ANDAL DIESEL SHED

Eastern Railway

MCDO
for

December2012

Page : 1

P. SHARMA. Sr. Divl. Mech. Enggr. (Diesel)

Andal Diesel Shed Eastern Railway, Andal Ph. & Fax No. 03412374563

D.O. No. ADL / STAT / PCDO / 1.

Dated: 1st, January -2013

Dear Sri Kumar

Sub: MCDO for the month of December2012 1.0
A.

ASSISTANCE REQUIRED: Requirement of Manpower: There are 09 posts of Supervisors lying vacant 07 in Mechanical (02 SSE + 05 JE) and 02 in Electrical (01 SSE + 01 JE) which are required to be filled up. One SSE (Electrical) is retiring in Jan13. One proposal for creation of 232 posts of artisan has been initiated but the same is not getting through for want of matching surrender. Shed is not able to undertake the maintenance schedule on time for want of manpower.

B.

Requirement of Traction Motors of DEMU Andal Diesel Shed is running 2 sets of DEMU (consisting of 2 DPCs) in passenger services. There is no spare Traction Motor available with the shed. Unit Exchange Spares are needed for day to day running in case of failures.

C.

Requirement of Fund for DEMU No fund for DEMU maintenance has been given in demand 06-700-32 and 06-700-28 for Andal Diesel shed. The maintenance of DEMU can not be under taken for want of material/ contractual payment. Failure in undertaking D check on time may result in stabling of rake.

D.

Requirement of RSB Wheel of WDG3A 12 sets RSB wheel of WDG3A and 06 sets of WDM3A required from Jamalpur workshop for unit Exchange to cut down the cycle time of Yearly schedule.

E.

Crisis of Material The list of Critical items is attached at ANNEXURE I

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2.0 2.1

POSITION REGARDING ACR / APAR, DAR CASES: ACR/APAR :

A) GAZETTED :
Nos. of ACRs initiated for 2011-12 : No ACR is pending

B) NON-GAZETTED :
(i) (ii) Pending ACR/APAR of previous 05 years : Nos. of APAR for 2011-12 : NIL. NIL

2.2

DAR CASES :
MAJOR Opening Balance Nil Cleared Nil Pending more than six months Nil Opening Balance 08 MINOR Cleared 10 Pending more than Six months Nil.

2.3

AUDIT CASES UNDER PART I & PART II AND SPECIAL ITEM :

Type Pt. I Pt. II Spl. letter Opening Balance 01 01 01 Cleared 01 01 01 Pending more than three months Nil Nil Nil Oldest cases with date Nil Nil Nil

2.4

STOCK SHEETS: ACCOUNTS & AUDIT:

Type A/Cs Audit Opening Balance Cleared Pending more than three months Oldest cases with date

No Stock sheet is pending of A/Cs & Audit of SSE (D)/Store/Fuel.

2.5 i.
ii.

USE OF INFORMATION TECHNOLOGY & ITES:

Loco movement is being maintained on line through FOIS at 24 hrs. basis. 04 locos are running with REMMLOT which help in immediate assistance to crew in case of any trouble while on run.

3.0 3.1

HIGHLIGHTS OF THE MONTH: GOOD WORK DONE:

Retro fitment of stiffer unit cam shaft (SUCS): To overcome failure of FE type Cam shaft, Andal shed has taken initiative to Retrofit stiffer type cam shaft in locomotives. Till date 06 Nos. of locomotive have been retrofitted in shed. ( Loco No: 14854,13379,13398,13001,14994 & 14824)

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 Introduction of Twin pipe Air Brake System in Freight locomotives:

With introduction of twin pipe freight stock Andal shed has taken initiative to make all freight locomotives fit for twin pipe air brake operation. As on date all 76 WDG3A locomotives based at Andal have made provision for twin pipe air brake operation.

Test Bench for testing of Electro-pneumatic Brake system of DEMU:

DEMU Rakes are provided with Electro-pneumatic Brake system. The relays and Valves though repaired/ overhauled in shed had to be taken to TRS shed/ ASN as Andal had no test bench. Sri Prahlad Singh JE (D)/Andal Diesel Shed has taken initiative and developed a test bench for testing the brake unit of DEMU in both Auto Mode and Electro-pneumatic Mode. This has saved the manpower involvement as well as improved reliability.

3.2

OUTAGE : Average outage for Mainline Locos (WDM2 / WDM3 / WDG3) was maintained at 90.69 against
the target of 85.44 .

Average outage for Shunting Locos (WDS6) was maintained at 15.37 against the target of 13.77 3.3 INEFFECTIVE% : Ineffective % for Mainline Locos(WDM2/WDM3/WDG) was maintained at 7.88%. Ineffective % for shunting locos (WDS6R) ineffective percentage was 05.69% 3.4 RELIABILITY :
There have been only 03 problem cases for Andal Diesel shed in current month compared to 06 cases in November-12.

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3.5

L. OIL CONSUMPTION:
2012-2013 (Up to November) Class

Lube oil to Fuel oil ratio

0.37 0.39 0.49

Lube oil consumption / 100 EKM 1.14 1.53 0.53

WDM2 / WDM3
WDG3 WDS6R

3.6

SHED CONSUMPTION OF HSD:

Comparative figure of HSD oil shed consumption in ltrs. Average 2011-2012 41167 Average 2012-2013 40546 November12 39300 December-12 39500

3.7

SAVING IN HSD OIL:

Huge amount in HSD oil have been saved in shed consumption as can be seen from the table below. Actual Shed Consumption during 2011-12 41167 Litres. Target for 2012-13 75500 Litres. Actual Shed consumption 201213 40546 Litres. SAVINGS Against Target. 34954 litres.

Thus in money value Railway revenue has been saved. Against Target: Rs. 1736165/-

3.8

Scrap Disposal of Andal Diesel Shed

2011-12 Ferrous Non-Ferrous 283.444 T 63.276 T December12 NIL 15.753 T Cumulative upto Dec12 157.383 T 25.593 T

3.9

SAFETY FITTINGS POSITION :

(As per CMPE/ER/KKKs letter No. MM/199/CME/1 dated 27-07-2010) Safety fittings position is attached at ANNEXURE II, Point No. 20.0

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4.0

PERFORMANCE AT A GLANCE (2012-2013) :

ITEM Sl. 1. 1.1 1.2 2 2.1 2.2 3 3.1 3.2 4 4.1 4.2 5 5.1 5.2 6 6.1 6.2 6.3 7 7.1 7.2 7.3 8 8.1 8.2 8.3 8.4 Outage (>Tgt) WDM2 /WDM3 / WDG3 WDS6 Ineffective% WDM2 /WDM3 / WDG3 WDS6 Problem Cases Nos Per 100 loco/ Month Equipment Failure Nos Per 100 loco/ Month Punctuality Loss Direct Per 100 loco/ month Schedule Done (M2+6R) Yearly H-Yearly Quarterly Schedule Due (M2+6R)( as on Yearly H-Yearly Quarterly L/Oil Cons. In lts./100EKM WDM2 / WDM3 WDG3 TOTAL WDS6 L.oil to F.oil ratio WDM2 /WDM3 WDG3 1.10 0.54 0.43 21052 4.92 1.58 21133 0.87 0.38 06 4.58 5.45 5.87 Nil
(Nov12)

ACTUAL 2011-12

Target 2012-13 up to Dec12 +6.73 +1.27 6.50% 5.70% 57.69 6.25 43.05 5.25

ACTUAL 2012-13 This Month +5.25 +1.60 7.88 % 5.69 % 03 2.88 08

(Nov12)

Cumm. +5.36 +1.63 7.19% 5.22% 54 5.84 31

(Up to Nov12)

+5.43 +1.88 7.00% 4.13% 76 6.15 73 5.91

7.76
(Nov12)

3.78
(Up to Nov12)

07
(up to Nov12)

Nil
(Nov12)

7.53 (up to Nov12) 30+0 41+2 54+4 5+3 4+5 12+3 1.14 1.53
(Up to Nov12)

25+1 As per 42+4 arising 64+3 30th Nov12) 0+0 Nil 0+0 Nil 2+1 Nil 1.16 1.54

4+0 5+0 10+1 (Nov12)

1.69

1.43

1.43 (Nov12) 0.66 (Nov12) 0.39 (Nov12) 0.43 (Nov12) 20153 4.82 (Nov12) 1.98 (Nov12) 38

1.40
(Up to Nov12)

0.53
(Up to Nov12)

0.37
(Up to Nov12)

0.39
(Up to Nov12)

8.5 8.6

Total Shed issue/month SFC Pass. Goods

19791 4.73
(Up to Nov12)

1.94
(Up to Nov12)

Training of Maintenance/Artisan Staff

251

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5.0

SYSTEM WISE FAILURE : MECHANICAL

SYSTEM SUB-SYSTEM ENGINE BASE / CRANKCASE ENGINE BLOCK CYLINDER HEAD ASSEMBLY VALVE LEVER MECHANISM CRANKSHAFT / CAMSHAFT PISTON ASSEMBLY CON. ROD ASSEMBLY MAIN BRG. & CAM SHAFT BUSHING MISC FOR POWER PACK TOTAL AIR INTAKE FILTER SYSTEM TURBO & SUPER CHARGING SYSTEM AFTER COOLER & MANIFOLDS 2. ENGINE SYSTEMS FUEL OIL SYSTEM MANIFOLD A/COOLER T-JUMPER OTHERS OST FIP HP TUBE OTHERS W/ PUMP OTHERS RTTMB COMPONENT 09-10 10-11 11-12 12-13 Up to Dec12

1. POWER PACK ASSEMBLIES

CYL. LINER CYL.HD CAMSHAFT CAMGEAR SPLIT GEAR EXT. SHAFT

01 02 01 01 01

02 01

02 01 01

01

02 02

02 01

06 01 01

04 01 02 04 02 03 02 05 02 03 01

07 01 01 02 04 05 03 04 03 02 05

04 02 03 02 01

INJECTION SYSTEM & SAFETY CONTROL LUBE OIL SYSTEM WATER COOLING SYSTEM TRANSMISSION COOLING SYSTEM PG GOVERNOR MISC. FOR ENGINE SYSTEMS TOTAL EXPRESSOR, COMP & EXHAUSTER BRAKE VALVES (AUTOMATIC, INDEPENDENT & CONTROL VALVES) BRAKE VALVES (MAIN SYSTEM) BRAKE VALVES (OTHERS) MISC FOR EXPRESSOR & BRAKES TOTAL LOCO SUPER STRU. U/FRAME TRUCK WHEEL, AXLE & AXLE BOXES BRAKE RIGGING MISC FOR VEHICLE & STRUCTURE TOTAL OTHERS, MISC. MECHANICAL TOTAL

03 03 03 01 01 04 02 03

01 01 03 04 02

22 01

4.VEHICLE & 3. COMP. & EXHT. STRUCTURES

25 01 01

30 01 01 01 01

19

01 02 02 01

01 01 03 01 01 05 03

04 01 01 01

01 5. 07 01

03 01

TOTAL MECHANICAL

37

33

45

32

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ELECTRICAL
SYSTEM 12-13 Up to Dec12

SUB-SYSTEM PANELS CARDS SEMICONDUCTORS OUTSIDE PANELS RESISTORS, RHEOSTAT, SHUNT TRANSFORMERS & REACTORS RELAYS & CONTACTORS SWITCHES & CIRCUIT BREAKERS GOVERNOR & GOVERNOR PUMP MISC FOR POWER & CONTROL TOTAL TRACTION GEN./ ALTERNATOR

COMPONENT 09-10 10-11 11-12 01

1. POWER AND CONTROL

01 01 02 PG MCBG 01 TG TA AUX.GEN. EXCITER 02 02 03 01 01 04 01 02 02

01 05 01

01 04 02 05 07

2. TRANSMISSION

TRACTION MOTOR EXCITER GEN./ AUX. GENERATOR CABLES FTTM BLOWER RECTIFIER TOTAL BATTERIES LIGHTING & ALARMS MOTORS FUEL PUMP, CRANKCASE

02 01 02

04 01 04 03 14

08

05 01 01

3. AUXILIARIES

5.

AXLE GENERATOR / TACHO GEN. EDDY CURRENT CLUTCH COIL ASSLY. BRAKING BLOWER MOTOR ELECTRICAL METERS / SPEEDOMETER MISC FOR AUXILIARY TOTAL CONTROL UNIT AND DISPLAY UNIT CPS ASSEMBLY SHUNT AND MODULES SENSORS AND TRANSDUCERS MISC. SUB ASSEMBLIES DISTRIBUTION UNIT MISC. FOR MEP CONTROL LOCOS TOTAL OTHERS, MISC ELECTRICAL TOTAL

FPM CCM TACHO

01

01 01

01 01 02 01

01

02

02

02

05

03 01

4. MEP

01

02

03

01

01 03

01 03 00

03 05

03 04

TOTAL ELECTRICAL

15

13

31

22

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6.0

SPECIAL DRIVE DURING THIS MONTH:

Five (06) No. drives were launched in month of May to improve reliability. Faults were identified and defective components were replaced / overhauled

Sl 1.

Name of Drive Checking the condition of steel copper piping of Lube oil system if rubbing or not Checking PF, SF, Strainer casing for welded type/seamless Air dryer functioning & OVH date Check all locomotives fitted with modified F2 Feed valve. Additional COC fitted in Air dryer pipe line for isolating Air Dryer in emergency situation. Centrifuge stand new bolt fitted (12mmX40mmX1.75mm)

Advising authority Sr. DME(D)

Section

No. of Loco covered 121/121 103/104 103/104 103/104 91/104 40/104

Nos. of Loco defect noticed

Fault noticed

Action Plan

Med/ Mech. Sr. DME(D) Med/ Mech. AME(D) AME(D) Air Brake DME(D) Air Brake DME(D) OVH/Mech. Air Brake

2.

12 02 20 10 07

3. 4. 5.

36/91

13

6.

103/104

7.0

WORKS IN PROGRESS REGARDING INFRASTRUCTURE:

Sl No 1. 2. 3. 4. Items Extension of Diesel shed for homing 120 locomotives with other infra structural improvements. Andal diesel shed - provision of covered shed etc. for CNCUnder Floor Wheel Lathe. Andal Diesel shed creation of infrastructure of DEMU rake. Andal Diesel shed renovation of Shed Room with Aluminium sheet ridges and gutters along with north like glass and replacement of pipe line to carry rain water. Present status 70% work completed. Under processing for roof. 30% work progressed. Work started.

8.0

PROGRESS OF RSP ITEMS UNDER TAKEN IN SHED :

Sl No 01. Item No LB II PB No 1092 Year of sanction 10-11 Items MBCS including commissioning of REMMLOT Qty. 15 Present status Case sent to HQ on 15.10.12 after making current year fund.

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Position for Sanctioned RSP item of Andal Diesel Shed in 2011-12 (Rly.Bds power)
Sl.No. 01. Items Modified Hand Brake Assembly ( LB No.1690 of 11-12) Motorised truck assembly for WDG3A locos (LB-1697 of 11-12) Qty. 60 Nos Allocation BOND Anticipated cost 965 thousand 23391 thousand Present Status LOA issued on 08/10/12 M/s Mechwel/ Howrah PO on DLW No. 09/11/6049/9/00773 dated 26.10.11. Waiting for material. PO done in favour of M/s BHEL. Waiting for material. Re-tender due to BHEL unwilling to supply the material due to small quantity.

02.

02 Nos.

DRF

03.

Eddy Current Clutch.-BHEL Drg. No. 14360018001 (LB-1693 of 11-12) Alternator mounted rectifier with 36 diode and fuses (LB-1694 of 11-12) Power rectifier (Separately mounted) Drg. No. 26670500064 (LB-1695 of 11-12)

02 Nos.

BOND

1050 thousand. 1370 thousand 1370 thousand

04. 05.

01 No. 01 No.

BOND BOND

Position for Sanctioned RSP item of Andal Diesel Shed in 2012-13 (Rly.Bds power)
Sl.No. 01 02. 03 04. 05. 06. 07 Items Auxiliary Alternator with Rectifier Regulator for 1400 HP DEMU. L.C.C Governor-Model No. LCC 107B1 & B2 for 1400 HP DEMU Fuel Lifter Pump for 1400HP DEMU Air Compressor with pulley and other accessories for 1400 HP DEMU Actuator 1400 HP part No. 3875875 for DEMU Engine Control Panel for 1400 HP DEMU Turbo charger for 1400 HP DEMU Qty. 01 No. 01 set 1 No. 01 set. 01 No. 01 No. 1 No. Allocation CAP CAP CAP CAP CAP CAP CAP Anticipated cost 298 thousand 1029 thousand 318, thousand 189 thousand 133 thousand 192 thousand. 151 thousand The items will be procured through Divisional store i.e. Sr. DMM/ASN due to value of the item are less that 03 lacs as per order of CMPE/ER/KKK vide L/No. MM286/Vol.XII dated 17.12.12. Present Status Vetted requisition sent to HQ on 01.10.12.

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9.0

MASTER PLAN FOR REPLACEMENT OF M&P FOR NEXT 05 YEARS TO BE MADE :

(A) RAILWAY BOARD ITEMS FOR THE YEAR 2007-08 : COMPUTERIZED BOX. WATER LOAD 01 PO in favour of M/S Measurernatics / Roorkee. A.G.

(B)

RAILWAY BOARD ITEMS FOR THE YEAR 2009-10 : EOT CRANE 3 TON (14.00 MTS. 01 Indent sent to COFMOW on 12.11.09. SPAN). Tender opened on 11.02.10. Tender No.OP1901,Case under commercial revaluation. Case under TC. Process for re-tendering. Re-tender on 18.07.11/under TC. Order finalized in favour of M/S Cranex. DP 12.08.12./GA Drawing approved.

(C)

RAILWAY BOARD ITEMS FOR THE YEAR 2011-12 : Hyd. Torque wrench & Power 01 Tender opened on 15.06.12. Under pack Bolting Application of TC. Documents asked from store. Running Diesel locomotives.

(D)

RAILWAY BOARD ITEMS FOR THE YEAR 2012-13 : 40 ton EOT crane (15 MTS span) Automobile truck 01 Vetted requisition sent to HQ on 08.10.12 in favour Mackwell. 01 Req. under vetting.

(E)

GM LUMP SUM FOR THE YEAR 2011-12 : DM Water plant, 01

Torque Analyzer/ 01 Electronic Vetted Req. sent to HQ on 01.10.12.. Master Torque Wrench Tester. Induction Heater Model No. PIH 01 Vetted Req. sent to Sr. DMM/Store. 2001

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10.0

Diesel loco Training School at UDL has started training of Running Staff at UDL for ASN based Diesel crew. The training conducted is as below: Category Maintenance staff Cause Dsl. Refresher course for Technicians Grade MCM Tech I Tech II Tech III Ancl. Driver, Asst. Dr. Driver, Asst. Dr. Current month 02 15 08 13 NIL 09 NIL Cumulative 16 94 57 48 36 11 07 Overdue

NIL

Running staff Refresher & others

NIL

Yours faithfully,

(P. Sharma.) Sri Hemant Kumar. Chief Mechanical Engineer, Eastern Railway, K O L K A T A.

Copy for information to: Sri Sanjay Biswas. Chief Motive Power Engineer, Eastern Railway, KOLKATA.

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