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

9

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

13

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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