COMPRESSOR

SECTION

AUDIT REPORT
2017-18

UPDATED ON: 17.04.2017

Proposed by Certified by
SSE/COM/DSL/KZJ DME/DSL/KZJ

Approved
Sr.DME/DSL/KZJ
 INDEX

S. No Description Page No
1. Various jobs in section
2. Action plan HHP
3. Action plan ALCO
4. Staff competency level
5. ANALYSIS OF FAILURES,
OCCURRENCES, MESSAGES AND
SHED FINDINGS
6. Shed messages
7. Make wise population and failures
8. Stocked item position
9. Non stocked item position
10. M&P
11. Tools
12. Modifications under progress/ to be
carried out
13. Reliability improvement action plan
 VARIOUS JOBS IN WDG4 LOCOMOTIVES

1) Light schedules attention (30,60,90,120,150,180,210,270,300 & 330)

2) Yearly Schedule Attention (Y-1, Y-2, Y-3, Y-4, Y-5 & Y-6)

3) Overhauling of WDG4 Loco Valves.

VARIOUS JOBS DONE IN ALCO LOCOMOTIVES

1) Shift schedule attention ( Trip & Mly)

2) Qly & Hly schedule attention (M-4,M-8,M-12,M-16, M-20, RB,POH & COMMN. NEW

LOCO)

3) Overhauling of Yearly (M-24,M-48 & M-72)

4) Overhauling of Inlet & Discharge valve.

5) Overhauling of Oil pressure indicator, relief valve & safety valves.

6) Overhauling of Inter cooler and After cooler.

 ACTION PLAN FOR 2017-18 (HHP)

Section COMPRESSOR
Section Supervisor Sri G. SHAKTIVEL Section Officer ADME-II

01. Performance Review 02. Failure Analysis

17-18
Sl. Type of Sl.
15-16 16-17 Actual till Description 2015-16 2016-17 2017-18
No. Failure Target No.
now
01 TPs 01 00 01 1 MR efficiency poor 0 4
02 OTPs 02 00 01 a. LP inlet valve plates dirty 2 4
03 SFs 26 38 30 b. LP inlet valve spring tension less 2 4
c. LP inlet valve spring broken 1 0
2 HP outlet to cooling coil flange gasket perished 0 0
3 Water leaking
a. Inlet water pipe crack 0 0
b. Inlet water pipe cone slack 1 0
c. Cylinder inspection cover dummy leaking 0 0
d. Cyl. head to liner gasket perished 2 0
4 I/Cooler safety valve blowing 3 0
5 Sealing wire in sump 0 0
6 Oil throwing / Excess ring gap 1 0
7 Drive shaft unusual sound 1 0
8 Spectro unusual 0 2
9 HP Discharge Valve, Inlet valve broken 1 0
10 Breather valve defective 0 0
11 Crank shaft Oil seal leaking 0 0
12 Copper gasket burnt or broken 1 0
13 HP Unloader pipe elbow broken 0 0
14 LP Inlet/Discharge valve bolt broken. 1 0
15 Piston unloader broken 1 0
16 Abnormal loading (suction unloader spring broken) 7 2
17 Oil indicator float broken. 2 0
18 M.R. pipe crack 1 0
19 Lube oil leaking from dip Stick foundation bolts slack 1 1
20 Lube oil pump Allen screw slack 1 0
21 Compressor Crank shaft not rotating. 1
 Total 29 38
03. CAPA to improve Reliability
2017-18
Sl. Total Qty./
Description Actual till
No. Population Target
now
1 All torquing procedures to followed as per 85 Locos 85 Locos
the manual
2 Monitoring of Spectro analysis for various 85 Locos 85 Locos
parameters in every schedule.
3 Monitoring of oil consumption in every 85 Locos 85 Locos
schedule
4 Monitoring of Crank case vacuum in every 85 Locos 85 Locos
schedule
5 Fitment of modified hose pipe. 85 Locos 85 Locos
6. Torquing of dipstick foundation bolts. 85 Locos 85 Locos
7. Provision of MR clamp 85 Locos 85 Locos
8. Oil indicator float removed and dummy in 30 Locos 30 Locos
only M/s. ELGI Compressor
ACTION PLAN FOR 2017-18 (ALCO)
 01. Performance Review 02. Failure Analysis
17-18
Sl. Type of Sl.
15-16 16-17 Actual till Description 2015-16 2016-17 2017-18
No. Failure Target No.
now
01 TPs 01 00 00 1 After cooler tube broken 0 0
02 OTPs 02 02 02 2 Inter cooler tube crack 1 0
03 SFs 03 02 02 3 Idler Gear shaft broken/Snap ring worn out 1 0
4 H/P or L/P piston liner scoring/ seized 0 0
5 Oil throwing from breather valve/ air intake filter 0 0
6 MR pipe line threads worn out 0 0
7 Fast coupling hub teeth broken 0 0
8 Brass Spindle not projecting 2 0
9 Inter cooler Safety Valve blowing. 0 0
10 Unloader copper Pipe line Crack. 0 0
11 Cylinder head to liner gasket perished. 1 0
12 MR pipe line/ Distance piece crack 1 0
13 Spectro unusual 0 1
14 Crank shaft oil seal leaking 0 0
15 Cardium leakage 0 0
16 Molykote leakage 0 0
17 CCV less 1 0
18 Fan blade broken. 0 1
19 H.P. Piston Ring jammed. 0 1
20 After cooler header gasket busted. 0 1
TOTAL 07 04
03. CAPA to improve Reliability
2017-18
Sl. Total Qty./
Description Actual till
No. Population Target
now
1 Lube oil pump body ZYGLO test in M24,M-48 & M- 91 Locos 30 Locos
72 sch. to avoided occurrences.
2 Compressor bed welding to be DPT tested and re- 91 Locos 30 Locos
weld on need base to avoid vibration in M-24 and
above schedules
3 Ensure no leakage in the joints in every schedule 91 Locos 91 Locos
4 Sump examination in every M-8 & M-16 schedule 91 Locos 91 Locos
5 Vacuum level monitoring in every schedule 91 Locos 91 Locos
6 Breather valve overhauling in M-8 and above 91 Locos 91 Locos
schedule.
7 100% checking of gaskets by Lab. before fitment. 91 Locos 91 Locos
8 Monitoring of Compressor oil consumption in 91 Locos 91 Locos
every schedule
9 To avoid Intercooler and After cooler failures, 91 Locos 91 Locos
Pneumatic testing of Intercoolers with 6kg/cm2
air pressure and After cooler with 10 Kg/cm2 air
 Staff competency level

SL. Name To.

Desg. DOB DOA DORC Expertise in Grading Remarks
No No
1. B.Omaji Sr. Tech - 10-04-1957 16-05-1981 Shift Very Good
2. Abdus Salam Sr. Tech - 11-10-1957 02-04-1982 All Rounder Very Good
3. K. Subba Rayudu Tech-I 138 01-06-1960 01-02-1993 Yearly O/H Very Good
4. P.A. Ebenazer Tech-I 177 25-09-1960 19-03-1991 Unloaders O/H Very Good
5. SK. Anwar Hussain Tech-II 229 04-12-1968 13-09-1989 All Rounder Very Good
6. K. Krishna Murthy Tech-II 281 06-12-1980 19-10-2010 Qly/Hly & Shift Very Good
7. S.Rajashekar Reddy Tech-III 308 08-02-1981 13-02-2002 All Rounder Very Good
8. Varun chauhan Tech-III 310 18-08-1985 30-03-2007 All Rounder Very Good
9. D. Santosh Kumar Tech-III 295 18-10-1991 11-09-2010 All Rounder Very Good
10. Raja Krishana Aacharya Tech-III 328 04-05-1985 03-05-2014 Shift Very Good
11. P.Balaraj Tech-III 370 25-09-1985 27-08-2009 Qly , Hly &Shift Very Good
12. P. Naresh Tech-III 385 20-04-1986 29-05-2013 Qly/Hly/Shift Very Good
13. A Sailaja Tech-III 374 05-04-1990 15-07-2010 Discharge valves O/H Very Good
14. N. Roja Tech-III 380 12-09-1992 24-06-2011 Discharge valves O/H Very Good
15. V. Mahendar DKH 519 10-06-1985 29-05-2013 Shift Very Good
16. Sravan Kumar DKH 534 10-01-1985 10-06-2013 Yly Overhauling/ shift Very Good
17. G. Lavanya DKH 561 12-10-1980 02-09-2015 Discharge valves O/H Very Good
 I. ANALYSIS OF FAILURES,OCCURRENCES, MESSAGES AND SHED FINDINGS
a) ALCO:
Sl. Component 2014-15 2015-16 2016-17 2017-18
No. TP OTP SF TOT TP OTP SF TOT TP OTP SF TOT TP OTP SF TOT
1 After cooler tube broken 01 0 04 05 0 0 0 0 0 0 0 0
2 Inter cooler tube crack 0 0 0 0 0 01 0 1 0 0 0 0
3 Idler Gear shaft broken/Snap
0 0 0 0 01 0 0 01 0 0 0 0
ring worn out
4 H/P or L/P piston liner
01 01 0 02 0 0 0 0 0 0 0 0
scoring/ seized
5 Oil throwing from breather
0 0 03 03 0 0 0 0 0 0 0 0
valve/ air intake filter
6 MR pipe line threads worn
0 0 02 02 0 0 0 0 0 0 0 0
out
7 Fast coupling hub teeth
0 0 01 01 0 0 0 0 0 0 0 0
broken
8 Brass Spindle not projecting 0 0 0 0 0 0 02 02 0 0 0 0
9 Inter cooler Safety Valve
0 0 03 03 0 0 0 0 0 0 0 0
blowing.
10 Unloader copper Pipe line
0 0 03 03 0 0 0 0 0 0 0 0
Crack.
11 Cylinder head to liner gasket
01 0 01 02 01 0 0 1 0 0 0 0
perished.
12 MR pipe line/ Distance
0 0 02 02 0 01 0 1 0 0 0 0
piece crack
13 Spectro unusual 0 0 05 05 0 0 0 0 0 0 01 01
14 Crank shaft oil seal leaking 0 01 01 02 0 0 0 0 0 0 0 0
15 Cardium leakage 0 0 01 01 0 0 0 0 0 0 0 0
16 Molykote leakage 0 0 03 03 0 0 0 0 0 0 0 0
17 CCV less 0 0 0 0 0 0 01 01 0 0 0 0
18. Fan blade broken. 0 0 0 0 0 0 0 0 0 01 0 01
19. H.P. Piston Ring jammed. 0 0 0 0 0 0 0 0 0 0 01 01
20. After cooler header gasket
0 0 0 0 0 0 0 0 0 01 0 01
busted.
TOTAL 03 02 31 36 2 2 3 7 00 02 02 04

b) HHP:
Sl. Component 2014-15 2015-16 2016-17 2017-18
No. TP OTP SF TOT TP OTP SF TOT TP OTP SF TOT TP OTP SF TOT
1 MR efficiency poor 0 0 0 0 0 0 0 0 0 0 04 04
a. LP inlet valve plates dirty 0 0 10 10 0 0 2 2 0 0 24 24
b. LP inlet valve spring
0 0 01 01 0 0 2 2 0 0 04 04
tension less
c. LP inlet valve spring
0 0 17 17 0 0 1 1 0 0 0 0
broken
2 HP outlet to cooling coil
0 0 02 02 0 0 0 0 0 0 0 0
flange gasket perished
3 Water leaking
a. Inlet water pipe crack 0 01 03 04 0 0 0 0 0 0 0 0
b. Inlet water pipe cone
0 0 0 0 0 1 0 1 0 0 0 0
slack
c. Cylinder inspection cover 0 0 01 01 0 0 0 0 0 0 0 0
dummy leaking
Sl. Component 2014-15 2015-16 2016-17 2017-18
No. TP OTP SF TOT TP OTP SF TOT TP OTP SF TOT TP OTP SF TOT
d. Cyl. head to liner gasket
0 0 01 01 0 0 2 2 0 0 0 0
perished
4 I/Cooler safety valve blowing 0 0 05 05 0 0 3 3 0 0 0 0
5 Sealing wire in sump 0 0 01 01 0 0 0 0 0 0 0 0
6 Oil throwing / Excess ring
0 01 01 02 0 0 1 1 0 0 0 0
gap
7 Drive shaft unusual sound 0 0 02 02 0 0 1 1 0 0 0 0
8 Spectro unusual 0 0 02 02 0 0 0 0 0 0 02 02
9 HP Discharge Valve, Inlet
0 0 02 02 0 0 1 1 0 0 0 0
valve broken
10 Breather valve defective 0 0 02 02 0 0 0 0 0 0 0 0
11 Crank shaft Oil seal leaking 0 0 01 01 0 0 0 0 0 0 0 0
12 Copper gasket burnt or
0 01 0 01 1 0 0 1 0 0 0 0
broken
13 HP Unloader pipe elbow
0 0 02 02 0 0 0 0 0 0 0 0
broken
14 LP Inlet/Discharge valve bolt
0 0 0 0 0 0 1 1 0 0 0 0
broken.
15 Piston unloader broken 0 0 0 0 0 0 1 1 0 0 0 0
16 Abnormal loading (suction
0 0 01 01 0 0 7 7 0 0 02 02
unloader spring broken)
17 Oil indicator float broken. 0 0 0 0 0 0 2 2 0 0 0 0
18 M.R. pipe crack 0 0 0 0 0 0 1 1 0 0 0 0
19 Lube oil leaking from dip
0 0 0 0 0 1 0 1 0 0 01 01
Stick foundation bolts slack
20 Lube oil pump Allen screw
0 0 0 0 0 0 1 1 0 0 0 0
slack
21 Compressor Crank shaft not
0 0 01 01
rotating.
Total 0 03 54 54 1 2 26 29 00 00 38 38

II. Shed messages

a) TP
S No Loco No Date of Actual message Shed findings Corrective action
failure taken

b) OTP
S No Loco No Date of Actual message Shed findings Corrective action
failure taken

c) Shed findings
S No Loco No Date of Actual message Shed findings Corrective action
failure taken
III. Make wise population and failures.

a) COMPRESSOR
FRPCPY
S ALCO WDG4 WDP4 Total Failures Failures of Failures of
Make
No LY CY
16-17 17-18 16-17 17-1816-17 17-1816-17 17-18 16-17 17-18
1 ELGI 80101 81 00 00
2 ELGI 3CDB 15 03 03
3 KCW 623 03 00 00
4 KCW 523 01 00 00
5 KE 6 02 00 00
6 6 CD4UC 01 01 01
7 OTHERS 00 00 00
8 GD 55 32 32
9 ELGI 30 06 06
10 OTHERS 00 00 00

b) FAN BLADE BROKEN of ALCO

FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 ELGI 91 01 01
2

c) SPECTRO of ALCO
FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 ELGI 80101 91 01 01
2

d) PISTON RING of ALCO

FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 ELGI 3CDB 91 01 01
2

e) AFTER COOLER TOP HEADER GASKET of ALCO

FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 CEC 91 01 01
2
 a) SPECTRO of HHP
FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 ELGI 30 02 02
2 GD 55 00 00

b) ABNORMAL LOADING & UNLOADING of HHP

FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 ELGI 30 02 02
2 GD 55 00 00

c) MR EFFECIENCY of HHP
FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 ELGI 30 00 00
2 GD 55 32 32
d) CRANK SHAFT of HHP
FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 ELGI 30 01 01
2 GD 55 00 00

e) DIPSTICK of HHP
FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 ELGI 30 00 00
2 GD 55 01 01

IV. STOCKED ITEM POSITION

a) ALCO Locos
Sl. SOH
PL.NO DESCRIPTION AAC Remarks
No Section Stores
01 11182611 AIR INTAKE STRAINER 40 02 04
WITH BEND
02 11382934 CYLINDER LP 100 12 49
EXHAUSTER COMP
03 11488311 LUBE OIL PUMP 10 02 03
ASSEMBLY
04 11731217 HP CYL LINER DIA 50 12 36
144mmFOR COMP
05 11812175 KIT PISTON RINGS FOR 100 12 190
LPEXHAUST
06 17305007 DISCHARGE VALVE 100 06 42
ASSLY ELGI
07 17305019 INLET VALVE ASSLY 45 30
ELGI A070072
 b) HHP Locos
Sl. SOH
PL.NO DESCRIPTION AAC Remarks
No Section Stores
01 17380108 Piston assembly LP to 04 02 05
EMD pt
02 17380121 SPRING VALVE FOR 600 100 600
UNLOADER VALV
03 17380170 CYLINDER HIGH 06 01 01
PRESSURE to DLW
04 17453057 ELEMENT FILTER 800 25 103
(FIBER GLASS)
05 80010179 SERVO PRESS 100 RR 1800 200 00
COMP OIL

V. Non STOCKED ITEM POSITION

a) ALCO Locos
Sl. SOH Remarks
PL.NO DESCRIPTION AAC
No Section Stores
01
02
03
04
05

b) HHP Locos
Sl. SOH Remarks
PL.NO DESCRIPTION AAC
No Section Stores
01
02
03
04
05

VI. M&P
Additional
Sl. no Description Available Remarks
Requirement
1.
2.
3.

VII. Tools
Additional
Sl. no Description Available Remarks
Requirement
1.
2.
3.

VIII.Modifications under progress/ to be carried out

 Sl.
Description Reference Status Remarks
No
1.
2.
3.
4.

IX. Reliability improvement action plan

2016-17 2017-18
Sl. Total Qty/ Act
Description
No Population Target Act till now Target till
now
1. Lube oil pump body ZYGLO test in M24 sch. 91 Locos 40 Locos 40 Locos 30 Locos
to avoided occurrences.
2. Compressor bed welding to be DPT tested 91 Locos 40 Locos 40 Locos 30 Locos
and re-weld on need base to avoid vibration
in M-24 and above schedules
3. Ensure no leakage in the joints in every 91 Locos 91 Locos 91 Locos 91 Locos
schedule
4. Sump examination in every M-4 and above 91 Locos 91 Locos 91 Locos 91 Locos
schedule
5. Vacuum level monitoring in every schedule 91 Locos 91 Locos 91 Locos 91 Locos
6. Breather valve overhauling in M-8 and 91 Locos 91 Locos 91 Locos 91 Locos
above schedule.
7. 100% checking of gaskets by Lab. before 91 Locos 91 Locos 91 Locos 91 Locos
fitment.
8. Monitoring of Compressor oil consumption 91 Locos 91 Locos 91 Locos 91 Locos
in every schedule
9. To avoid Intercooler and After cooler 91 Locos 40 Locos 40 Locos 91 Locos
failures, Pneumatic testing of Intercoolers
with 6kg/cm2 air pressure and After cooler
with 10 Kg/cm2 air pressure under
submerged water tank.
10. Intercooler and After cooler cleaning in a 91 Locos 40 Locos 40 Locos 91 Locos
Orion tank, circulation of Orion inside the
tubes of Intercooler and After cooler with
developed pump system.
11. Breather valve checking on the compressor 91 Locos 91 Locos 91 Locos 91 Locos
test stand
12. Annealing of all copper pipe lines during 91 Locos 40 Locos 40 Locos 91 Locos
yearly schedule and straightening of pipe
lines wherever unrequited bending is
available
13. Ensure DPT testing of all bed welding joints 91 Locos 30 Locos 30 Locos 91 Locos
during yearly schedule
14. Conversion of all non-modified valves into 91 Locos 91 Locos 91 Locos 91 Locos
modified valves
15. Checking of loading/unloading time and 91 Locos 91 Locos 91 Locos 91 Locos
monitoring of previous trend in the loco, MR
efficiency, Crank case vacuum , Oil level
and addition of oil per no. of working days
on online(consumption/working days)
 2016-17 2017-18
Sl. Total Qty/ Act
Description
No Population Target Act till now Target till
now
16. Torquing of all bed bolts during yearly and 91 Locos 40 Locos 40 Locos 91 Locos
yearly SR attention
17. Crank shaft ball bearing changing in M-48 91 Locos 05 Locos 05 Locos 91 Locos
Sch.

18. Cardium compound converted to molykote 91 Locos 40 Locos 40 Locos 91 Locos

in yearly & out of course.

19. Compressor Oil changing in YLY SR 91 Locos 40 Locos 40 Locos 91 Locos

20. Checking of MR pipe alignment in M4 & 91 Locos 91 Locos 91 Locos 91 Locos

above schedule.

21. development of test benchs

a)Test bench for leakage testing of inlet and
discharge valves.
B Test bench for HHP locos
c)pneumatic test bench for testing
Intercooler and After cooler at 6kg/cm2 and
10kg/cm2 respectively.