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DIESEL LOCO SHED, KAZIPET

BRIEF OF THE SHED:

The shed was opened on 21st April, 1973 with a fleet of 30 WDM2 locos and Grown up to present Loco Holding of 142 locos of different types of Diesel Locomotives.

Diesel Loco Shed,Kazipet is certified with Integrated Management System (ISO-9001:2015, ISO 14001:2015 & OHSAS 18001:2007) and with 5S certification.

                      

ACTIVITIES OF DIESEL LOCO SHED, KAZIPET: Maintenance of WDM3A, WDG3A Type ALCo locos and WDG4, WDG4D type HHP locos.

  • Yearly schedules of PSU (NTPC/MSEB) locos under deposit works.
  • Maintenance and operation of 140T BD Crane.
  • Maintenance and operation of ART (MFD re-railing equipment).
  • Diesel Traction Training Centre for imparting training to Running Staff as well as Maintenance Staff.

NOTABLE ACHIEVEMENTS

-No accident on loco account in last09 years

-No case of fire on locomotive in last 09 years

-Achieved Best Efficiency shield award in 2007-08, 2012-13 & 2014-15,2016-17

-Diesel Loco shed, Kazipet has got IMS certification in 2017-18

-Diesel Loco shed, Kazipet has got 5S certification in 2017-18

MILESTONES


2002  -WDG-3A locos inducted

2010  -Received GM’s merit certificate & cash award for best ever freight outage and reliability in 2009 -10

2011  - Received GM’s certificate & cash award for best ever freight outage in 2010 -11

2012   -WDG4HHP locos inducted

2015   -WDG-4DHHP locos inducted

2017   -InductedCReDI& DPCS HHP locos

OFFICERS SETUP :


Loco Holding:

Type of locomotives

No. of Locomotives

WDM3A

38

WDG3A

53

WDG4

59

WDG4D

30

Total

180



Staff Strength:

Description

Sanction

Actual

Vacant

Supervisors

87

52

35

Artisans

680

571

109

Group ‘D’

105

88

17

Ancillary

48

36

12

Ministerial (NP+P)

45

32

13

Others

54

40

14

Total

1019

819

200


PERFORMANCE AT A GLANCE:


Parameter

Target/Actual

2014-15

2015-16

2016-17

Outage

Target

72.37

83.28

96.49

Actual

77.85

90.75

101.61

Ineffective % age

Target

8.44

8.14

7.78

Actual

7.19

6.54

5.35

Lube to HSD oil % age

Target

1.06

1.06

0.64

Actual

0.51

0.46

0.45

Lube oil consumption

In Ltrs / 100 EKMs

Target

2.35

2.35

2.35

Actual

2.19

2.01

1.99

Specific fuel consumption (Goods)

in Ltrs./1000 GTKMs

Target

1.70

1.60

1.60

Actual

1.66

1.57

1.58

Specific fuel consumption (Passenger)

in Ltrs./1000 GTKMs

Target

3.40

3.10

2.90

Actual

3.36

3.07

2.86

Statistical failures

Target

48

52

48

Actual

50

44

34

Direct punctuality

Target

38

29

29

Actual

27

28

25




Railway Consumer Depot for Fuel dispensation:

Description

Qty

HSD oil tank capacity 456 KL (2 tanks) installed on 22.03.1977

232 KL + 224 KL

HSD oil daily issues

30 KL

Lube oil Tank capacity 100 KL (2 tanks)

50 KL + 50 KL

Lube oil daily issues

1.5 KL

No. of Decanting points

01


No. of issue points

04

No. of pumps (Two diesel & one electric)

3


Bulk Lube Oil Dispensing plant:

Description

Qty

Main Tanks (50 KL each)

2

Auxiliary Tanks (5 KL each)

2

No. of issue points

9


Action taken on Implementation of Annexure-6 of corporate safety Action plan:

Ref item No

Recommendation

Status

77/1

Availability of DBR

All Locos have been provided

28.5/2

Air Dryers for Loco

All Locos have been provided

75/3

Provision of twin beam head lights

All Locos have been provided

28.4/4

Provision of Microprocessor based Paperless SPMs

All Locos have been provided

69/5

Provision of Auto switching on of flasher lights

All Locos have been provided

28.2/6

High prominence LED flasher Light

82 Locos have been provided so far


Maintenance support-Stores:

Total items Stocked

1275 new heading 193

A Category items

52


B Category items

179

C Category items

1044

Total AAC Value

23.93 Cr.

There are 03 issue wards, 01 CPW ward for centralized items and 01 receipt ward.


Maintenance support- laboratory:


  • Laboratory facility for testing.

·Coolant Water.

·Lubricants.

·Cleaning chemicals.

·Metallurgical analysis of materials.

·Spectrographic analysis of lubricants to detect water element.

·NDT (Zyglo, Dye penetrate Test and Magna flux Test) testing of Loco Components.

·UT Testing of Axles and Bearings.

  • Reclamation of drain Lube oil as dash pot oil for coaches.
  • Pollution control to protect environment.
  • Maintenance of effluent treatment plant, incinerator.
  • Maintenance of DM plant for coolant water.
  • Maintenance of RO plant for drinking purpose.

HINDI IMPLEMENTATION:
90% of staff are working in Bilingual and Hindi meetings are being conducted every 3 months. Diesel Loco Shed, Kazipet achieved first prize during Hindi exhibition on 26.10.2010 for implementation of Hindi as RajyaBhasha in SC Division.

                

HIGHLIGHTS AND INITIATIVES

HIGHLIGHTS
•    During year 2016-17, the availability is maintained above 5.30 % over the Target.
•    During year 2016-17, the ineffective %age is contained below 4.42 % as against the permissible limit of 10%.
•    Fabrication of links for Wheel lifting & Equipment for   wheel  floating in event of Locked axle/ Break down of  Locomotive wheels
Cases of locked axle failure of locomotive are occasionally encountered on-line while on run due to bearing failures. This may cause blocking of the section affecting punctuality of trains. This has to be attended by the nearest loco shed staff either by extracting traction motor pinion in the event of Motor seizure or by floating the affected wheel in case of Axle box seizure.
Floating the affected wheel of the loco is a quick method to clear the section in minimum time. Shed has developed links of blocks of standard dimensions for all types of locomotives and kept by ART/KZJ.
A three days demonstration was also organized by ART/KZJ of DSL/KZJ to all the ART and Shed staff of SCR.
                  

Floating blocks b/w Axle boxWheel Floating by using dolly trolly& stay plate End wheel


Implementation Of 5S Principles:

Diesel Loco Shed, Kazipet has been certified with 5S certification on 17-10-2017 by M/s. Quality Circle Forum of India.



The 5S system of work place management has been implemented at DLS/KZJ. With 5S principles at work place, unnecessary wastage in terms of material, time and man power was avoided, there by resulting in optimum utilization of resources.


Integrated Management System Certification:

    Diesel Loco Shed, Kazipet has got  IMS certification (for three systems ISO: 9001:2015, ISO 14001:2015, BS-OHSAS 18001:2007) on 10-08-2017

            


•    Energy Audit:
Energy Audit of Diesel Shed, KZJ was carried out by Electrical Maintenance Branch during 2016.  It was decided to put LED lights and solar panels wherever feasible for reducing the electricity consumption and to identify areas for energy conservation. 

•    Water  Audit:
An inspection was carried out by DME/D/KZJ & ADEN/S/KZJ for carrying out water audit of water consumption and to implement effective measures to save the water.  It was decided to install water flow measuring meters at prominent locations. 
•    Fire  Audit:
A fire Audit was conducted by Sr.DSO/SC, Sr.DSC/SC and Sr.DME/D/KZJ during August 2017 to ensure firefighting equipment in order. 
•    Internal Technical Seminar
Internal Technical seminar conducted on 03-06-16 by DME/DSL/KZJ with power pack section staff & Supervisors regarding fitment of water raisers on Alco locos during heavy schedule.  This year M/s.Medha is requested to conduct a technical seminar on Common Rail Electronic Fuel Direct Injection which is a new technology being tested on loco No.70384

Disaster Management – Fire Fighting Plan

         
Fire safety Precautions display boards are provided at various locations.


INITIATIVES:

•    Action plan with measurable targets have been defined for each section (20 sections available in shed) to achieve better reliability and availability of locos.
•    Loco schedule history has been computerized. Similarly Loco failures, Loco schedules, Wheel Profiles, Stores, and components failures etc., also computerized in access database for quick and proper analysis.
•    Safety Action plan has been defined and implemented to turn out the locos from shed with all safety parameters certified at SSE and Officers’ level. The staff, Supervisor & officer responsible for checking each safety parameter is defined in the Plan and meticulously monitored. There is No derailment on Loco Account.
•    Audit plan for all sections in the shed has been defined and displayed in sections in form flexi charts for conducting regular audits to achieve best reliability and availability of Locos.
•    Technical audits are regularly being conducted in all sections to stream line the working to achieve better reliability and availability of locos.
•    A number of test gadgets have been developed to improve the reliability of various sub assemblies of the locomotive.

DIESEL TRACTION TRAINING CENTRE

Diesel Loco shed, Kazipet is attached with a training center for imparting training to running staff and maintenance staff.
     
    Courses offered:
    Refresher Courses for LPs and Maintenance staff
    Induction courses, Pre promotional courses for  Maintenance Staff
    Infrastructure:
    Four Class Rooms available with teaching aids
    Two Model rooms
    One library
    One computer lab.


DTTC HOSTEL/KAZIPET

A Hostel with 27 Rooms available.  Hostel housekeeping and Maintenance is outsourced including cooking of food.
 


Highlights / Events of the Current month

Utmost importance is being given to the safety of all the employees especially in the work spot of Diesel Loco Shed, Kazipet. Conducting the meetings not only for the maintenance of the locomotives but also to the safety of the employees regularly to avoid even small injuries to the shed staff and supervisors. 100% procurement of new safety items of all sections in place of old items is one of the important jobs. Observation of usage of safety items is one of the routine jobs of all the shed

Visits of dignitaries and inaugurations:

GM/SCR inspected the shed on 26-08-2014.

CME/Plg/SC inspected the shed on 17-04-2014.

ED/(MP)/RDSO/LKO visited the shed on 25-02-2014.

General:DIGNITARIES INSPECTIONS:

 -- Nil-

Good work done / System improvement / Development :

A special drive is started to detect the cracks in the knuckle pin area through DPT during M4 and above schedules. 52 locos are covered in the drive and detected 06 are defective.

In the shed, first of its kind a control stand modification carried out on loco no. 18983. The vertical type control stand is converted to desk type for LP convenience.

A Computerised SFC kit provided in Load Box is commissioned and kept in use.

A Test stand is fabricated for torqueing WDG4 power assembly.

A tool is fabricated for removing the cup disc of lube oil relief and regulating valve.

The shed has renewed the HP tube contour checking gadget. With the modified gadget the accurate length of the HP tubes can be checked.

The shed has fabricated the stand for piston assembly for WDG 4 locos and also developed Valve springs removal gadget.

Diesel Loco Outage in total percentage:

DLS/KZJ has achieved 6.96 % Outage excess over the target (outage Target is 72.0 (for WDM3A WDG3A), Actual outage is 77.01 for this month, despite one loco in POH shops.  Actual Ineffective %age is 6.48 as against the target of 8.5 %.

Inspection of Officers:

Officers

Day time

Night time

Total

Sr.DME

Nil

2

2

DME

Nil

2

2

ADME I

Nil

2

2

ADME II

Nil

2

2

ACMT

Nil

2

2

                                                                      ____________________________________________________________________________




Source : South Central Railway CMS Team Last Reviewed on: 20-11-2017  


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