PRESENTATION ON STUDY OF MAINTENANCE SCHEDULES OF IMPORTANT LOCO EQUIPMENTS

Maintenance of GR
In Ludhiana Shed In Lallaguda Shed In Vijayawada Shed

In Kanpur Shed

Maintenance of TFP
In Ludhiana Shed In Lallaguda Shed In Vijayawada Shed

In Kanpur Shed

Maintenance of Traction Motor Bearings

In Ludhiana Shed In Lallaguda Shed In Vijayawada Shed

In Kanpur Shed

Maintenance of Axle Box Bearings

In Ludhiana Shed In Lallaguda Shed In Vijayawada Shed

In Kanpur Shed

The Study reveals that . . . . .

schedules of maintenance and scope of maintenance are varying from shed to shed failure patters of these equipments are also varying from shed to shed there is a need to correlate the variations of maintenance practices and failure patterns of these important equipments Ten Cs of Maintenance is an effective tool to improve the maintenance skills of Artisan staff

Maintenance practice of GR in ELS/Ludhiana

Old Gaskets replaced to prevent air entry through Breather top

BDV & DGA of oil monitored in IC Schedules

Condition of PHGR & Silica Gel monitored in every schedule

GR never opened until any abnormality

Maintenance practice of GR in ELS/Lallaguda

BDV of oil & condition of PHGR & Silica gel monitored in every schedule DGA monitoring is not being done Oil is directly filled through nozzle GR is opened in 2nd IC, cleaned and flashed with oil Centrifuging is being done to maintain BDV of oil

Maintenance practice of GR in ELS/Vijayawada

BDV of oil is monitored. If it is found below 30 KV, oil is filtered Oil filling is done indirectly by taking filtered oil in plastic cans GR is completely opened in 2nd IC, parts are examined and filled with filtered oil

Maintenance practice of GR in ELS/Kanpur

BDV & DGA of oil is monitored. Efforts are made to ensure of working of PHGR, but with little results GR is opened only when BDV/DGA is found abnormal

Maintenance practice of TFP in ELS/Ludhiana

TFP is removed in IOH, but not in IOH. Core is never lifted out. BDV & DGA of oil is closely monitored in every IC schedule.

Maintenance practice of TFP in ELS/Lallaguda

In all new TFP, core is lifted out in 1st IOH and all bolts are tightened. Centrifuging of TFP oil is done in AOH/IOH to improve BDV to about 60 KV. TFP oil is not replaced except when it is found discoloured or DGA is found abnormal.

Maintenance practice of TFP in ELS/Vijayawada

Most of the Transformers are very old. During major schedules, winding is heated by flowing current by shorting secondary winding during centrifuging to achieve BDV of 55 to 60 KV. The above process has also helped in reducing QLM dropping.

Maintenance practice of TFP in ELS/Kanpur

Lifting of core is on case to case basis based on the condition of TFP, date of POH, weather conditions and availability of man power DGA & BDV is monitored in every IC schedule During Centrifuging, BDV of 70 to 75 KV is achieved

Maintenance practice of TM Bearings in ELS/Ludhiana

Replacement of bearing on condition basis Neither Pinion nor Bearing is removed on Pinion side Bearing is removed on Commutator side in IOH and its condition is checked.

Maintenance practice of TM Bearings in ELS/LGD & BZA

Replacement of bearing on condition basis, but compulsorily after completion of 6 years of service If details of its life are not available, it is removed and checked during major schedule or unschedule maintenance

Maintenance practice of TM Bearings in ELS/Kanpur

Replacement of bearing on condition basis

During every major schedule,

o Pinions are removed o Bearings of both ends are examined for any abnormality

Maintenance practice of Axle Box Bearings in ELS/Ludhiana

Bearings are not removed from axle box, but axle box along with bearings is removed

Wear particle analysis is done in every IC schedule.

Maintenance practice of Axle Box Bearings in ELS/Lallaguda

Axle Box along with Bearings is removed during every major schedule

During IOH, bearing is also removed from the axle box to check the condition of the bearings and ovality of the axle boxes
Wear particle analysis is done only when some abnormality is suspected after taking grease sample in IC schedules

Maintenance practice of Axle Box Bearings in ELS/Kanpur

Bearings are not removed from axle box, but axle box along with bearings is removed

Cleaning is done through a mechanised cleaning plant

Maintenance practice of Axle Box Bearings in ELS/Vijayawada

Bearings are not removed from axle box, but axle box along bearings is removed.

After cleaning, checking is done for any abnormality. Wear particles are analyzed in IC on condition basis only.

Ten C s of Maintenance:
1. Connections connections must be done correctly

2. Contacts contacts should be proper, perfect and sufficient in area. Generally lugs are found bent causing flow of current through bolts and heating
3. Clearance proper clearances must be ensured to avoid flashing in electrical system and rubbing in mechanical systems. 4. Cleaning - Cleaning should be done to ensure dust and rust free contacts
Contd..

5. Capacity Capacity should be checked and ensured to take electrical / mechanical loads
6. Clamping clamping should be done properly to avoid vibration and breaking of over-hung cables, bus bars etc. 7. Crimping it plays very important role. Generally W type crimping should only be done to ensure proper contact between lug and cable to avoid overheating 8. Corners sharp corners should be avoided to avoid flashing due to charge concentrations and cracking due to stress concentrations
Contd..

9. Cooling cooling should be ensured to avoid temperature rise and burning 10. Conductivity it should be sufficient to avoid high voltage drops or pressure drops.