3HC554000R 16-11-23 13-12-23 27 07/2008 RSW-CB staff jointly investigated the failure with GZB Shed staff and stator lead found burnt and has been changed by contractual staff. Appropriate penalty has been imposed on contractor. 11 304111 ELGI-1103 02-11-23 01-01-24 60 10/2007 Mfg. year of armature is 1998. RSW-CB staff jointly investigated the failure with GZB Shed staff and found overheating of upper side pole of stator. Appropriate penalty has been imposed on contractor.

18. POH of Bio-Toilets of MEMU Coaches Action Taken by CBW :

19. Bookings noticed in off-POH MEMU MC 304101 Action Taken by CBW :

20. Regarding isolate Brake cylinder of SPIC-30009 Action Taken by CBW :

21. Sliding door guide observed flat in off-POH MEMU coaches Action Taken by CBW :

22. Failure of brake controller in OFF-POH MEMU MC No. 304113 Action Taken by CBW : Material failure, Warranty claim has been raised on UDM with Advice Note No. 99521-23-28485 dated 23.02.2024 It is a part of 69 part kit of Brake controller under PL 31352200 Practices to ensure no failure in future: Staff has been counselled and Special attention shall be given to sealing washer fitment while overhauling of brake Controller with above mentioned Brake Controller POH Kit to Escort make from now on.

23. MSU tube found red hot in OFF-POH MC No. 30142 Action Taken by CBW :

24. M aintenance friendly POH of MEMU coaches Action Taken by CBW :

25. Water content inside EP unit in SPIC 30009 Action Taken by CBW :

26. Major failure (breakage of hytrel washer) in MEMU TC 314222 within two months Action Taken by CBW: Warranty Material Failure. EMU/GZB is requested to provide broken hytrel washers for failure analysis and warranty replacement clai m through UDM.

27. Repeated major failure (RTL smoked) in M EMU M C 30073 within 20days Action Taken by CBW : Corrective Action taken :- RTL was joint checked and it is suspected that tap changer coil aux contact of coil/ SR relay contact or coil may have malfunctioned once. Practices to ensure no failure in future : Tap changers are being thoroughly checked on endurance test bench in section and then also after fitment on coaches during LT testing

28. Improper line gauge on three axles of MEMU Motor coach no.30108 Action Taken by CBW :

29. Failure of T M Bearing (FAG Germany) in MEMU in OFF-POH MEMU MC No. 304113 Action Taken by CBW : Material failure on firm. ( Schaeffler India Ltd.) During joint inspection with firm and EMU/GZB at CBW it was concluded that : Failure of PE side bearing, which seized due to breakage of bearing rivets of cage and after that rollers have deformed. Firm has been advised t0 take necessary action and ensure quality of material.

30. Failure of MCP contactor in MEMU MC No. 304125 Action Taken by CBW :