Rail Condition Based Monitoring on the Right Track
Managing the safe, reliable and cost-effective operation of their 100+ locomotive fleet is a fundamental priority for a busy commuter rail operator in North America. Underpinning their success is a pro-active maintenance activity, constantly seeking improvements in component and equipment reliability.
In 2009, PCMS supported the maintenance team in undertaking a stress-wave and vibration testing project, which identified a significant potential for reducing the failure levels of their power assemblies.
PCMS ensured that all engine mechanical failure modes were fully tested and documented, as well as undertaking prior research to specify the prime sensor locations necessary to identify abnormal wear and monitor possible future failure trends.
Analysis of the baseline data indica
ted an issue with the lash adjusters on the valve rail on cylinder 15, a problem which had not been previously detected in routine maintenance checks. A stress-wave polar plot of cylinder combustion at the time of fuel injection indicated that combustion valves were incorrectly open and that valve closing alarm levels had been exceeded.
Based on PCMS recommendations, the lash adjusters were removed and examined. One pair of adjusters were found to have seized (as ringed in diagram.) Replacing the lash adjusters cost approx. $400, compared with the likely cost of $40000 - $120000 in lost time, repairs and secondary damage if the unit had been left in operation.