AIR BRAKE

SECTION

AUDIT REPORT
2017-18

UPDATED ON: 17.04.2017

Proposed by Certified by
SSE/ABS/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

2) Yearly Schedule Attention

3) Sanders attention

4) Trouble shooting in WDG4/WDP4D Locos.

5) Overhauling of WDG4 Loco Valves.

6) Overhauling of Air dryers

VARIOUS JOBS DONE IN ALCO LOCOMOTIVES

1) Sanders attention

2) Shift schedule attention

3) Qly & Hly schedule attention

4) Trouble shooting

5) Overhauling of valves

6) Overhauling of A9 & SA9

7) Overhauling of C3W distributor valves

8) Overhauling of Air dryers

 ACTION PLAN FOR 2017-18 (HHP)

Section Air Brake

Section Supervisor Sri M. SHYAMA RAO Section Officer ADME-II

01. Performance Review 02. CCB 1.5 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 8 01 02 1 PCB Card DBI 0 1
02 OTPs 4 14 08 2 SV2 0 0
03 SFs 50 44 20 3 SVJ 0 0
4 DIZ 0 0
5 CPZ 0 0
6 ADZ2 0 0
7 SS9A 0 0
8 SS9B 0 0
9 EPA1 0 0
10 EPA2 1 0
11 EPA3 1 1
12 FOR4 0 0
13 VENT VALVE 775096 0 0
14 ANALOG CONVERTER 774009 2 4
15 MAGNET VALVE MVEM/MVER I94900/1024 0 0
16 MAGNET VALVE 53 I88806/024 0 0
17 MAGNET VALVE BP II16356/1024 0 0
18 MAGNET VALVE 16 774257 0 0
19 PISTON VALVE PVERI/PVBC I88098/341 4 2
20 PISTON VALVE PVBIT I88098/391 0 0
21 PISTON VALVE PVBP/BPCO I98866 0 0
22 KR-5EO RELAY VALVE II39251 1 0
23 J1 RELAY VALVE 735690 1 1
24 MR FILTER 775012 2 3
25 FILTER WBFIL 100AA002 2 4
26 KE VALVE KIT-I 1.186/2 1 1
27 EPCU PARTS KIT 775004 0 0
28 BCEV 775009 2 2
29 DOUBLE CHECK VALVE II40529 0 0
30 EMERGENCY VALVE 171095 0 2
31 BRAKE CONTROLLER 774902 2 1
32 ANGLE COCK GASKETS (FPBP) 1 1
33 HORN SHELLS 11 0
34 HORN MAGNET VALVES 5 3
35 SAND MAGNET VALVE 8 6
36 MVCC 6 8
37 MMC 2 0
38 AUTO DRAIN VALVE 4 6
39 GAUGES 2 5
40 OTHERS 0 0
TOTAL 58 51
03. CAPA to improve Reliability
2017-18
Sl. Total Qty./
Description Actual till
No. Population Target
now
01 Provision of BP/FP guards. 85 Locos 25 Locos
02 Checking of couplers intact in CCB 1.5/ 2.0 85 Locos 85 Locos
 02. CCB 2.0 Failure Analysis of HHP Locos
Sl.
Description 2015-16 2016-17 2017-18
No.
1 JUNCTION BOX ASSY, PSJB, 74V 787090 0 1
2 CONTROL PROTION : BC HI-TEMP 789009 0 0
3 VALVE ASSY, DRIVERS BACK-UP 787609 0 0
4 VALVE ASSY, 821 VENT 785260-1000 0 0
5 CONTROL PORTION , BP 787321-2004 0 0
6 CONTROLLER ASSY, EBV-A 787452-2004 1 0
7 CONTROLLER ASSY , EBV-B 787453-2004 0 0
8 CONTROL PORTION , 16-PIPE 787556-2004 0 1
9 CONVERTER ASSY, LON 422/485 787729-2004 0 0
10 CONTROL POSTION , 20-PIPE 787775-2004 1 1
11 CONTROL PORTION , RELAY 788244-2004 0 0
12 CONTROL PORTION , ER 788753-2004 1 0
13 EMERG. BRAKE VALVE I69411 0 0
14 PRESSURE GOVERNOR II35830/04535 0 0
15 ACTUATOR , PER II51450/2 0 0
16 ANGLE COCK GASKETS (FPBP) 0 1
17 HORN SHELLS 0 0
18 HORN MAGNET VALVES 0 0
19 SAND MAGNET VALVE 0 2
20 MVCC 0 0
21 AUTO DRAIN VALVE 0 3
22 GAUGES 0 3
23 OTHERS 0 0
24 MMC 0 0
TOTAL 3 12
 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 05 03 02 1 A-9 Valve 5 02
02 OTPs 05 12 06 2 SA-9 Valve 9 05
03 SFs 93 57 30 3 C2 relay valve 1 00
4 Add.C2 valve 2 00
5 AFMV 2 02
6 BP/FP Angle coc gskt. 19 03
7 C3W valve 1 22
8 D-1 Emer. valve 2 00
9 D-1 Pilot valve 2 01
10 D24B valve 1 01
11 EPG 1 01
12 Horn shell/ magnet valve 5 01
13 Sanders 3 06
14 MU2B 4 01
15 F-1 selector 0 03
16 MR-Safety valve 3 00
17 ABD valve 2 01
18 Limiting valve 2 03
19 N-1 reducing valve 0 01
20 Wiper motor 2 00
21 Pipe joints 1 00
22 GAUGES 13 05
23 MMC 12 04
24 Others 11 05
TOTAL 103 04
03. CAPA to improve Reliability
Sl. Description 2017-18
 Total Qty./ Actual till
No. Target
Population now
01 100% Testing of all rubber parts by Lab. before 91 Locos 91 Locos
fitment.
02 Rejection of Low shelf life items. 91 Locos 91 Locos
03 Procurement of kits through approved sources 91 Locos 91 Locos
04 Checking the dimensions of 'O' rings before 91 Locos 91 Locos
fitment.
05 Ensuring 100% functioning of air dryers. 91 Locos 91 Locos
06. Modification to BP/FP guards. 91 Locos 91 Locos
07 Provision of spring loaded sand box lids. 91 Locos 91 Locos
08 Securing of sand box. 91 Locos 91 Locos
09 Checking of all Air brake testing parameters in 91 Locos 91 Locos
QLY and above Sch.
10 Cleaning of all air brake pipe lines during yearly 91 Locos 91 Locos
Sch.
11 100% annealing of all copper pipelines during 91 Locos 91 Locos
Hly & above Sch.
12 Application of Araldite on angle cock sealing 91 Locos 91 Locos
rings and Over hauling during quarterly Sch.
Instead of M-12 Sch.
13 Proper application of grease during overhauling 91 Locos 91 Locos
of Valves (avoiding excess greasing.)
14 Provision of safety clamps during heavy 91 Locos 91 Locos
Schedules
15 Ensuring availability of ready unit exchanger 04 Units 04 Units
spares.

16 Ensuring 100% calibration of all gauges during 91 Locos 91 Locos

Hly & above schedule.
17 Conducting failure meeting every month and Every Month Every
reviewing the action plan. Month
18 EMD type J filters to be fitted in yearly Sch. 09 Locos 09 Locos
19 Monitoring of purge time during every schedule. 91 Locos 91 Locos
20 During fitment of valves surface preparation & 91 Locos 91 Locos
certification by supervisor to be ensured.
21 Ensuring working of D1 emergency brake valve 91 Locos 91 Locos
during every schedule.
22 Ensuring sealing of additional BP cut out COC. 91 Locos 91 Locos
23 BP Gauge tapping 28 Locos 28 Locos
 Staff competency level

SL. Name To.

Desg. DOB DOA DORC Expertise in Grading Remarks
No No
1. S.Eswarprasad Sr. Tech - 06-01-1960 03-7-1979 Sanders & Light Repair Good
2. N.Laxminarasimha Rao Sr. Tech - 06-08-1958 27-05-1988 Light repair Good
3. Md. Manzuruddin Tech-I 111 15-08-1959 30-04-1982 Valves Ohg & development jobs Very Good
4. K. Narender Chary Tech-I 130 08-10-1959 03-10-1983 Sanders Good
5. M.Vedaprakash Babu Tech-I 158 09-07-1963 01-06-1992 Development jobs, Light repair Good
6. MD.Moosa Tech-I 160 04-07-1960 01-01-1993 Trouble shooting & development Good
jobs
7. M.Cheralu Tech-I 163 18-12-1959 01-05-1979 Sanders Average
8. A.Sailu Tech-I 168 10-09-1966 19-09-1992 Light repair Good
9. G. Sreenu Babu Tech-I 172 30-05-1970 04-12-1997 Qly/ Hly/ Yly Schedule Good
10. Prasanna Kumar Tech-I 203 21-06-1972 20-02-1992 Sanders Good
Mahanthy
11. Sd.Kaleem ahamed Tech-I 205 01-7-1963 26-05-1988 Valves Ohg & development Very Good
12. R.Rajender Tech-I 206 19-02-1961 19-07-1980 Qly/ Hly/ Yly, Trouble shooting Good
13. B.Yadagiri Tech-I 216 15-03-1980 12-09-2003 Qly / Hly & Light repair Good
14. B.Venkat Ramana Tech-II 221 25-08-1974 20-08-2005 Light repair & Trouble shooting Very Good
15. S.Sekhar Tech-II 242 20-11-1958 20-07-1982 Sanders Average
16. M.Shankar Tech-II 249 16-03-1971 19-09-1992 Trouble shooting/ Modification Good
17. G.Bhaskar Tech-II 276 07-09-1976 07-08-2009 Light repairs , Heavy repair Good
18. A.Kankaiah Tech-II 279 03-11-1960 28-09-1991 Sanders Good
19. CH. Radha Tech-III 290 10-01-1969 06-4-1998 Valves Ohg & records Very Good
20. S.Satyanarayana Tech-III 292 17-03-1963 07-03-1985 Light repair & Sanders Average
21. D.Chandra Mouly Tech-III 309 05-02-1982 19-09-2002 Heavy repair & modification Very Good
22. Rajesh Kumar Ranjan Tech-III 322 12-07-1992 03-05-2014 Light Repair Very Good
23. Satish Chandar Saini Tech-III 327 09-01-1988 03-05-2014 Light Repair Average
24. Praveen sultana Tech-III 358 20-02-1977 15-04-2006 Valves Ohg & records Good
25. E.Sadanandam Tech-III 378 08-11-1986 10-06-2011 Heavy repair & modification Very Good
26. L. Kanka Raju Tech-III 400 16-12-1986 07-04-2015 Heavy repair Good
27. Jagdish Kumar Meena DKH 533 04-06-1986 10-07-2013 Light Repair Good
28. N. Saidaiah DKH 549 05-04-1990 13-11-2014 Light Repair Average
29. G. Shirisha DKH 556 23-02-1996 04-02-2015 Valves Cleaning Good
30. Y. Sunita DKH 560 14-06-1996 26-08-2015 Valves Cleaning 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 A-9 Valve 03 0 11 14 0 0 5 5 0 1 1 02
2 SA-9 Valve 0 0 4 4 1 0 8 9 0 0 5 05
3 C2 relay valve 0 0 5 5 0 0 1 1 0 0 0 00
4 Add.C2 valve 0 0 6 6 1 0 1 2 0 1 1 02
5 AFMV 0 0 3 3 0 0 2 2 0 0 3 03
6 BP/FP Angle coc gskt. 0 1 31 32 1 0 18 19 0 0 22 22
7 C3W valve 0 0 0 0 0 0 1 1 0 0 0 00
8 D-1 Emer. valve 1 0 0 1 0 0 2 2 0 1 1 01
9 D-1 Pilot valve 0 0 2 2 0 0 2 2 0 0 1 01
10 D24B valve 0 0 11 11 0 0 1 1 0 0 1 01
11 EPG 0 0 2 2 0 0 1 1 0 0 1 01
12 Horn shell/ magnet valve 0 1 10 11 0 0 5 5 0 1 5 06
13 Sanders 0 0 2 2 0 1 2 3 0 1 0 01
14 MU2B 0 0 0 0 0 0 4 4 0 0 3 03
15 F-1 selector 0 0 0 0 0 0 0 0 0 0 0 00
16 MR-Safety valve 0 0 3 3 1 0 2 3 0 0 1 01
17 ABD valve 0 0 14 14 0 0 2 2 0 0 3 03
18 Limiting valve 0 0 0 0 0 0 2 2 0 0 1 01
19 N-1 reducing valve 0 0 1 1 0 0 0 0 0 0 0 00
20 Wiper motor 0 0 9 9 0 0 2 2 0 0 0 00
21 Pipe joints 0 1 2 3 1 0 0 1 2 2 1 05
22 GAUGES 0 0 0 0 0 1 12 13 0 0 4 04
23 MMC 0 0 0 0 0 2 10 12 0 2 3 05
24 Others 2 1 24 27 0 1 10 11 1 3 0 04
TOTAL 6 4 140 150 5 5 93 103 03 12 57 72

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 PSB CARD DBI 0 0 0 0 0 0 0 0 1 0 0 01
2 PSB CARD SV2 2 0 0 2 0 0 0 0 0 0 1 01
3 PSB CARD SVJ 0 0 0 0 0 0 0 0 0 0 0 00
4 PSB CARD DIZ 0 0 0 0 0 0 0 0 0 0 0 00
5 PSB CARD CPZ 0 0 2 2 0 0 0 0 0 0 0 00
6 PSB CARD ADZ2 0 0 0 0 0 0 0 0 0 0 0 00
7 PSB CARD SS9A 0 0 0 0 0 0 0 0 0 0 0 00
8 PSB CARD SS9B 0 0 0 0 0 0 0 0 0 0 0 00
9 PSB CARD EPA1 0 0 0 0 0 0 0 0 0 0 0 00
10 PSB CARD EPA2 0 0 0 0 0 0 1 1 0 0 0 00
11 PSB CARD EPA3 0 0 0 0 0 0 1 1 0 1 0 01
12 PSB CARD FOR4 0 0 0 0 0 0 0 0 0 0 0 00
13 Brake controller valve 0 0 1 1 1 0 0 1 0 0 0 00
14 PVERI 0 0 0 0 0 0 0 0 0 0 0 00
15 PVBIT 0 0 0 0 0 0 0 0 0 0 0 00
16 PVBC 0 0 1 1 1 0 1 2 0 0 0 00
17 BCEV 0 0 0 0 0 0 0 0 0 0 1 01
18 AW4-16 0 1 0 1 1 0 0 1 0 0 0 00
19 AW4-ER 0 0 0 0 0 0 0 0 0 0 0 00
 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
20 TRANSDUCER 0 0 0 0 0 0 0 0 0 0 0 00
21 Other Valves 0 0 4 4 1 0 1 2 0 3 11 14
22 Horn Magnet Valve 0 0 3 3 0 0 5 5 0 0 2 02
23 Sand Magnet Valve 0 0 0 0 0 0 0 0 0 0 0 00
24 Horn shells 0 0 8 8 1 1 9 11 0 0 0 00
25 Wipers 0 0 10 10 0 0 11 11 0 1 1 02
26 CCB 2.0 0 1 0 1 1 0 5 6 0 0 8 08
27 Auto Drain Valves 0 0 0 0 0 0 10 10 0 0 2 02
28 OTHERS 2 1 15 18 2 2 4 8 0 9 7 16
29 Angle cock 0 0 0 0 0 1 0 1 0 0 1 01
30 GAVGES 0 0 0 0 0 0 2 2 0 0 5 05
TOTAL 4 3 44 51 8 4 50 62 01 14 44 59

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) Air dryer
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 Knorr Bremse 14 18 00 00 00 00
2 FTIL 59 15 00 00 00 00
3 SIL 15 31 00 00 02 02
4 Trident 02 11 00 00 00 00
5 Prag Polymers 00 10 00 00 00 00
b) A9 valves of ALCO
FRPCPY
S Make Population Failures
Failures of Failures of
No VALVE/KIT
LY CY LY CY LY CY
1 FTIL/India Supply. Co. 60 01 0.83%
2 SIL/ India Supply. Co. 40 01 1.2 %
3. FTIL/AK 60 00 0%
4. SIL/ AK 40 00 0%

c) SA9 valves of ALCO

FRPCPY
S Make Population Failures
Failures of Failures of
No VALVE/KIT
LY CY LY CY LY CY
1 FTIL/AK 110 05 4.5%
2 SIL/ AK 90 04 4.4%

d) C2 Relay valves of ALCO

FRPCPY
S Make Population Failures
Failures of Failures of
No VALVE/KIT
LY CY LY CY LY CY
1 FTIL/AK 60 01 1.6%
2 SIL/ AK 40 00 0%
e) Additional C2 Relay valves of ALCO
FRPCPY
S Make Population Failures
Failures of Failures of
No VALVE/KIT
LY CY LY CY LY CY
1 FTIL/AK 60 01 1.6%
2 SIL/ AK 40 01 1.4%
f) Air Flow Measuring valves of ALCO
FRPCPY
S Make Population Failures
Failures of Failures of
No VALVE/KIT
LY CY LY CY LY CY
1 Midland/Topgrip 50 01 2.0%
2 Topgrip 50 01 2.0%
g) Angle Cock of ALCO
FRPCPY
S Make Population Failures
Failures of Failures of
No VALVE/KIT
LY CY LY CY LY CY
1 SNE/AK 400 19 4.00%

h) C3W Distributor valves of ALCO

FRPCPY
S Make Population Failures
Failures of Failures of
No VALVE/KIT
LY CY LY CY LY CY
1 FTIL/FTIL 60 00 0.0%
2 SIL/FTIL 40 01 2.0%
i) D-1 Emergency valves of ALCO
FRPCPY
S Make Population Failures
Failures of Failures of
No VALVE/KIT
LY CY LY CY LY CY
1 FTIL/AK 80 01 1.2%
2 SIL/AK 120 01 0.8%

j) D-1 Pilot valves of ALCO

FRPCPY
S Make Population Failures
Failures of Failures of
No VALVE/KIT
LY CY LY CY LY CY
1 Rotex/Recon 80 00 0.0%
2 Recon/Recon 20 01 5.0%

k) Feed valves of ALCO

FRPCPY
S Make Population Failures
Failures of Failures of
No VALVE/KIT
LY CY LY CY LY CY
1 C2N /SIL/AK 55 00 0.0%
2 F2 ESCORTS/ESCORTS 10 00 0.0%
3 D24B EIW EIW 26 01 3.0 %

l) EPG valves of ALCO

FRPCPY
S Make Population Failures
Failures of Failures of
No VALVE/KIT
LY CY LY CY LY CY
1 Rotex/Recon 80 01 1.0%
2 Recon/Recon 20 01 5.0%

m) Horn Shells valves of ALCO

FRPCPY
S Make Population Failures
Failures of Failures of
No VALVE/KIT
LY CY LY CY LY CY
1 Elgi/Tirupati 120 02 1.6%
2 Tirupati/Tirupati 80 02 2.0%

n) MU2B valves of ALCO

FRPCPY
S Make Population Failures
Failures of Failures of
No VALVE/KIT
LY CY LY CY LY CY
1 FTIL/MGM 65 02 3.0%
2 SIL/MGM 35 02 5.0%
o) MR Safety valves of ALCO
FRPCPY
S Make Population Failures
Failures of Failures of
No VALVE/KIT
LY CY LY CY LY CY
1 FTIL 30 01 3.0%
2 SIL 70 00 0.0%

p) Limiting valves of ALCO

FRPCPY
S Make Population Failures
Failures of Failures of
No VALVE/KIT
LY CY LY CY LY CY
1 FTIL/FTIL 35 00 0.0%
2 SIL/FTIL 65 01 2.0%

CCB 1.5 OF HHP LOCOS

a) PCB DBI valves & cards of HHP

FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 KB 33 01 3.0 %

b) PCB EPA3 valves & cards of HHP

FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 KB 33 01 3.0 %

c) ANALOG CONVERTER 774009 valves & cards of HHP

FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 KB 66 04 6.0 %

d) PISTON VALVE PVERI/PVBC I88098/341 valves & cards of HHP

FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 KB 66 02 3.0 %

e) J1 RELAY VALVE 735690 valves & cards of HHP

FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 KB 33 01 3.0 %
f) MR FILTER 775012 valves & cards of HHP
FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 KB 33 03 9.0 %

g) FILTER WBFIL 100AA002 valves & cards of HHP

FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 KB 99 04 4.0 %

h) KE VALVE KIT-I 1.186/2 valves & cards of HHP

FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 KB 33 01 3.0 %

i) BCEV775009 valves & cards of HHP

FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 KB 33 02 6.0 %

j) MVCC valves & cards of HHP

FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 SELAM 26 06 20.0 %
2 ROTEX 07 02 20.0%

k) AUTO DRAIN valves & cards of HHP

FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 FTIL 20 02 10.0 %
2 TRIDENT 13 04 30.0%

l) AUTO DRAIN valves & cards of HHP

FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 FTIL 20 02 10.0 %
2 TRIDENT 13 04 30.0%
 CCB 2.0 OF HHP LOCOS
a) JUNCTION BOX ASSY, PSJB, 74V 787090 valves & cards of HHP
FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 KB 52 01 1.9 %

b) CONTROL PORTION, 20-PIPE 787775-004 valves & cards of HHP

FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 KB 52 01 1.9 %

c) CONTROL PORTION, 16-PIPE 787556-2004 valves & cards of HHP

FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 KB 52 01 1.9 %

d) SAND MAGNET valves & cards of HHP

FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 KB 52 02 4.0 %

e) GAUGES valves & cards of HHP

FRPCPY
S Population Failures
Make Failures of Failures of
No
LY CY LY CY LY CY
1 SELAM 40 02 5.0 %
2 TOPGRIP 60 02 3.5 %
IV. STOCKED ITEM POSITION
a) ALCO Locos
Sl. SOH
PL.NO DESCRIPTION AAC Remarks
No Section Stores
1 11360021 SA9 IND BRAKE 10 02 01
VALVE ASSLY
2 113601050 C2 Relay valve 12 01 01
3 11440557 Window Wiper 60 06 00
4 11445476 DUPLEX AIR 80 50 11
PRESSURE GAUGE
5 11452780 A9 BKV Valve 10 01 01
6 11805766 PARTS KIT FOR 24 02 03
SILMAKE AIRDRYER
7 11813672 R/KIT FOR 11/4"BP/FP 00 200 00
ANGLECOCK
8 17390059 MODIFIDE D1 AUTO 09 00 01
DRAIN VALVE
9 38147828 HOSE COUPLING 240 10 49
WITH END FITTING
10 38147830 HOSE COUPLING AIR 240 00 03
BTAKE
11 38167013 CUT OFF ANGLE 42 00 16
COCK

b) HHP Locos
Sl. SOH
PL.NO DESCRIPTION AAC Remarks
No Section Stores
01 17455327 D.L.FILTER 40 06 05
ELEMENT
02

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. Ratchet NIL YES
2. Extension Handle -6 NIL YES
3. Box- NIL YES
4. Box 9/16 NIL YES
5. Box 12mm NIL YES
6. Nose Pliers NIL YES
7. Cutting Pliers NIL YES
8. Pipe wrench-14 NIL YES
9. Adjustable-12 NIL YES
10. Hammer NIL YES
11. Open spanner-1011mm NIL YES
12. Open spanner-1213 mm NIL YES
13. Open spanner- 9/16 NIL YES
14. Open spanner-1415mm NIL YES
15. Open spanner-1617mm NIL YES
16. Open spanner-19/3211/16 NIL YES
17. Open spanner-3/47/8 NIL YES
18. Open spanner-2022mm NIL YES
19. Open spanner-15/161 NIL YES
20. Open spanner- 15/81 5/16 NIL YES
21. Ring spanner-1 1 1/16 NIL YES
22. Ring spanner-15/161 NIL YES
23. Ring spanner 7/8 NIL YES
24. Ring spanner 9/16 NIL YES
25. Ring spanner 12mm13mm NIL YES
26. Ring spanner 10mm11mm NIL YES
27. Allen key 3/8 NIL YES

VIII.Modifications under progress/ to be carried out

Sl.
Description Reference Status Remarks
No
1. EMD J FILTER -- 08 Locos Under Progress
2. BP Gauge Tapping -- 28 Locos Under Progress
3.
4.
IX. Reliability improvement action plan
2016-17 2017-18
Sl. Total Qty/
Description Act till Act till
No Population Target Target
now now
1. 100% Testing of all rubber parts by Lab. 91 Locos 91 Locos
All locos Completed
before fitment.
2. Rejection of Low shelf life items. 91 Locos Completed Under
All locos
Progress
3. Procurement of kits through approved 91 Locos Done 91 Locos
All locos
sources
4. Checking the dimensions of 'O' rings before 91 Locos 91 Locos
All locos Completed
fitment.
5. Ensuring 100% functioning of air dryers. 91 Locos All locos Checked 91 Locos
6. Modification to BP/FP guards. 91 Locos All locos Provided 20 Locos
7. Provision of spring loaded sand box lids. 91 Locos Under 20 Locos
All locos
Progress
8. Securing of sand box. 91 Locos Under 91 Locos
All locos
Progress
9. Checking of all Air brake testing parameters 91 Locos 91 Locos
300 Checked
in QLY and above Sch.
10. Cleaning of all air brake pipe lines during 91 Locos 45 Locos
46 Checked
yearly Sch.
11. 100% annealing of all copper pipelines 91 Locos 91 Locos
46 Checked
during Hly & above Sch.
12. Application of Araldite on angle cock 91 Locos 91 Locos
sealing rings and Over hauling during 300 Done
quarterly Sch. Instead of M-12 Sch.
13. Proper application of grease during 91 Locos 91 Locos
overhauling of Valves (avoiding excess 91 Done
greasing.)
14. Provision of safety clamps during heavy 91 Locos 45 Locos
46 Done
Schedules
15. Ensuring availability of ready unit 91 Locos 04 Nos.
exchanger spares. All locos 04 Nos. Unit Unit

16. Ensuring 100% calibration of all gauges 91 Locos All locos 91 Locos
Done
during Hly & above schedule.
17. Conducting failure meeting every month Every month Every Every Every
and reviewing the action plan. month Month Month
18. EMD type J filters to be fitted in yearly Sch. 91 Locos All locos 82 09 Locos
Completed
19. Monitoring of purge time during every 91 Locos All locos 91 Locos
Completed
schedule.
20. During fitment of valves surface 91 Locos All locos 91 Locos
45
preparation & certification by supervisor to
completed
be ensured.
21. Dry blowing of air brake pipe lines during 91 Locos All locos 45 45 Locos
Yly schedule. completed
22. Ensuring working of D1 emergency brake 91 Locos All locos 45 Locos
Completed
valve during every schedule.
23. Ensuring sealing of additional BP cut out 91 Locos All locos 91 Locos
Completed
COC.