Compressor and Expressor failures.
Compressor and Expressor failures of Diesel loco shed and action
plan to control these failures were discussed with SSE/D/Expressor/.
28 out of curse attention cases for
various compressor sub assemblies and items have been reported by shed
since April 2011.The action plan has been prepared to weed out the contributors
of low reliability of compressor items. Shed should implement the same and
progress report to be furnished through MCDO.
1.
Rubber roller – Total 7 cases of failure of rubber roller have
been occurred at an
average service life of 9
months. The reason of failure were due to bad quality of
rubber and defective flexible coupling.
1.1
Rubber
roller to be checked for physical deformity during pre commissioning of RB
and POH locos.
1.2
Analysis
of old removed rollers to be done before fitment of new roller. If wear is
found not uniform it indicates misalignment.
1.3
Excessive
wear indicates poor material quality.
1.4
The
entire rollers to be of same hardness.
1.5
Run
out of shaft to be checked in M24 and above schedule.
1.6
Vibration
to be checked in all schedules.
2.0
Lube oil pump gear –
two
nos. gears failed due to poor quality of gear. One from DMW failed in 26 months
and the other was M/S KR make that failed in just one month of service life.
2.1 DP test and gear profile check to be
introduced from M-12 and above schedule.
2.2 Lube oil pump gear to be replaced in
M-24 schedule after lab test.
3.0
After cooler – One after cooler
failed due to over aged cooler retained in service.
3.1
Replace
after coolers in M 24 schedule.
3.2
After
coolers to be Hydraulic tested at 14 Kg/cm2 pressure before fitment.
3.3
Visual
checking in every schedule.
4.0
Liner – One liner failed
due to over aged liner retained in service.
4.1
Upgraded
liner to be introduced.
4.2
Conventional
liner to be replaced in M-12 and above schedule.
4.3
Warranty
claim to be raised of released liners if found any abnormality.
5.0
Lube oil Relief
valve – Two nos. new relief valves found defective
of M/S ELGI make.
5.1
Relief
valves to be replaced with test bench tested one in M4 schedule.
5.2
Poor
quality of spring to be reported to OEM.
5.3
Springs
to be tested for load deflection.
6.0 Valve
- One valve failed of M /S ELGI
make.
6.1 Shed should replace all valves in RB and
POH locos with tested valve during
commissioning check.
6.2 All valves to be removed and refitted
after DP tested in M2 and above schedule.
6.3 Renew valves in M24 sch.
7.0
Flexible coupling – One Flexible
coupling failed due to defective material.
7.1
Clamping
to be done at end plate of flexible coupling from M12 and above schedule. One
special drive to be initiated to provide clamp in all locos.
7.2
Vibration
of flexible coupling to be done in every schedule.
8.0
Piston ring – Two cases of piston
ring failure reported by shed due to more gaps.
8.1
Piston
ring to be replaced in M12 schedule and onward in conventional compressor.
8.2
In
upgraded compressor Piston ring to be replaced in M-24 schedule.
8.3
Blow
by test to be conducted in M4 and above schedule.
8.4
Warranty
claim to be raised for released material.
9.0
HP Piston – Three cases of
failure of HP Piston due to defective material
9.1
HP
Piston to be replaced in M12 schedule.
9.2
Only
zyglo tested piston and wrist pin to be fitted.
10.0
Pipe lines failure – Three locos failed
due to old pipe lines fitted during POH resulting air leakage joints.
10.1
All
joints of pipelines in RB and POH locos to be checked for thread profiles of
couplers and joints.
10.2
Alignment
should be checked and fitment should be done by using thread locking compound.
10.3
Condition
of clamps to be checked and clamps to be renewed if found bent or crack on
welding.
10.4
DPT
of coupling and spacer should be done in M24 schedule.
11.0
Intercooler safety
valve – Failure
was due to less initial thread dia.
11.1
Intercooler
safety valve to be replaced with tested one during pre commissioning of RB and
POH locos.
11.2
Measurement
of thread dia in M4 & above schedule.
12.0
Plug cap – One loco failed for
defective plug.
12.1
Condition
and thread to be checked by plug gauge before fitment.
12.2
Lab
test of plug should be done before fitment.
13.0
Oil indicator - One loco was failed
due to defective Oil indicator.
13.1
Oil
indicator teeth to be checked by lab from M12 and above schedule.
13.2
Oil
indicator to be replaced in M24 and above.
14.0 Other measures
for improving reliability of compressor-
14.1. Correction of AAC
14.2 Categorization of compressor into 'A' &
'B', & 'C' category based on compressor oil
consumption. All ‘B’ & ‘C’
category compressors to be attended in next 3 months to
upgrade to ‘A’ category.
14.3 Temperature monitoring in every schedule
and corrective action in case of
abnormalities.
14.4 Sectional monitoring of compressor in
every schedule in addition to attention by
Mech. Running section.
14.5 Daily one hour training to staffs on
quality issues of the section and conduction of
Quiz
with proper record keeping.
14.6 Gradation of staffs on the basis of
knowledge & skill category into three categories
as
'A','B','C. The staffs in ‘B’
& ‘C’ to be upgraded to ‘A’
category by intensive
training in next three months.
14.7 Overdue material retained in service to be
listed out and proper action plan to be
chalk out for replacement phase-wise.
14.8 Proper clamping of all pipelines in M12
and above schedules.
14.9 Bedding test of compressor after
overhauling.
14.10 Vibration checking of compressor in all
schedules.
14.11 Use of thread locking compound in joints.
14.12 Efficiency test of compressor in all
schedules.
14.13 Loading & unloading time to be
maintained strictly with in limit.
14.14 RPM Vs MR pressure graph to be plotted to
check compressor efficiency.
14.15 Over hauling of compressor sub assemblies
in M12 schedule and above for all
types of compressor.
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