fax : 0522-2452581/2465716 hkkjrljdkj&jsyea=ky; vuqla ......2018/05/30 · 17. chittaranjan...

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Fax : 0522-2452581/2465716

Telephone : 0522-2465716

e-mail:[email protected]

lR;esot;rs

Hkkjrljdkj&jsyea=ky;

vuqla/kkuvfHkdYivkSjekudlaxBu

y[kuÅ& 226011

Government of India - Ministry of Railways

Research, Designs & Standards Organization,

Lucknow – 226011

No. EL/2.2.13 Date: 3.7.2018

izeq[k fo|qr vfHk;ark]

1- e/; jsyos] eqEcbZ lh,lVh&400 001

2- iwoZ e/; jsyos] gkthiqj&844 101

3- iwoZrVh; jsyos] pUnz’ks[kjiqj] Hkqcus“oj&751 017

4- iwoZjsyos] Qs;yhZIysl] dksydkrk&700 001

5- mRrj e/; jsyos] Cykd ,&2] lqcsnkjxatbykgkckn& 211

033

6- mRrj jsyos] cM+ksSnk gkÅl] ubZ fnYyh&110 001

7- mRrj if'pe jsyoss t;iqj& 302006

8- mRrj iwoZ jsyos xksj[kiqj& 273001

9- mRrj iwoZ QzsUVh;j jsyos ekyhxkWo xqokgkVh&781011

10- nf{k.k e/; jsyos] jsyfuyk;e] fldanjkckn&500 371

11- nf{k.k iwoZ e/; jsyos] fcykliqj& 495 004

12- nf{k.k iwoZ jsyos] xkMsZujhp] dksydkrk&700 043

13- nf{k.k jsyos] ikdZVkmu] psUubZ&600 003

14- nf{k.k if'pe jsyos gqcyh&580020

15- if'pe e/; jsyos] tcyiqj&482 001

16- if'pe jsyos] ppZxsV] eqEcbZ& 400 020

17- fpRrjatu jsy batu dkj[kkuk] fpRrjatu& 713 331

18- Mhty jsy batu dkj[kkuk] okjk.klh&221004

Principal Chief Electrical Engineers,

1. Central Railway, Mumbai, CST-400 001.

2. East Central Railway, Hazipur-844 101.

3. East Coast Railway, Chandrashekharpur,

Bhubaneshwar -751 017

4. Eastern Railway, Fairlie Place, Calcutta-700 001.

5. North Central Railway, Block-A, Subedarganj,

Allahabad- 211 033.

6. Northern Railway, Baroda House, New Delhi-110 001.

7. North Western Railway, Jaipur- 302 006

8. North Eastern Railway, Gorakhpur-273001

9. North East Frontier Railway, Maligaon, Guwahati-

781011

10. South Central Railway, Secunderabad-500 071.

11. South East Central Railway, Bilaspur-495 004.

12. South Eastern Railway, Garden Reach, Kolkata-700

043.

13. Southern Railway, Park Town, Chennai-600 003.

14. South Western Railway, Hubli- 580020

15. West Central Railway, Jabalpur-482 001.

16. Western Railway, Churchgate, Mumbai-400 020

17. Chittaranjan Locomotive Works, Chittaranjan-713 331

18. Diesel Locomotive Works, Varanasi-221 004.

Sub: Minutes of Meeting of performance review meeting of bearings of traction motor & MSU

for Electric Locomotivesheld atRDSOon30.05.2018

Ref: RDSO’s letter no. EL/2.2.13 dated 19.04.2018

1. Performance review meeting of bearings of traction motor & MSU for Electric

Locomotiveswas held at RDSO on 30.05.2018for improving reliability of bearings.

2. Minutes of Meeting had been uploaded on RDSO website and it may be downloaded

using following path:-

www.rdso.indianrailways.gov.in → Directorates → Electric Loco →Important

Letters/Documents →Minutes of Meeting of performance review of bearings held at

RDSO/LKO on 30.05.2018.

(P.K. Saraswat)

for Director General/ Electrical

http://www.rdso.indianrailways.gov.in/

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Copy to:

1. Secretary (Electric Traction), Railway Board, Rail Bhawan, New Delhi-110 001 :-

(Kind Attn. Shri A.K. Goswami, DEE/RS) - for kind information please.

2. M/s FAG Bearings India Ltd., Maneja, Vadodara-390 013

3. M/s SKF India Limited, 17th Floor Building no. 5B,

Cyber City, DLF Phase-III, Gurgaon-122 002

(P.K. Saraswat)

for Director General/ Electrical

For information and necessary action please.

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Minutes of Meeting of performance review meeting of Traction Motor, MSU & Axle Box

bearings for Electric locomotives held at RDSO on 30.05.2018.

1. Present: As per list enclosed as Annexure - I

2. At the outset, PEDSE welcomed all the participants of the meeting and advised

Zonal Railways, CLW and firms to take all the necessary actions to improve the

reliability of bearings and to minimize on the line failures of bearings.

3. Officer along with supervisors from Railways/CLW and representatives of M/s Schaeffler,

M/s SKF, M/s NEI and M/s Timken attended the meeting.

4. During the meeting, supply issues of bearings, failures of traction motor, MSU & axle box

bearings and action to be taken to improve reliability of bearings were discussed. Failure

analysis has been made on the basis of failure data received from various Railways.

5. Bearing failure analysis of TM type 6FRA6068:

5.1. Shed wise loco holding (as per E-loco) and traction motor holding as on 1.4.2018 is

given below:

Table-1: Population of traction motor type 6FRA6068 (as on 01.4.2018)

Shed WAP7 WAG9 WAG9H Total Locos No. of TMs

BSL 0 0 15 15 90

AQ 28 89 63 180 1080

KYN 0 1 63 64 384

HWH 48 0 0 48 288

GMO 0 77 97 174 1044

VSKP 12 0 129 141 846

GZB 86 0 0 86 516

LDH 0 0 21 21 126

CNB 0 0 11 11 66

ED 4 0 0 4 24

RPM 70 0 0 70 420

LGD 72 73 39 184 1104

KZJ 0 0 28 28 168

TATA 4 2 131 137 822

BNDM 0 0 32 32 192

SRC 12 0 0 12 72

BIA 19 0 95 114 684

BRC 28 0 0 28 168

TKD 58 30 49 137 822

NKJ 0 0 19 19 114

Total 441 272 792 1505 9030

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5.2. There are 9030 Traction Motors of type 6FRA6068 in service and 18060 bearings of TM type

6FRA 6068 in service.

5.3. Shed wise failure analysis:

Based on the failures reported by Railways, shed wise failure analysis is given below:

Table-2: Shed wise FRPCPY for 6FRA6068 TM bearings

SN Sheds 2015-16 2016-17 2017-18

P F %F P F %F P F %F

1 AQ 1848 14 0.76 1848 5 0.27 2100 5 0.24

2 KYN 720 10 1.39 768 11 1.43 768 5 0.65

3 VSKP 342 4 1.17 942 1 0.11 1764 4 0.23

4 GMO 1462 8 0.55 1704 4 0.23 1908 17 0.89

5 HWH 228 0 0.00 408 0 0.00 576 5 0.87

6 CNB 48 0 0.00 132 0 0.00

7 GZB 924 11 1.19 1080 3 0.28 1044 6 0.57

8 LGD 1884 8 0.42 2088 5 0.24 2208 3 0.14

9 BIA 468 2 0.42 578 2 0.35 1368 10 0.73

10 TATA 840 1 0.12 1272 4 0.31 1644 7 0.43

11 RPM 564 2 0.35 612 8 1.31 792 7 0.88

12 TKD 1008 0 0.00 1380 0 0.00 1776 0 0.00

13 BRC 96 0 0.00 180 0 0.00 336 8 2.38

14 BSL 0 180 0 0.00

15 LDH 0 252 1 0.40

16 ED 0 96 0 0.00

17 KZJ 0 372 2 0.54

18 BNDM 0 384 4 1.04

19 SRC 0 144 0 0.00

20 NKJ 0 228 0 0.00

Total 10384 60 0.58 12908 43 0.33 18072 84 0.46

P= Population of bearings (DE+NDE), F= Number of Failures, %F= FRPCPY

5.4. Total 84 bearing failures have been reported in 2017-18 with FRPCPY of 0.46% for bearings of

TM type 6FRA6068 in 2017-18. Highest FRPCPY of 2.38% is reported by BRC shed, which

had reported 8 bearing failures with population of just 336 bearings in service. TKD had reported

zero bearing failures in 2017-18 with population of 1776 bearings.

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5.5. Shed, loco, bearing type and year wise failure details:

Table-3: Bearing type wise failures

Shed

2015-16 2016-17 2017-18

Total WAG9 WAP7 WAG9 WAP7 WAG9 WAP7

DE NDE DE NDE DE NDE DE NDE DE NDE DE NDE

AQ 12 2 2 2 1 2 3 24

KYN 6 4 7 4 5 26

VSKP 2 2 1 4 9

GMO 5 3 4 7 10 30

HWH 2 3 5

GZB 10 1 3 5 1 20

LGD 5 3 4 1 2 1 0 16

BIA 2 2 9 1 13

TATA 1 4 6 1 12

RPM 1 1 1 7 1 6 17

BRC 8 0 8

LDH 1 1

KZJ 2 0 2

BNDM

4

4

Total 31 13 14 2 23 7 6 7 42 15 17 10 187

44 16 30 13 57 27 187

G. Total 60 43 84 187

5.6. Out of total 84 reported TM bearing failures in 2017-18, 57 failures were in WAG9 class of

locomotives and 27 failures in WAP7 class of locomotives. Out of 57 failures reported in WAG9

locomotives, 42 were DE bearing failures and 15 were NDE bearing failures. Similarly, out of 27

failures reported in WAP7 locomotives, 17 were DE bearing failures and 10 were NDE bearing

failures.

5.7. Loco & bearing type wise failure details of last three years are given in table-4.

Table-4: Loco type/bearing type wise failures

Year:2015-16, 16-17 & 17-18

Loco DE NDE Total

WAG9 96 35 131

WAP7 37 19 56

Total 133 54 187

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Table-5: Make wise & year wise failure details of bearings

Make Bearing 2015-16 2016-17 2017-18 G. Total

FAG (IMP) DE 24 10 40 74

NDE 4 9 12 25

S. Total 28 19 52 99

SKF (IMP) DE 20 19 16 55

NDE 11 5 9 25

S. Total 31 24 25 80

NSK DE 0 0 1 1

NDE 1 0 0 1

S. Total 1 0 1 2

Not KNOWN DE 0 0 5 5

NDE 0 0 1 1

S. Total 0 0 6 6

G. Total 60 43 84 187

Table-6: Line Failure (LF) & Shed Detection (SD) cases of bearings for last 3 years

Cause of failure 2015-16 2016-17 2017-18 Total

LF SD LF SD LF SD

Bearing seizure/cause not

identified

20 0 11 2 27 0 60

Cage Broken/ defective 9 0 7 1 12 1 30

Inner racer cracked 1 5 0 4 3 2 15

Inner racer rotate 3 1 0 0 2 6 12

Outer racer cracked 2 3 1 1 1 0 8

Outer racer rotate 0 0 2 3 0 0 5

Lubrication problem 0 0 0 3 0 0 3

Oil ingress 0 1 0 0 2 0 3

Roller came out 1 0 0 0 0 0 1

Bearing temp. excess 0 0 0 0 0 1 1

High Metal Content 0 0 0 0 0 15 15

other 3 11 2 6 5 7 34

G. Total 39 21 23 20 52 32 187

60 43 84 187

Table-7: Line failure distribution of bearings for last three years


FAG (IMP) DE 17 8 33 58

NDE 1 2 2 5

S. Total 18 10 35 63

SKF (IMP) DE 14 11 9 34

NDE 7 2 3 12

S. Total 21 13 12 46

Not known DE 5 5

G. Total 39 23 52 114

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Table-8: Shed detection of bearing defects for last three years


FAG (IMP) DE 7 2 7 16

NDE 3 7 10 20

S. Total 10 9 17 36

SKF (IMP) DE 6 8 4 18

NDE 4 3 9 16

S. Total 10 11 13 34

NSK DE 1 0 1

NDE 0 1 1

S. Total 1 1 2

NOT KNOWN DE 1 1

Grand Total 21 20 32 73

5.8. It is observed that number of line failures is higher than shed detection cases and effort has to be

made by sheds to improve the maintenance to eliminate the line failure cases.

5.9. It is observed that in 2017-18, for WAG9 class of locomotives, DE bearing FRPCPY is 0.69%

and NDE bearing FRPCPY is 0.25%. FRPCPY of M/s Schaeffler (FAG) make DE bearings is

1.44% & NDE bearings is 0.47%. FRPCPY of SKF make DE bearings is 0.37% & NDE

bearings is 0.21%. FRPCPY of Schaeffler (FAG) is higher than SKF.

Table-9: Make wise failure analysis for WAG9 TM bearings for year 2017-18

5.10. It is observed that in 2017-18, for WAP7 class of locomotives, DE bearing FRPCPY is 0.75%

and NDE bearing FRPCPY is 0.26%. FRPCPY of M/s Schaeffler make DE bearings is 2.07% &

NDE bearings is 0.47%. FRPCPY of SKF make DE bearings is 0.45% & NDE bearings is

0.26%. FRPCPY of FAG is higher than SKF.

Table-10: Make wise failures analysis for WAP7 TM bearings for year 2017-18

Make DE NDE

P F %F P F %F

FAG (IMP) 629 13 2.07 645 3 0.47

SKF (IMP) 1571 7 0.45 1554 4 0.26

NOT KNOWN 470 0 0.00 471 0 0.00

Total 2670 20 0.75 2670 7 0.26

Make DE NDE

P F %F P F %F

FAG (IMP) 1875 27 1.44 1903 9 0.47

SKF (IMP) 2453 9 0.37 2406 5 0.21

NSK 87 1 1.15 87 0 0.00

NOT

KNOWN

1681 5 0.30 1700 1 0.06

Total 6096 42 0.69 6096 15 0.25

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5.11. It is observed that, out of total 84 bearing failures in 2017-18, 27 failures happened within one

year, which indicates bearing fitment issues. All the sheds were requested to follow all the

instructions related to bearing fitment properly to avoid failures due to fitment issues.

Table-11: Age wise failure analysis of bearings for the year-2017-18

Loco <6M 6M to

1Y

1Y to

2 Y

2Y to

3Y

3Y to

4 Y

4 to 5

Y

5Y to

6Y

6Y to

7Y

7Y to 8

Y

8Y to

9Y

Total

WAP7 0 8 11 5 0 3 0 0 0 0 27

WAG9 5 14 12 5 6 6 1 6 1 1 57

Total 5 22 23 10 6 9 1 6 1 1 84

6. 6FXA7059TM Bearings failure analysis

6.1. Population of TM type 6FXA7059 as on 01.04.2018 is given below:

Table-12: Population of 6FXA7059 TM (as on 01.04.2018)

6.2. No TM bearing failures of TM type 6FXA7059 had been reported by GZB & BRC from 2015-

16 to 2017-18. FRPCPY for TM bearings of TM type 6FXA7059 is zero.

7. HS 15250A TM bearing failure analysis

7.1. Population of TM type HS15250A

Table-13: Population of TM type HS15250A (as on 01.04.2018)

Shed WAP4 WAG5

HA/HB WAG7 Total No. of TMs

BSL 43 43 258

AQ 54 54 324

KYN 50 50 300

ASN 76 35 111 666

HWH 91 91 546

MGS 68 114 182 1092

GMO 58 58 348

WAT 21 3 24 144

ANGL 163 163 978

GZB 36 36 216

LDH(D) 5 5 30

LDH 18 147 165 990

KJZY 22 22 132

TKD(D) 5 5 30

Shed No. of WAP5 No. of TMs

GZB 72 288

BRC 62 248

Total 134 536

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Shed WAP4 WAG5

HA/HB WAG7 Total No. of TMs

JHS 117 90 207 1242

CNB 48 125 173 1038

GD(D) 3 30 33 198

AJJ 22 89 34 145 870

ED 113 83 196 1176

ED(D) 5 5 30

RPM 16 16 96

BZA 33 142 175 1050

LGD 35 35 210

KZJ 160 160 960

TATA 39 39 234

BNDM 2 186 188 1128

BKSC 125 125 750

BKSC(D) 5 5 30

SRC 80 80 480

BIA 118 118 708

BRC 72 46 118 708

BL 104 68 172 1032

TKD 20 20 120

ET 75 75 450

ET(D) 14 14 84

NKJ 114 73 187 1122

Total 774 562 1959 3295 19770

7.2. There are 19770 number of TM type HS 15250A in service and 39540 bearings in service in TM

type HS 15250A.

7.3. Based on the failures reported by Railways, shed wise bearing failure analysis of TM type HS

15250A is given below:

Table-14: Shed wise FRPCPY for HS15250A TM bearings

Sheds 2015-16 2016-17 2017-18


BSL 636 1 0.16 588 1 0.17 516 2 0.39

AQ 636 0 0.00 620 0 0.00 648 1 0.15

KYN 1488 20 1.34 1404 26 1.85 1404 1 0.07

ANGL 1692 2 0.12 1800 2 0.11 1956 2 0.10

VSKP 612 1 0.16 492 0.00 264 2 0.76

MGS 2088 7 0.34 2172 3 0.14 * * *

GMO 792 13 1.64 696 12 1.72 516 11 2.13

HWH 1092 1 0.09 1092 3 0.27 1092 2 0.18

ASN 1236 4 0.32 1200 1 0.08 1200 6 0.50

JHS 2484 3 0.12 2484 2 0.08 2484 4 0.16

CNB 2460 4 0.16 2460 5 0.20 2076 0 0.00

GZB 540 0 0.00 444 0 0.00 420 1 0.24

BZA 2052 4 0.19 2040 2 0.10 2100 6 0.29

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Sheds 2015-16 2016-17 2017-18


KZJ 1908 24 1.26 1920 30 1.56 1920 1 0.05

LGD 564 0 0.00 480 0 0.00 420 0 0.00

BIA 708 2 0.28 708 0 0.00 1416 2 0.14

BNDM 2400 2 0.08 2424 7 0.29 2460 0 0.00

TATA 1044 1 0.10 780 1 0.13 468 0 0.00

SRC 960 2 0.21 960 7 0.73

BKSC 996 1 0.10 1200 1 0.08 1500 0 0.00

AJJ 1656 5 0.30 1656 5 0.30 1632 7 0.43

ED 2264 92 4.06 2264 92 4.06

RPM 336 0 0.00 192 0 0.00

ET 750 1 0.13 900 1 0.11 1900 0 0.00

NKJ 2256 3 0.13 2256 6 0.27 2256 2 0.09

TKD 348 1 0.29 348 2 0.57 348 0 0.00

BL 1948 1 0.05 1968 3 0.15 1812 0 0.00

BRC 1296 2 0.15 1140 2 0.18 1416 4 0.28

LDH 2004 6 0.30 1968 0 0.00 1980 3 0.15

Total 35686 109 0.31 38800 209 0.54 37620 156 0.41

(* Data from MGS not received)


TM type HS15250A in 2017-18. Highest FRPCPY of 4.06% is reported by ED shed, which had

reported 92 bearing failures with population of2264 bearings in service. FRPCPY of GMO is

2.13%, which is also considered high. GMO had reported 11 bearing failures with population of

just 516 bearings in service.

7.5. CNB, LGD, BNDM, TATA, BKSC, RPM, ET, TKD & BL sheds had reported zero bearing

failures for TM type HS 15250A in 2017-18.

7.6. Shed wise and type wise distribution of bearing failures of TM type HS 15250A in 2017-18 is

given below:

Table-15: Shed wise & bearing type wise failures

Shed DE NDE Total

AJJ 6 1 7

ANGL 2 2

ASN 3 3 6

BRC 4 4

BSL 2 2

ED 67 25 92

GMO 10 1 11

GZB 1 1

HWH 1 1 2

KZJ 1 1

NKJ 2 2

SRC 5 2 7

VSKP 2 2

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Shed DE NDE Total

BIA 2 2

JHS 4 4

BZA 3 3 6

LDH 3 3

AQ 1 1

KYN 1 1

G. Total 116 40 156

It is observed that in Hitachi TM also, failures of DE bearing are higher than the NDE bearing.

Out of 156 bearing failures reported, 116 are DE bearing failures and only 40 are NDE bearing

failures.

7.7. Make wise distribution of bearing failures of TM type HS 15250A in 2017-18

Table-16: Make wise & bearing type wise failure details of bearings

Make DE NDE Total

P F %F P F %F

FAG (IMP) 5023 22 0.44 4162 11 0.26 9185

FAG (IND) 2039 13 0.64 2361 6 0.25 4400

NEI 2361 34 1.44 1977 3 0.15 4338

NSK 1375 10 0.73 1812 1 0.06 3187

SKF (IMP) 3581 15 0.42 3909 7 0.18 7490

SKF (IND) 1776 22 1.24 1906 12 0.63 3682

Make Not

Specified 2651 0 0.00 2687 0 0.00 5338

G. Total 18806 116 0.62 18814 40 0.21 37620


TM type HS15250A in 2017-18. FRPCPY for DE bearing is 0.62% and for NDE bearing is 0.21%.

7.9. For DE bearings, NEI had contributed largest number of failures (34) with highest FRPCPY of

1.44%. SKF (IND) bearings had contributed 22 failures with FRPCPY of 1.24%.

7.10. For NDE bearings, SKF (IND) had contributed largest number of failures (12) with highest FRPCPY

of 0.63%.

7.11. It is observed that performance of indigenous bearings of both FAG and SKF is not at par with their

imported bearings. Both the firms were requested to improve the quality and reliability of their*

indigenous bearings.

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7.12. It is observed that Shed Detection (SD) cases are higher than the Line Failures (LF) cases of bearings

in 2017-18. Sheds were requested to further improve their maintenance practices and eliminate the

line failure cases.

Table-17: Make wise & failure type wise distribution of bearing failures of HS 15250A

Make LF SD G. Total

FAG (IMP) 3 30 33

FAG (IND) 2 17 19

SKF (IMP) 4 18 22

SKF (IND) 6 28 34

NEI 15 22 37

NSK 10 1 11

G. Total 40 116 156

Table-18: Bearing type wise & failure type wise distribution of bearing failures of HS 15250A

Bearing type LF SD G. Total

DE 35 81 116

NDE 5 35 40

G. Total 40 116 156

7.13. Age wise failure distribution of bearing failures of HS 15250A in 2017-18

Table-19: Age wise failure distribution of bearing failures of HS 15250A in 2017-18

7.14. Hitachi TM bearings are must change item in POH. Periodicity of POH is given below:

WAP4: 6 years ±3 months or 15 lakh kms whichever is earlier.

WAG7: 10 years ±3 months or 12 lakh kms whichever is earlier.

It seen that some of the failed bearings were not replaced in POH. Some examples are given

below:

Type <6M 6M to

1Y

1Y to 2

Y

2Y to

3Y

3Y to 4

Y

4 to 5

Y

5Y to

6Y

6Y to

7Y

7Y to 8

Y

8Y to

9Y

9Y to

10 Y

10Y to

11 Y

>12Y Total

DE 3 6 33 10 25 10 6 4 5 7 2 1 4 116

NDE 1 2 15 5 4 5 3 1 0 3 0 1 0 40

Total 4 8 48 15 29 15 9 5 5 10 2 2 4 156

Shed loco DOC DOF make Remark

BRC WAP4/25014 15.04.08 29.07.17 NSK failed 9-10 year

ED WAP4/22568 11.06.07 24.11.17 FAG Failed 10-11

AJJ WAG7/24660 01.01.05 21.06.17 NEI Failed after 12 year

GMO WAG7/27085 04.01.05 20.03.18 SKF Failed after 12 year

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7.15. All the sheds were requested to ensure timely replacement of bearings as per prescribed schedule

to improve the reliability.

8. 3-Phase loco MSU bearings failure analysis for 2017-18

8.1. Failure data as received from Railways is given below:

Table-20: Shed wise 3- phase loco MSU bearing failures

(*Population not received from shed)

8.2. It is observed that only 13 MSU bearing failures were reported with FRPCPY of 0.09%.

8.3. Shed wise and type wise distribution is given below:

Table-21: Shed wise & bearing type wise bearing failures

WAG9 WAP7

G. Total Shed DE NDE Total DE NDE Total

GMO 1 1 2 2

SRC 1 1 1

VSKP 1 2 3 1 1 4

LGD 1 1 1 1 2

AQ 1 1 1 1 2 3

KYN 1 1 1

G. Total 3 5 8 2 3 5 13

8.4. There were total 13 MSU bearing failures reported in 3-phase locomotives. 8 MSU bearing

failures were in WAG9 locomotives and 5 were in WAP7 locomotives. Number of DE bearing

failures is 5 and NDE bearing failures is 8.

Shed P F %F

BSL 180 0 0

AQ 2100 3 0.14

KYN 768 1 0.13

HWH 576 0 0

GMO 1908 2 0.10

VSKP * 4 -

GZB 1044 0 0

LDH 252 0 0

CNB 132 0 0

ED 48 0 0

LGD 2208 2 0.09

TATA 1644 0 0

SRC 144 1 0.69

BIA 1368 0 0

BRC 336 0 0

TKD 1776 0 0

NKJ 228 0 0

Total 14712 13 0.09

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8.5. Out of these 13 failures, make of bearing is specified for only one case (which is SKF). Make of

bearing is not specified in remaining twelve cases by the sheds.

8.6. Out of these 13 failures, 8 failures were line failures and 5 were shed detection cases.

8.7. Cause wise analysis is given below:

Table-22: Cause wise 3-phase loco MSU bearing failure analysis

Cause of failures DE NDE G. Total

Bearing seizure/cause not identified 1 5 6

Cage Broken/ defective 1 1

Gear case oil found metal content 2 2

NDE bearing grease metal content 1 1

other 2 1 3

Grand Total 5 8 13

Table-23: Line failure and shed detection distributionof3-phase loco MSU bearing failure

9. Hitachi MSU bearings failure analysis for 2017-18

9.1. Failure data as received from Railways is given below:

Table-24: Shed wise conventional loco MSU bearing failures

Cause of failure LF Total SD Total G. Total

DE NDE DE NDE

Bearing seizure/cause not

identified

1 4 5 1 1 6

Cage Broken/ defective 1 1 1

Gear case oil found metal

content

2 2 2

NDE bearing grease metal

content

1 1 1

other 1 1 2 1 1 3

G. Total 2 6 8 3 2 5 13

Shed P F %F

BSL 516 1 0.19

AQ 648

KYN 1404

ASN 1200 1 0.08

GMO 516

WAT * 1

ANGL 1956 1 0.05

GZB 432 1 0.23

LDH 1980

KJZY 264

JHS 2484

CNB 2076

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(*Population not received from shed)

9.2. It is observed that only 11 MSU bearing failures were reported with FRPCPY of 0.039%. Out of

these, 7 failures were of DE bearing and 4 failures were of NDE bearing. Out of these 11

failures, 10 were line failures and only 1 was shed detection case.

10. 3-phase loco axle box bearing failure analysis:

10.1. Make wise performance of axle box bearings were discussed as detailed below:

Table-25: Make wise& year wise failure details of Axle Box bearings

From the above table, it can be seen that performance of M/s Schaeffler is worst among

the all. Whereas performance of M/s SKF India is not good as compared to M/s SKF,

Germany.

10.2. Representative of ELS/AQ told that firms are not giving quotation for step size bearing.

Firms were advised to give the quotation for step size bearing to all Railway.

Shed P F %F

AJJ * 1

ED 2352

BZA 2100 2 0.09

LGD 420

KZJ * 1

TATA 468

BKSC 1500

SRC 960 2 0.20

BIA 1416

BL 1788

TKD 360

ET 948

NKJ 2256

Total 28044 11 0.039

Bearing type 2015-16 2016-17 2017-18

P F % F P F %F P F %F

SKF, Germany (BC-20067A) 2184 32 1.47 2243 10 0.45 2413 14 0.58

SKF, India (BC2-0067D/W33) 1686 15 0.89 2272 36 1.58 2629 38 1.45

NEI 5521 54 0.97 6255 57 0.91 6921 77 1.11

Schaeffler, Vadodara 281 5 1.77 350 4 1.14 715 21 2.93

Total 9672 86 0.89 11120 107 0.96 12678 150 1.18

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10.3. Excess metal content in M/s Schefler make bearing reported by ELS/GZB was discussed

during the meeting. As per joint note with M/s Schaeffler& ELS GZB, M/s Scheafler

stated that this may be due to Zinc phosphate coating on inner racer to minimize axle

wear during cold mounting/dismounting of the inner racer and complete bearing unit. In

view of this it was decided that performance of newly supplied bearings from M/s

Schaeffler should be monitored by sheds closely.

11. Instructions issued by RDSO to improve the reliability of TM & MSU bearings

11.1. TM Bearings are essentially maintenance free. No maintenance is prescribed during IT,

IA/IB. Lubrication with specified quantity of specified grease is prescribed during IC &

MOH. Replacement of TM bearings (DE+NDE) is prescribed during IOH &POH.

Proper handling &fitment as per ABB Maintenance manual and lubrication of the

bearings as per SMI-307 needs to be ensured.

11.2. As per SMI-307, Periodicity of re-greasing in minor schedule from existing IC schedule

to every alternate schedule (i.e. Ist IB, 2nd IA, 2nd IC ) for Traction Motor (TM)

bearings of 6FRA6068 TM have been modified. Lubrication will be carried out using

grease gun equipped with digital grease meter as per SMI-322.

11.3. Fitment of bearing of 3-phase TM type 6FRA6068 shall be as per SMI-278 dated

23.12.2013.

11.4. Interference between assembly components of 6FRA6068 TM are specified in MS-415

dated 3.10.2012 and its amendment no. 2.

11.5. List of important instructions issued by RDSO related to TM & MSU bearings is given

below:

Table-26: List of important SMI/MS/TC related to TM & MSU bearings

SN Date About

SMI-322 27.04.2018 Use of grease gun equipped with digital grease meter

SMI-318 16.10.2017 Use of Bore Gauge for measurement of internal diameters

SMI-314 29.9.2017 Use of Dial Snap Gauges for measurement of shaft diameter

SMI-307 5.6.2017 Revision of the periodicity of re-greasing in minor schedule from existing

IC schedule to every alternate schedule

SMI-306 17.4.2017 Induction heating of MSU for bearing fitment

SMI-301 8.11.2016 Use of Induction Heater for heating of End Shields for bearing fitment

SMI-300 2.11.2016 Defining periodicity of overhauling schedule of MSU of

WAG9/WAG9H/WAP7 locomotives

SMI-278 24.12.2013 Fitment procedure of TM 6FRA6068 DE bearings

MS-466 15.11.2017 Modification in drawing of Outer bearing cap DE to achieve adequate

lateral thrust in Traction motor(TM) assembly of 6FRA6068 TM

MS-460 12.06.2017 Modification in drawing of bearing cap NDE to achieve adequate lateral

thrust in Traction motor(TM) assembly of 6FRA6068

MS-456 9.1.2017 Modification in drawing of supporting ring to achieve adequate ‘C’

Clearance in MSU assembly of 6FRA-6068 TM

MS-439 23.11.2016 Modification in drawing of Outer Bearing Cap (DE) to drain out ingressed

gear case oil from TM type 6FRA6068.

TC-12323 23.9.2014 Must Change Items in POH

TC-104 16.7.2010 Storage & Handling of Lubricants

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12 Other issues discussed during the meeting:

12.1 BRC had placed PO No. 22173802104591 dated 20.11.2017, qty-55 set of bearings

(NU224 & NH219) for traction motor type 6FXA7059 on M/s Anupam marketing Pvt.

Ltd., Mumbai (agent of M/s SKF) which had supplied only 13 set of bearings out of 55

sets and 42 sets of bearing still pending for supply. BRC sheds is facing crises of

bearings. M/s SKF was advised to expedite the supply.

12.2 All the bearing manufacturers were requested to expedite the supply of bearings to Loco

sheds and production units and gear for supply of bearings as per increased loco

production targets. It was informed that about 6000 sets of 3 phase TM bearings are

required per annum to meet the production and replacement requirements.

12.3 ELS/AQ had discussed following cases of bearing failures where DE End shield bore

diameter was found less and assembly components were not in kit form:

a. DE End shield bore diameter found under size, details given below:

Loco No. 30263/3 32035/3 32035/5

TM Sr. No. TMTG-4156 TMTG-7695 TMTG-7679

Comm. Dt. 01/2015 Ex. CLW 12/2017 Ex. CLW 12/2017 Ex. CLW

Date of

failure

30.08.2016 01.03.2018 19.02.2018

Bearing

Make

FAGG (17 Rollers) Ex.

CLW 01/2015

FAGG (17 Rollers)

Ex. CLW 12/2017

FAGG (17 Rollers) Ex.

CLW 12/2017

End shield

make

M/s KPE/HWH Sr. No.

96 KPE 05/14

KMRI, HWH KMRI, HWH

Root cause DE End Shield ID (Bore

Dia) found under size

319.920/928/978mm.

(Std 319.950/990 mm)

DE End Shield ID

found less.

319.920/930/955 mm

DE End Shield ID

found less.

319.944/950/960 mm.

Based on the above, ELS/AQ had requested to keep the standard value of

ID near 319.970 mm.

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b. ID low & Assembly components not found in kit form. Details are given

below:

Loco No. 31749/6 31645/2

TM Sr. No. TMTG-5101 TMTG-5075

Comm. Dt. 03.2016 Ex. CLW 10/2015 Ex. CLW

Dt. removed 10.10.2017 12.11.2017

Make End shield make :- M/S. KMRI,

HWH.

End shield make :- M/S. KMRI, HWH.

Observation Found ID of end

shield=319.930/938 mm.

(under size)

Found ID of End shield=319.936/938

mm. (under size)

All machine parts not in kit.

KMRI/KPE/KEW mixed with

each other.

All machine parts not in kit.

KMRI/KPE/KEW mixed with each

other.

12.4 CLW was advised to ensure proper dimensions of the bearing components. CLW had

informed that they had started the actual measurement of mating components and such

issues will not come in future.

12.5 During the Workshop-cum-seminar held at ELS/TKD on 27.04.2017, M/s SKF had

suggested use of polymer sleeve for bearing fitment for smooth transition of rollers on

inner racer. M/s SKF was requested to provide specification and drawing to ELS/TKD &

RDSO and ELS/TKD was advised to procure and supply two sets of sleeves to all the

Electric Loco Sheds. However, M/s SKF had not yet provided the required

drawing/details of the proposed sleeve. M/s SKF is again requested to provide

specification and drawing of the proposed sleeve to ELS/TKD & RDSO and to provide

some samples of the sleeve to ELS/TKD.

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Annexure-I

List of Participants

SN Name (S/Shri) Designation Railway

RDSO

1. O.P. Kesari PEDSE

RDSO

2. P.K. Saraswat DSE (TM)

3. Pratibha Gupta JDSE (C&S)

4. Rajesh Kumar ADE (TM)

5. Girraj Kishore ADE (C&S)

6. L.C. Mahawar SSE/Elect.

Railways

7. R. S. Chaturvadi Sr. DEE/TRS/CNB NCR

8. Anurag Agrawal Dy. CEE/TMD CLW

9. Dinesh Varma DEE/TRS/BNDM SER

10. Rahul Agrawal DEE/TRS/BL WR

11. KapilDeo AEE/ELS/LDH NR

12. KirteshMeena AEE/TRS/NKJ NKJ

13. Ashish Kr Maddhesiya SEE/D/CON CLW

14. Santosh Kumar SSE/ELS/LDH NR

15. Pradeep Kumar Gupta SSE/ELS/BRC WR

16. Kunal Misra SSE/ELS/BRC WR

17. Madhure Pande SSE/TRS/JHS NCR

18. Saurabh Arya SSE/TRS/CNB NCR

19. Pawan Kumar Singh SSE/TRS/BL WR

20. M.R. Ghooi SSE/TM/AQ AQ

21. Shishir Kumar JE/TRS/NKJ NKJ

Firms

22. Savrajit Roy Chowdharay Asst Manager SKF

23. Pulkit Sharma Asst. Manager SKF

22 Santosh Lele Application Engg. Schaeffler

23 Sandeep Lal Technical Services Schaeffler

24 Shailendra Prasad Sales Manager Timken

25 Suresh Kumar Head Application Timken

26 Himmanshu Dandekar Manager NEI

27 Ravi Sharma Manager NEI

28 Amrendra Singh Att. Manager NEI