1
FINAL REPORT
ON
MID TERM REHABILITATION
OF THREE PHASE ELECTRIC
LOCOMOTIVES
August’2015
By:
Executive Director Standard Electrical/RDSO Chief Electrical Loco Engineer/NR Chief Electrical Loco Engineer/WR Chief Workshop manager/ELW/BSL
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SUMMARY OF RECOMMENDATIONS
1. Mid Term Rehabilitation (MTR) and Technological Upgradation (TU) is recommended to be carried out after completion of 18 years of service of three phase passenger locomotives (WAP5 & WAP7) along with POH schedule and Technological Upgradation of three phase goods locomotives (WAG9 & WAG9H) to be undertaken by Electric loco sheds during 2nd IOH after 18 years of service in accordance with scope of work brought out in this Report.
2. For GTO based three phase passenger locomotives, main components of propulsion system i.e. traction Converter, auxiliary converter will be replaced from existing GTO based technology which is going in obsolescence mode with latest state of art IGBT based technology. Vehicle control units of old generation will be replaced by new generation Vehicle control units preferably developed by C-DAC. The inherent advantage of this conversion will be improved adhesion due to bogie control system will be replaced by individual axle control. The released material shall be overhauled and may be used by loco sheds for meeting their normal maintenance requirements. This work shall be undertaken as a part of Technology Upgradation (TU) work.
3. Due to inclusion of MTR & technology upgradation work following
schedule of POH and MTR is recommended. Passenger locomotives: WAP5/WAP7
Activity 1st POH MTR+2nd POH
3rdPOH End of life
Years 9±0.5 18 ±0.5 27±0.5 35
Goods locomotives: WAG9/WAG9H
Activity 1st POH TU+2nd IOH
2rd POH End of life
Years 12±0.5 18 ±0.5 24±0.5 35
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INDEX
S. No. Description Page Nos. 1 Background 5 2 Report 6 3 Need of Mid Term Rehabilitation 6 4 Recommendations for works to be carried
out during Mid Term Rehabilitation 8
5 Technology Upgradation 9 6 Assessment of expenditure on Mid Term
Rehabilitation and productive life of locomotives
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7 Conclusion and Recommendation 9 8 Annexure-I-Holding of Three Phase
Locomotives 11
9 Annexure-II-Periodicity and Time taken in various schedules
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10 Annexure-III-List of must change items during POH
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1.0 BACKGROUND:
1.1 Indian Railways imported 22 WAG9 locomotives and 11 WAP5 locomotives
from M/s. ABB, Switzerland in 1996-97. Northern Railway vide their letter No.
147-Elect/TRS/3Part-III dated 19.10.2012has informed that initially 10 no. of
WAP5 locomotives were commissioned at ELS/GZB in 1997. 1st POH of
initially commissioned locomotives have been done in 2004-05 after 9 years
of service. NR had further informed that seven locomotives were due for2nd
POH in 13-14which were also having approximate life of 18 years. Northern
Railway has further stated that the bodies of these locomotives are also got
damaged and require rehabilitation. Further, ELW/BSL has observed,
extensive corrosion in the shell/cabs/flooring of the WAP-5 locos during 2nd
POH. The existing holding of three phase locomotives are placed at
Annexure-I. Keeping in view the condition of these locomotives there is a
need to decide on the issue of Mid Term rehabilitation of these locomotives.
1.2 Further, Railway Board vide letter No. 2009/Elect (TRS)/720/1 Pt.2 dated 02-
9-14 constituted a committee of EDSE/RDSO(Convener), CELE/NR,
CELE/WR and CWM/BSL to assess requirement of Mid Term Rehabilitation in
three phase electric locomotives and to deliberate on the other terms of
reference as per para 1.3 of this report.
1.3 Terms of reference of committee are as under:
a) To assess the requirement of Mid-Term Rehabilitation of 3-phase
electric locomotive and the activities which shall be required to be
undertaken by workshop or through OEM duly taking into account works
done during 1st and 2nd POH.
b) Committee to also look into aspects of replacement needed on account
of obsolescence of GTO based propulsion and other associated
equipment of 3-phase locos.
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2.0 REPORT
2.1 Existing Maintenance System:
The existing major maintenance schedules are given in the table below. As it
is clear from the table, that POH of passenger locomotives is done after a
period of nine years or operation up to twenty four lakh kms (whichever is
earlier)and POH of goods locomotives is done after twelve years of service or
operation of twenty four lakh kms (whichever is earlier). The details of
periodicity and time taken in various schedules of three phase locomotives
are given at Annexure-II. The list of must change items in POH schedule are
as per Technical Circular No. RDSO/2013/EL/TC/0123, Rev.‘0’ dated
16.05.2013 and amendment no.2 dated 10-11-14. The same is enclosed in
Annexure-III. Presently, there is no provision of Mid Term Rehabilitation
during the productive life of three phase locomotives.
Schedule Periodicity WAP5/WAP7 WAG9/WAG9H
MOH 18 months 18 months IOH 4.5 years±6 months or 12
lakhs kms whichever earlier
6 years±6 months or 12 lakhs kms whichever earlier
POH 9 years±6 months or 24 lakhs kms whichever earlier
12 years±6 months or 24 lakhs kms whichever earlier
2.2 Need of Mid Term Rehabilitation:
2.2.1 The committee visited ELS/GZB on 22.09.14 to obtain first hand
information of the locomotives due for Mid-Term Rehabilitation. Committee
members further held a meeting at Northern Railway headquarters at
Baroda House on 12-1-15.The committee has discussed and deliberated
upon the existing maintenance practices of POH schedule and the
requirement of Mid-Term Rehabilitation.
2.2.2 The issue of obsolescence of GTO based Technology and inherent
advantages of IGBT based Technology has also been deliberated upon by
the committee. The existing GTO based Technology was introduced
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worldwide during nineties. The GTO based Power/Auxiliary converter
electronics of the existing locos has become obsolete and the same is
proceeding out of production and need to be replaced by the state of the art
IGBT based devices due to following inherent disadvantages:
Oil filled complex design of Valve sets comprising GTO thyristors;
Complex snubber Circuit design;
No protection against output faults;
Bulky Gate drive units;
Limited capability of Processors, memory and DSP;
Proprietary MICAS- S2 control system;
80196 based microcontrollers;
Application Specific Integrated Circuit;
DOS based platform;
Sourcing problems of different components of control systems such
as GTOs and snubber circuit capacitors; and
Maintenance prone system.
2.2.3 Keeping in view the above disadvantages, I.R. have introduced IGBT
based propulsion equipment in more than 280 three phase locomotives.
Apart from the above, IGBT based propulsion system gives individual axle
control in place of bogie control in existing GTO based systems which
results in improved adhesion. Thus, these systems need to be introduced
in more quantity in existing locomotives as the maintenance of Traction
Converter based on GTO Technology is becoming difficult due to
obsolescence issues in almost all the components. This work of provision
of IGBT based propulsion equipment can be taken up by POH shop during
MTR for passenger locomotives and of goods locomotives by Electric Loco
Sheds during 2nd IOH of after 18 years of service life.
2.2.4 In view of above, it is recommended that the schedule of Mid Term
Rehabilitation also needs to be introduced for three phase passenger
Locomotives along with the work of technology upgradation. As the codal
life of 3 phase electric locomotive is 35 years, the MTR of passenger
locomotives (WAP5 & WAP7) may be undertaken during POH schedule of
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these locos. The work of technological upgradation i.e. replacement of
GTO based converters and MICAS based VCUs by TCN based VCUs may
be undertaken by electric Loco sheds for goods locomotives
(WAG9/WAG9H).
3.0 Recommendations for works to be carried out during Mid Term
Rehabilitation:
Apart from the must change items specified in POH schedule circulated
vide RDSO Technical Circular No. RDSO/2013/EL/TC/0123 Rev.0 dt.16-5-
13, amendment no.2 dated 10-11-14 for WAP5& WAP7 locomotives items
included in RDSO’s SMI/MS/TC issued from time to time following items
are recommended for replacement during Mid Term Rehabilitation.
3.1 ELECTRICAL WORKS
3.1.1 Auxiliaries:
The codal life of auxiliary machines is 12 years however, auxiliary
machines are also got replaced during the maintenance so the schedule of
replacement of auxiliary machines shall be done as per the yardstick
decided for conventional locomotives. As per this yard stick, auxiliary
machines shall be replaced if it has served life of 18 years, shall be
rehabilitated/rewinded if completed a life of 8 years and shall be overhauled
if completed service life of less than 8 years.
3.1.2 Brake System:
Brake Electronics cards and Vigilance Control Unit cards to be replacedas
life of these cards as per OEM is 15 years. Replacement of Metal seated
NRV by PU seated NRV provided after compressor shall be done as per
RDSO’s letter no EL/3.2.19/3-Phase dated 11.09.2012.
3.2 Mechanical Items:
3.2.1 Bogie & Wheels:
All the work specified in POH schedule and must change items circulated
as per RDSO Technical Circular No. RDSO/2013/EL/TC/0123 Rev.0 dt.16-
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5-13, amendment no.2 dated 10-11-14 shall be done during MTR of
passenger locomotives.
3.3 Technology Upgradation: In technology upgradation, following items
need to be replaced and provided:
3.3.1 Traction Converter & Auxiliary Converter: GTO based Traction
Converters and Auxiliary Converters shall be replaced with IGBT based
Traction Converter and Auxiliary Converter. This will also result in
replacement of GTO based obsolete technology. The released items of
these converters shall be overhauled and issued to Zonal Railways as
spares.
3.3.2 Vehicle Control Unit:
The MICAS-S2 VCUs may be replaced with TCN based VCUs preferably
with VCUs developed by M/s C-DAC. The released cards of MICAS-S2
VCU shall be utilized as spares. This will also result in replacement of old
generation cards.
4.0 Assessment of expenditure on Mid Term Rehabilitation and productive life of locomotives:
The cost of technology upgradation shall be additionally Rs. 306.00 lakhs
(approximately) and additional cost of MTR over POH shall be 20 lakhs
(approximately) in passenger locomotives. It may be noted here that the
cost of material is only considered assuming that the cost of manpower
shall be approximately same in both cases. It is expected that after Mid
Term Rehabilitation of three phase locomotives, the reliability of
locomotives shall improve considerably. Thus, it may be concluded that
keeping in view the improvement in reliability, the cost of MTR over POH is
very nominal.
5.0 Conclusion and Recommendation:
5.1 In view of above discussion, the Mid Term Rehabilitation of three phase
passenger Locomotives (WAP5/WAP7) is recommended to be carried out
after completion of 18 years of service along with POH schedule. The
scope of work shall be as brought out in this Report as per para 3.1 & 3.2.
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The technological upgradation work of passenger locomotives may also be
undertaken during MTR with POH schedule as per para 3.3.The
technological upgradation work of goods locomotives (WAG9/WAG9H)
may be undertaken by Electric loco sheds as per para 3.3.
5.2 For GTO based three phase locomotives, during rehabilitation work, main
components of propulsion system i.e. traction Converter, auxiliary converter
will be replaced from existing GTO based technology which is going in
obsolescence mode to latest state of art IGBT based technology. Vehicle
control units of old generation will be replaced by new generation TCN
based Vehicle control units. The inherent advantage of this conversion will
be improved adhesion as bogie control system will be replaced by
individual axle control. The released material shall be overhauled and used
by loco sheds for meeting their normal maintenance requirements.
5.3 Due to provision of new equipment in propulsion chain, the reliability of
three phase Locomotives undergone rehabilitation/ Technological
upgradation work is expected to increase.
5.4 The period of POH and MTR recommended for three phase locomotives is
as follows.
Passenger locomotives: WAP5/WAP7
Activity 1st POH MTR&2ndPOH 3rd POH End of life Years 9±0.5 18 ±0.5 27±0.5 35
Goods locomotives: WAG9/WAG9H
Activity 1st POH TU+2nd IOH
2rd POH End of life
Years 12±0.5 18 ±0.5 24±0.5 35
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ANNEXURE-I THREE PHASE ELECTRIC LOCOMOTIVE HOLDING AS ON 01-4-15
Railway Shed WAP5 WAP7 WAG9 WAG9H
CR AQ 15 90 50
CR KYN 1 40
ECoR WAT 10
ECR GMO 78 39
ER HWH 19
NR GZB 43 74
SCR LGD 43 73 32
SECR BIA 7 51
SER TATA 2 47
SR RPM 31
WCR TKD 23 30 14
WR BRC 38
Total 81 212 274 283
Grand Total 850
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ANNEXURE-II PERIODICITY AND TIME TAKEN IN VARIOUS SCHEDULES OF THREE
PHASE ELECTRIC LOCOMOTIVE ISSUED VIDE RDSO LETTER NO. EL/3.1.35/16 DATED 30-3-07
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Annexure-III List of “MUST CHANGE ITEMS during POH” for three phase electric locomotives as per Technical Circular No. RDSO/2013/EL/TC/0123, Rev.‘0’ dated 16.05.2013
SN DESCRIPTION OF ITEM/SUB-ASSEMBLIES REPLACEMENT DURING POH
A LOCO BODY: 1 PU painting of locomotive To be done 2 Roof Hatch Gaskets
The pantograph and converter roof hatch gaskets. To be replaced 3 Roof hatch rubber seals
The rubber seals around the pantograph and converter roof hatches and the roof beam. To be replaced
4 Body Structure i) Fiber body above buffer To be replaced ii) CBC coupler (WAP5 & WAP7 only). To be replaced iii) Decals (stickers). To be replaced 5 Exterior
Seals involved in fitment of side body and roof filters To be replaced
6 Draft gear & couplers i) Complete CBC assembly including Draft gear. To be replaced ii) Transition coupling. To be replaced iii) Knuckle, clevis, clevis pin and yoke pin To be replaced iv) Striker block wear plate. To be replaced
7 Buffers i) Buffers along with fasteners. To be replaced ii) All rubber rings. To be replaced
8 Cattle guard i) Cattle guard along with its hardware. To be replaced
9 Doors and steps i) Door seals. To be replaced
10 Washer and Wipers i) Wiper motor driver shaft seal, wiper arm, pneumatic end water
hoses, wiper blade and idler shaft assembly. To be replaced
11 Wind screen and windows i) Front lookout glass and side glass. To be replaced ii) Seals of cab windows, sliding window, splashed shield,
Wind screen shield and rubber flap on the cab side window drainage channel outlet.
To be replaced
B1 UNDERFRAME :
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1 Sanding equipments i) Sand in all sand boxes. To be replaced ii) Sander hosepipe and seal in the sand box lids. To be replaced 2 Battery Box i) All fasteners of battery boxes. To be replaced ii) Battery box ventilation hose. To be replaced
B2 BOGIE AND RUNNING GEAR: 1 Secondary Suspension i) All Secondary Suspension springs. To be replaced ii) Dampers. To be replaced iii) The lateral bump stops. To be replaced iv) Insulating bases of secondary suspension (WAP5 only). To be replaced
2 Primary Suspension i) All Primary Suspension springs. To be replaced ii) Dampers. To be replaced
3 Traction link i) Traction link assembly with housing. To be replaced ii) Safety sling, pins and R- clips. To be replaced iii) Aclathan / Vulkollan Rings and tab washers. To be replaced iv) All fasteners of Aclathan /Vulkollan ring retaining plate. To be replaced v) All Nylock Nuts opened for lifting of locos at:
A. Secondary Dampers (Yaw, Vertical, horizontal) B. Primary Dampers top side. C. Traction link D. Gear Case Support arm.
To be replaced
4 Bogie Frame and brake Gear i) All pins, bushes and pads of brake rigging To be replaced ii) All rubber components, hoses and fasteners on the bogie To be replaced iii) The hoses between –
a) the bogie frame connection and the brake cylinders and b) the locomotive under frame and bogie.
To be replaced
iv) Overhauling kit of brake caliper. To be replaced v) Replacement of Brake hanger of WAP7/WAG9 To be replaced vi) Replacement of safety sling of brake hanger of WAP7/WAG9 To be replaced
5 Wheel set & Axle box i) Taper Roller bearing unit (CRU150/SKF, BC2-0067A) for
WAP7, WAG9 & WAG9H. To be replaced
ii) Taper Roller bearing Unit (SKF 1639457A) for WAP5 To be replaced iii) Fasteners of brake discs. To be replaced iv) Axle box „O’ ring and cover bolts. To be replaced
6 Gear case/ Transmission i) Gear case oil. To be replaced
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ii) Gear case bearing along with associate components (for WAP5 only). To be replaced
iii) Gearbox oil seal / ‘O’ rings. To be replaced iv) All gear case fasteners and TM fixing bolts. To be replaced v) Drain plug washer and oil filling plug washer. To be replaced vi) Gauge glass oil seal. To be replaced vii) TM support arm, Gear case support arm (for WAP5 only) &
Axle guide rod. To be replaced
7 Crown Gear Coupling (WAP5) i) The membrane and the oil of Crown Gear coupling To be replaced
8 Spheriblock
i) The Spheriblocks of the axle guide rod, gear case support arm, TM & TM support arm (WAP5).
To be replaced
ii)
The Spheriblocks of the axle guide rod and TM support arm (WAP7/WAG9).
To be replaced
C POWER SUPPLY SYSTEM : 1 Pantograph
1.1
Pantograph type AM12, IR01 & PAN01 for freight locomotives
i) As per TC No. RDSO/2007/EL/TC/0094(Rev’0’)
To be replaced
1.2 Pantograph for M/E locomotives i) As per OEM’’s maintenance manual Also as per
instruction for conventional electric locomotives
2 Primary voltage Transformer i)
The rubber cable conduit between transducer & terminal box and the roof cable duct.
To be replaced
3 High voltage bushing insulator i) The seal on the high voltage bushing and cork gasket To be replaced
,Bushing to be replaced if tan delta and capacitance value more (refer RDSO’s letter no.EL/3.2.21/1 dt 10.12.2012)
4 Main circuit breaker (VCB) i) All items specified in latest version of RDSO’s Special
maintenance Instruction no. ELRS/SMI/0236 To be replaced
5 Harmonic Filter Resistor
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i) The cable glands & seal of the filter resistor junction box on the converter roof hatch.
To be replaced
ii) Replacement of the seal of the filter resistor. To be replaced iii) Harmonic Filter Capacitor To be replaced in
POH on condition basis as per maintenance manual
iv) Harmonic Filter Resister All insulator to be replaced To be replaced in POH
6 Main transformer i) The silica gel in breather assembly. To be replaced ii) All sealing gaskets including tank cover gasket of TFP.(as per
TC 0076) To be replaced
iii) All rubberised cork sheets. To be replaced iv) All TFP bushings rubber seals. (as per TC 0076 latest version) To be replaced v) All transformer foundation bolts & bushing lock nuts To be replaced vi) Transformer Oil. To be replaced vii) Main Transformer Drain Oil Cock rubber Parts To be replaced viii) Transformer conservator Gauge glass gasket, Rubber parts To be replaced ix) Oil Hose (Vent Tube) from main transformer to conservator,
Equalizing pipe along with its accessories. To be replaced on condition basis
D PROPULSION SYSTEM : 1. Traction Converter i) The rubber parts of servo motor of pre-charging & main
contractor. To be replaced
ii) The rubber parts of main cylinder of pre-charging &main contractor.
To be replaced
iii) The air cooling hoses, seals on the traction converter doors (WAG9/WAG9H).
To be replaced
iv) The air cooling hoses, seals on the traction converter doors (WAP5/WAP7).
To be replaced
v) Silica gel in breather assembly. To be replaced vi) Converter Oil. To be replaced vii)
Contact tips of Electro-pneumatic and Electro-magnetic contactors.
To be replaced
viii) Traction converter oil Flexible pipe line To be replaced in POH
ix) Stoochi coupling Rubber Parts To be replaced in POH
x) DC Link capacitor & Resonance circuit capacitor i) Dry type to be replaced in POH on condition basis as per maintenance manual
ii) Oil filled to be replaced with
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dry type
xi) Traction Converter Gauge glass rubber Parts To be replaced xii)
As Per RDSO Guide line Modified Heat sink to be provided on SR Rack
To be done in POH, if not
modified 2 Traction Motor i) Traction motor bearing (DE +NDE) To be replaced ii) Suspension tube bearing. To be replaced iii) Bull gear (WAG9/WAG9H/WAP7) To be replaced
on condition basis during rediscing
iv) TM pinion (WAG9/WAG9H) To be replaced v) TM pinion (WAP7). To be replaced vi) End plate “O” Rings & the gaskets on the terminal box of TM To be replaced vii) TM bellows. To be replaced viii) Gasket of temperature sensor cover. To be replaced ix) The helical inserts of Junction box of TM. To be replaced x) Holder fixing bolt To be replaced xi) Power cable of TM To be replaced xii) Temperature sensor complete assembly including cable To be replaced xiii) All plastic conduit pipes. To be replaced xiv) All hardware of TM body. To be replaced xv) TM holder plate for suspension 12R To be replaced xvi) Bellow Plate of TM side. To be replaced
3 VCU bus station and Electronics of Power Converter & Auxiliary Converter
i) Back up batteries in VCU bus station diagnostic & communication computers, DIA, DD A1 & 2.
To be replaced
ii) The seals in the UIC socket. To be replaced iii) All Fiber-optic cable of Power Converter, including spares. To be replaced iv)
Rehabilitation of cards as per RDSO guidelines No. EL/G/2008/01 Rev.1 with latest amendment.
To be replaced
v) Instrument cooling fans. To be replaced
E. AUXILIARY SYSTEM : 1 Auxiliary Converter
i) Gasket of DC link capacitor bank. To be replaced ii) Gasket of WRE, GG and battery charger modules To be replaced iii) Bearing of internal cooling fan. To be replaced iv) Seals on the Aux. Converter cabinets & equipment modules To be replaced v) Contact tips of EMC. To be replaced vi) Contact tips of contactors in the BUR 1, 2 & 3. To be replaced vii) Set of Rotary switch To be replaced viii) All DC Link Bank Capacitors i) Modified DC
Link Capacitor Bank to be provided
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ii) To be replaced in POH on condition basis as per maintenance manual
ix) Male & Female contact of GG & WRE Module To be replaced 2 Battery Set i) Battery To be replaced
ii) Battery Box To be replaced on condition basis
3 Lights i) The head light gasket, head light seals (between headlight
retaining ring & head light housing), Marker Light rubber gasket and its “O” rings and the flasher light gasket (between flasher & loco roof).
To be replaced
ii) Head light lamp. To be replaced 4 Oil Cooling Piping i) The “O” rings in the main transformer & main converter To be replaced ii) Oil cooling piping joints. To be replaced 5 Oil Cooling Pumps i) The bearings & “O” rings. To be replaced 6 Oil Cooler Blower / Motor i) The bearings of oil cooler blower motor and associate
component. To be replaced
ii) Impeller of oil cooler blower. To be replaced 7 Oil Cooler Blower Seals i) The seals between the oil cooler blower & the filter duct,
between the oil cooler blower filter & the pantograph roof hatch on the oil cooler blower unit, between the oil cooler blower & machine room floor, on the oil cooler blower filter & ducting and on the oil cooler blower inspection door (WAP5/WAP7).
To be replaced
ii) The seals between the oil cooler blower & the filter duct, between the oil cooler blower filter & the pantograph roof hatch on the oil cooler blower unit, between the oil cooler blower & machine room floor, on the oil cooler blower filter & ducting and on the oil blower inspection door (WAG9/WAG9H).
To be replaced
8 Machine Room Blower Motor i)
The drive & non drive end bearings along with associated components.
To be replaced
9 Machine Room Blower Seals i) The seals of machine room blower filter plenum & duct,
inspection door, blower filter & ducting and between the machine room blower and machine room floor, between the machine room blower filter and filter duct and the machine room blower filter duct seal and wear plate (WAP5/WAP7)
To be replaced
ii) The seals of machine room blower filter plenum & duct, inspection door, blower filter & ducting and between the machine room blower and machine room floor, between he machine room blower filter and filter duct and the machine
To be replaced
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room blower filter duct seal and wear plate (WAG9/ WAG9H).
10 Traction Motor Blower Seals i) The traction motor blower filter, plenum, wear plate and duct
seals (WAP5/WAP7). To be replaced
ii) The traction motor blower filter, plenum, wear plate and duct seals (WAG9/ WAG9H).
To be replaced
iii) The seals on the TM blower filter & ducting (WAP5/WAP7) To be replaced iv) The seals on the TM blower filter & ducting (WAG9/ WAG9H). To be replaced
v) The seals between the TM blower & machine room floor and between the plenum box and body side panel (WAP5/WAP7).
To be replaced
vi) The seals between the TM blower & machine room floor And between the plenum box and body side panel (WAG9/ WAG9H).
To be replaced
vii) The seals on the TM blower inspection cover (WAP5/WAP7) To be replaced viii) The seals on the TM blower inspection cover (WAG9/
WAG9H). To be replaced
11 Traction Motor Blower Motor i) The drive & non drive end bearings along with associated
components. To be replaced
12 TM & Oil cooler Blower Scavenger i) The hoses at the oil cooler blower filter scavenger boxes
(WAP5/WAP7). To be replaced
ii) The hoses at the oil cooler blower filter scavenger boxes (WAG9/ WAG9H).
To be replaced
iii) The equaliser hoses between the TM & oil cooler blower Scavenger& the filter (WAP5/WAP7).
To be replaced
iv) The equaliser hoses between the TM & oil cooler blower Scavenger& the filter (WAG9/ WAG9H).
To be replaced
v) The seal at the oil cooler blower scavenger duct slip joint (WAP5/WAP7). To be replaced
vi) The seal at the oil cooler blower scavenger duct slip joint (WAG9/ WAG9H). To be replaced
vii) The seals and gaskets on the TM and oil cooler blower scavenger ducting (WAP5/WAP7). To be replaced
viii) The seals and gaskets on the TM and oil cooler blower scavenger ducting (WAG9/WAG9H). To be replaced
ix) Rubber hoses. To be replaced 13 TM & Oil cooler Blower Scavenger Motor i) The driving & non-driving end bearings along with
associated components. . To be replaced
14 Machine Room Blower Scavenger Motor i) The driving & non-driving end bearings along with associated
components. To be replaced
15 Machine Room Blower Scavenger i) The flexible duct between the machine room blower
scavenger motor and filter. To be replaced
ii) Rubber hoses. To be replaced iii) The equaliser hoses between the machine room blower
scavenger motor and the filter (WAP5/WAP7). To be replaced
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iv) The equaliser hoses between the machine room blower scavenger motor and the filter (WAG9/ WAG9H).
To be replaced
v) The seals and gaskets on the machine room blower scavenger ducting (WAP5/WAP7). To be replaced
vi) The seals and gaskets on the machine room blower scavenger ducting (WAG9/ WAG9H). To be replaced
16 Main Compressor Motor i) The main compressor drive motor bearings along with
associated components. To be replaced
17 Cab heater/Blower motor and crew fan motor i) Bearing of cab heater Blower motor and crew fan motor. To be replaced 18 Cubicles i) The rubber parts of servo motor of EP Contactors in cubicles. To be replaced ii) The rubber parts of main cylinder of EP Contactors in
cubicles. To be replaced
iii) Contact tips of EP contactors. Filter of fire detection unit. To be replaced
F AIR SUPPLY AND PNEUMATIC SYSTEM: 1 Main Compressor i) The main element & the safety element of the air intake filter
& other parts as prescribed in manual. To be replaced
ii) Suction air filter element. To be replaced iii) Compressor oil. To be replaced iv) Secondary oil filter. To be replaced v) Gaskets of concentric valves. To be replaced vi) The main compressor resilient mountings & mounting pads. To be replaced vii) CP delivery pipe. To be replaced viii) HP & LP cylinder, HP & LP concentric valves all make. To be replaced ix) Concentric valve kit. To be replaced x) The delivery hose from the main compressor. To be replaced xi) Inter cooler after cooler assembly To be replaced xii) Copper Interconnecting pipes between intercooler and after
cooler (WAP5/WAP7). To be replaced
xiii) Copper Interconnecting pipes between intercooler and after cooler (WAG9/WAG9H). To be replaced
xiv) Overhaul kit of Inter cooler after cooler assembly. To be replaced xv) Overhaul kit of Main Compressor (Elgi / Knorr Bremse). To be replaced xvi) Overhaul kit of Main Compressor (D&M / SWIL) (WAP5/
WAP7) To be replaced
xvii) Overhaul kit of Main Compressor (D&M / SWIL) (WAG9/ WAG9H). To be replaced
2 Auxiliary Compressor i) The delivery hose between the auxiliary compressor and
brake frame and overhauling kit. To be replaced
ii) Compressor oil. To be replaced 3 Pneumatic Valves, Cocks and Filters To be replaced i) All rubber components (WAP5/WAP7). To be replaced ii) All rubber components (WAG9/WAG9H). To be replaced
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4 Horn To be replaced i) Horn gasket and other rubber
parts of Horn. To be replaced
5 Brake Pneumatics i) Overhauling kit of Complete E- 70 / CCB brake system. As per OEM’s
instructions ii) Overhauling kit of driver brake controller and automatic brake
controller. As per OEM’s instructions
iii) TBU and PBU kit (WAP7). To be replaced iv) TBU and PBU kit (WAG9/ WAG9H). To be replaced v) Brake activating mechanism (main cylinder & parking brake
cylinder) To be replaced
6 Air dryer i) Overhauling kit of air dryer. (As per OEM’s manual,
makewise) To be replaced
ii) Body connector male & female To be replaced
G INTERIOR : 1 Cab Door and Machine Room Door
i) The door seals, door window seals. To be replaced 2 Drivers Seat i) The seat cover and cushion of driver seat. To be replaced ii) Driver seat. To be replaced 3 Cab Interior
i) Anti skid flooring in cab. To be replaced 4 Cab. Equipment i) Vigilance, Sanders, PVEF pedal switches. To be replaced ii) All switches BPFA, BLPR, ZPRD, BLDJ, ZPT, BPVR, BPVG
etc. To be replaced
iii) Cab activation switch. To be replaced
H . ADDITIONAL ITEMS :
SN DESCRIPTION OF ITEM /SUB ASSEMBLIES REPLACEMENT DURING POH
1. TEST ROOMS ITEMS i) Pre Charging contactor, Main Contactor EPC of SR, FB
Panel Copper contact to be replaced. To be replaced
ii) 80 Amp Contactor . To be replaced iii) 150 amp contactor (07 nos) to be replaced with contactors
along with Snubber Circuit & auxiliary switches. To be replaced
iv) Replace 100% FB Panel EP Contactor Insulating base C Type. To be replaced
v) FB Panel Air Supply Pipe Line Set to be replaced by new one. To be replaced vi) All Driver Desk Switches . To be replaced vii) All pneumatic panel solenoid valves to be replaced by
modified ones. To be done in POH ,if not done earlier
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viii) All auxiliary switches of precharging and EPC contactor To be replaced ix) Angle transmitter To be replaced
2. ITEMS OF RELAY SECTION i) Indication Lamps To be replaced ii) All gauges To be replaced iii) 63 Amp MCB of OBC and TMB 59.1/1 and 59.1/2,53.1/1 and
53.1/2 To be replaced
iv) 40 Amp MCB of CP 47.1/1 and 47.1/2 To be replaced v) MRB contactor 54.2/1 and54.2/2 with timer To be replaced vi) Contactor 136.3, 126.5, 136.4, 126.7/1, 130.1, 211, 126.6,
126.7/2 To be replaced
vii) BPVG push button switch To be replaced viii) Marker Light To be replaced ix) All Programme Switches To be replaced x) All desk meters, Push button switches To be replaced xi) All types of push button switches To be replaced xii) Flasher Unit & Lamp Unit To be replaced xiii) All tube lights & CFL lamps with fittings To be replaced xiv) DC-DC Converter To be replaced 3. ITEMS OF INSPECTION SECTION
i) All side filters & roof filters(MRB,TMB,OCB) To be replaced ii) All door locks To be replaced
Note: 1. The lubricants shall be used wherever applicable as per RDSO‘s Technical Circular No. ELRS/TC/0034 (Rev.4) dated 21-7-2008 or latest.
2. The must change items for WAP7 locomotives fitted with conventional type brakerigging shall be as per RDSO Modification sheet No. RDSO/2009/EL/MS/0381 dated 7-9-09 and RDSO letter EL/3.1.35/2(3 phase) dated 20-10-11.
3. Technical Circular No. RDSO/2013/EL/TC/0123, Rev.’0’ dated 16/05/2013 supersedes LRS/TC/0021 (Rev’01)-2002, dated 16.04.02 may be considered as obsolete.
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List of “MUST CHANGE ITEMS during POH” for three phase electric locomotives as per Technical Circular No. RDSO/2013/EL/TC/0123, Rev.‘0’ amendment no. 2 dated 10-11-14.
S. No.
Description of item/Sub assembly Replacement during POH
D PROPULSION SYSTEM : 2 Traction Motor
i) Traction motor bearing (DE +NDE) along with outer/inner labyrinth pins and accessories
To be replaced
3 VCU bus station and Electronics of Power Converter & Auxiliary Converter
vi)
Rehabilitation of cards as per RDSO guidelines No. EL/G/2008/01 Rev.1 with latest amendment.
Rehabilitation of cards during POH or 12 years whichever is later.
G INTERIOR : 4 Cab. Equipment iv) cab heater flexible duct To be replaced