P. K.

Kataria DEE TD Bhusawal

TYPE OF REGULATING EQUIPMENT

Three types of regulating equipment are used in Indian Railways 1. WINCH TYPE 2. SMALL 3 PULLY TYPE 3. MODIFIED 3 PULLEY TYPE

P. K. Kataria DEE TD Bhusawal

SCHEDULE MAINTENANCE FOR REGULATING EQUIPMENT

P. K. Kataria DEE TD Bhusawal

P. K. Kataria DEE TD Bhusawal

In fortnightly inspection, during foot patrolling all regulating equipment must be checked for :
1. Free movement using 10 kg weight 2. Condition of SS wire rope 3. Rubbing of wire rope at drum or pulley 4. Mast position for leaning 5. Condition of guide tube & eye hook 6. Y value for abnormal reading. 7. Position of equalizing plate 8. Riding of SS wire rope on drum 9. Straightness of anti falling device
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FORTNIGHTLY INSPECTION SCHEDULE : 1 Apply 10 kg weight & watch the movement of ATD drum. It must move downward after application of weight & move upwards after removal of weight. 10 kg In case of 3 pulley the weight required for free movement will be 17 kgs.
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FORTNIGHTLY INSPECTION SCHEDULE : 2 SS wire rope must not have any strands broken or bird cages

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FORTNIGHTLY INSPECTION SCHEDULE : 3

SS wire rope must not rub on drum

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FORTNIGHTLY INSPECTION SCHEDULE : 4 Leaning mast may affect the free movement of ATD, hence mast must be checked for Leaning

P. K. Kataria DEE TD Bhusawal

FORTNIGHTLY INSPECTION SCHEDULE : 5 Guide tube must not be bent & all fastener must be available. Counterweight eye must be available & free over the guide tube

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FORTNIGHTLY INSPECTION SCHEDULE : 6 Y Value must not be abnormally high or low. It must be as per temperature marking.

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FORTNIGHTLY INSPECTION SCHEDULE : 7 Equalizing Plate must not be in tilted condition

TILTED EQUILIZING PLATE

STRAIGHT EQUILIZING PLATE

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FORTNIGHTLY INSPECTION SCHEDULE : 8

SS Wire rope must not ride on the drum

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FORTNIGHTLY INSPECTION SCHEDULE : 9 Anti falling device must be straight

Anti falling rod must have washer at ends

Anti falling rod must have sleeve as per calculation

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ANNUAL OVER ALL MAINTENANCE SCHEDULE Annual overhaul maintenance is carried out on Nos of holding of regulating equipment and periodic overhaul maintenance schedule is carried out on rest Nos. During fortnightly checks if any defect which is serious enough to affect the performance of ATD must be attended on top priority and should not wait for date to fall for annual maintenance.
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Annual overhaul maintenance schedule on a regulating equipment needs following attentions in addition to the fortnightly inspection 1. Alignment of Drum, center to center distance of hole in bent arms. 2. Damage to grooves, side wall of drum or pulley. 3. EYE & Clevis free to swivel, cracks or defects 4. Felt & Grease Seals 5. Hex pie (sleeve on anti falling rods) 6. Lubrication of SS Wire Rope 7. Z, X & Y value adjustment y z x 8. Mast anchor fittings
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ANNUAL OVERHAUL MAINTENANCE SCHEDULE : 1 Alignment of Drum must be proper. Center to center distance of hole in bent arms.

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ANNUAL OVERHAUL MAINTENANCE SCHEDULE : 2

Drum grooves must have clear and no damage of its wall must be allowed

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ANNUAL OVERHAUL MAINTENANCE SCHEDULE :3 EYE & Clevis free to swivel, cracks or defects, tighten the bolts& nuts for looseness if any

Check for beveled washer between clevis & eye & availability of split pins
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ANNUAL OVERHAUL MAINTENANCE SCHEDULE : 4 Felt & Grease Seals must not get damage.

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ANNUAL OVERHAUL MAINTENANCE SCHEDULE :5 If there is no sleeve provided on anti falling rods, length of sleeve must be calculated as per TI/MI/0035(Rev1)

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1. Measure actual value of X or Z of ATD say Z1 2. Measure X or Z at the ambient temp. for given tension length using formula. say Z2 3. Calculate Travel = Z3=Z1-Z2 4. Now find the length of pipe as per the temp & chart given in TI/MI/0035-Rev 1. say X 5. The length of pipe to be provided = X-Z3

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ANNUAL OVERHAUL MAINTENANCE SCHEDULE :6 SS Wire Rope Must be lubricated using the BALMEROL ROPE LUBE 1000 on the portion touching to small pulley & drum surface & prone to friction due to movement of ATD

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ANNUAL OVERHAUL MAINTENANCE SCHEDULE :7

Z Value must be measured carefully & if there is difference with the value as per temperature chart must be adjusted either by adjuster or cutting the wire. Value of Z may be calculated by the formula as follow:
Z= 1250 + (17/1000*half tension length)*(35-Temp.)
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ANNUAL OVERHAUL MAINTENANCE SCHEDULE :7

X Value must be measured carefully & if there is difference with the value as per temperature chart must be adjusted either by adjuster or cutting the wire. Value of X may be calculated by the formula as follow:
X= 1300 + (17/1000*half tension length)*(35-Temp.)
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ANNUAL OVERHAUL MAINTENANCE SCHEDULE :7 Y Value must not be abnormally high or low. It must be as per temperature marking.

Calculation for Winch type Y = 2500 + (17/1000*Half tension length)*(35-Temp)*5 Calculation for 3 pulley Modified Y = 2300 + (17/1000*Half tension length)*(35-Temp)*3
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HTL 750 750 750 750 750 750 750 750 750 750 750

TEMP 30 31 32 33 34 35 36 37 38 39 40

X 1.314 1.301 1.288 1.276 1.263 1.250 1.237 1.225 1.212 1.199 1.186

Y 2.819 2.755 2.691 2.628 2.564 2.500 2.436 2.373 2.309 2.245 2.181
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P. K. Kataria DEE TD Bhusawal

ANNUAL OVERHAUL MAINTENANCE SCHEDULE :7 Mast anchor fitting must be correctly fitted so that its eye is in horizontal plane

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In periodical overhaul Schedule complete set of Drum / pulley is removed from the mast & new overhauled set is replaced in stead of the old one. Periodical maintenance schedule is carried out at each location after every 4 years. The POH schedule must be done very carefully to avoid the failure on line. Heart of the POH schedule is replacement & checking done on drum & bearings.
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STEPS OF POH AT DEPOT: 1. Cleaning of complete set 2. Checking of grooves healthiness 3. Dismantling drum/pulley & bent arms 4. Removal of bearings from drum / pulley 5. Checking of housing of bearings in drum/pulley 6. Replacing the bearings. 7. Fitment of the drum/pulley & bent arms 8. Check for wire rope. 9. Steps for replacement of ATD at site
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PERIODICAL OVERHAUL MAINTENANCE SCHEDULE :1 1. Complete set must be observed visually with due care for any damage/cracks/deformation. If it is found proper investigation must be done 2. Complete set of drum/pulley must be cleaned for dirt/dust/oil/grease etc. 3. Cleaning must be done by using kerosene & cloth.

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PERIODICAL OVERHAUL MAINTENANCE SCHEDULE :2 Drum must be checked for damage of groove using GO-NO GO Gauge , grazing inside. It must be inspected for cracks or deformation very carefully.

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PERIODICAL OVERHAUL MAINTENANCE SCHEDULE :3 Bent arms nuts etc must be properly opened using proper spanners & tools
Bent arms Nuts

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PERIODICAL OVERHAUL MAINTENANCE SCHEDULE :4 Bearings must be removed using bearing puller jig with due care. Hammering with local arrangement must not be done it may damage the housing & Bearings.

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PERIODICAL OVERHAUL MAINTENANCE SCHEDULE :5 Checking of housing with GO NO GO gauge

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PERIODICAL OVERHAUL MAINTENANCE SCHEDULE :6 The bearings must be replaced after each POH with a new bearing of NBC 6305 LLU or SKF 6305 2RS1

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PERIODICAL OVERHAUL MAINTENANCE SCHEDULE :7 Fitment of drum/pulley should be done as carefully as it was dismantled. It must be checked thoroughly for its performance like free movement on the bearing axis. Tightness of nuts & bolts. Alignment etc.

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PERIODICAL OVERHAUL MAINTENANCE SCHEDULE :8 Through checking of SS Wire Rope must be done using magnifying glass for loose wire/strands, broken wires/strands, rusting, pitting/corrosion and bird caging. If any thing found abnormal it must be replaced with new one immediately.
BROKEN STRANDS

CAGING AT BEND END REVERSAL OF ROPE MUST BE DONE.

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After getting Power Block with proper message confirmation & testing & putting Discharge rods on OHE Following steps is carried out: 1. Measurement of X, Z & Y values & analysis of X, Z & Y value for adjustment during the schedule. 2. Putting cum along clamps of contact & catenary wire. 3. Using pulley arrangement putting tirfor 3 tons for OHE & 1.5 tons for balance weight. 4. Taking load so as to lift the balace weight & pull the catenary to enable to release the ATD Drum/pulley set. 5. Remove the old set & fix the new overhauled set. 6. Setting the OHE & Balanceweigth in its original position. 7. Measurement of X,Z & Y values.
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