Xxiv MSG Meeting

XXIV MSG (TL&AC) MEETING
RAILWAYS:
PERIOD 1.1.2008 TO 31.12.2008 ANNEXURE 11.7.11.11
NAME OF THE EQUIPMENT: RAILWAY CARRIAGE FAN (110 V 400 mm DC)
SUMMARY OF ANALYSIS
S.N. Particulars KD R Kanwar NOVA Rail coach B K Engg
Chopra (SPJ) Engg
1 No of Railway
carriage fan in
service
2 No of failures of
Railway carriage
fan under
warranty
3 No of Railway
carriage fan
After warranty
4 Total No of
failure of
Railway carriage
fan
5 Failure
rate/100/year
(FRPCPY)
DETAILA OF FAILURE
S.N. Nature of defects K D R Kanwar NOVA Rail coach B K Engg
Chopra (SPJ) Engg
1 Armature failure
2 Field failure
3 Commutator
failure
4 Brush & Brush
holder
5 Blade
6 Guard
7 Guard Ring
8 Shaft key and
cotter pin
9 Bearing failure
10 Other failure
RAILWAYS:
PERIOD 1.1.2008 TO 31.12.2008 ANNEXURE 11.1.11.6
NAME OF THE EQUIPMENT: RAILWAY CARRIAGE FAN (110 V 400 mm DC)
SUMMARY OF ANALYSIS
S. Particulars Shankar Kailash Shivam Shah Concrode Samir
N.
1 No of Railway 2217 915 1056 82 900 562
carriage fan in
service
2 No of failures of Nil Nil Nil Nil Nil Nil
Railway carriage
fan under
warranty
3 No of Railway 365 84 102 07 211 54
carriage fan After
warranty
4 Total No of 365 84 102 07 211 54
failure of Railway
carriage fan
5 Failure
rate/100/year
(FRPCPY)
DETAILA OF FAILURE
S. Nature of defects Shankar Kailash Shivam Shah Concrode Samir
N.
1 Armature failure 62 25 42 74 14
2 Field failure 158 42 22 59
3 Commutator 33 15 39 32
failure
4 Brush & Brush 84 02 21 16 04
holder
5 Blade
6 Guard
7 Guard Ring
8 Shaft key and
cotter pin
9 Bearing failure 28 07
10 Other failure 17 07 16 04
XXIV MSG (TL & AC Meeting
Failure Analysis of FRP Tray Box
Make ----------------
For period from 01.01.2008 to 31.12.2008
Railway-- WCR
1 No. of failure Nil
2 No. of FRP Tray in service 2100
3 FRPCPY
S.N. Nature of failure

Nil
XXIV MSG (TL& AC) MEETING
FAILURE ANALYSIS OF 400 MM SWEEP (FIXED TYPE) BLDC FAN
ANNEXURE - 21
FOR PERIOD FROM 01.01.2008 TO 31.12.2008
RAILWAYS -WCR
1 No of failure 25
2 No. of fan in service 296
3 FRPCPY
S.N. Name of failure

1. PCB defective 06 Nos
2. PCB Burnt/ shorted 05 Nos.
3. Sensor magnet shifted
4. Breakage of FRPP Blade.
5. Fan burnt
6. Fan defective 08 Nos.
7. Jamming of rotor 04 Nos.
8. Loose connector
9. Sensor Magnet loose
10. Magnet broken
11. Bearing failure 02 Nos.
12. Rotating pinion defective
13. Misc. failure
Note: - SWIEVLING TYPE OF BLDC FAN SHALL NOT BE INCLUDED

FAILURE ANALYSIS OF AC EQUIPMENT
(PERIOD 01.01.2008 TO 31.12.2008)
ANNEXURE 30
Name of Equipment : Development item – Bushes for TL & AC Alt. Suspension.
As per MOM of 21st MSG, it was decided to carry out field trial of following two types
of bushes.
A – Grade SFB 35 MS 1
B - Grade Metalon GSM
Four Railways (SR, NWR, ER & CR) were advised to provide for in AC and Non AC
Coaches (40 each ) vide this office letter no. EL/1.6.9.15 Dt 06.102006.
Performance may be furnished in the given format.
SUMMARY OF ANALYSIS
Railway AC Coaches Non- AC Coaches Type of bushes
Coach No. Date of Coach No. Date of

fitment fitment
(PERIOD01.01.2008 TO 31.12.2008)
Annexure – 32
Name of Railways : WCR Make : EXIDE
Summary of Analysis
S.N. Details (Particulars) Cell battery Lug Date 2000

2004 2005 2006 2007 2008
1. Number of cells Checked 324 216 270 108 180
2. Number of cells 32 12 24 04 Nil
condemned due to less
capacity with lug date
3. Percentage
Note:
Separate data required for different make approved by RDSO
ix) 6v, 120Ah (LMLA)

x) 2V, 1100 Ah (LMLA)
xi) 2V, 1100Ah (VRLA)
(PERIOD01.01.2008 TO 31.12.2008)
Annexure – 31
Name of Railways: WCR Make: EXIDE
Name of Equipment:
Summary of Analysis
S.N. Details (Particulars) Cell/ Battery Lug Date 2000

2004 2005 2006 2007 2008
32 12 24 04 Nil
Details of failure
S.N. Details (Particulars) 2004 2005 2006 2007 2008

1. Cells dead/ Not retaining charge 10 12 02 04 Nil
2. Reverse polarity 12 07
3. Low voltage or low sp. Gr. 06 02
4. Cells open circuit
5. Container/ lid cracked
6. Lid sealing with container open 01
7. Lug melted/ broken
8. Cells burst/ over heated 04
9. Terminal loose from lead bush
10. Sealing compound melt
11. Capacity less then 80%
12. Misc. failure
Note :
1. During POH if measured capacity of a cell is less than 80% it shall be counted
as failure. How ever, condemnation on age basis (4 year) shall not be counted
as failure.
2. Lug date shall be date (year) of commissioning.
3. Date required for 2008.2007,2006,2005 and 2004 lug date.
4. Separate date required for different make approved by RDSO.
i) 12 V, 70 Ah (LHB)
ii) 6V, 120 Ah (LMLA)
iii) 8V, 450 Ah (LMLA)
iv) 2V, 210Ah (LA)
v) 2V, 525 Ah (LMLA)
Annexure 39.1 to 39.4
PERIOD 1.1.2008 TO 31.12.2008
NAME OF THE EQUIPMENT: Battery fuse box & terminal box.
RAILWAY WCR…………………..
SUMMARY OF ANALYSIS
S.N. Particulars Abrol International NEC Rail Tech.

Switch gear Switchgear
1. No. of battery fuse box 200 100 150 150
& terminal box in
Service
2. Total No. of failures of Nil Nil Nil Nil
Battery fuse box &
terminal
3. Failure rate/ 100/
year(FRPCPY)
DETAILS OF FAILURE
S.N. Nature of defects Abrol International NEC Rail Tech.

Switch gear Switchgear
1 Nil Nil Nil Nil Nil
2
3
4
5
6
7
8
9
10
11
PERIOD 1.1.2008 TO 31.12.2008
NAME OF THE EQUIPMENT: All types of HRC fuse links and fuse base
RAILWAY…WCR………………..
SUMMARY OF ANALYSIS
S.N. Particulars Siemens KEL C&S Make GE Power

1. No. of HRC fuse
links & fuse base in
Service
2. Total No. of HRC
fuse links and fuse
base
3. Failyrerate/100/year
(FRPCY)
DETAILS OF FAILURE
S.N. Nature of defects Siemens KEL C&S Make GE Power

PERIOD 1.1.2008 TO 31.12.2008
NAME OF THE EQUIPMENT: Toggle Switch
RAILWAY…WCR………………..
SUMMARY OF ANALYSIS
S.N. Particulars R.J. Enterprises Madan Brothers DR Auto shanta

1. No. of Toggle switch in 4100 3000 2500 600
service
2. Total No. of Failures of 69 124 203 68
Toggle Switch
3. Failure rate/100/ year
(FRPCY)
DETAILS OF FAILURE
S.N. Name of defects R.J. Enterprises Madan Brothers DR Auto shanta

1 Contact damaged 69 124 203 68
2
3
4
5
6
7
8
9
11
12
PERIOD 1.1.2008 TO 31.12.2008
NAME OF THE EQUIPMENT: Modular Switch
RAILWAY WCR
SUMMARY OF ANALYSIS
S.N. Particular Crabtree Record General

Electricals Electricals
1. No. of Modular Switch in 205
service
2. Total No. of failures of 14
Modular switch.
3. Failure rate/100/year
(FRPCY)
DETAILS OF FAILURE
S.N. Nature of defects Crabtree Record General

Electricals Electricals
1 Switch damaged 14
2
3
4
5
6
7
8
9
10
11
PERIOD 1.1.2008 TO 31.12.2008
NAME OF THE EQUIPMENT: Switch Board Cabinet
RAILWAY - WCR
SUMMARY OF ANALYSIS
S.N. Particulars SSK Stesalit International Instrumentation Abrol

1. No. of SBC in
service
2. Total no. of
Failures of SBC
3. Failure
rate/100/year
(FRPCY)
DETAILS OF FAILURE
S.N. Nature of SSK Stesalit International Instrumentation Abrol

defects
PERIOD 1.1.2008 TO 31.12.2008
NAME OF THE EQUIPMENT: LED type Emergency Light
RAILWAY - WCR
SUMMARY OF ANALYSIS
S.N. Particulars Maave DR Signitron Safe Intra System Matshusi Global Dhingra ICElectricals
Auto system Aids
1 Total no of 06
failure of EL
2. Failure
rate/100/yea
r (FRPCY)
DETAILS OF FAILURE
S.N. Nature Maave DR Signitron Safe Intra System Matshusi Global Dhingra ICElectricals
of Auto system Aids
defects
1 Battery 06
failure
XXIV MSG (TL&AC) Meeting
Annexure 65
Failure Analysis of 2.5 KVA 110 V DC/230 V AC Inverter
Make
Railways - WCR
1.. No. of failure 05

2. No of Inverter in 29
service
3. FRPCY

1 Inverter fault. 01 ( Dubas make)
2 IGBT fault 02 ( Waves make)
3 Driver card failure. 01 ( Waves make)
4 Relay card failure. 01 (Waves make)
5
6
7
8
9
10
11
12
XXIV MSG (TL&AC) Meeting
Annexure 69
Failure Analysis of Amalgamated transformer ( B/Charger)
Make ……………
Railways WCR
1. No. of Failure 05
2. No. of B/ Charger in service 34
3. FRPCPY

1 Transformer faulty 05
XXIX MSG (TL&AC) MEETING
FAILURE ANALYSIS OF AC / TL EQUIPMENT
(Period 01.01.2008 to 31.12.2008)
Annexure - 24
Name of the equipment: 4.5/18/25 KW RRU
S.N. Particulars Railway

1 Equipment in service 350
2 Failed within warranty 02
3 Failed after warranty 70
4 Total equipment failed 72
5 FRPCPY
Details of failure

1 Power diode 02
2 Field diode
3 Auxiliary free wheeling diode 12
4 Excitation transformer burnt 24
5 Internal wiring cable
6 PCB condemned/ defective
7 Magnetic amplifier defective 35
8 Voltage detector
9 Current detector
10 Potentiometer defective 03
11 Current transformer 31
12 Main field/ HRC fuse blown
13 OVR failure 04
14 Other failure
Note
1. Data required separately for all RDSO approved makes as per Master list.
(Period 01.01.2008 to 31.12.2008)
Annexure – 23
Name of the equipments: 4.5 KW/18KW/ 25 KW ERRU Make.

1. Equipment in service 26
2. Failed within warranty 02
3. Failed after warranty 01
4. Total equipment failed 03
5. FRPCPY

1 Power diode module
2 Field diode module
3 Hall sensor
4 Indication board failure
5 Transformer burnt
6 Power supply card
7 Main PCB (UVC) defective 03
8 Capacitor
9 OVP failure
10 IGBT failure
11 Other failure
Note:
Data required separately for all RDSO approved makes as per Master list
(Period 01.01.2008 to 31.12.2008)
Annexure – 22
Name of the equipments: 4.5 KW/18KW/ 25 KW Alternator Make.

1. Equipment in service 360
2. Failed within warranty Nil
3. Failed after warranty 07
4. Total equipment failed 07
5. FRPCPY
Details of failure

1 Field winding SC/OC 02
2 Stator winding SC/OC/earth 02
3 Alternator bearing defective/ seized
4 Alternator shaft broken /bent/worn out 02
5 Alt. Suspension bush worn out
6 Terminal block loose connection/ over heat
7 Phase wire cut/OC/ earth
8 Rotor jam/rubbing 01
9 Lead wire OC /burnt/cut
10 Pulley/ Key loose
11 Field wire cut/OC/earth
12 Other failure
Note:
1. Phase wire (serial no. 7) and field wire (serial no. 11) is the
cable from alternator to RRU.
2. Lead wire (serial no. 9) is the cable from Alternator winding to
terminal board.
3. Data required separately for all RDSO approved makes as per
master list.
(Period 01.01.2008 to 31.12.2008)
Annexure – 25
Name of the equipments: V Belt (OLD COACHES) Make.
Summary of Analysis
S.N. Particulars
1. No. of belt in service 1440
2. Failed within 6 months Nil
3. Failed after 6 months 350
4. Total belts failed 350
5. FRPCPY
West Central Railway SSE (TL/AC) Office
Jabalpur
L.No. ETL/JBP/MSG/36 Dt. 15.05.2009
Sr.DEE (G) JBP
Sub: 24th MSG meeting (TL&AC).

Ref: CEE/WCR JBP’ s L. No. WCR/L/02/2106/1378 dt. 06.04.09.
In connection with above, data for 24th MSG meeting (TL depot.) are
enclosed here with for your information and further necessary action please.
This is for your information and necessary action please.
DA:- MSG annexure – 15 Nos.
SSE (AC/TL) JBP

(PERIOD01.01.2008 TO 31.12.2008)
Annexure – 32
Name of Railways : WCR Make : HBL
Summary of Analysis

2004 2005 2006 2007 2008
2. Number of cells
3. Percentage
Note:

x) 2V, 1100 Ah (LMLA)
(PERIOD01.01.2008 TO 31.12.2008)
Annexure – 31
Name of Railways: WCR Make: HBL
Name of Equipment:
Summary of Analysis

2004 2005 2006 2007 2008
32 22 05 12 Nil
Details of failure

2. Reverse polarity 12 02 03
3. Low voltage or low sp. Gr. 10 03 05
4. Cells open circuit 03
6. Lid sealing with container open
7. Lug melted/ broken 04
8. Cells burst/ over heated
12. Misc. failure 02
Note :
as failure.
i) 12 V, 70 Ah (LHB)
iv) 2V, 210Ah (LA)
(PERIOD01.01.2008 TO 31.12.2008)
Annexure – 32
Name of Railways : WCR Make : LABCO
Summary of Analysis

2004 2005 2006 2007 2008
1. Number of cells Checked Nil 108 216 108 Nil
2. Number of cells
3. Percentage
Note:

x) 2V, 1100 Ah (LMLA)
(PERIOD01.01.2008 TO 31.12.2008)
Annexure – 31
Name of Railways: WCR Make: LABCO
Name of Equipment:
Summary of Analysis

2004 2005 2006 2007 2008
Nil Nil 02 Nil Nil
Details of failure

1. Cells dead/ Not retaining charge Nil Nil Nil Nil
2. Reverse polarity
3. Low voltage or low sp. Gr. 02
12. Misc. failure
Note :
as failure.
i) 12 V, 70 Ah (LHB)
iv) 2V, 210Ah (LA)

(PERIOD01.01.2008 TO 31.12.2008)
Annexure – 32
Name of Railways : WCR Make : Southern Batteries
Summary of Analysis

2004 2005 2006 2007 2008
2. Number of cells
3. Percentage
Note:

x) 2V, 1100 Ah (LMLA)
(PERIOD01.01.2008 TO 31.12.2008)
Annexure – 31
Name of Railways: WCR Make: Southern Batteries
Name of Equipment:
Summary of Analysis

2004 2005 2006 2007 2008
14 08 26 14 08
Details of failure

1. Cells dead/ Not retaining charge 05 01 12 02 06
2. Reverse polarity 07 03 06 08 02
3. Low voltage or low sp. Gr. 05 02 04
4. Cells open circuit 01 02
5. Container/ lid cracked 01
8. Cells burst/ over heated 04
12. Misc. failure
Note :
as failure.
vi) 12 V, 70 Ah (LHB)
vii) 6V, 120 Ah (LMLA)
viii) 8V, 450 Ah (LMLA)
ix) 2V, 210Ah (LA)
x) 2V, 525 Ah (LMLA)
(PERIOD01.01.2008 TO 31.12.2008)
Annexure – 32
Name of Railways : WCR Make : JUMBO
Summary of Analysis

2004 2005 2006 2007 2008
2. Number of cells
3. Percentage
Note:

x) 2V, 1100 Ah (LMLA)
(PERIOD01.01.2008 TO 31.12.2008)
Annexure – 31
Name of Railways: WCR Make: JUMBO
Name of Equipment:
Summary of Analysis

2004 2005 2006 2007 2008
05 12 02 03 Nil
Details of failure

2. Reverse polarity 02
12. Misc. failure
Note :
as failure.
i) 12 V, 70 Ah (LHB)
iv) 2V, 210Ah (LA)

(PERIOD01.01.2008 TO 31.12.2008)
Annexure – 32
Name of Railways : WCR Make : Kirlosker
Summary of Analysis

2004 2005 2006 2007 2008
2. Number of cells
3. Percentage
Note:

x) 2V, 1100 Ah (LMLA)
(PERIOD01.01.2008 TO 31.12.2008)
Annexure – 31
Name of Railways: WCR Make: Kirlosker
Name of Equipment:
Summary of Analysis

2004 2005 2006 2007 2008
02 08 06 03 01
Details of failure

1. Cells dead/ Not retaining charge 03 02 02 01
2. Reverse polarity 02 05 01 01
12. Misc. failure
Note :
as failure.
i) 12 V, 70 Ah (LHB)
iv) 2V, 210Ah (LA)
(PERIOD01.01.2008 TO 31.12.2008)
Annexure – 32
Name of Railways : WCR Make : Star Plus
Summary of Analysis

2004 2005 2006 2007 2008
1. Number of cells Checked Nil Nil 180 Nil 36
2. Number of cells
3. Percentage
Note:

x) 2V, 1100 Ah (LMLA)
(PERIOD01.01.2008 TO 31.12.2008)
Annexure – 31
Name of Railways: WCR Make: Star Plus
Name of Equipment:
Summary of Analysis

2004 2005 2006 2007 2008
04 Nil
Details of failure

1. Cells dead/ Not retaining charge
2. Reverse polarity 04
3. Low voltage or low sp. Gr.
12. Misc. failure
Note :
as failure.
i) 12 V, 70 Ah (LHB)
iv) 2V, 210Ah (LA)
(PERIOD01.01.2008 TO 31.12.2008)
Annexure – 32
Name of Railways : WCR Make : Microtex
Summary of Analysis

2004 2005 2006 2007 2008
2. Number of cells
3. Percentage
Note:

x) 2V, 1100 Ah (LMLA)
(PERIOD01.01.2008 TO 31.12.2008)
Annexure – 31
Name of Railways: WCR Make: Microtex
Name of Equipment:
Summary of Analysis

2004 2005 2006 2007 2008
18 04 06 24 01
Details of failure

1. Cells dead/ Not retaining charge 06 08 01
2. Reverse polarity 08 04 06 07
4. Cells open circuit 04
12. Misc. failure 04
Note :
as failure.
i) 12 V, 70 Ah (LHB)
iv) 2V, 210Ah (LA)
XXIV MSG (TL&AC) MEETIN
(PERIOD01.01.2008 TO 31.12.2008)
Annexure – 32
Name of Railways : WCR Make : HI- Tech.
Summary of Analysis

2004 2005 2006 2007 2008
1. Number of cells Checked Nil Nil Nil 90 Nil
2. Number of cells
3. Percentage
Note:

x) 2V, 1100 Ah (LMLA)
(PERIOD01.01.2008 TO 31.12.2008)
Annexure – 31
Name of Railways: WCR Make: Hi –Tech.
Name of Equipment:
Summary of Analysis

2004 2005 2006 2007 2008
Nil Nil Nil Nil Nil
Details of failure

1. Cells dead/ Not retaining charge Nil Nil Nil Nil Nil
2. Reverse polarity
12. Misc. failure
Note :
as failure.
i) 12 V, 70 Ah (LHB)
iv) 2V, 210Ah (LA)
XXIV MSG (TL&AC) MEETIN
(PERIOD01.01.2008 TO 31.12.2008)
Annexure – 32
Name of Railways: WCR Make : Bharat
Summary of Analysis

2004 2005 2006 2007 2008
1. Number of cells Checked Nil Nil 72 324 270
2. Number of cells
3. Percentage
Note:

x) 2V, 1100 Ah (LMLA)
(PERIOD01.01.2008 TO 31.12.2008)
Annexure – 31
Name of Railways: WCR Make: Bharat
Name of Equipment:
Summary of Analysis

2004 2005 2006 2007 2008
Nil Nil 06 02 Nil
Details of failure

1. Cells dead/ Not retaining charge Nil Nil 06 02 Nil
2. Reverse polarity
12. Misc. failure
Note :
as failure.
i) 12 V, 70 Ah (LHB)
iv) 2V, 210Ah (LA)

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XXIV MSG (TL&AC) MEETING

Failure Analysis of FRP Tray Box

For period from 01.01.2008 to 31.12.2008

1 No. of failure Nil

2 No. of FRP Tray in service 2100

S.N. Nature of failure

FAILURE ANALYSIS OF 400 MM SWEEP (FIXED TYPE) BLDC FAN

FOR PERIOD FROM 01.01.2008 TO 31.12.2008

S.N. Name of failure

Note: - SWIEVLING TYPE OF BLDC FAN SHALL NOT BE INCLUDED

Name of Equipment : Development item – Bushes for TL & AC Alt. Suspension.

Performance may be furnished in the given format.

Railway AC Coaches Non- AC Coaches Type of bushes

Coach No. Date of Coach No. Date of

Name of Railways : WCR Make : EXIDE

S.N. Details (Particulars) Cell battery Lug Date 2000

Separate data required for different make approved by RDSO

ix) 6v, 120Ah (LMLA)

S.N. Details (Particulars) Cell/ Battery Lug Date 2000

S.N. Details (Particulars) 2004 2005 2006 2007 2008

S.N. Particulars Abrol International NEC Rail Tech.

S.N. Nature of defects Abrol International NEC Rail Tech.

S.N. Particulars Siemens KEL C&S Make GE Power

S.N. Nature of defects Siemens KEL C&S Make GE Power

S.N. Particulars R.J. Enterprises Madan Brothers DR Auto shanta

S.N. Name of defects R.J. Enterprises Madan Brothers DR Auto shanta

S.N. Particular Crabtree Record General

S.N. Nature of defects Crabtree Record General

S.N. Particulars SSK Stesalit International Instrumentation Abrol

S.N. Nature of SSK Stesalit International Instrumentation Abrol

Failure Analysis of 2.5 KVA 110 V DC/230 V AC Inverter

For period from 1.1.2008 to 31.12.2008

1.. No. of failure 05

S.N. Nature of failure

Failure Analysis of Amalgamated transformer ( B/Charger)

For period from 1.1.2008 to 31.12.2008

S.N. Nature of failure

Name of the equipment: 4.5/18/25 KW RRU

S.N. Particulars Railway

S.N. Nature of failure

Name of the equipments: 4.5 KW/18KW/ 25 KW ERRU Make.

S.N. Particulars Railway

S.N. Nature of failure

Name of the equipments: 4.5 KW/18KW/ 25 KW Alternator Make.

S.N. Particulars Railway

S.N. Nature of failure

Name of the equipments: V Belt (OLD COACHES) Make.

L.No. ETL/JBP/MSG/36 Dt. 15.05.2009

Sr.DEE (G) JBP

Sub: 24th MSG meeting (TL&AC).

This is for your information and necessary action please.

DA:- MSG annexure – 15 Nos.

SSE (AC/TL) JBP

Name of Railways : WCR Make : HBL

S.N. Details (Particulars) Cell battery Lug Date 2000

Separate data required for different make approved by RDSO

ix) 6v, 120Ah (LMLA)

S.N. Details (Particulars) Cell/ Battery Lug Date 2000

S.N. Details (Particulars) 2004 2005 2006 2007 2008

Name of Railways : WCR Make : LABCO

S.N. Details (Particulars) Cell battery Lug Date 2000

Separate data required for different make approved by RDSO

ix) 6v, 120Ah (LMLA)