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CAMTEC/E/12-13/S&M-Precaution/1.0

Summer & Pre-Monsoon Precautions for AC Electric Locomotives August, 2012

1

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PRE-SUMMER & PRE-MONSOON PRECAUTIONS

for AC ELECTRIC LOCOMOTIVES

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August, 2012 Summer & Pre-Monsoon Precautions for AC Electric Locomotives

2

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PRE-SUMMER & PRE-MONSOON

RECAUTIONS for

AC ELECTRIC LOCOMOTIVES

xq.koRrk uhfrxq.koRrk uhfrxq.koRrk uhfrxq.koRrk uhfr

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QUALITY POLICY

“To develop safe, modern and cost effective

Railway Technology complying with Statutory

and Regulatory requirements, through

excellence in Research, Designs and

Standards and Continual improvements in

Quality Management System to cater to

growing demand of passenger and freight

traffic on the railways”.



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4

FOREWORD

A few essential precautions if taken prior to the

commencement of the summer and monsoon can minimize the failures which are caused due to high temperature, moisture, water leakage etc.

CAMTECH has prepared this handbook on “Pre-Summer &

Pre-Monsoon Precautions for AC Electric Locomotives” to spread awareness amongst the field staff and sensitize them.

Local instructions may also be issued & followed as per failure trend and requirements from time to time.

I am sure that this handbook will be useful to field staff in organizing drives and cyclic checks which will improve the reliability of the electric locomotives. CAMTECH Gwalior A.R.Tupe Date : 24.08.2012 Executive Director



5

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e-mail: [email protected]



6

PREFACE

To ensure reliable and safe operation of electric locomotives, it is essential to adopt correct maintenance practices and seasonal precautions.

Railway board and Zonal Railways issue instructions for pre summer and pre-monsson preparedness time to time to avoid typical failures.

CAMTECH has prepared this handbook on “Pre-Summer & Pre-Monsoon Precautions for AC electric locomotives” based on the instructions contained in ACTM Vol.III, Railway Board instruction issued in Feb.,2012 and feedback received from various Zonal Railways.

It is clarified that this handbook does not supersede any

existing instructions issued by Railway Board, RDSO or Zonal Railways. This hand book is for guidance only and it is not a statutory document.

I am sincerely thankful to all field personnel who helped us in preparing this handbook.

Technological up-gradation & learning is a continuous process. Please feel free to write to us for any addition/ modification in this handbook.

CAMTECH, Gwalior Peeyoosh Gupta Date: 23rd August 2012 Jt. Director Electrical



7

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8

CONTENTS

S.No. Description Page No.

Foreword iv Preface vi Contents viii

I. PRE SUMMER PRECAUTIONS FOR CONVENTIONAL AC ELECTRIC

LOCOMOTIVES 01

II. PRE SUMMER PRECAUTIONS FOR THREE PHASE AC ELECTRIC LOCOMOTIVES 05

III. PRE-MONSOON PRECAUTIONS FOR

CONVENTIONAL AC ELECTRIC LOCOMOTIVES 12

IV. PRE-MONSOON PRECAUTIONS FOR THREE PHASE AC ELECTRIC LOCOMOTIVES 16

REFERENCE 19



9

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� Ensure that spare head

light lamp, spare fuse for

flasher light and marker

light are available in both

cabs.

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� Also ensure that spare

fuses of different sizes

are available in BD board.



1

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PRE SUMMER PRECAUTIONS FOR CONVENTIONAL AC ELECTRIC LOCOMOTIVES

Sr. Item

1 All TMs to be checked for proper fitment of inspection covers. A cyclic check to be conducted on all locomotives for ensuring proper pressure in commutator chamber of all TMs.

2 A cyclic check should be done on all locomotives for ensuring proper cleaning of side body filters. Monitor depression inside loco by a manometer and it should not be more than 6 – 7 mm.

3 Transformer oil cooling radiator of all locomotives should be cleaned by blowing air, checked for proper cleaning and air suction through MVRH one cycle.

4 One cyclic check of SL coils cleaning and blowing to be ensured and intactness of SL covers both top and bottom properly must be ensured.

5 All relays must be provided with covers along with proper gasket to ensure dust free environment for relay operation – one cyclic check.

6 A cyclic check to be taken in all locomotives to ensure modified oil dipstick/ cap on suspension bearing oil pump of all TMs.

7 All Trip sheds must be strictly instructed to top up suspension bearing oil up to maximum mark and for this purpose availability of oil in Trip sheds must be ensured at the level of Sr.DEE/TRS.



2

Sr. Item

8 Nil oil leakage through suspension bearing must be ensured. One cyclic check to be completed by March.

9 All blowers must be checked for delivery of rated air output. In case of malfunctioning of blower relay, case should be properly investigated and working of blower properly shall be ensured.

10 Proper working of all blower relays in the locomotive must be ensured one cycle check by March.

11 RSI block Elmex and SBs at different locations must be checked for dust freeness to avoid any chances of tracking – cycle check.

12 Working of cab fans must be ensured in all locomotives - cycle check

13 All types of rubber hoses must be closely examined for their physical condition and should be changed on condition basis – cycle check.

14 SB oil pump to be opened, sump to be cleaned on all locos – cycle check.

15 Re-greasing of MVMT bearing during IC to be ensured.

16 Loco interior to be thoroughly cleaned of accumulated oil and dust - one cycle check.

17 Drivers must be alerted to feel the axle boxes as often as possible and their temperature should be monitored at various out pits / sheds on return.

18 There should be no leakage of grease from Axle box front cover and rear dust guard.



3

Sr. Item

19 Earthing shunts should be intact.

20 Gear case half ring and half ring felt should be properly fitted - cyclic check do be done.

21 Sunvisors in both cabs should be secured. One cycle check.

22 Roof insulators should be cleaned thoroughly. One cycle.

23 Clean oil bath filters of CP & ensure proper fittings. Cyclic check.

24 Fuses with covers should be secured. Cyclic check.

25 Apply petroleum jelly on reverser contacts.

26 Cab heaters to be disconnected by providing insulating plate in fuse box.

27 Inspection covers, terminal covers and bellows of traction motors should be checked for proper fitting and tightened by providing necessary gasket.

28 Secure and properly clean Traction Motor expanded metal protective screens.

29 Transformer sealing gasket should be checked and replace if need be to avoid dust ingress.

30 No leakage of transformer oil from transformer GR-MPH circuit and other accessories and proper cleaning in its vicinity. - Cyclic check.

31 Ensure transformer oil in gauge glass and oil level in tap changer not more than 20 deg.C.



4

Sr. Item

32 Battery boxes should be cleaned. - One cycle.

33 Top up batteries with distilled water.

34 Petroleum jelly to be applied on battery connections.

35 There should be no leakage of compound from gear case & half ring.

36 There should be no oil leakage in the loco from CP.

37 Ensure cyclic check of cables, dressing, bunching, provision of gromets by March.

38 Check battery charger and adjust voltage / current.

39 RSI blocks should be checked & there should be no dust accumulation.

40 Secure dust proof transparent covering of Aux. Interlock assembly, RS assembly.

41 Ensure proper greasing of all TMs in IC schedule.

42 TM leads should be checked for proper cleating.

43 Proper greasing of bearings of all Aux. Motors to be done during inspection schedules.

44 Ensure that all the Aux. Terminal covers are intact.

45 Ensure no over-aged battery in service. A cyclic check to be completed.



5

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PRE SUMMER PRECAUTIONS FOR THREE PHASE AC ELECTRIC LOCOMOTIVES

1. Ensure air delivery measurements at different locations as indicated in the table given below to avoid dust ingress in machine room and proper cooling of electronic cards. (Ref: RDSO/SMI/255 dtd.08.05.2009)

If the values of anemometer reading are found less than specified values, suitable action needs to be taken such as filter cleaning, checking of blockage in duct, cleaning of radiator and checking of air delivery of concerned blower etc. Location wise data shall be maintained.

S. No.

Location at which air delivery reading should be taken

Min. Value of anemometer

reading (m/sec.)

To be performed in

Schedule

1. Above SR gate unit 3.0 MOH, IOH & POH

2. Above incoming hose side of SR electronics

2.5 MOH, IOH & POH

3. Above middle of SR electronics heat sink

0.8 MOH, IOH & POH

4. Above opposite side of incoming hose of SR electronics

1.0 MOH, IOH & POH

5. Control Electronics heat sink top right back side

2.0 MOH, IOH & POH



6

S. No.

Location at which air delivery reading should be taken

Min. Value of anemometer

reading (m/sec.)

To be performed in

Schedule

6. Control Electronics heat sink top left back side

2.0 MOH, IOH & POH

7. Front left side above electronic rack heat sink of BUR

1.2 IA, IB, IC, MOH, IOH& POH

8. Back side of electronics rack heat sink of BUR

8.5 MOH, IOH & POH

9. Front middle above heat sink of GG module of BUR


10. Front right side above WRE module heat sink of BUR


11. Below under frame of opening of SCMRB


12. OCB in under frame at middle of radiator side wall


13. In under frame at TM end shield jally

12.0 IA, IB, IC, MOH, IOH & POH

14. Below under frame at opening of SCTM




7

2. Blowing of all filters during every schedule from 15th March to end of July.

3. Washing and blowing of radiators during every schedule from 15th March to end of July.

4. Reverse blowing of radiator in working condition of OCB1 and 2 in one cycle.

5. Checking and washing of MRB-1 and 2 filters by removing in every schedule from 15th March to end of July.

6. Ensure working of churning fan in CEL-1 & 2, SR-1 & 2 and BUR electronics. (Loco wise record shall be maintained).

7. There should not be any air leakage from duct joints of blowers.

8. Checking of overheating of 35 sq.mm cables and 70 sq.mm cables in HB-1 & 2 panels.

9. Checking of oil leakage in capacitors of DC link of SR-1 & 2, BUR-1, 2 & 3 and FB panels.

10. Washing of OCB-1 & 2 filter by pressurized water until clean water delivering from filters from 15th March.

11. Check BA cables male and female contacts for any sign of flashing/overheating.

12. Ensure availability of 100% ceramic filters in batteries.

13. Clean vent plugs of Batteries. All vent plug holes should be clear.

14. Check oil leakage at following points: (i) All flange joints of pipe, radiator, pumps, and

conservators.



8

(ii) Near SR-1 + 2 pumps a) At isolating cocks b) At sensor joint c) At bellow of pipes d) At conservators

(iii) All gate valves and pipes at under-frame.

(iv) All pressure sensors/temperature sensors fitting points, gauge glass of SR-1 &2, conservator 1 & 2.

15. Carry out a cyclic check on all locomotives for ensuring proper cleaning of TM blower filters.

16. Ensure Gear Case oil to ½ mark.

17. Check all blowers for delivery of rated air output.

18. Closely examine all types of rubber hoses for their physical condition and should be changed on condition basis - cycle check.

19. Thoroughly clean loco interior for accumulated dust - one cycle check.

20. Ensure securing of sun-visors in both cabs.

21. Clean filters of compressors (CP) and ensure proper fittings.

22. Check terminal covers and bellows of traction motors for proper fitting and also check bellow plates and bolts.

23. Ensure no leakage of transformer oil from transformer, converter, MPH circuit and other accessories and also ensure proper cleaning in its vicinity.

24. Ensure no oil leakage from gear case. A cyclic check shall be completed.



9

25. Ensure no over-aged battery in service. A cyclic check shall be completed.

26. Ensure sealing gasket of doors, windows, filters etc to avoid entry of dust inside Machine room. A cyclic check shall be completed.

27. Ensure transformer oil and SR oil in gauge glass between minimum and maximum level.

28. Check working of fire detection unit. In FDU one cycle check of potentiometer output value shall be done. Check RR section during pre testing and get it corrected from Relay section if required.

29. Ensure intactness of earthing wire connection with Traction Motor.

30. Carry out blowing of Harmonic Filter Resistance on roof.

31. Ensure proper cleaning of inter/after coolers of main compressors by compressed air.

32. Ensure cleaning of battery boxes.

33. Top up batteries with distilled water in all schedule inspections.

34. Ensure instructions contained in RDSO’s letter no.EL/3.2.1/3-ph dated 30.07.09 for arresting oil leakage cases from transformers i.e.

i. Oil leakage from Bushings and Bushing plates.

ii. Oil leakage from the Stuchi coupling & rubber hose pipe of conservator tanks.

RDSO Technical circular No. ELRS/ TC/ 0076 dtd. 17.09.2002 on “Oil leakage from the transformer bushings and cover in three phase locomotives” may be referred.



10

35. Ensure provision of modified cooling radiators for better cooling of traction converter control electronics. (Ref: RDSO letter no. EL/11.5.5/5 dated 15.02.10).

Refer RDSO purchase specification No. RDSO/ 2009/ EL/ SPEC/ 0100 Rev. (0) dtd Nov, 2009 for procurement of modified cooling radiator.

36. Ensure removal of interlocks of control circuit contactors No.126 from MCPA circuit (Ref : RDSO/ 2011/ EL/ MS/ 399 Rev. 0. dated 08.08.11)

37. Ensure partial blocking of opening duct of back side of auxiliary converter of three phase electric locomotives as shown in figure 1.

Ref : RDSO MS no. RDSO/2009/ EL/ MS/ 0385 (Rev.0), Dated 15.12.2009)

This modification will improve front side cooling of power modules of auxiliary converter.

Blocked around 75%

100% Open duct

Figure 1

Figure 2



11

38. Ensure implementation of modification sheet for shifting of the termination of 4GKW, 1.8 KV, 70 mm2 cable and 2 x 2.5 mm2 cables housed in lower portion of HB-2 panel and provision of Synthetic resin bonded glass fiber (SRBGF) sheet for three phase locomotives as per MS RDSO/2011/EL/MS/0400 Rev.’0’ dated 10.08.11.

39. Ensure implementation of modification sheet for relaying of cables in HB-2 panel of three phase locomotives to avoid fire hazards as per MS of RDSO/2011/EL/MS/0401, Rev.’0’ dated 10.08.11.

40. Ensure implementation of modification sheet for auto switching of machine room/corridor lights to avoid draining of batteries in three phase electric locomotives as per MS of RDSO/2011/EL/MS/0403,Rev.’0’ dated 30.11.11.

41. Carryout measurement of cable continuity for all four earthing brushes.



12

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PRE-MONSOON PRECAUTIONS FOR CONVENTIONAL AC ELECTRIC LOCOMOTIVES

Sr. Item

1 Test the water-tightness of loco body including roof by means of a high pressure water jet and seal all leakage points. (It must be ensured that the loco is well away from live OHE to prevent the water jet coming into contact with live wires)

2 Special attention should be given to the following points and gasket for water leakage:

a. Loco body joints and hood joints.

b. Joints of the mounting bases of roof equipment.

c. Head light gaskets.

d. Joints of look out glasses and corridor side glasses.

e. Door gaskets.

f. Sand box gasket and covers.

g. Joints of marker light.

h. Cover of multiple operation / coupler sockets.

i. VCB cover joints.

j. Side body filter joints with super structure.

k. Glass shutters.

l. Roof gasket.



13

Sr. Item

Note: After the first rain the loco should be inspected thoroughly to detect and attend to leakage points. Special attention should be paid to the above water leakage points.

3. Cleanliness of roof gutters and drain pipes and accumulation of water on the roof.

4. Roof bus bars clamps should be greased to prevent accumulation of water.

5. Check the Cab floor above sand boxes for any water leakage into the sand boxes.

6. Roof joints with super-structure-roof gasket should be in good fettle (condition).

7. Proper functioning of all eight sanders by providing sand of size between 2 microns to 20 microns should be ensured.

8. Ensure arrangements for filling good quality of sand on all crew changing points.

9. Ensure availability of register where acknowledgement of drivers is taken after filling up sand.

10. Ensure entry in log book regarding functioning of sanders and availability of sand.

11. Ensure working of sand drying plant and build up adequate stock of dry screened sand at sanding points.

12. One cyclic overhauling of additional C-2 relay valve.



14

Sr. Item

13. Proper working of wipers should be ensured.

14. Provision of head light dome and protection cap over horns and sand boxes.

15. Replacement of Silica gel of transformer and GR breather.

16. Overhauling and Reconditioning of air drier in VCB locomotive on the basis of silica gel colour of desiccant.

17. Paraffin/ petroleum jelly should be applied to the terminals of lead acid battery.

18. Check TM inspection covers and terminal blocks cover gasket and replace them, if necessary. Apply leaguare varnish to TM terminal.

19. Check the bottom covers of the smoothing reactor for any damage, replace, if any cracking are observed.

20. Ensure proper functioning of water separation and drain cock of the pneumatic pipe system. During monsoon, the pneumatic system should be drained more often to discharge the accumulated water.

21 Provision of RTV compound on MCP terminal box at cable entry point to restrict water entry. Ensure gasket on Terminal box cover or provide RTV.

22 Provision of RTV compound on axle box to restrict water entry in axle box. Ensure gasket on Terminal box cover or provide RTV.

23 Provision of RTV compound on SPM pulse generator (PG) to restrict water entry.



15

Sr. Item

24 High flood marks 9” should be painted on the cattle guard to give the indications to the drivers of water levels over the rails.

25. The transformer oil and tap changer oil should be tested for dielectric strength in a cycle before the outset of monsoon, and filtered if BDV is less than 40 kV.

26. Dissolved Gas Analysis (DGA) of transformer oil.

27. Ensure adequacy transformer/ GR oil levels and also ensure healthy condition of silica gel.

28. Drain cock and sampling cock covers of transformers are to be sealed properly to avoid moisture entry.

29. Drain the compressed air pipe line manually where the automatic drain valves are removed and cocks are provided.

30. Apply a coat of anti-corrosive paint on the roof bolts while the loco comes to shed.

31. Ensure opening / closing of side window shutters.

32. Insulation resistance of vital equipment like TM, SL lying on shop floor to be improved by baking in oven, varnishing and proper covering.

33. All air dryers to be in proper working order.

34. All EMU type After-Cooler to be regularly drained by drivers as well as at out pits.

35. One cycle calibration of QD relay setting for proper pickup and dropout current.



16

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PRE-MONSOON PRECAUTIONS FOR THREE PHASE AC ELECTRIC LOCOMOTIVES Follow pre-monsoon precautions as given in part – III for conventional locomotives.

In addition to above following precautions shall also be followed.

S.No. Item

1. Check water leakage from machine room filter and TM blower filter joints during water tightness test.

2. Replacement of Silica gel of Converter.

3. The transformer and converter oil should be tested for dielectric strength in a cycle before the onset of monsoon, and filtered if BDV is less than 40 kV.

4. Dissolved gas analysis of transformer and converter oil.

5. Insulation resistance of vital equipment like TM, Auxiliary blowers lying on shop floor to be improved by baking in oven, varnishing and proper covering.

6. Ensure implementation of modification sheet no. RDSO/ELRS/MS/0328 (Rev.0) dtd. 29.10.2003 for provision of water discharge outlet in TM & oil Scavenge blowers.

7. Checking of Megger value of Harmonic filter Resistance and cleaning if found less.

8. Battery box covers to be made water tight.

9. Side body air filters to be cleaned and maintain dust free environment.

10. Provision of drain pipe in SCTM bottom half to drain out accumulated water.



17

�� NOTES



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19

REFERENCES

1. Para 30514 of Indian Railways Manual of AC Traction Maintenance and Operation Vol. III – Electric Rolling Stock.

2. Railway Board letter no.2005/Eect.(TRS)/440/23 dtd. 10.02.2012. (Summer & Monsoon preparedness).

3. Field study & Literature received/ collected from various electric loco sheds.

*****



20

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21

To upgrade maintenance technologies and methodologies and achieve improvement

in productivity, performance of all Railway assets and manpower which

inter-alia would cover reliability, availability, utilisation and efficiency.

If you have any suggestions and any specific Comments please write to us.

Contact person : Director (Elect.) Postal Address : Indian railways

Centre for Advanced Maintenance technology, Maharajpur, Gwalior. Pin code – 474 005

Phone : 0751 – 2470740

0751 – 2470803 E-mail : [email protected] Fax : 0751 - 2470841

OUR OBJECTIVE



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INDIAN RAILWAYS

CENTRE FOR ADVANCED MAINTENANCE TECHNOLOGY MAHARAJPUR, GWALIOR- 474 005

Preventive Maintenance is more economical than corrective repairs.

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