Tuesday, October 30, 2012

Inside the locomotive assembly line


Audit of following Work Instructions was done in Shop # 19. Report is as follows:-

Manufacturer of BA panel ( W 19.005):-
Points noticed:-

  • BA panel frames ( Mostly of M/S Modern) were rusted at many places. This was either due to inferior paint or due to outdoor storage in CLW

  • Busbar to earth clearances of 60 mm as prescribed in para 3.9 of this WI are  to be strictly maintained.

  • Para 3.6 of this WI needs modification. QD and Q20 have gone into CPU nowadays and SHAA has become SHTM.


  • Arc chute bolt and nuts material should be same.
  • Gas welding quality needs improvement.
  • Line contactors of M/S Stesalit  make had spring washers whereas CLW make don’t have spring washers. This needs to be addressed by design.



Monday, October 22, 2012

Three Phase Locomotive Assembly


Audit of following 3 Work Instructions was done in Shop # 19. Report is as follows:-

Fabrication of AC2 panel ( W 19.006):-
Observations:-
  • Drilling as mentioned in the para # 3.2 of this WI is irrelevant. Same should be modified.
  • VS diodes fixing plates have 4 corner holes but are fixed on 2 mid holes. Same should be procured accordingly.


Arc welding of joints ( W 19.007):-
Observations:-
  • Pre-heating of electrodes as mentioned in para 34.1 of this WI should be ensured.

Prepartion of Cable of various size ( W 19.008):-
Observations:-
  • Cables of this section not being sent for ‘pull-out’ test, were sent for same.


Other Observations:-


  • HSBC contactors are lying on the floor since long in zero bay of shop #19. This is making them dusted all around. They should be stored properly.

Locomotive Assembly in CLW


Audit of following 2 Work Instructions was done in Shop # 19. Report is as follows:-

Assembly of transformer ( W 19.017):-
Observations:-




  • Quality of welding ( of bend plate , brackets ) was discussed for scope of improvements. It was found there is shortage of welder in the shop.


Other inspections:-

  • LMS was inspected for pin manufacturing process. Same will be further continued.

Saturday, October 20, 2012

How Locomotives are assembled?


Audit of following 3 Work Instructions was done in Shop # 19. Report is as follows:-

Calibration of Pantograph ( W 19.018):-
Observations:-

  • Calibration being done in test shed on AM-12 was observed . Practical method being adopted by using a kind of jig is entirely different from the one given in WI.

  • WI should be modified accordingly.

  • Measurement of Panto lock down force of 17 kg as mentioned in para 3.8 of this WI is to be ensured.





Oxy fuel welding of pipes ( W 19.019):-
Observations:-
  • This WI has become obsolete since pipes these days come with bellows.



Transformer oil filtration ( W 19.020):-
Observations:-
  • This WI has not been revised since 1996, as new types of filtration plants have come after that.

  • Floor are near oil-filtration plant was found very dirty and slippery, same attended.









Bushing fitment in locomotive


Audit of following 2 Work Instructions was done in Shop # 19. Report is as follows:-

Fitment of condenser type main bush ( W 19.021):-
Observations:-
  • Use of dummy condensor bushing as mentioned in para 3.3 to para 3.7 of this WI is  difficult practically.

  • These days gel filled bushing are in use for 3-phase locomotives, Hence the WI mentioning use of oil in para 3.12 and 3.13  needs modification.

Fitment of condenser type main bush ( W 19.021):-
Observations:-
  • Flange bolts being used on the roof of LPS make looked rusty, same attended.




  • This WI is incomplete and needs to be re-issued as it does not mention the adhesive tape used in the process of fitment.