IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE)

e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 8, Issue 1 (Jul. - Aug. 2013), PP 31-46

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Measurement and Evaluation of Reliability, Availability and
Maintainability of a Diesel Locomotive Engine

S.Kunar
1
, G.Ghosh
2
, K.Mandal
3
, D.Bose
4
, S.P.Sau
5

1
Production Engineering, Jadavpur University, India
2, 3,4
Mechanical Engineering &
5
Computer Science and Technology, NITTTR, India

Abstract : The growing complexity of equipments and systems often lead to failures and as a consequence the
aspects of reliability, maintainability and availability have come into forefront. The failure of machineries and
equipments causes disruption in production resulting from a loss of availability of the system and also increases
the cost of maintenance. The present study deals with the determination of reliability and availability aspects of
one of the significant constituent in a Railway Diesel Locomotive Engine. In order to assess the availability
performance of these components, a broad set of studies has been carried out to gather accurate information at
the level of detail considered suitable to meet the availability analysis target. The Reliability analysis is
performed using the Weibull Distribution and the various data plots as well as failure rate information help in
achieving results that may be utilized in the near future by the Railway Locomotive Engines for reducing the
unexpected breakdowns and will enhance the reliability and availability of the Engine. In this work, ABC
analysis has been used for the maintenance of spare parts inventory. Here, Power pack assemblies, Engine
System are used to focus on the reliability, maintainability and availability aspects.
Keywords: Availability, ABC analysis, engine system, maintainability, power pack assemblies, reliability,
Weibull Distribution.

I. Introduction
The Reliability of an item is the probability that the item will perform a specific function under
specified operational and environmental conditions at end throughout a specified time [1].Reliability must have
certain criteria. It depends on numerous factors, most of which are random. It is difficult to measure reliability
since there is no instrument by means of which this may be done for particular equipment. The respective
reliabilities of the various components of complex equipment depend on the technology of their production, the
quality of materials used in their manufacture, the conditions or environment in which they operate and so on.
In view of these considerations, the reliability of equipment is closely related to several uncertainty factors. The
Quantitative study of uncertainty, therefore, forms the starting point for a quantitative analysis of reliability. The
theory which deals with the study of uncertainty is the probability theory. The maintenance policy will cover
issues regarding general repairs, repair or discard policies, emergency recorder policies, inventory control,
provisioning of spares, etc. It is possible to define some of the maintenance policies in advance and take design
decision accordingly. The process of designing involves decision regarding module size, test procedures, built-
in-redundancies, and degree of automation, inspection intervals, special test equipment, and safety requirements
and so on Availability is a performance criterion for repairable systems that accounts for both the reliability and
maintainability properties of a component or system. ABC analysis helps segregating the item from one another
and fells how much valued the item is and controlling if to what extent is in the interest of the organization [2].

II. Railway Diesel Locomotive Engine and its Components
The following fig 1 shows a Railway Diesel Locomotive Engine. The engine is of V design, and is
manufactured in 16 cylinders. The cylinders are arranged into pairs of cylinders, each pair using a common
throw on the crankshaft. The cylinders are divided into two banks, left and right.

Measurement and Evaluation of Reliability, Availability and Maintainability of a Diesel Locomotive
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Figure1. Railway Diesel Locomotive Engine.

A Railway Diesel Locomotive Engine has the following main sub-systems.
1. Power pack assemblies
2. Engine System

III. Failure
Failure is any event that impacts a system in a way that adversely affects the system criteria. For
example, the criteria could include output in a sold-out condition, or maintenance cost or capital resources in a
constrained budget cycle, environmental excursions or safety, etc. A failure definition should contain specific
criteria and not be ambiguous. Failure definition can change on a given system over time.
Field failures do not generally occur at a uniform rate, but follow a distribution in time commonly
describe as a "bathtub curve." The life of a device can be divided into three regions: Infant Mortality Period,
where the failure rate progressively improves; Useful Life Period, where the failure rate remains constant; and
Wear out Period, where failure rates begin to increase. Within a population of units is a small sub-group of units
with latent defects that will fail when exposed to a stress that would otherwise be benign to a good unit. With
the failure of the weak units, the remaining population is more reliable, and the failure rate is known to
decrease. Units that pass the Infant Mortality Period have a high probability of surviving the conditions
provided by the system and its environment. Failures that occur during the Useful Life Period are residual
defects surviving Infant Mortality, unpredictable system or environmental conditions, or premature wear out.


Figure 2. Bath-tub curve describing failure rates at different periods of life

3.1 Relablty Predcton
A reliability prediction is simply the analysis of parts and components which effort to predict and
calculate the rate at which an item will fail. A reliability prediction is one of the most common forms of
reliability analyses for calculating failure rate and MTBF, MTTR, Availability etc [3].

3.1.1 Mean Time to Failure (MTTF)
It is the expected value of time t or the mean of the TTF (Time to Failure) distribution when one item is
put into operation [4]
When and only when failure rate is a constant or = (t) then
--- (3.1)

Measurement and Evaluation of Reliability, Availability and Maintainability of a Diesel Locomotive
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3.1.2 Mean Time between Failures (MTBF)
It is the expected average time between failure events that cause the item to go down. Therefore
MTBF can be defined as the average time (generally expressed in hours) that a component works without
failure If and only if the item has constant failure rate then,
--- (3.2)
3.2 Failure Distribution
The goal of system modeling is to provide quantitative forecasts of various system performance
measures such as downtime, availability, and number of failures, capacity, and cost. Evaluation of these
measures is important to make optimal decisions when designing a system to either minimize overall cost or
maximize a system performance measure within the allowable budget and other performance-based constraints.
Two important factors taken into account in the analysis of a system are the failure and repair
behaviors of the system components. The failure and repair rates of components are often defined in terms of
distributions, or how the failures and repairs occur during the time period the system is operational. Therefore,
selecting the appropriate distributions for these failure and repair times is critical to analyze system metrics
accurately.
A useful way to easily visualize the characteristics of a failure or repair distribution is through the use
of Probability Density Functions (PDF) [5]. In general, the shape or type of failure distribution depends upon
the component's failure mechanisms. Similarly, the shape or type of repair distribution depends upon several
factors associated with component repairs. Several methods are used to determine the distribution that best fits a
given failure or repair pattern. Or, if failures or repairs are known to follow a particular distribution, the specific
parameters that define this pattern can be determined by using the known failure and repair times.
If the type of distribution is not known in advance, then the distribution that best fits the failure or
repair times can be found using statistical methods. To find the best distribution manually, probability plot
papers are used. Alternatively, engineering software products can also be used to generate probability plots and
determine best-fit distributions. In general, it is better to use available software tools because best-fit
distributions are determined using scientific analysis rather than human judgment, which must be used when
manually creating probability plots. Such engineering software products are commonly referred to as "Weibull"
analysis tools, simply because Weibull is a widely accepted, commonly used distribution for describing failure
and repair rates.
Determining the failure and repair distributions of a system and its components is a significant part of
evaluating the reliability of the design. Distributions may be referred to as single-parameter or two-parameter
distributions. For single-parameter distributions, only one variable is used to define the shape of the curve.
Two-parameter distributions require two variables to accurately model the distribution.

3.3 Collection of Data
The most essential precondition for reliability and failure analysis or maintenance planning is the
availability of relevant data. For the present analysis, data related to Railway Diesel Locomotive Engine, its
Mechanical system and Electrical system failures during last five years [2007 January to 2011 December] are
collected. The database includes no. of breakdowns related to different types of systems or components failures
of Diesel Locomotive Engine and their monthly or year wise available No. of failure of a component or system,
cause of failure and corrective action taken previously.
The documentation of failure data (table 1 and fig.3) on Diesel Locomotive Engine, daily breakdown
record has been collected from the daily maintenance statistics lab in the DEISEL SHED.

Table 1. No. of Failures of different components
Sl. No. Name of Different Components No. of Failures
01 Power pack assemblies 10
02 Engine system failure

06

Measurement and Evaluation of Reliability, Availability and Maintainability of a Diesel Locomotive
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Figure 3. No. of Failures of different components

3.4 Failures of Power pack assemblies
Fig.4 shows the different failure zones of power pack assemblies. It has been observed that maximum
failure occurs at Cam shaft joint flange broken and thread warm out.

Figure 4. Failures of Power pack assemblies Figure 5. Cam shaft joint flange
broken
1. Cam shaft joint flange broken and thread warm out refer fig.5.
2. Cylinder head crack.
3. Extension shaft 2
nd
coupling ratter pad damage.
4. Cylinder head valve broken refer fig.6.
5. Cylinder head dummy plug thrown out.

Figure 6. Cylinder head valve broken
3.5 Failures of Engine system
From survey it has been observed that the flexible hose burst, piston ring broken and H.P tube damage
each comprises as well as 33% refer fig. 7.








Figure.7 Failures of Engine system Figure.8 Flexible hose burst
1. Flexible hose burst. (A/Cooler) refer fig.8.
Measurement and Evaluation of Reliability, Availability and Maintainability of a Diesel Locomotive
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2. Piston ring broken refers fig.9 & 10.
3. HP tube crack


Figure 9. Piston ring broken Figure10. Piston ring broken

IV. Reliability Analysis
The Locomotive Engine under investigation is composed three components. The components are
Power pack assemblies, Engine system.

4.1 Hazard Model & Probability Distribution
The initial stage of reliability analysis is to predict the hazard model of the failures and to choose a
distribution among various probability distributions like Normal distribution, Exponential distribution, Poison
distribution, Weibull distribution etc. The probability distributions are grouped as follows:
Hazard model with constant failure rate can be followed by normal, exponential distributions.
Hazard model with increasing or decreasing failure rates can be followed by Weibull distribution.

4.2 Graphical Evaluation for Reliability Prediction
There are generally two ways for graphical evaluation visualizes -Exponential plot and Weibull Plot.
When the failure rate is constant, the distribution follows exponential probability law and when failure rate is
not constant i.e. non-linear hazard model follows Weibull distribution.

4.3 Linear Regression Analysis: Selection of Distribution
The observed data regarding the failures of different components of the Railway Diesel Locomotive
Engine shows that the failure rates of the components are not constant. So the Weibull distribution model can be
adopted. Moreover the technique of linear regression analysis confirms the suitability to use Weibull
distribution for the different components of the Railway Diesel Locomotive Engine. The analysis determines
the best-fit line in the least square sense. The least square test has been performed to obtain the
increasing/decreasing rate of failures [6].
Linear regression analysis has been carried out by using the Probability equation.

(4.1)
Where,
x = Breakdown hours
Y = f(x) = Cumulative % failures
N = number of trials
R
x, f(x)
= Correlation coefficient
Failure data of the different components of the Diesel Locomotive Engine is used for determining the
correlation co-efficient (Table 1). From the concept of probability, we know that the correlation coefficient
must be in between -1.0 to +1.0. If the correlation coefficient is positive, then the failure rate is increasing,
otherwise the rate is decreasing. The correlation coefficients of the different components of the Railway Diesel
Locomotive Engine under study shows increasing rate of failures. Weibull distribution can be applied for the
estimation of reliability of the different components of the Railway Diesel Locomotive Engine.



R
x, f(x)
=

Measurement and Evaluation of Reliability, Availability and Maintainability of a Diesel Locomotive
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Table 2: Correlation Coefficient
Name of Components Correlation Coefficient
Power Pack Assemblies 0.796
Engine System 0.779

4.4 Weibull Distribution
About all the distributions available for reliability calculations, the Weibull distribution [7] is the only
unique to the field. Allodia Weibull (1887-1979) pointed out that normal distributions are not applicable for
characterizing initial metallurgical strengths during his study on metallurgical failures. He then introduced a
function that could embrace a great variety of distributions and used seven different case studies to demonstrate
how this function allowed the data to select the most appropriate distribution from a broad family of Weibull
distributions. Probably the most widely used distribution in reliability engineering, the Weibull distribution can
model failures caused by fatigue, corrosion, mechanical abrasion, diffusion and other degradation processes.
The two parameter Weibull distribution requires characteristic life () and shape factor () values. Beta
() determines the shape of the distribution. If is greater than 1, the failure rate is increasing. If is less than 1,
the failure rate is decreasing. If is equal to 1, the failure rate is constant. There are several ways to check
whether data follows a Weibull distribution, the best choice is to use a Weibull analysis software product. If
such a tool is not available, data can be manually plotted on a Weibull probability plot to determine if it follows
a straight line. A straight line on the probability plot indicates that the data is following a Weibull distribution.

Figure 11. Weibull Distribution

Reliability analysis of the selected components of the Railway Locomotive Engine has been carried out
with due consideration of failure as an indication of the underlying cause of failure has been summarized in
term of Weibull shape parameter. Weibull shape parameter also indicates whether the failure rate is constant
or increasing or decreasing if = 1.0, >1.0, <1.0 respectively. The cumulative % failures versus operating
time data are plotted on Weibull graph [Fig.12 & 13] and the values of the parameters are obtained using the
statistical software MINITAB15.

Table 3: Weibull plot for Power pack assemblies
SL.
NO
MONTH
MONTHLY
OPERATING
TIME(HOURS)
NO OF
FAILURES
PERCENTAGE
FAILURES

CUMULATIVE
% FAILURES

1 January'07 720 0 0 0
2 620 0 0 0
3 576 0 0 0
4 600 0 0 0
5 708 0 0 0
6 700 0 0 0
7 734 0 0 0
8 734 0 0 0
9 648 0 0 0
10 734 0 0 0
11 672 0 0 0
12 670 0 0 0
13 January'08 724 0 0 0
14 686 1 10 10
Measurement and Evaluation of Reliability, Availability and Maintainability of a Diesel Locomotive
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15 732 0 0 10
16 638 0 0 10
17 734 0 0 10
18 710 0 0 10
19 660 0 0 10
20 710 0 0 10
21 708 1 10 20
22 744 0 0 20
23 624 0 0 20
24 734 0 0 20
25 January'09 696 0 0 20
26 600 0 0 20
27 733 0 0 20
28 708 0 0 20
29 720 3 30 50
30 696 0 0 50
31 734 0 0 50
32 718 0 0 50
33 710 0 0 50
34 672 0 0 50
35 710 0 0 50
36 744 1 10 60
37 January'10 600 2 20 80
38 600 0 0 80
39 720 0 0 80
40 576 0 0 80
41 744 0 0 80
42 696 0 0 80
43 600 0 0 80
44 720 0 0 80
45 720 0 0 80
46 696 0 0 80
47 672 0 0 80
48 734 0 0 80
49 January'11 732 0 0 80
50 576 0 0 80
51 144 2 20 100
52 552 0 0 100
53 504 0 0 100
54 648 0 0 100
55 720 0 0 100
56 696 0 0 100
57 600 0 0 100
58 600 0 0 100
59 648 0 0 100
60 732 0 0 100

Table 4: Weibull plot for Engine system
SL.
NO
MONTH
MONTHLY
OPERATING
TIME(HOURS)
NO OF
FAILURES
PERCENTAGE
FAILURES

CUMULATIVE
% FAILURES

1 January'07 720 0 0 0
2 620 0 0 0
3 576 0 0 0
4 600 1 16.667 16.667
5 708 0 0 16.667
Measurement and Evaluation of Reliability, Availability and Maintainability of a Diesel Locomotive
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6 700 1 16.667 33.333
7 734 0 0 33.333
8 734 0 0 33.333
9 648 0 0 33.332
10 734 0 0 33.332
11 672 0 0 33.332
12 670 0 0 33.332
13 January'08 724 0 0 33.332
14 686 0 0 33.332
15 732 0 0 33.332
16 638 0 0 33.332
17 734 0 0 33.332
18 710 0 0 33.332
19 660 0 0 33.332
20 710 0 0 33.332
21 708 0 0 33.332
22 744 0 0 33.332
23 624 0 0 33.332
24 734 0 0 33.332
25 January'09 696 0 0 33.332
26 600 0 0 33.332
27 733 1 16.667 50
28 708 0 0 50
29 720 0 0 50
30 696 0 0 50
31 734 0 0 50
32 718 1 16.667 66.667
33 710 0 0 66.664
34 672 0 0 66.664
35 710 0 0 66.664
36 744 0 0 66.664
37 January'10 600 0 0 66.664
38 600 0 0 66.664
39 720 0 0 66.664
40 576 0 0 66.664
41 744 0 0 66.664
42 696 0 0 66.664
43 600 0 0 66.664
44 720 0 0 66.664
45 720 0 0 66.664
46 696 0 0 66.664
47 672 0 0 66.664
48 734 0 0 66.664
49 January'11 732 0 0 66.664
50 576 1 16.667 83.333
51 144 0 0 83.333
52 552 0 0 83.333
53 504 0 0 83.333
54 648 0 0 83.333
55 720 0 0 83.333
56 696 0 0 83.333
57 600 0 0 83.333
58 600 1 16.667 100
59 648 0 0 100
60 732 0 0 100

Measurement and Evaluation of Reliability, Availability and Maintainability of a Diesel Locomotive
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1000 100
99.99
95
80
50
20
5
2
1
0.01
Monthly Operating Time (Hours)
C
u
m
u
l
a
t
i
v
e

p
e
r
c
e
n
t
a
g
e

f
a
i
l
u
r
e
s
Correlation 0.796
Shape 5.29975
Scale 699.492
Mean 644.407
StDev 139.949
Median 652.752
IQR 191.009
Failure 2760
Censor 0
AD* 252.464
Table of Statistics
Weibull Plot for Power pack assemblies
Weibull - 95% CI

Figure 12. Weibull plot for Power pack assemblies

1
0
0
0
9
0
0
8
0
0
7
0
0
6
0
0
5
0
0
4
0
0
3
0
0
2
0
0
1
5
0
99.99
95
80
50
20
5
2
1
0.01
Monthly Operating Time (Hours)
C
u
m
u
l
a
t
i
v
e

P
e
r
c
e
n
t

o
f

f
a
i
l
u
r
e
s
Correlation 0.779
Shape 6.18723
Scale 707.317
Mean 657.303
StDev 123.809
Median 666.635
IQR 167.349
Failure 3127
Censor 0
AD* 279.469
Table of Statistics
Wibull plot for Engine system
Weibull - 95% CI

Figure 13. Weibull plot for Engine system

V. Availability Analysis
Availability is a performance criterion for repairable system or any normal system that accounts for
both the reliability and maintainability properties of a component of a system is operating properly when it is
required to use. As a matter of fact availability is the probability that a system is not failed or undergoing a
repair action / maintenance job when it needs to be used. So the estimation of availability plays vital role of
both reliability and maintainability aspects are considered for a system or components under investigation.

5.1 Availability
Availability is a performance criterion for repairable systems that accounts for both the reliability and
maintainability properties of a component or system. It is defined as the probability that the system is operating
properly when it is requested for use. That is availability is the probability that a system is not failed or
undergoing repair action when it needs to be used [2].
A
IN
= MTBF / (MTBF+MTTR) --- (5.1)
It is possible to define three types of availability depending on the time elements we consider.

5.1.1 Inherent Availability
This is a probability that a system or equipment shall operate satisfactorily when used under stated
conditions in an ideal support environment, without consideration for any scheduled or preventive maintenance
at any given time. Mathematically it is expressed [2] as
A
IN
=MTBF/ (MTBF+MTTR) --- (5.2)

5.1.2 Achieved Availability
This is a probability that a system or equipment shall operate satisfactorily when used under stated
conditions in an ideal support environment at any given time. It may be expressed as [2]

A
a
= MTBM / (MTBM+MDT) --- (5.3)
Measurement and Evaluation of Reliability, Availability and Maintainability of a Diesel Locomotive
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Where, MTBM is the mean active-maintenance down time resulting from both preventive and
corrective maintenance.

5.1.3 Operational Availability
In any real operation, we cannot reduce administrative down time and supply downtime to zero. A
certain amount of delay will always be caused by time elements such as these and if they are taken into account
then we obtain the operational availability. It may be defined as the probability that a system or equipment shall
operate satisfactorily when used under stated conditions and in an actual supply environment at any given time.
It may be expressed [2] as
A
OP
= MTBF/ (MTBF+MDT) --- (5.4)

In general the availability of a system is a complex function of reliability maintainability and supply
effectiveness. This can be expressed as
As = f (Rs, Ms, Ss) --- (5.5)

Where, As = System Availability, Ss = Supply Effectiveness, Rs= System Reliability,
Ms= System Maintainability.

Table 5. Estimation of availability of Power Pack Assemblies
SL.N
O.

MONTH
UPTI
ME
(HOU
RS)
DOWNT
IME
(HOURS
)
NO. OF
FAILURE
S
MTB
F
(HO
URS)
HAZA
RD
RATE
MDT
(HOU
RS)
AOP
MTTR
(HOU
RS)
AIN
1 January'07 720 24 0 0 1 1
2 620 12 0 0 1 1
3 576 144 0 0 1 1
4 600 120 0 0 1 1
5 708 36 0 0 1 1
6 700 20 0 0 1 1
7 734 10 0 0 1 1
8 734 10 0 0 1 1
9 648 72 0 0 1 1
10 734 10 0 0 1 1
11 672 48 0 0 1 1
12 670 24 0 0 1 1
13 January'08 724 10 0 0 1 1
14 686 10 1 686 0.00145
77
10 0.985 3 0.995
15 732 12 0 0 1 1
16 638 82 0 0 1 1
17 734 10 0 0 1 1
18 710 10 0 0 1 1
19 660 84 0 0 1 1
20 710 10 0 0 1 1
21 708 12 1 708 0.00141
24
12 0.983 3.6 0.983
22 744 0 0 0 1 1
23 624 72 0 0 1 1
24 734 10 0 0 1 1
25 January'09 696 48 0 0 1 1
26 600 72 0 0 1 1
27 733 10 0 0 1 1
28 708 12 0 0 1 1
29 720 0 3 240 0.00416
67
0 1 0 1
30 696 24 0 0 1 1
31 734 10 0 0 1 1
32 718 26 0 0 1 1
33 710 10 0 0 1 1
34 672 72 0 0 1 1
35 710 10 0 0 1 1
36 744 0 1 744 0.00134
41
0 1 0 1
37 January'10 600 120 2 300 0.00333
33
60 0.833 18 0.943
38 600 48 0 0 1 1
39 720 24 0 0 1 1
40 576 144 0 0 1 1
Measurement and Evaluation of Reliability, Availability and Maintainability of a Diesel Locomotive
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41 744 0 0 0 1 1
42 696 24 0 0 1 1
43 600 120 0 0 1 1
44 720 24 0 0 1 1
45 720 24 0 0 1 1
46 696 0 0 0 1 1
47 672 24 0 0 1 1
48 734 48 0 0 1 1
49 January'11 732 12 0 0 1 1
50 576 120 0 0 1 1
51 144 192 2 72 0.01388
89
96 0.428 28.8 0.7142
52 552 168 0 0 1 1
53 504 216 0 0 1 1
54 648 72 0 0 1 1
55 720 24 0 0 1 1
56 696 48 0 0 1 1
57 600 120 0 0 1 1
58 600 120 0 0 1 1
59 648 72 0 0 1 1
60 732 12 0 0 1 1

Table 6. Estimation of availability of Engine system

SL.
NO.
MONTH
UPTI
ME
(HOU
RS)
DOW
N
TIME
(HOU
RS)
NO.
OF
FAIL
URES
MTB
F
(HOU
RS)
HAZA
RD
RATE
MDT
(HOU
RS)
AOP
MTTR
(HOU
RS)
AIN
1 January'0
7
720 24 0 1 1
2 620 12 0 1 1
3 576 144 0 1 1
4 600 120 1 600 0.0016 120 0.833 36 0.948
5 708 36 0 1 1
6 700 20 1 700 0.0014 20 0.972 6 0.991
7 734 10 0 1 1
8 734 10 0 1 1
9 648 72 0 1 1
10 734 10 0 1 1
11 672 48 0 1 1
12 670 24 0 1 1
13 January'0
8
724 10 0 1 1
14 686 10 0 1 1
15 732 12 0 1 1
16 638 82 0 1 1
17 734 10 0 1 1
18 710 10 0 1 1
19 660 84 0 1 1
20 710 10 0 1 1
21 708 12 0 1 1
22 744 0 0 1 1
23 624 72 0 1 1
24 734 10 0 1 1
25 January'0
9
696 48 0 1 1
26 600 72 0 1 1
27 733 10 1 733 0.0013 10 0.986 3 0.996
28 708 12 0 1 1
29 720 0 0 1 1
30 696 24 0 1 1
31 734 10 0 1 1
32 718 26 1 718 0.0013 26 0.964 7.8 0.989
33 710 10 0 1 1
34 672 72 0 1 1
35 710 10 0 1 1
36 744 0 0 1 1
37 January'1
0
600 120 0 1 1
38 600 48 0 1 1
39 720 24 0 1 1
40 576 144 0 1 1
41 744 0 0 1 1
42 696 24 0 1 1
43 600 120 0 1 1
Measurement and Evaluation of Reliability, Availability and Maintainability of a Diesel Locomotive
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44 720 24 0 1 1
45 720 24 0 1 1
46 696 0 0 1 1
47 672 24 0 1 1
48 734 48 0 1 1
49 January'1
1
732 12 0 1 1
50 576 120 1 576 0.0017 120 0.827 36 0.941
51 144 192 0 1 1
52 552 168 0 1 1
53 504 216 0 1 1
54 648 72 0 1 1
55 720 24 0 1 1
56 696 48 0 1 1
57 600 120 0 1 1
58 600 120 1 600 0.0016 120 0.833 36 0.943
59 648 72 0 1 1
60 732 12 0 1 1

Table 6. Availability of different components of the Railway Diesel Locomotive Engine
SL. NO. NAME OF THE DIFFERENT COMPONENTS AVAILABILITY
1 Power pack assemblies 0.993
2 Engine system 0.997















Figure 14. Availability graph for different components


Figure 15. Availability of power pack assemblies
Measurement and Evaluation of Reliability, Availability and Maintainability of a Diesel Locomotive
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Figure 16. Availability of Engine system

VI. Development of Spares Planning and Control System
6.1 Maintenance
The definition often stated maintenance as an activity carried out for any equipment to ensure its
reliability to perform its functions [8].Maintenance to most people is any activity carried out on an asset in order
to ensure that the asset continues to perform its intended functions or to repair any equipment that has failed or
to keep the equipment running or to restore to its favorable operating condition. Over the years, many new
strategies have been implemented as maintenance strategies which are intended to overcome the problems
which are related to equipment breakdown. Some of the common maintenance strategies [9] are as follows:-

Table 7. Maintenance Strategy
MAINTENANCE STRATEGY MAINTENANCE APPROACH SIGNIFICATION
Corrective Maintenance Fix it when broke Large maintenance budget.
Preventive Maintenance Scheduled Maintenance Periodic component replacement.
Predictive Maintenance Condition based Monitoring
Maintenance decision based on equipment
condition.
Proactive Maintenance Detection of sources of failures.
Monitoring and correcting root causes of
failure.

6.2 Classification for selective control of spare parts inventory- ABC Analysis
The objective of carrying out ABC analysis is to develop policy guidelines for selective controls of
spare parts. The ABC classification of the spare parts of Railway Diesel Engine has been performed on the basis
of their annual consumption in rupees. The entire procedure for making ABC analysis is summarized in the
following steps:
i) Annual consumptions in rupees have been calculated for each spare part.
ii) The sorting of spare parts has been performed on the basis of annual consumptions in rupees in descending
order.
iii) Cumulative annual usage and cumulative % usage are estimated which are shown in Table 8 .The parts are
categorized considering the cumulative % usage.
iv) The Pareto chart figure 17 is obtained for the spare parts by plotting cumulative percentage usage against
the ranks of the parts in descending order to visualize the ABC categories.

Table 8. ABC Analysis of the spare parts
RANK SPARE PART
ANNUAL USAGE
[IN RUPEES.]
CUMULATIVE
ANNUAL USAGE
CUMULATIVE
% USAGE
CATEGORY
1 Power pack 82,15,810.90 18633720 48.67127014 A
2 Engine system 68,45,035.00 25478755 66.55049917 B
Measurement and Evaluation of Reliability, Availability and Maintainability of a Diesel Locomotive
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Figure 17.Paratoo chart

VII. Results & Discussions
7.1 Reliability Estimation
Reliability estimation of the different components of the Locomotive Engine of Railways provides the
values of shape parameters as well as reliability (Table 9) which focuses on the performance of the components
of the Locomotive Engine during the period of January, 2007 to December, 2011.

Table 9. Reliability of the Railway Locomotive Engine components
SL.
NO.
NAME OF THE DIFFERENT
COMPONENTS
SHAPE PARAMETER
()
(FROM WEIBULL
PLOT)
MEAN
OPERATING
HOUR
(IN HOURS)
RELIABILITY
FAILURE
PROBABILI
TY
FAILURE
PROBABILI
TY
1 Power pack assemblies 5.299 644.407 64.476
35.523
35.5237
2 Engine system 6.187 657.303 65.878
34.121
34.1212




Figure 18. Reliability of different components for Locomotive Engine

From Fig.18, it is found that the estimated Reliability of the different components of the Railway
Diesel Locomotive Engine is in the range of 59% to 68%. The reliability of the Transmission cables the
maximum (67.998%) whereas the minimum (59.9987%) reliability is for the vehicle and structure.

Figure 19. Shape parameter of different components
Measurement and Evaluation of Reliability, Availability and Maintainability of a Diesel Locomotive
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Weibull shape parameter is the indicative of the possible failure mechanism and the causes of failures
of any component. Table 10 shows the classification of shape parameters according to their values indicating
possible failure mechanism and cause of failure.

Table 10. Classification of shape parameter
SHAPE PARAMETER VALUE POSSIBLE FAILURE MECHANISM CAUSES OF FAILURE
>2 Age related pattern
Accelerated wear and tear of
components.
1 Time independent pattern
Process error, design fault, mal
operation
< 1 Early failure
Manufacturing failure, and
reconditioning fault.

The values of the shape parameters of the different components of the Railway Diesel Locomotive
engine are given in Table 9 & Fig.19. It is evident that the possible failure mechanism of various components
falls into the category of age related pattern and failures occur due to accelerated wear and tear of components
(Table 10).

7.2 Availability of Different Components of the Railway Locomotive Engine
As per the definition of operational availability, the availability of different components of the
Railway Diesel Locomotive Engine is calculated for a particular month starting from January, 2007 to
December, 2011. After that the average operational availability of each component is calculated. A detailed
average operational availability of different components of the Railway Diesel Locomotive Engine is given
Table 11 and Fig.20.

Table 11. Estimated Operational Availability of the Railway Diesel Locomotive Engine components
SL. NO. NAME OF THE DIFFERENT COMPONENTS
AVERAGE OPERATIONAL
AVAILABILITY
1 Power pack assemblies 0.997
2 Engine system 0.990


Figure 20. Operational availability of different components
Considering operational availability and inherent availability vs. time period for different components
of the Railway Diesel Locomotive Engine (Fig.15 to16) show the availability patterns of Railway Diesel Engine
during the period under study (January, 2007 to December, 2011).
Figure.15: shows that the power pack assemblies undergoes preventive maintenance and overhauling
for shorter period during the months of December 2009 to January 2010, and December 2010 to February
2011 as both the inherent and operational availability are coinciding with each other.
Figure.16: shows that the engine system comes under preventive maintenance and overhauling during
the months of April2007 to May 2007, and January 2011 to February2011 and September2011 to October2011
as both the inherent and operational availability are coinciding with each other.

7.3 Analyses of the Major Causes of Failures and Recommendations for Their Remedies
After analyzing the failures of the Railway Diesel Locomotive Engine components, the major causes
of failures include careless and inexperienced handling, improper and excessive loading, environmental,
careless operation, degradation etc




Measurement and Evaluation of Reliability, Availability and Maintainability of a Diesel Locomotive
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7.4 Proposed Maintenance Schedule
It is true that the failures of the engine parts cannot be fully prevented i.e. 100% availability cannot be
achieved, but the probability of failure and frequency of failures, and thus risk can be checked or lowered
through proper condition monitoring of the Railway Diesel Locomotive Engine components.
Following are the causes and the recommended preventive measures to be taken for the major
components of the engine.

Table 12.Power pack assemblies failures
Causes Corrective actions
6l Liner chrome layer peeled off Letter sent to DMW for necessary corrective action.
Cylinder head crack Letter sent to dy. cme/jmp for farther preventive action in POH
8l Cam shaft sheared in two pieces Welding of cam lobe cam lobes should be avoided.
Cylinder. Head dummy plug thrown out.
Dummy plug should be checked during OVH. lock tight 609 to
be applied if found loose
Cylinder. Head valve broken Replace

Table 13.Engine system
CAUSES CORRECTIVE ACTIONS
Flexible hose burst.(a/cooler)01
After cooler inlet and out let hose should be changed during m-
12 and above schedule in case of twin a/cooler
Lube oil pump defective-01
Instruction has been given that, lube oil pump should be OVH
during m-48 schedule
Fuel oil solid t-jumper broken.-1
Firm has been advised for quality control of material.
DPT testing should be done before fitment

VIII. Conclusion
This study has focused mainly on the estimation of the reliability and availability of a specific
Railway Locomotive Engine along with maintainability aspects.
The collection of the past data is the most vital precondition to carry out such analysis. The initial stage of the
present study has revolved around the collection of well defined data regarding the breakdowns and
maintenance of the Engine.
It has been found that worker inefficiency, overloading, degradation of the system components with
time are mainly the contributing factors for the failures of Railway Diesel Locomotive Engine.
.From the Reliability prediction of the engine components it was found that the reliability of the components
ranging from 59% to 68% where maximum reliability found in case of transmission cable (67.998%) and
minimum reliability found in case of vehicle and structure (59%). As the maximum systems of the Engine are
found to be moderate Reliability and to upgrade its maintenance process of the Locomotive Engine.
The availability patterns describe the performance of the Engine. The plant is having no such correct
spare parts provisioning system for a cost effective and timely managed maintenance practice. Whenever any
breakdown occurs, the maintenance department places an indent on the requirements for a particular spare part
to the store, if the spare is available in the store they supply it to maintenance department and if not, then order
is placed to the purchase department as a result maintenance process gets delayed. A spare parts provisioning
model has been introduced to estimate the safety stock. In-depth and continuous study it is required to analyzing
the effects of the preventive maintenance action for the Railway Locomotive Engine components, controlling
and monitoring of spare parts on reliability aspects.

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