Amtrak Mechanical Department - Work Management System (WMS) Request for Equipment Modification Campaign

Transcription

1 Amtrak Mechanical Department - Work Management System (WMS) Request for Equipment Modification Campaign Title: F59PHI Locomotive truck 1800lb vertical shock absorber ride quality/upgrade Modification Number: (leave blank) Modification procedure was developed by: X Amtrak staff (Check one) Supplier/vendor/other Campaign Manager: Ray Higuera Phone: Modification Implementation Table WMS Equipment WMS Equipment Number Unit Numbers Affected Requested Requested Class Type (if not entire of Units (if not for entire Equipment Start Date Completion Equipment Class) Class) Date Diesel Loco F59PHI /15/08 09/30/08 Is Modification to be performed only at the Back Shop? X No Yes (Check one) Modification Cost Table (Double click form to open, click outside of form to close) (Change labor rate to $62.00 for Capital programs; otherwise use $40.00 labor rate) "A" "B" "C" "D" "E" "F" "G" Vehicle Type Number of Units Man-Hours per Unit Labor-Hour Cost Total Labor Cost Total Labor Material Cost Total Material per Unit Cost per Unit Cost Total Cost (B X C) (A X D) (A X F) (E + G) F59PHI $40.00 $ $2, $4, $60, $62, $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $0.00 $ $2, $60, $62, Charge Code (Check Expense unless known to be a Capital Program) (leave Work Element Number and Function blank) X EXPENSE Work Element Number: Function: CAPITAL PROGRAM Work Element Number: Function: 1

2 Scope Description of Problem: Since 1998 complaints were filed with the Federal Railroad Administration (FRA) by various operating organizations, which have alleged Amtrak s F59PHI locomotives used in operation within the Pacific Northwest and Southwest regions have experienced excessive motion and harsh ride quality levels during revenue service. During November 1998 ride quality test were conducted in California s San Joaquin corridor using a Caltrans F59PHI locomotive as it was determined by the FRA the reported excessive motion was a direct result of operating track conditions. Further ride quality testing was conducted by Amtrak engineering in October 2001, with the assistance of the Federal Railroad Administration, ENSCO, Rail Science and NUCARS DATA. The results of the provided ride quality data has allowed the information to be analyzed by Amtrak engineering to develop a possible minor improvement in ride quality although the report also displays most of the excessive motion is due to operating track conditions. The results of the ride quality analysis data indicates minor improvement of vertical and lateral acceleration of approximately 15% when utilizing a combination of four 1800lb vertical shock absorbers and two 1200lb lateral shock absorbers. The analysis indicates when the F59PHI locomotive is modified with the combination of shock absorbers indicated above it decreased vertical and lateral acceleration responses (excessive motion) moving at speed operations of 70MPH in 20-mile sections within the Pacific Northwest. A field engineering test plan authorized by Amtrak Director of Engineer Ed Daly, allowed for the fabrication and purchase of new 1800lb Sachs of America shock absorbers and the fabrication of four shock absorber brackets to support the new truck shocks. The results of field testing during the past several months on locomotive 450 following Beechgrove has allowed an extended period of evaluation which indicates there has been no failure of primary or secondary suspension or truck frame components which may have been affected by the additional vertical upgrade of compression or accelerations associated to the new 1800lb shock absorber and brackets. Operations feedback from Amtrak s BLE organizations is positive when compared to locomotives which have not been modified. The positive results of this modification will enhance the ride quality and operational characteristics of the F59PHI locomotive fleet. The modification requires the removal of all four existing truck vertical shock absorbers and brackets on each of 21 F59PHI locomotives. 4-new fabricated and modified shock absorber brackets designed to accept a new 1800lb vertical shock absorber shall be applied and bolted at all four truck axle positions. A total of 7-F59PHI locomotives have already undergone this modification during overhaul at Beechgrove. The remaining F59PHI fleet locomotives which total 14, shall be modified in the field with RSE authorization. Quantity per Vehicle Bill of Materials (List all items on a per-vehicle basis giving quantities and AAMPS numbers; attach list if necessary) Units of Measure AAMPS Number Description 4 ea AAMP lb. vertical shock absorber (Hadady PT.No. C-17527) (requested) 1 ea Shock mount bracket (upper w/handbrake bushing) 3 ea Shock mount bracket (upper) 1 ea Shock mount bracket (lower) 8 ea McMaster ¾ X 3 ¼ 10 UNC Bolt, Grade 8 Zinc-plated 91257A848 8 ea McMaster ¾ X 3 ¾ 10 UNC Bolt, Grade 8 Zinc-plated 91257A ea ¾ -10-nut w/nylon insert 16 ea McMaster ¾ Washer, Flat Zinc-plated 90126A Ea McMaster ¾ lock washer, Zinc-plated heavy duty 91104A Ea McMaster 4315A108 ¾ steel bushing, spacer Procedure (List below or Attach a "Step by Step" procedure) (Include all Special Safety Precautions, Tools needed and conclude with all Required Tests) (Attach any separate Drawings, Procedure instructions, etc.) 1) All applicable Amtrak safety rules are to be followed and all necessary safety equipment is to be used. Wear appropriate personal protective equipment (safety glasses, leather gloves and ear protection) as required. All personnel must be trained in the proper use of equipment necessary to perform this modification. Before starting, make sure all safety precautions are taken to secure equipment from movement and apply all local facility Blue Flag protection. 2

3 Submitted by: Campaign Manager: Ray Higuera Date: 01/28/08 Verified As To Completeness: Director, Rolling Stock Engineering: Date: Approved By: Superintendent, Public Health: Date: Sr. Director, Rolling Stock Engineering: Date: Deputy Chief Mechanical Officer: Date: Modification Campaign Issued In WMS: Director, Rolling Stock Engineering: Date: 3

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5 ROLLING STOCK & ENGINEERING STATEMENT OF MODIFICATION All AMTRAK F59PHI LOCOMOTIVES (Upgrade Existing Secondary Suspension) (1800Lb Shock and Bracket upgrade) FRA Tier I Applicable Regulations 49-CFR Suspension Systems (Standard for Design and Construction) (Passenger Locomotives) January 30, 2008 Written By: Ray Higuera Fleet Engineer Principle Engineer: Jon Fedora Senior Director of Engineering: Paul Steets Signature/Date: January 30, 2008 Signature/Date: January 30, 2008 Signature/Date: January 30,

6 SCOPE To establish an improved ride quality environment for Amtrak EMD F59PHI type locomotives used for revenue service in Amtrak s Pacific Northwest and Southwest operating regions. The test plan requires a method to improve ride quality by reducing vertical and lateral acceleration movements in the secondary truck suspension (vertical shock absorbers) designed on EMD type F59PHI locomotives. Prior ride quality test data conducted in real operating conditions indicate minor to moderate vertical and lateral acceleration movements, which are contributable to track operating effects and condition. These accelerated movements have reportedly cause vertical and lateral movements which have been considered to be excessive by operating personnel. The test requires the replacement of the OEM specified 1200lb vertical shock absorber with a new higher compression load shock absorber rated at 1800lbs. The new wider and higher compression rated shock absorber requires the fabrication of new brackets at each vertical truck location for modified adaptation. The configuration of higher rated shock absorber compression has been shown to reduce lateral and vertical acceleration movement by approximately 15%. Although the test plan modification did not completely eliminate all of the excessive accelerated movement, which has been considered to be partially track related, the dampening is a considerable improvement as field tested and is noticeable and acceptable by Amtrak operating crafts. A proto modification has been applied to one unit 450 following overhaul at Beechgrove and has successfully passed field-testing. The test results and continuous satisfactory operation including positive feedback without any reportable failures allows for engineering approval of this modification. The RSE test results constitute authorization for modification of the Amtrak F59PHI locomotive fleet. A fleet modification is requested for all Amtrak F59PHI locomotives, which can be performed during field maintenance. A request to perform this modification will ensure the Amtrak locomotive fleet is more reliable/available and safe. 2

7 All pertinent modification documentation to support this request has been edited or developed by both RSE field engineering and Beech grove mechanical, technical engineering staff. Documentation and drawings attached: Ray Higuera Field Engineering Locomotives West Cc: J. Fedora M. Scaringe P. Steets M. Burshtin P. Ferguson Ed Daly 3

8 Remove Upper Vertical Damper Support EMD Pt. No Remove 1200 lb. Vertical Damper EMD Pt. No Remove Lower Vertical Damper Support EMD Pt. No

9 INSTALLATION PROCEDURES 1800LB TRUCK SHOCK ABSORBER & BRACKETS FOR EMD F59PHI TYPE LOCOMOTIVES (UNITS ONLY) OVERVIEW: Following complaints of ride quality by various operating organizations which operate the EMD F59PHI type locomotives, Amtrak RSE was requested to review and develop a modification to improve excessive vertical and lateral motions. To satisfy their concerns RSE has developed a truck vertical shock upgrade from the OEM 1200lb to a more robust 1800lb shock absorber. The basis for this modification is justified and documented by over the road testing which included the FRA. BENEFITS: The modification will reduce vertical shock compressions and secondary lateral accelerations improving the ride quality of the locomotive. The modification shall be tested and installed on Amtrak units 450 through 470 only. MATERIAL REQUIRED: Quantity per Vehicle Units of Measure AAMPS Number Description 4 ea AAMP lb. vertical shock absorber (Hadady PT.No. C-17527) (requested) 1 ea Shock mount bracket (upper w/handbrake bushing) 3 ea Shock mount bracket (upper) 1 ea Shock mount bracket (lower) 8 ea McMaster ¾ X 3 ¼ 10 UNC Bolt, Grade 8 Zinc-plated 91257A848 8 ea McMaster ¾ X 3 ¾ 10 UNC Bolt, Grade 8 Zinc-plated 91257A ea ¾ -10-nut w/nylon insert 16 ea McMaster ¾ Washer, Flat Zinc-plated 90126A ea McMaster ¾ lock washer, Zinc-plated heavy duty 91104A ea McMaster ¾ steel bushing, spacer 4315A108 1 gal Paint-EN-POLY ALUMINUM ATTACHMENTS: Amtrak drawing C LB Shock Bracket ********** BG ********** BG ********** BG Hadady drawing C lb Shock Absorber Vertical TOOLS: ¾ Ratchet ¾ Torque Wrench Req. sockets Req. wrenches Rev-A-01/28/ lb shock mod Rfh-doc 1

10 SAFETY: INSTALLATION PROCEDURES 1800LB TRUCK SHOCK ABSORBER & BRACKETS FOR EMD F59PHI TYPE LOCOMOTIVES (UNITS ONLY) INSTRUCTIONS: Ensure all Amtrak safety rules are followed, including the use of necessary safety equipment. Wear appropriate personal protective equipment (safety glasses, leather gloves and ear protection) as required. All personnel must be trained in the proper use of equipment necessary to perform this modification. Before starting, make sure all safety precautions are taken to secure equipment from movement and apply all local facility Blue Flag protection. Note: Chock wheels to prevent accidental movement when brake cylinders are released to perform modification. REMOVAL & PERPARATION: Remove existing 1200lb vertical shock absorbers and upper and lower brackets at each truck position as noted in figure-1. Figure-1 Rev-A-01/28/ lb shock mod Rfh-doc 2

11 INSTALLATION: INSTALLATION PROCEDURES 1800LB TRUCK SHOCK ABSORBER & BRACKETS FOR EMD F59PHI TYPE LOCOMOTIVES (UNITS ONLY) Install new upper & lower shock brackets and new 1800Lb vertical shock absorbers as noted and displayed in (Figure-2). (Figure-2) Assembly Part Amtrak Part No. Ref. No. Number Qty Description 1 C ABSORBER ASSEMBLY..Shock N/A BUSHING..Rubber (not shown) N/A A108 4 SLEEVE..Metal N/A 4 BG BRACKET..Upper shock mount-upper *** BG BRACKET..Upper shock Mount w/handbrake A850 6 BOLT..Hex Head ¾ x 10 x 3 ¾ -upper/top 6 2 NUT..3/4-10-Hex w/nylon insert A848 2 BOLT..Hex Head ¾ x 10 x 3 ¼ 8 2 NUT..3/4-10-Hex w/nylon insert BOLT..Hex lock ¾-10 x 1 ¾ -upper/bottom *** 91257A850 2 BOLT..Hex Head ¾ x 10 x 3 ¾ -upper/top A047 6 WASHER..Lock 3/4 11 BG BRACKET..Lower shock Mount A036 4 WASHER..Flat 3/4 Rev-A-01/28/ lb shock mod Rfh-doc 3

12 INSTALLATION PROCEDURES 1800LB TRUCK SHOCK ABSORBER & BRACKETS FOR EMD F59PHI TYPE LOCOMOTIVES (UNITS ONLY) 1. Ensure item 3 metal spacer sleeves are inserted behind lower brackets as shown in figure Insert top ¾ nylon nuts on upper bracket into rear retainer slot in truck frame 3. Torque all bolts as required Torque all shock bolts to (366N.m-(270 ft-lbs) per EMD M.I Torque all upper Shock bracket bolts to (414N.m-(305 ft-lbs) per EMD M.I Torque all lower Shock bracket bolts to (156N.m-(115 ft-lbs) per EMD M.I REPORTING: Record and close WMS work order as required. Rev-A-01/28/ lb shock mod Rfh-doc 4

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