TSO on water cooling system
Analysis of recent failures of water system reveals need for improvement in existing maintenance practices being carried in Shed. Item wise maintenance instructions are being issued here under :
Measurement of water level & concentration drop: Whenever loco touches the shed its incoming water level and indium/XT (corrosion inhibitor) concentration should be recorded.
Leakage from water jumper: Bending clip and hose quality should be ensured. Hose length should be checked before fitment. Suitable adhesive should be applied on hose before fitment on water jumper. Locktite or equipment sealant should be used on clamping screw. Use of only approved fastener to be ensured. Colour matching of water jumper and block should be done before fitment of jumper gasket. Shed should progressive switch over to swivel type water jumper of approved source.
Care should be taken that after changing water jumper, water leakage
is checked both in hot & cold condition.
Expansion tank: Old expansion tank should be replaced during M24 lor above schedule. New hose should be provided one round between expansion tank no.l 1 & tank no. 2 to avoid choking of water flow. Pressurized cooling cap should be fitted in all locomotives.
No seepage of water from cap should be permitted.
Water pump overhauling : Detailed maintenance procedure is given in Annexure.
However, special attention should be kept on following points :
Replacement of shaft during M24 and above.
Use of radius gauge to check fillet radius.
No uneven surface, cut mark, sharp corner, pitting to be permitted on
vulnerable locations (change of cross section & key way)
Colour matching of sleeve in case of use of shaft without sleeve and hydraulic
testing of assembly at 5 kg/cm2 for 6 hours.
Use of stainless steel shaft as per latest drawing.
Cooling down time (CDT) : CDT should be recorded during T2 and above schedule. CDT has top up measured as the time taken in cooling the engine from 85 degree to 65 degree C.
CDT readings beyond 4’ warrant focussed attention of cooling water system e.g. cleaning of radiator. TSP treatment, descaling, internal cleaning of radiator, water pump pressure etc. hot water jet cleaning of radiator should be done after proper air lowing during every schedule.
Radiator fan breakages –
Petty coat clearance should be measured during every schedule and kept 6mm
uniform.
DPT of radiator fan in medium and above schedule.
No. Dent/cut/pitting to be allowed on vulnerable area (upto 10” from bolts)
One round changes of stay rod as holes have become oval.
Weeding out of over aged radiator fan.
Analysis of recent failures of water system reveals need for improvement in existing maintenance practices being carried in Shed. Item wise maintenance instructions are being issued here under :
Measurement of water level & concentration drop: Whenever loco touches the shed its incoming water level and indium/XT (corrosion inhibitor) concentration should be recorded.
- Any drop of water level of 2” or more or drop in concentration of inhibitor Within 14 days is indicator of water leakage. Loco should be thoroughly checked and leakage should be attended.
- Water level and concentration drop statement should be prepared by lab and given to SSE/Running and AME/Running for taking necessary action. It must be discussed during daily power meeting.
Leakage from water jumper: Bending clip and hose quality should be ensured. Hose length should be checked before fitment. Suitable adhesive should be applied on hose before fitment on water jumper. Locktite or equipment sealant should be used on clamping screw. Use of only approved fastener to be ensured. Colour matching of water jumper and block should be done before fitment of jumper gasket. Shed should progressive switch over to swivel type water jumper of approved source.
Care should be taken that after changing water jumper, water leakage
is checked both in hot & cold condition.
Expansion tank: Old expansion tank should be replaced during M24 lor above schedule. New hose should be provided one round between expansion tank no.l 1 & tank no. 2 to avoid choking of water flow. Pressurized cooling cap should be fitted in all locomotives.
No seepage of water from cap should be permitted.
Water pump overhauling : Detailed maintenance procedure is given in Annexure.
However, special attention should be kept on following points :
Replacement of shaft during M24 and above.
Use of radius gauge to check fillet radius.
No uneven surface, cut mark, sharp corner, pitting to be permitted on
vulnerable locations (change of cross section & key way)
Colour matching of sleeve in case of use of shaft without sleeve and hydraulic
testing of assembly at 5 kg/cm2 for 6 hours.
Use of stainless steel shaft as per latest drawing.
Cooling down time (CDT) : CDT should be recorded during T2 and above schedule. CDT has top up measured as the time taken in cooling the engine from 85 degree to 65 degree C.
CDT readings beyond 4’ warrant focussed attention of cooling water system e.g. cleaning of radiator. TSP treatment, descaling, internal cleaning of radiator, water pump pressure etc. hot water jet cleaning of radiator should be done after proper air lowing during every schedule.
Radiator fan breakages –
Petty coat clearance should be measured during every schedule and kept 6mm
uniform.
DPT of radiator fan in medium and above schedule.
No. Dent/cut/pitting to be allowed on vulnerable area (upto 10” from bolts)
One round changes of stay rod as holes have become oval.
Weeding out of over aged radiator fan.
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