reliability-centered maintenance program on the...
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Reliability-Centered Maintenance Program onthe ACELA Express Train sets
Amtrak ACELA Express
Amtrak currently runs ACELA Express Servicefrom Washington, DC to New York City andBoston.
There are currently 34 train assignments in thisThere are currently 34 train assignments in thiscurrent time table representing the NortheastCorridor covering every hour from 5 am to 7 pm.
The ACELA Fleet has 20 Train sets configuredwith two Power Cars and six Coach Cars each.
Acela Power Cars
Continuous 4,600 kW/ 6,000 HP
4 asynchronous AC traction motors
3 GTO-Type inverters, 2 for propulsion and 1 forauxiliary power required by the power car and passengercars.cars.
Top operating speed of 150mph (165mph designed)
The Main Transformer has two primary windingsconnected in parallel for operating overhead AC supplyof 12kV at 25Hz or 12.5kV at 60Hz and seriesconnection when the overhead input is 25kV at 60 Hz.
Braking system incorporates blendedregenerative/rheostatic dynamic Braking
High Speed Trainset Tilting System
Each Passenger Car is equipped with an activecomputer controlled and electro hydraulicallyactivated tilting system.
Maintains low lateral acceleration throughcurves at high speed.curves at high speed.
The curve detection is sensed by the lead powercar triggering the tilt function.
Amtrak currently operates at 7 inch cantdeficiency (it is designed and tested at 9 inchcant deficiency).
ACELA Passenger Demandfor Service
12
14
16
18
20
0
2
4
6
8
10
12
2005 2006 2007 2008 Future?
Required
Fleet
ACELA Passenger Demandfor Service
Amtrak developed Continuous Maintenanceprogram (CM) for Planned Maintenance(PM) to increase availability of equipment.
PM requirements divided into manageablePM requirements divided into manageablesegments performed during Service andInspection dwell time.
Previous to CM two Trainsets wereshopped for PM
Amtrak and RCM: Background
Amtrak established Condition-BasedMaintenance (CBM) as corporate policy inJuly 2006
Amtrak reviewed and validated all AcelaTrain set maintenance requirements usingTrain set maintenance requirements usingReliability-Centered Maintenance (RCM),per 49 CFR Part 238 Appendix E.
Acela Level I (Daily), Level II (92Day) andLevel III (Long Term) requirements werereviewed and completed in 2006.
Reliability-CenteredMaintenance
Reliability-Centered Maintenance (RCM) asused by Amtrak incorporates severaltechniques and tasks:
Maintenance Effectiveness ReviewMaintenance Effectiveness Review
Root Cause Analysis
Condition Based Monitoring
Maintenance Effectiveness Review(MER)
Maintenance EffectivenessReview
MER analysis identify the applicability andeffectiveness of maintenance tasks.
• Applicability criteria is the specific set ofconditions for a given task type that must be metto improve or maintain system or equipmentinherent reliabilityto improve or maintain system or equipmentinherent reliability
• Effectiveness criterion judges whether a specifictask would be capable of reducing the failure forits failure consequence.
Task periodicities are based on evidence ofneed and assessment of risks.
Maintenance EffectivenessReview
Cross Functional Stakeholders
Mechanics who perform the tasks
Operational Management RepresentativeOperational Management Representative
Equipment Engineering Representative
Operator or End User
OEM Representative
Facilitator
Maintenance EffectivenessReview
Task Type
On Condition, renew life based on comparisonwith standard, initiating action upon reachingpotential failure point.potential failure point.
Age Limit, renew life regardless of condition,taking action prior to “anticipated” failure point.
Failure Finding, determine whether a hiddenfailure has occurred, initiating corrective actionwhen initial failure occurs.
Maintenance EffectivenessReview
Failure Consequences
Safety, functional failure results inpossible loss of occupants or equipment
Operational, functional failure results inOperational, functional failure results inindirect economic loss plus direct cost ofrepair
Non-operational, functional failure resultsin direct cost of repair
MER ComponentAnalysis Spreadsheet
1. ComponentInformation
• Part Number
• Description
• Car (PC/TC)
• Quantity
2. FunctionalDescription
3. Risk Assessment
• Probability of Failure(failure history: OEM andRev. Service)
• Severity of Failure(FMECA failure effects)• Quantity
4. Condition Baseline
• OEM Recommended Life Cycle
• Bench Test Results
• Teardown Inspection Results
(FMECA failure effects)
5. In-Service Monitoring Plan
• Current ITM and Monitoring
• Additional Diagnostic Capabilities
• Additional Test Procedures
Root Cause Analysis
Root Cause Analysis
Amtrak has incorporated a standard maintenancepractice on how a Root Cause Analysis sessionis performed. The method used is based onReliability Center Incorporated’s PROACTsystem.
Preserving Event DataPreserving Event DataOrdering the Analysis TeamAnalyzing the DataEstablishing Root CausesCommunicating the FindingsTracking for Results
• Constant displacement pump and unloading circuitinstallation
– Increased pump reliability and reduction in service delays– Improved onboard oil filtration, decreasing hydraulic oil
contamination and reduction in component wear– Reduction in necessary periodic external filtration to maintain
standard ISO level
• Minimum and centering pressure switch upgrade
TILT SYSTEM RCA RESULTS
• Minimum and centering pressure switch upgrade– Reduction of in service failures
• Tilting load locking valve replacement with dualpressure transducer
– Allows for condition based monitoring and implementation ofcontinuous maintenance tasks
– Reduction of in service failures
• Quick connect fitting upgrade– Reduced external hydraulic leakage– Reduction of in service failures
ACELA Tilting Delay Minutes By Month
Based on Amtrak's ARROW Reports
188171
152
124104
159
120140160180200
Min
ute
so
fD
ela
yAcela Tilting Delay Minutes
8268
79
53
104
80
21
48 4454
020406080
100120
Oct
06
Nov06
Dec06
Jan
07
Feb07
Mar
07
Apr07
May
07
Jun
07
July
07
Aug07
Sep07
Oct
07
Nov07
Dec07
Months
Min
ute
so
fD
ela
y
ACELA Tilting System MDBF
Maximum Likelihood Estimation (MLE)
46,289
32,89135,000
40,000
45,000
50,000
Me
an
Dis
tan
ce
Be
twe
en
Fa
ilu
re
Series1 Linear (Series1)
Acela Tilting System MDBF
15,509
27,551
11,848 10,42812,251
23,494
11,391
18,53516,199
32,891
8,300
12,72613,751
0
5,000
10,000
15,000
20,000
25,000
30,000
35,000
Nov 06
Dec 06
Jan07
Feb07
Mar 07
Apr 07
May 07
June07
July07
Aug07
Sep07
Oct 07
Nov 07
Dec 07
Months
Me
an
Dis
tan
ce
Be
twe
en
Fa
ilu
re
Condition Based Monitoring
Condition-Based Monitoring
Dynamic Monitoring detects potential failures that emitabnormal energy such as vibration or acoustical waves.
Particle and Chemical Monitoring detects potentialfailures by analyzing discrete particles or traceablequantities of chemicals released in the component’soperational environment.
Physical Monitoring detects potential failures by Physical Monitoring detects potential failures byanalyzing changes in the physical structure such ascracks, wear or dimension.
Temperature Monitoring detects potential failures bysensing temperature differentials in the component’soperational environment.
Electrical Monitoring detects potential failures thatproduce changes in resistance, conductivity, dielectricstrength and potential.
Remote Condition Monitoring
Actual, En-route Notification ofReportable DC Ground Fault
Element of June 2007 Acela FleetHealth Analysis
Proposed Dynamic health display tobe located in Maintenance Facilities
Seventy-Two (72) Annulments Have BeenAvoided Since October 2006
150
200
250
Amtrak takes overAcela Maintenance
Acela annulmentstrend was 8 per month
Savings = 72
Cumulative Acela Annulments since January 2006
0
50
100
Jan-06
Feb-
06
Mar-0
6
Apr-0
6
May
-06
Jun-06
Jul-0
6
Aug
-06
Sep
-06
Oct-0
6
Nov
-06
Dec
-06
Jan-07
Feb-
07
Mar-0
7
Apr-0
7
May
-07
Jun-07
Jul-0
7
Aug
-07
Sep
-07
Oct-0
7
Nov
-07
Dec
-07
Jan-08
Actual FY06 Projected
New “RCM” Acela ITM Actual annulmentsnow average 3 per
month
Fewer Terminations
30
40
50
60
70
Amtrak takes overAcela Maintenance
Acela terminationsFY06 trend line
Cumulative Acela Terminations since January 2006
Actual terminations trending
Savings = 9
0
10
20
30
Jan-
06
Feb
-06
Mar
-06
Apr
-06
May
-06
Jun-
06
Jul-0
6A
ug-0
6S
ep-0
6O
ct-0
6
No
v-06
Dec-
06
Jan-
07
Feb
-07
Mar
-07
Apr
-07
May
-07
Jun-
07
Jul-0
7A
ug-0
7S
ep-0
7O
ct-0
7
No
v-07
Dec-
07
Cumulative FY06 Projected
Acela Maintenance
New “RCM” Acela ITM
Actual terminations trendinglower
Reliability-Centered Maintenance Program onthe ACELA Express Train sets