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Government of lndia - Ministry of Railways

Research, Designs & Standards Organization,

Lucknow -226071

Date:24.11.2016No. EL/2.2.13

Chief Electrical Engineers,

1. Central Railway, Mumbai CST-400 001.2. Northern Railway, Baroda House, New Delhi-l10 001.3. North Central Railway, Hastings Road, Allahabad- 2110014. Eastern Railway, Fairlie Place, Kolkata -700 001.5. East Central Railway, Hazipur-844101.6. East Coast Railway, Chandrashekharpur, Bhubaneshwar-7 51016.7. Southern Railway, Park Town, Chennai-600 003.8. South Central Railway, Secunderabad-500 371.9. South Eastern Railway, Garden Reach, Kolkata -700 043.10. South East Central Railway, Bilaspur-49500411. Western Railway, Churchgate, Mumbai-400 020.12. West Central Railway, Jabalpur-482001.13. Chittaranjan Locomotive Works, Chittaranjan-7l3 331 (WB)

Sub: Minutes of workshop held at Electric Loco Shed, Ajni on maintenance practices of3-phase traction motors & MSU bearings.

Ref: Railway Board's letter number 2005/Elect. (TRS)/440/18/51 (3 phase) dated02.09.2016

1. RDSO had organized aworkshop in association with OEMs of bearings on properstorage, fitment and maintenance practices of traction motor and MSU bearings on07.09.2016 as per Railway Board's instructions vide letter under reference atELS/AQ/CR. In this workshop, officers, supervisors and staff from Electric LocoShed AQ, LGD, RPM, BRC, GZB, KYN, TATA, TKD and BIA had participated.

2. Minutes of workshop is availablefollowing path:

Letters/Documents

on RDSO's website and may be downloaded using

> Directorate > Electric Loco ---1' Important

@.K. Saraswat)for Director General/ Electrical

Copy to:secretary (Electric Traction), Railway Board, Rail Bhawan, New Delhi-110 001:(Kind Attn.: Shri A.K. Goswami, DEE/RS/RB)- for kind infcrrmationrrur,

(P.K. Saraswat)for Director General/ Electrical

Minutes of Workshop held at ELS/AQ on 7.9.2016 Page 1 of 15

Minutes of Workshop held at Electric Loco Shed Ajni on 07.09.2016 for

maintenance practices of 3-phase Traction Motor & MSU bearings

1. Railway Board vide letter no. 2005/Elect. (TRS)/440/18/5 (3phase) dated 02.09.2016

had directed RDSO to carry out a workshop at ELS/AQ on failure of traction motor and

MSU bearings of three phase locomotives. Accordingly, workshop was organized at

ELS/AQ on 07.09.2016.

2. ADRM/NGP, Sr.DEE/TRS/Ajni, DSE/TM/RDSO, Dy.CEE/TMM/CLW,

DEE/TRS/LGD, BSL, AEE/TRS/KYN, BRC, TKD, Ajni and supervisors from various

sheds of Indian Railways were present during the workshop. Representatives of bearing

manufacturers M/s SKF India, M/s FAG India and Representatives of M/s SPM were also

present. List of Participants is attached as annexure-I.

3. During the workshop, bearing failures were discussed, and it was observed that TM

bearing FRPCPY is less than 0.5 % and hence bearing failures cannot be attributed as

design failures.

4. Failure details of bearings of 6FRA6068TM:

RDSO had received TM bearing failure data for year 2016-17 from ELS/TKD, KYN,

GMO, LGD and AQ only.

i. As on 01.08.16, 1007 locomotives are in service (WAP7-279, WAG9- 272,

and WAG9H-456) with 6FRA6068 traction motor. Number of 6FRA6068

traction motors in service is 6042

ii. Shed wise loco holding and traction motor holding is given below:-

Shed WAP-7 WAG-9/9H Total Locos No. of TMs

LGD 54 118 172 1032

AQ 17 145 162 972

GMO 141 141 846

TKD 33 63 96 576

GZB 83

83 498

TATA 76 76 456

BIA 11 59 70 420

KYN 64 64 384

RPM 50

50 300

VSKP

33 33 198

HWH 24

24 144

BRC 7 11 18 108

LDH

11 11 66

CNB

7 7 42

Total 279 728 1007 6042


iii. NU2236 bearing is used in the DE side and NJ320 bearing is used in the NDE side of TM 6FRA6068. M/s SKF/Germany, Austria and M/s Schaeffler Technologies AG & Co. KG/Germany, Romania, Italy (Brand name-FAG) are part-1 approved sources for bearings of TM 6FRA6068. M/s NSK was also approved in part-I category and was delisted on 24.11.2009 due to supply issues.

iv. Shed wise failures of bearings of 6FRA6068 TM are given below

Shed No. of TMs 2012-13 2013-14 2014-15 2015-16 2016-17 (up

to Aug-16) Total

LGD 1032 7 7 9 12 0 35

AQ 972 4 10 13 10 1 38

GMO 846 6 3 6 10 2 27

TKD 576 1 4 8 0 0 13

GZB 498 2 3 6 3

14

TATA 456 0 2 1 2

5

BIA 420 0 3 2 0

5

KYN 384 1 1 2 5 8 17

RPM 300 -- -- 0 0

VSKP 198

HWH 144 0 2 4 1 7

BRC 108

LDH 66

CNB 42

Total 6042 21 35 51 43 11 161

(Blank shows data not received from Shed)

v. Total bearing failures in last 4 financial years and current financial year

are 161 i.e. 1.33%. Average FRPCPY is approximately 0.33%.

vi. Shed wise, Locomotive wise and bearing type wise distribution of failures is given below :

SHEDS WAG9/9H WAP7 Grand

Total DE NDE Total DE NDE Total

LGD 22 0 22 13 0 13 35

AQ 32 4 36 0 2 2 38

GMO 20 7 27 0 0 0 27

GZB 1 0 1 8 5 13 14

TKD 13 0 13 0 0 0 13

RPM 0 0 0 0 0 0 0

HWH 0 0 0 5 2 7 7

BIA 5 0 5 0 0 0 5

TATA 1 4 5 0 0 0 5

KYN 17 0 17 0 0 0 17

Total 111 15 126 26 9 35 161


Loco No. of

Locos 2012-13 2013-14 2014-15 2015-16

2016-17

(up to Aug-16) Total

WAG9/9H 728 16 25 38 36 11 126

WAP-7 279 5 10 13 7 0 35

Total 1007 21 35 51 43 11 161

Bearing 2012-13 2013-14 2014-15 2015-16 2016-17


DE 19 30 44 34 10 137

NDE 2 5 7 9 1 24

Total 21 35 51 43 11 161

Loco Bearing 2012-13 2013-14 2014-15 2015-16 2016-17


WAG9/9H DE 16 23 35 27 10 111

NDE 0 2 3 9 1 15

S. Total 16 25 38 36 11 126

WAP-7 DE 3 7 9 7 0 26

NDE 2 3 4 0 0 9

S. Total 5 10 13 7 0 35

Total DE 19 30 44 34 10 137

NDE 2 5 7 9 1 24

G. Total 21 35 51 43 11 161

vii. Make wise distribution of failures of bearings of 6FRA6068 TM is given below :

Make Bearing 2012-13 2013-14 2014-15 2015-16 2016-17


FAG DE 9 22 28 18 3 80

NDE 1 2 5 4 1 13

S. Total 10 24 33 22 4 93

SKF DE 4 7 9 15 7 42

NDE 0 1 2 3 0 6

S. Total 4 8 11 18 7 48

NSK DE 5 1 5 1 0 12

NDE 0 0 0 0 0 0

S. Total 5 1 5 1 0 12

Not

Known

DE 1 0 2 0 0 3

NDE 1 2 0 2 0 5

S. Total 2 2 2 2 0 8

G. Total 21 35 51 43 11 161


viii. Make wise distribution of line failures (bearing seizure cases) of bearings of 6FRA6068 TM is given below :

Make Bearing 2012-13 2013-14 2014-15 2015-16 2016-17


FAG DE 7 17 18 12 3 57

NDE 1 2 1 2 0 6

S. Total 8 19 19 14 3 63

SKF DE 4 6 8 11 2 31

NDE 0 1 1 2 0 4

S. Total 4 7 8 7 2 35

NSK DE 0 0 2 0

2

NDE 0 0 0 0

0

S. Total 0 0 2 0

2

Not

Known

DE 1 0 1 0

2

NDE 1 2 0 2

5

S. Total 2 2 1 2

7

G. Total 14 28 31 29 5 107

ix. Make wise distribution of shed detection cases of bearings of 6FRA6068 TM is

given below :

Make Bearing 2012-13 2013-14 2014-15 2015-16 2016-17


FAG DE 2 5 10 6 0 23

NDE 0 0 4 3 1 7

S. Total 2 5 14 8 1 30

SKF DE 0 1 1 4 5 11

NDE 0 0 1 1 0 2

S. Total 0 1 3 2

13

NSK DE 5 1 3 1

10

NDE 0 0 0 0

0

S. Total 5 1 3 1

10

Not

Known

DE 0 0 1 0

1

NDE 0 0 0 0

0

S. Total 0 0 1 0

1

G. Total 7 7 20 14 6 54


x. Cause wise year wise failure analysis of bearings of 6FRA6068 TM is given

below :

Cause of failure Y 12-13 Y 13-14 Y 14-15 Y 15-16 2016-17 (up to Aug’16)

Grand

Total

LF SD LF SD LF SD LF SD LF SD

Cage broken/defective 4 2 15 4 22 3 13 1 3 0 53

Seizure 4 9 2 5 0 21

Inner racer defective 4 2 2 1 5 1 5 2 22

Rotation of OR/

End frame loose 1 2 4 0 3 12

Less RC 5 1 5 7

Roller cracked/

defective 2 2 5

Labyrinth rubbed 1 1

Oil ingress 1 1 1

Starvation of Grease 1 4 1

Outer racer

cracked/defective 2 2

Pitting mark 1 1 1

Temperature excess 0 1

Misc. 1 6 0 12

Grand Total 14 7 28 7 31 20 29 14 5 6 161

(LF – Line Failure, SD – Shed Detection)

xi. Cause wise make wise failure analysis of bearings of 6FRA6068 TM is given

below :

Cause of failure FAG SKF NSK NOT

KNOWN Grand

Total

LF SD LF SD LF SD LF SD

Cage broken/

defective

42 10 15 67

Inner racer defective 3 6 5 10 1 25

Labrinth rubbed 1 1

Less RC 1 6 7

Oil ingress 1 1 2

Roller cracked/

defective

2 3 5

Rotation of OR/

End frame loose

2 5 2 1 1 1 12

Seizure 8 7 7 22

Starvation of Grease 1 1

Pitting mark on bearing 1 1 2

Outer racer

cracked/defective

4 4

Temperature excess 1 1

Misc. 5 4 1 1 1 12

Total 63 30 35 13 2 10 7 1 161

(LF – Line Failure, SD – Shed Detection)


5. Failure details of bearings of 6FXA7059TM:

As on 1.8.2016, 100 WAP-5 locomotives are in service with 6FXA7059 traction motor.

Number of 6FXA7059 traction motors in service is 400.

A. Shed wise loco holding and traction motor holding is given below:

Shed WAP-5 No. of TMs

GZB 47 188

BRC 53 212

Total 100 400

B. NU224 bearing is used in the DE side and NJ219 bearing is used in the

NDE side of TM 6FXA7059. M/s SKF/Germany, Austria and M/s

Schaeffler Technologies AG & Co. KG/Germany, Romania, Italy (Brand

name-FAG) are part-1 approved sources for bearings of TM 6FXA7059.

C. Shed wise failures of 6FXA7059 TM bearings are given below:

Shed No. of

TMs

2012-13 2013-14 2014-15 2015-16

(up to Aug’15)

Total

GZB 188 0 0 1 0 1

BRC 212 0 0 2 0 2

Total 400 0 0 3 0 3

(Failure data after August’2015 not received)

D. All the 3 failures are bearing seizure cases of M/s FAG make NDE

bearings. 2 Failures were within service life of 2 – 3 years and one failure

was within service life of 3 – 4 years.

E. Total bearing failures in last 3 financial years and 2015-16 year are 3 i.e.

0.45%. Average FRPCPY is approximately 0.15%.

6. RDSO has carried out technical Audits of CLW and various Loco Workshops/sheds

namely BSL Workshop, KPA Workshop, ELS/HWH, ELS/GZB, ELS/LGD & ELS/AQ.

Major observations of these audits were discussed in the workshop. Some of the common

aspects which were observed at most of the places are summarized below:

A. Bearing storage: Lot of dust and dirt observed on stacked bearing cartons, First in

First Out (FIFO) system is not being followed in most of the cases.

Photo 1 to 3: Bearings storage


Recommendation:

(i) Air-conditioned storage ward may be developed for storage of bearings,

varnishes, rubber components etc.

(ii) Bearings should be kept in clean room, separate from other components.

(iii) It is advised to keep the bearings little away from walls to avoid ingress of

water/moisture in a stack of not more than 5 bearings.

(iv) Large size bearings should be stored in horizontal condition only.

(v) Bearings should also not be stored directly on floor.

(vi) First-In-First-Out (FIFO) system should be followed to avoid prolonged

storage of bearings.

B. Storage of Grease/Lubricants: Grease/Lubricants were stored in dusty and open

areas in some of the sheds/workshops.

Photo 4 to 6: Lubricants storage

Recommendation:

(i) All barrels must be stored, preferably indoors; away from extreme heat/cold,

dust, acidic fumes and moist atmospheric conditions.

(ii) Lubricating oil barrels should be stored horizontally preferably on wooden

rails dunnage to avoid contact with ground. The barrel bungs should be in

the clock position at 3 & 9.

(iii) Grease barrels must be stored vertically preferably covered with tarpaulin, if

not stored indoors.

(iv) Technical circular No. RDSO/2010/EL/TC/0104 (Rev.0) should be followed

for storage & handling of lubricant/greases used for Electric Locomotives

C. Greasing of Bearings: Greasing is done with bare hands. Quantity of grease

provided is not measured/ recorded.

Photo 7 & 8: Greasing with bare hands


Recommendations:

(i) Bearings should be handled with protective industrial gloves.

(ii) Lint free cloth should be used for cleaning purpose.

(iii) As ABB Manual does not prescribes the initial grease quantity required to be

provided in the Traction Motor Bearings, all the Railways are requested to

weigh the grease quantity provided in the initial assembling of the bearings,

so that RDSO can standardise the grease quantity to be provided.

(iv) ABB manual (Volume F-5 Propulsion System – Document No.

3EHM620902 Grease instruction for roller bearings with synthetic

grease)prescribes greasing by means of grease gun using the prescribed tool.

These instruction needs to be followed.

D. Use of Induction Heaters: Sheds/Workshops are using the heating Ovens in place of

Induction heater for heating the end frame (bearing housing).Induction heaters which

are used for heating of racers are not having the essential features like temperature

display, temperature hold, auto cut off & de-magnetization. Induction heating is done

mostly in time mode instead of temperature mode. It is observed that due to improper

heating of the end shields in oven, bearing is inserted by hammering which is not

desirable.

Photo 9 to 11: Induction Heater, heating oven and induction heater for End Frame

Recommendation:

(i) Electric loco sheds should procure sufficient number of induction heaters

equipped with essential features like temperature display, temperature hold,

auto cut off & de-magnetization.

(ii) Induction heating should always be done in temperature mode as

same/similar components of different manufactures may have different

properties.

(iii) Temperature setting should not be more than 1200C for bearing assembly

components.

(iv) Induction heater should also be in cleaned condition. Dust/dirt may enter in

to bearing through induction heater also.

(v) End frame heating should also be done using induction heater as prescribed

in SMI 301.


E. Bearing mounting area:

Bearing mounting area should be separate and other activities like component

cleaning, air blowing etc. should not be done near the bearing assembly area.

Photo 12 &13: Blowing/Cleaning being carried out in bearing mounting area

F. Availability and use of Torque Wrenches:

M20 screws of DE & NDE End frame are tightened without use of torque wrench

during assembly at some of the sheds. Tightening Torque of 372 Nm is specified for

M20 Coarse thread hexagon head bolts and screws in ‘WAG-9 Maintenance and

Repair Manual, Indent No. 3EHW 411479 Chapter Preface Page 17/18’. Suitable

torque wrenches were not available with some of the Sheds/Workshops.

Photo 14 &15: Assembly of traction motor without using torque wrench

Recommendation:

(i) Sufficient number of torque wrenches to be procured and use during assembly.

(ii) It is preferable to use torque wrench with fixed predefined torque. In torque

wrench with adjustable torque, there is a probability that torque may not be set

at required value

(iii) Torque wrenches should be calibrated periodically.


G. Compliance of SMI no. RDSO/2013/EL/SMI/0278 (rev `0`) dated 24.12.2013:

SMI-278 for fitment of Drive End bearing (NU 2236) in 6FRA6068 TM was issued

by RDSO due to large number of bearing seizures. It is observed that this SMI is not

followed properly by most the Railways. Following observations are made:

(i) Free Radial Clearance of Bearing is not measured

(ii) Ring gauge is not available.

(iii) Plug Gauge is not available

(iv) Dye transfer test (Colour matching) with ring gauge to check the suitability

of pinion not done.

(v) Colour matching of pinion with shaft taper is also not carried out.

(vi) Pinion travel of 12 mm needs to be ensured while pinion insertion. Some

sheds are not measuring the pinion travel; rather they are measuring the gap

between labyrinth outer face and pinion inner face by feeler gauge and

keeping it at 3 to 5 mm.

(vii) Axial clearance is not measured.

(viii) Radial clearance after assembly is not measured.

(ix) Insulation Resistance measurement of NDE side bearings is carried out

Recommendation:

(i) It is recommended to procure ring gauge and plug gauge. These should be

used during assembly.

(ii) Colour matching needs to be done as prescribed in SMI-278.

(iii) Measurement of dimensions of mating components is necessary to ensure

proper interference. It should be recorded.

(iv) Axial clearance and radial clearance needs to be measured properly and

recorded.

(v) Mounting of pinion needs to be done as per procedure specified in SMI-278.

(vi) Proper procedure of measurement of radial clearance using dial gauge as per

SMI-278 was demonstrated.

(vii) It is advised to follow the SMI-278 completely to ensure proper fitment of

bearings.

H. SPM meter: Some of the Sheds/workshops did not have the Shock Pulse Meter

for bearing condition monitoring.

7. Observations of technical audits related to MSU failures of 3 Phase locomotives

A. It is observed that most of MSU failures are due to breakage of socket head screw. It

is observed that released/non-standard fasteners are used in some workshops. It is

advised to follow the instructions issued vide RDSO letter number EL/2.2.13

dated 12.2.2016 to use socket head screw of approved makes only in MSU of 3-

Phase Locomotives/Conventional Locomotives. It is preferable to replace the old

fasteners of MSU by new fasteners of approved make. If released fasteners are of

un-approved make, they must be replaced with new fasteners of approved make.


B. As per CLW Specification No. CLW/MS/3/049 Alt-4, following makes of socket

head screw shall only be used in the MSU of WAG-9 Locomotives:

(a) Un-Brako (Precision Fasteners)

(b) G.K.W.

(c) Laxmi Precision

(d) Sundaram Fasteners (TVS)

C. It is observed that Oil bath heating is used in some workshops instead of induction

heating for bearing assembly components. Even though, oil bath heating gives

uniform heating, it suffers from the drawback of ingress of dirt/dust/grease etc. in

the oil and on the components being heated. Use of Induction Heater is

recommended.

D. It is recommended to check the actual fit dimensions of MSU & assembly

components (mating parts) and axle bearing seating area as specified in paragraph

1.4 of ABB document no. AEB 452511 ‘Drive 15 AN 21 R1 Instructions for

Assembly and Disassembly’. Workshops are advised to measure and record the

dimensions.

E. Torque wrench of 80 Nm & 9.5 Nm are prescribed for use during assembly

procedure of MSU. These should be used during assembly.

F. Hammering should not be used for bearing insertion.

G. Full grease quantity to be provided by Workshop in MSUs without making

difference of POH wheel or work order wheel.

H. It is observed that Workshops are not using assembly components in kit form. It is

advised to use store and use assembly components in kit form only.

I. It is observed that different Workshops are following different periodicity for

MSU overhauling. RDSO had issued SMI no. 300 dated 2.11.2016 specifying

following :

Overhauling of MSU of WAG9, WAG9H and WAP7 locomotives shall be

carried out at the time of re-discing which is carried out nearly at the time

of IOH around service life of 12 Lakh KMs.

Instructions given in ABB document no. AEB 452 511(Drive 15 AN 21

R1 Instructions for assembly and disassembly) and AEB 452 569 ((Drive

15 AN 21 R1 Instructions for maintenance and operation) to be followed.

J. It has been observed that ‘C’ clearance is not coming within limits. Range of ‘C’

Clearance is specified as 0.1 to 0.7 mm in ABB maintenance Manual document

No. 3EHW 411416. Observed value of ‘C’ clearances is found less than 0.05 mm

in most of the cases. RDSO vide letter no. EL/1.3.10/3 dated 26.10.2016 had

proposed to modify depth of step available in Supporting ring from existing 7.55-

0.1 to 7.30-0.1 in Drawing No. 1209-01.21-036. After this modification, range of

C clearance will be from 0.1 to 0.9 mm.


8. Various Instructions already issued by RDSO to improve the reliability of

bearings

A. 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.However, proper

handling, fitment & lubrication of the bearings needs to be ensured.

B. Detailed instructions for fitment of DE bearings of 6FRA6068TM (NU

2236) issued vide SMI number 278 dated 23.12.2013. It should be

followed completely.

C. Interference between assembly components of 6FRA6068 TM are

specified in MS-415.Dimensions of various assembly components like

labyrinths, outer racer, inner racer, shaft diameter, Bearing housing

diameter are specified to get the desired interference.

D. SMI-273 dated 23.12.2011 had been issued for detecting the cases of

rotation of outer racer. It prescribes for checking of metal content in the

grease and permissible temperature rise of bearing housing.

E. Detailed Instructions for storage and handling of lubricant/greases had

been issued by TC No: RDSO/2010/EL/TC/0104 (Rev.0) dated

16.7.2010.

F. TC-34 (Rev-4) dated 21.7.2008 specifies following lubricants :

i. Servoplex SHC 120 (IOC) – For WAG9/WAP7 TM bearings

ii. MOBILUX EP2 – For WAP5 TM bearings

G. Lubrication quantity specified in ABB manuals is :

i. WAG9/WAP7 : DE: 400gm NDE: 130 gm

ii. WAP5 : DE: 35gm NDE: 25 gm

H. Instructions had been issued vide letter number EL/3.2.182 dated

31.7.2007 for procurement of TM bearing assembly components in kit

form to improve the reliability.Assembly Components of 6FRA6068TM

are given in RDSO’s vendor directory at S.N. 28.2 page 35/197.Assembly

Components of 6FXA7059TM are given in RDSO’s vendor directory at

S.N. 28.3 page 36/197.


9. Basic precautions to improve the reliability of bearings

A. Ensuring dust free environment for bearings handling.

B. Ideal ambient temperature for bearing storage is 20˚C - 25˚C with

relative humidity of less than 60%

C. Bearings should normally be not stored for more than 1 – 1.5 years. Re-

lubrication and re-packing is required as per OEM instructions if longer

storage period is required.

D. Use ‘First in First Out’ system for consumption of bearings

E. Use of induction heaters with demagnetization feature for mounting and

dismounting.

F. Bearings should not be heated beyond 120 degree Celsius.

G. Use of prescribed lubricants

H. Replacement of assembly components in kit form

I. Exit hole of grease gun should be covered when not in use.

J. Covered containers should be used for handling of lubricants

K. Bearings should not be stored in vertical condition

L. Chemicals should not be stored along with bearings

Bearings should not be stored on the floor

10. M/s FAG & M/s SKF had also given their presentations during the workshop covering

important aspects for better reliability of bearings. Salient points based on their

presentations are given below:

Do’s

i. Store and keep bearing in clean environment

ii. Keep bearing in proper stacked condition

iii. Adopt ‘FIFO’ (First in First out)system while consuming the bearings

iv. Always measure the critical dimensions / parameters of mating components of

bearings & ensure the dimensions are as per drawing only

v. Check the free rotation of the bearing prior to its mounting

vi. Strictly follow the temperature range for heating the bearing / components in

order to avoid overheating & finally pre- mature failures

vii. Ensure the mounting place and mounting tools are clean before mounting

viii. Select the right tool & method for mounting

ix. Use only dry compressed air for cleaning the bearings

x. Lubricant container should be kept covered

xi. Greasing to be done by grease gun in measured quantity only

xii. If bearing is not to be used immediately after cleaning, Rust preventive oil should

be applied.


Don’ts

i. Do not wash or clean the new bearing

ii. Do not drop bearing on the floor or transport bearing by improper modes

iii. Don’t do mounting in dusty and open environment

iv. Don’t use improper tools for mounting

v. Do not handle bearings with dirty and moist hands

vi. Do not remove the bearings from carton until ready for mounting

vii. Strictly restrict use of non standard mating components

viii. Avoid use of cotton waste or dirty clothes to wipe the bearing

ix. Never scratch or nick the bearing critical surfaces

x. Avoid overheating of bearings beyond 1200 C

xi. Do not keep bearing open from the original pack and in heaped condition

xii. Do not remove seal of the bearing

xiii. Do not use unspecified grease and do not grease sealed bearings.

xiv. Do not use the condemned bearing / components

xv. Do not use unclean solvent for cleaning

xvi. Do not use hammers for mounting and dismounting

11. Presentation on use of Shock Pulse Meter for condition Monitoring of Bearings:

M/s SPM had given presentation on use of Shock Pulse Meter for condition monitoring

of bearings. They had explained the basic concepts involved in condition monitoring of

bearings.

12. ELS/LGD: DEE/RS/LGD had given presentation on bearings failures of ELS/LGD. It

was emphasized that most of the DE bearing failures are due to oil entry in TM which

causes grease to come out from bearing. DE bearing failures can be controlled by

controlling the oil entry and ensuring adequate lateral thrust on the bearing.

Similarly NDE bearing failures are mostly due to inadequate lateral thrust on the bearings

which can be ensured by measuring and ensuring the gap of 0.5 mm between bearing

housing (end frame) and outer labyrinth.

RDSO had issued modification sheet no. RDSO/2016/EL/MS/0439 (Rev.’0’) dated

23.11.2016 for modification in drawing of Outer Bearing Cap (DE) to drain out ingressed

gear case oil from TM type 6FRA6068. This modification sheet needs to be implemented

for controlling the oil entry in TM type 6FRA6068. NDE side clearances also need to be

ensured.

13. At the end of workshops, all the officers and supervisors were requested to meticulously

follow all the instructions related to bearings to further improve the reliability and

eliminate the bearing failures.


Annexure-I

List of participant

SN NAME (Shri) DESIGNATION SHED/RAILWAY

1. Trilok Kothari ADRM/ NGP CR

2. P.K. Saraswat DSE/TM RDSO

3. NamdeoRabade Sr.DEE/AQ CR

4. Naga Raju DEE/LGD SCR

5. M.K. Chatterjee Dy.CEE/TMM CLW

6. SourabhAnand ADEE/TRS/KYN CR

7. Diwaker Kumar ADEE/TRS/BRC WR

8. Puneet Jeph ADEE/TRS/TKD WCR

9. Vijay Gautam DEE/TRS/BSL CR

10. R.M.Srivastava ADEE/TRS/AQ CR

11. Amit Gupta DEE/TRS/AQ CR

12. P.M.Ravindram HSKI KYN

13. B. Nayak Tech-II/BIA SECR

14. NirijToppo SSE/BIA SECR

15. S.B.Chapariya Tech-II/ BIA SECR

16. DaviShanker MCF/TKD WCR

17. Harish Kumar Sharma SSE/TKD WCR

18. P.K.Mall SSE/TKD WCR

19. K. Sarabachary SSE/LGD SCR

20. D. Rama Rao SSE/LGD SCR

21. BiswanathBiswas SSE/3Ph/CLW CLW

22. Kunal Mishra SSE/BRCY WR

23. N.K.Saxena SSE/KYN CR

24. JivanBhole SSE/BSL CR

25. N. singh SSE/HR/BSL CR

26. M.R.Ghooi SSE/TM CR

27. L.C.Mahawar SSE/Elect. RDSO

28. Ram lakhan Gupta SSE/AQ CR

29. D.R. Bele SSE/AQ CR

30. N.Sharma SSE/AQ CR

31. Sandeep Lal Manager/Railway M/s FAG

32. Shivendra Sharma Engineer/Railway M/s SKF

33. Suvrajit Roy Choudhary Engineer/Railway M/s SKF

34. T.A. Rao Sr.Eng. Project SPM India

35. S. Ravi taj Sr. Eng. Project SPM India

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