The report details the failures and deficiencies of 83 BLW locos, primarily Wag9HC, with various inspections revealing 138 major defects over the inspection period. Key issues included problems with bogies, traction motors, and pneumatic systems, as well as repeated failures of critical components like electrical systems and air leakage concerns. The data highlights significant operational challenges and commissioning problems from the years 2022-23 and 2023-24.

1. BLW LOCOS FAILURE REPORT
ELS BSP

2. LOCO HOLDING
3 Phase
AGE GROUP WAG9HC
< 10 YR. 83
10 – 15 Yr. -
15 – 20 Yr. -
20 – 25 Yr. -
25 – 30 Yr. -
30 – 35 Yr. -
> 35 Yr. -
TOTAL 83

3. Commissioning issues at ELS BSP
Year MEDHA
2022-23 09
2023-24 33
Total WAG9HC Locos received from BLW : 83
Year Working condition Dead condition Total
2022-23 9 2 11
2023-24 63 9 72
Dead Locos received at ELS BSP from BLW : 11
BT
02
39
TOTAL
TOTAL
11
72
83

4. Major Defect noticed of BLW Locos
(During / after Commissioning)

5. Summary of Equipment Wise Deficiency
SN Equipment
Deficiency (No. of
Cases)
1 Bogie & Its Mech. Equip. 14
2 CBC/Draft gear 16
3 Traction Motor, Aux Motor 24
4 Wheel 6
5 Transformer, Oil seepage 3
6 Crack on Shell and on Other parts 5
7 Defects on Roof Equipment's 7
8 Water Leakage 6
9 Pneumatic issues 22
10 Traction converter 6
11 Auxiliary Converter 8
12 Other Equipment’s 21
Grand Total 138

6. Loco INSPECTION DATE OF
INSPECTION
DEFECT & DEFICIENCY DURING IC-0
43304 IC0 15-05-2023
• Shell found crack near transformer.
• BUR-2 isolated parameter fluctuated, Make:
Hind.
43255 IC0 05-06-23
Differential Amplifier 1 & 2 defective.
Make: Top Grid Instrument Company.
43306 IC0 15-06-23
• CP-2 leg welding is not proper.
• AFI Gauge Cab-1 found defective.
43320 IC0 15-07-23
16 CP red indication glowing and in EBV fault code
36 coming
43362 IC0 17-07-23
• Bogie 2 screw coupling damage 6 43401 IC-0 19-
07-23
• Fire extinguisher found Empty (22.5Kg), Make-
Supermax equipment.
• Cab-2 Flasher light glass broken.

7. 43365 IC0 02-08-23
• Auto drain valve air leakage, pnato base
insulator crack.
• Harmonic filter current > limit, sensor replaced
battery box 1 &2 all jumper cable crimping found
loose.
43343 IC0 07-08-2023
• Oil seepage found in outer covering bolt of TFP ,
TFP Make – CGL
• Auto drain valve air leakage.
43345 IC0 20-08-2023 Oil seepage found in outer covering bolt of TFP ,
Make - HIND RECTIFIRE Lt
43364 IC0 24-08-23 • Battery box 1 &2 all jumper cable crimping
found loose.
• BUR-2 parameter fluctuate, main power off.
Make- Hind rectifier.
43393 IC0 31-08-23 CAB 2 ALP side door glass broken, cab 1 ALP side
sunwiser missing

8. 43245 IC0 26-08-23
• panto base insulator flashing.
• Heavy abnormal sound produced in TFP Pump-2
side, Make - flowoil.
• MRB found ind. variation. MRS found all phase
and ind. variation. TMS also found ind. variation
and all phase earth.
• BUR-2 Isolated V-Phase GD Card defective, SR-1
card cage changed.
43301 IC0 -
• Flange wear found 4.5mm of 01 wheel.
• Red marker light not glowing CAB-2 LP side,
Make - EEIC.
• Auxiliary converter -3 isolate, checked and found
main control card defective, same replaced (HIND
RECTIFIER)
43418 IC0 08-10-23 •BP Pipe line air leakage found from 1 inch ferrul
joint at Machine room 1 behind OCB-1.
• Inductance unbalanced of TFP Pump-2, Make –
Flow oil pump pvt Ltd.
• Inductance unbalanced of TFP Pump-2, Make –
Flow oil pump pvt Ltd.

9. 43417 IC0 07-09-23
•White marker light half glowing CAB-2 LP side,
Make – KEPCO
• BUR-2 isolated parameter fluctuated, Battery
charging not working. Make: Hind
43392
IC0
07-09-23
• CHT Cable found burst. Battery box 1 & 2 all
jumper cable crimping found loose.
• cab 2 operating handle with plate missing.
• IU Bushing found heating mark in Main
transformer, TFP make - HIND RECTIFIRE Ltd., CHT
cable found heating make – EPIL.

10. 43398 IC0 10-10-23
• Cab 2 ALP side upper break adjuster found
defective.
• PT-2 (HRP) both carbon strip worn out and 4 to 5
place deep grove mark found.
• TM-4 de side leakage in grease channel.
• VCB o/P connector found melted and bottom 3
disc found flashed.
43351 IC0 17.06.2023
• Primary vertical clearances between axle box to
bogie frame at axle box no. 1,4,6,7,8,9, & 11 were
more than service limit.
• Cab-2 flasher control unit defective.
• FDU changed since buzzer not working.
43206 IC0 03.02.2023
ALL TM HOLDER SUSPENSION RADIUS CURVE NOT
PROPER FINISHING. (DOUBLE CURVE-11MM)

11. 43356 Cab-2 side 11/4” RS Valve handle very hard to operation
43204
CP-2 MR Pressure build up time more than 11 min its both low pressure cylinder
inlet and discharge valve defective.
43204 Cab-1 SA-9 Abnormal sound during the operation.
43345 CP-1 abnormal sound coming and MR Pressure not built up.
43356 MR -1 tank drain cock found defective its handle free from ball valve.
43345 CP-2 MR Abnormal sound coming MR pressure not built up.
43320 Both air compressor MR Pressure not built up.
43286 Air dryer not working
43287 CP-2 Fan jamming.
43244
Air leakage from ADV
Pneumatic

12. 43345 BPCP Not booting service BP CP massage coming in EBV unit
43401 Driver Brake Controller Cab -2 BP showing 4.6 kg/cm2
43194
CP-01 Pressure not built up time more than 13 min for developing 10
kg/cm2
43192 CP-2 Pressure not built up time more than 13 min for developing 10
kg/cm2
43239 CP-2 Fan blade found broken.
43355 CP-2 uncoupled from motor.
43351 CP-2 uncoupled from motor.
43333 CP-1 Abnormal sound coming .
43343 CP-2 MR Pressure not built up.
43317 Air leakage from Distributor Valve
43200 Heavy air leakage from pressure control valve

13. 43418, 43198 TMB-1 grease nipple NDE side missing
43322, 43245 ,43206, 43205, 43204,
43200, 41348
TM’s holder suspension radius curve finishing is not proper (double
curve-11mm).
43417, 43398, 43365, 43364,
43356,43353, 43345, 43255, 43249
43196, 43363 , 43362, 43354, 43392,
43243
MRB & both SCMRB grease hole not found.
Facing difficulties in greasing of both MRB & SCMRB. MAKE-CGL
TM & Aux. Motors

14. 41383 CBC DRAFT GEAR CBC YOKE BROKEN
41373 CBC BROKEN CBC BROKEN
41381 CBC COUPLER BODY CBC COUPLER BODY CRACK
43239 COUPLER HEAD COUPLER HEAD CRAKE
43399 CBC CBC DAMAGED
41382 CBC COUPLER COUPLER DAMAGED
43366 DRAFT GEAR DRAFT GEAR BROKEN
43255 DRAF GEAR COLLAR DRAF GEAR COLLAR BROKEN
41382 DRAF GEAR COLLAR DRAF GEAR COLLAR BROKEN
43363 DRAFT GEAR COLLAR DRAFT GEAR COLLAR BROKEN
41372 CBC Knuckle BREAK CONDITION
41373 CBC BREAK CONDITION
41381 CBC BREAK CONDITION
43239 CBC Coupler BREAK CONDITION
41348 knuckle 1 No. BREAK CONDITION
43362 knuckle 1 No. BREAK CONDITION
43362 Screw coupling BREAK CONDITION
41381 knuckle 1 No. BREAK CONDITION
41382 knuckle 1 No. BREAK CONDITION
43254 Knuckle 2 nos BREAK CONDITION
CBC & Draft Gear

15. Bogie & Mechanical
43207 Elastic ring BREAK CONDITION
43239 Axle Damper OIL LEAKGE
43196 Traction Link Bar CRAKE
43194 Traction Link Bar 2 no. CRAKE
43303 Axle Damper OIL LEAKGE
43303 Elastic Ring Change BREAK CONDITION
43400 Elastic ring BREAK CONDITION
43365 Axle Damper 8 no. OIL LEAKAGE
43365 Yaw Damper 4 no. OIL LEAKAGE
43365 Horizontal Damper 4 no. OIL LEAKAGE
43365 Vertical Damper 4 no. OIL LEAKAGE
43205 Helical spring Secondary 1 no. BREAK CONDITION
43343 Helical spring Primary Outer 1 no. BREAK CONDITION
43364 Horizontal Damper 1 no. OIL LEAKAGE

16. THANK YOU!