HKKJR LJDKJ Jsy Ea Ky : Report No. MP - MI-18 REV. - 02, April - 2008

Hkkjr ljdkj jsy ea=ky; GOVERENMENT OF INDIA MINISTRY OF RAILWAYS
MAINTENANCE INSTRUCTIONS FOR HEATLESS REGENERATIVE TWIN TOWER TYPE COMPRESSED AIR DRYER FOR DIESEL -ELECTRIC & ELECTRIC LOCOMOTIVES, EMUs / MEMUs AND DEMUs APPLICATION
Report No. MP.MI-18 REV. - 02, April - 2008
pkyu 'kfDr funskky; vuqla/kku vfHkdYi ,oa~ ekud laxBu y[ku & 226 011 Motive Power Directorate RESEARCH DESIGNS & STANDARDS ORGANISATION LUCKNOW - 226 011
CONTENTS
S.No
1. 2. 3. 4. 5. 6. INTRODUCTION
Title
Page No. 1 2 4 10 10 23
SCOPE OF MAINTENANCE INSTRUCTIONS DESCRIPTION OF WORKING OF AIR DRYER VARIOUS MAKES OF AIR DRYER FOR LOCOMOTIVES MAINTENANCE SCHEDULES OF AIR DRYER PRECAUTIONS INSTALLATION, OF AIR DRYER TO BE TAKEN DURING MAINTENANCE AND OPERATION
7. 8. 9. 10. 11. 12.
TROUBLE SHOOTING OF AIR DRYER ANNEXURE-I ANNEXURE-II ANNEXURE-III ANNEXURE-IV ANNEXURE-V
23 26 27 28 39 40
Maintenance Instructions For Heatless Regenerative Twin Tower Type Compressed Air Dryer For Diesel-Electric & Electric Locomotive, EMU/MEMU & DEMU Application
Maintenance Instructions For Heatless Regenerative Twin Tower Type Compressed Air Dryer For Diesel-Electric & Electric Locomotive, EMU/MEMU & DEMU Application 1. 1.1 Introduction Compressed air is used on Diesel-Electric & Electric locomotives, EMU/MEMU & DEMU for brake system and operation of other auxiliary devices. The compression cycle of ambient air includes compression in locomotive compressor and then cooling in after cooler. During compression, pressure & temperature of ambient air increases but its relative humidity decreases. However, absolute amount of the moisture present in the air remains same. After compression when the air is cooled in aftercooler, it becomes saturated and condensation takes place. This condensed moisture is drained out from main reservoirs. A major portion of moisture is removed in this process, but water still remains present in the form of vapour in the compressed air. This water vapour condenses in air brake equipment/valves, air pipes and auxiliaries during train operation. The condensation which takes place in air valves and air pipes leads to following problems:i) ii) iii) iv) v) vi) vii) viii) ix) 1.2 Malfunctioning of air valves due to rusting. Sluggish operation of moving parts of the valves. Poor performance of the valves due to washing away of the lubricant. High flow resistance and pre-mature blocking of filters. Rusting of air pipes. Poor performance and low life of rubber components of the valves. Sticky and greasy accumulation on the components of the air valve. Freezing of the water droplets when ambient temperature drops below freezing point. Choking of small chokes and strainer in the valves .
Condensation of water vapour in brake circuit can be overcome if dew point temperature of compressed air is reduced This can be achieved by reducing moisture content of compressed air by adsorbing the water vapour in air dryers. On DieselElectric & Electric locomotives, EMU/MEMU & DEMU heat less regenerative twin tower compressed air dryer is used. This type of air dryers use desiccant to adsorb the moisture. Desiccant used is normally in the form of granules. Each granule of desiccant may be considered as a vast honeycomb of very small pores. These pores give desiccant a very large internal surface area which attracts and absorb moisture. However, after some time, desiccant is completely saturated and no longer capable to adsorb moisture. Therefore, water adsorbed is to be given away from its pores by reactivation. This process is called regeneration. On the heatless air dryer used on the system, regeneration of saturated desiccant is done by drying it by dry air
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MP.MI-18 Rev. - 02, April-2008
(regenerative air). For this a small quantity (10 to 20 %) of the air dried by the desiccant is used. Rest of the dried air is used for braking operation. 1.3 The following specifications have been issued for air dryers for different applications from time to time: S. No. Specification No. (a) MP.0.0102.01 (b) MP.0.0155.01 (c) MP.0.01.00.06 (d) (e) (f) (g) MP.0.01.00.09 DLW GM P. L. No. 17450810 CLW/MS/3/041 MP.0.01.00.06 (Rev.0.03), March-2007 Applications For diesel locomotives For electric locomotives For diesel & electric locomotives, superseding the above specification For EMUs / MEMUs & DEMUs For WDG4 / WDP4 EMD design locomotives For WAG9 / WAP7 / WAP5 locomotives Diesel-Electric, Electric locomotives (including High HP Dsl- Elec. & Electric locos.), EMUS/ MEMUs & DEMUs (Present specification, superseding all the earlier specifications)
1.4
Maintenance manuals of various makes of air dryer, prepared by respective manufacturers are available. Railways / PUs should insist for supply of maintenance manual with air dryers. As per clause No. 8.1 of combined specification mentioned above the supplier has to supply one maintenance manual with every set of five air dryers. Air dryers are being used for last appx. 10 years. Based on the experience gained during this period, these instructions for maintenance of air dryers are being revised to increase awareness about working of air dryer and to bring uniformity in maintenance schedules to be carried out on air dryer. Scope Of Maintenance Instructions Description of working of air dryer Various makes of air dryers for locomotives Maintenance schedules of air dryer Precautions during installation, maintenance and operation of air dryer
1.5
2.
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Trouble shooting Testing This maintenance instruction supersedes earlier maintenance instruction MP.MI-18, Rev. 01, August-2006 for heatless regenerative twin tower type compressed air dryer for diesel/electric locomotive application.
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3.
Description Of Working Of Air Dryer There are many manufacturers for heatless regenerative twin tower air dryer. Among various designs, there are some differences in design and features. However basic principle of working of such air dryers remains same. Important components and operation of a typical twin tower heatless regenerative air dryer used on locomotives is described below.
3.1 3.1.1
System Components of a typical Air Dryer Pre-Coalescer: A borosilicate or other type of element designed to restrict and collect tiny aerosol contaminants, primarly oil and other contaminants, which may prove detrimental to the successful operation of any form of desiccant.
3.1.2
Desiccant Tower The desiccant beads, which extract the moisture from the air, are housed in two towers. These are also called desiccant towers.
3.1.3
Pressure Switch An integral pressure sensing device is located internally to control the air drying cycle. The air dryer cycles only when the predetermined pressure is reached. If an emergency arises and air pressure drops below the pre determined level cycling stops immediately and air flows through the air dryers to support the immediate air requirements.
3.1.4
Purge valve There is one purge valve located at the bottom of each desiccant tower. Alternatively, there is a common purge valve connected to both desiccant towers. Purge valve allows the regenerative air to discharge moisture through the desiccant tower to atmosphere.
3.1.5
Humidity Indicator A colour indicator is located at each outlet check valve as a visual indication to monitor the condition of air after passing through each desiccant tower. Alternatively, there is a common humidity indicator is located at the outlet of final filter.
3.1.6
Final Filter This is a unit, which removes any dust generated after the air has passed through the main dryer system. Alternatively, desiccant may be supplied in a fabric cloth bag, which can act as final filter. In such cases, separate final filter will not be required.
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3.2
Operation of air dryer (Fig 1) Compressed air after main reservoir (1) of diesel locomotive (MR-2 in case of electric loco) passes through a pre-coalescer filter (2). This removes significant amount of debris, moisture and oil from the compressed air. After pre-coalescer filter air enters into the actuator (3), which decides the entry of air to either of two desiccant towers (4a and 4b). Position of actuator is controlled by timer unit (5). For example, in a particular cycle, wet air enters from the bottom of the tower (4a) and passes through desiccant bed where moisture is adsorbed by the desiccant. Dry air with dew point less than ambient temperature comes out from the top and finally goes out of dryer to final filter (6). Final filter removes traces of desiccant powder, if any, from the dry air and air then goes to main reservoir-2 (7) of diesel locomotive (MR-3 in case of electric loco). A small part of the dry air (10-20% of inlet air capacity) is drawn from the dry air outlet of tower (4a) and is passed through regenerative orifice of non-return valve (8) and on to the desiccant bed of the other tower (4b). It removes the moisture collected in the second tower and thus reactivates the desiccant. The moisture laden air is vented through exhaust valve which is also called purge valve (9). Thus in this cycle tower (4a) works as dehydrating tower and tower (4b) works as regenerative tower. After completion of this cycle the working of two towers reverses and now the tower (4a) works as regenerative tower and tower (4b) works as dehydrating tower. In this way two towers alternatively work as dehydrating/regenerative towers. This reversal takes place after a predetermined time period. This is called cycle time of the air dryer. Cycle time of air dryer is normally 1 to 2 minutes.
3.3
Other Modifications i. Modification in pneumatic pipelines on locomotive to supply dry air to auxiliaries. ii. Modification of EPG to reduce failure of pressure switch Change in location of pressure switch Use of improved type of pressure switch on EPG iii. Changes in electrical circuit of air dryer to incorporate memory feature and to achieve synchronous operation of air dryer fitted on locomotives operating in multiple units. iv. Removal of by-pass arrangement
Modification Sheet No. MP MOD.BK.-05.27.00 Rev.00 dt. 30 08. 2000 may be referred.
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4.
VARIOUS MAKES OF AIR DRYER FOR LOCOMOTIVES Till date, air dryers supplied by M/s SAB WABCO, Harita/Hosur , M/s Stone India Limited, Calcutta and M/s Knorr-Bremse India Limited, Faridabad have been recommended either for regular use or for extended trials. Model numbers of air dryer of the above suppliers are given below:
4.1
D&M (Graham-White) make series 975-123 air dryers supplied by M/s SAB WABCO, Harita/Hosur are being fitted on diesel locomotives. Based on the tests conducted on air dryer in RDSO, a regenerative choke of 0.11" with memory feature has been recommended for diesel locomotives. Earlier on diesel locomotives, air dryers were fitted without memory feature. To provide these locomotives with memory feature, Railways can contact the supplier to supply new printed circuit board (PCB) with memory feature. D&M (Graham-White) make series 975-124 air dryer with regenerative choke size of 0.0625" with memory feature has been recommended for fitment on electric locomotives. Air dryers already fitted on electric locomotives have memory feature. Therefore, there is no need to change PCB on air dryer already fitted on electric locomotive.
4.2 4.3
WABCO vaporid air dryers supplied by M/s Stone India Limited, 16, Taratalla Road, Calcutta-700 088 have been recommended for use on diesel locomotives. Air dryer Model No.LTZW-5000 supplied by M/s Knorr-Bremse India Limited, 14/6 Mathura Road, Faridabad has been recommended for extended trials on diesel locomotives. Air dryer Model No.LTZW-15.2 supplied by the above firm has been recommended for extended trials on electric locomotives.
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Schematic Diagram of FTIL Make Air Dryer
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Schematic Diagram of SIL Make Air Dryer
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Knorr-Bremse India, November 2004
16
Schematic Diagram of Knorr Bramse Make Air Dryer
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4.
Various Makes Of Air Dryer For Locomotives The following vendors have approved for supply of air dryer for locomotives conforming to specification no. MP.0.01.00.06 till the date of publication of this maintenance instruction. S.N. Name of Vendor (Designer) & Applications 1. Faiveley Transport India Ltd.(Formerly SAB WABCO), Harita, Hosur (Graham White) Model no. 975-123 with orifice size 0.11 for all Diesel locomotives including WDG4 and WDP4 and electric locomotives WAG-9,WAP-7 & WAP-5, Model no. 975-129 with orifice size 0.0625 for Electric goods locomotives (excluding WAG-9), Model no. 975-129 with orifice size 0.052 for Electric passenger locomotives (excluding WAP-7 & WAP-5), Model no. 975-124 with orifice size 0.052 for EMU/MEMU& MG DEMU, Model no. 975-124 with orifice size 0.0625 for DEMU. 2. Stone India Ltd., 16, Taratalla Road, Kolkata (Wabtec /Vaporid) Drawing no. 09510102 with orifice size 0.0938 for Diesel locos. Drawing no. 09510101 with orifice size 0.0785 for Electric goods locos. Drawing no. 09510106 with orifice size 0.067 for Electric passenger locos. Drawing no. 09510103 with orifice size 0.052 for EMU/MEMU Drawing no. 09510104 with orifice size 0.0625 for DEMU Drawing no. 09510105 with orifice size 0.089 for ABB locos. 3. Knorr-Bremse India Ltd., 14/6, Mathura Road, Faridabad (Knorr Bremse) Model LTZ 015.2 with orifice size 2 mm for Diesel locomotives Model LTZ 015.2 with orifice size 1.4 mm for Electric locomotives Model LTZ 015.1 with orifice size 1.1 mm for EMU/ MEMUs/ MG-DEMUs Model LTZ 015.2 with orifice size 1.4 mm for DEMUs
5. 5.1
Maintenance Schedules Of Air Dryer Detailed maintenance procedure to be followed for various makes of air dryer is given in the maintenance manual of respective makes of air dryer. However, important aspects related to installation, periodicity of maintenance schedules and items to be checked in schedules are given below. Installation, Pneumatic and Electrical connections of air dryer As per Clause 7.7 of RDSO Specification no. MP.0.01.00.06, Installation of air dryer shall be carried out either by supplier or by the purchaser not by any third party. Installation charges should be quoted as an optional item.
5.2 5.2.1
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The envelope space for air dryer for diesel locos., electric locomotives, EMUs MEMUs and DEMUs the mounting hole dimensions are given in RDSO Specification no. MP.0.01.00.06. 5.2.2 Pneumatic and electrical connections on Diesel loco Pneumatic and electrical connections of air dryer fitted on diesel locomotives are shown in Drg.No. SK.DP-3348 Alt.1.(Annexure-I) The connections of air dryer electrical junction box are done as under: i) ii) iii) 5.2.3 Terminal A (+ve ) - For power supply Terminal B (+ve) - For memory Terminal C (-ve)
Negative connection
connected to wire No. 13 of loco connected to wire No. 13 of loco connected to wire No. 4 of loco
Pneumatic and electrical connections on Electric loco Pneumatic and electrical connections of air dryer fitted on electric locomotives are shown in Drg.No. SK.DP-3384 Alt.1 (Annexure-II) The connections of air dryer electrical junction box are done as under: i) ii) iii) Terminal A (+ve ) - For power supply Terminal B (+ve) - For memory Terminal C (-ve)
Negative connection
connected to wire No. 003 of loco connected to wire No. 401 of loco connected to wire No. B-ve of loco
5.2.4
Pneumatic and electrical connections on DEMUs For pneumatic connections of air dryer fitted on DEMUs & MG-DEMUs, Brake schematic Drg.No. SK.DP-3620 & Drg.No. SK.DP-3636 respectively may be referred. The electrical connections of air dryer are done as under: i) ii) iii) Terminal A (+ve ) Terminal B (+ve) Terminal C (-ve) Main +ve Supply
- Compressor (Load/unload signal) +ve Supply Main - ve Supply
5.2.5
Pneumatic and electrical connections on DEMUs For pneumatic connections of air dryer fitted on EMUs/MEMUs, modification Sheet No. MC/EMU/MSG/DC dt.21.03.2005 may be referred.
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The electrical connections of air dryer are done as under: i) ii) iii) 5.3 Terminal A (+ve ) Terminal B (+ve) Terminal C (-ve) Main +ve Supply
- Compressor (Load/unload signal) +ve Supply Main - ve Supply
Periodicity of maintenance schedules The maintenance schedules of air dryers should correspond to maintenance schedule of locomotive, which are typically as follows:
(A) For Diesel Locomotives i) ii) iii) iv) v) vi) T1 M-2 M-4 20 days 60 days 120 days 12 months 24 months 48 months
M-12 M-24 M-48 -
(B) For Electric Locomotives Schedule i) ii) Trip IA Passenger Freight Locomotive Locomotive 15/20 days 40 days 80 days 120 days 12 months 36 months 15/20 days 45 days 90 days 135 days 18 months 54 months
iii) IB iv) IC v) AOH
vi) IOH
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(C)
For EMU/MEMUs i) ii) iii) iv) Trip IA IC POH 10 days 45 days 180 days 18 months
(D) For DEMUs i) ii) iii) iv) v) Trip Monthly Quarterly Half yearly 7 days 1 month 3 months 6 months
Eighteen Monthly 18 months Schedule
Note: Maintenance sheds may modify the frequency of above schedules to match their existing schedules.
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5.4
Items To Be Checked During Maintenance Schedules
(A) For Diesel Locomotives S.N Items to be checked Remarks
T-1 SCHEDULE 1. 2. Open drain cock of final filter to drain off any accumulated water content Check the colour of It indicates condition of air after passing through air dryer. humidity indicator Indication of various colour are as under. Blue colour ---- Dryer is performing correctly Lavender ---- Dryer is suspect - Verify dryer is cycling. - If dryer is cycling correctly and auto drain valve of main reservoir No.1 is operating correctly, release the loco for service White ---- Possible damaged dryer - Verify dryer is cycling. - Remove humidity indicators and look for desiccant dust or residue on inside of manifold and humidity indicators. If desiccant dust or residue is seen Remove dryer for attention. If no desiccant dust or residue is seen on inside of manifold- Install new humidity indicators. Again verify dryer is cycling correctly & No.1 main reservoir drain valve is operating correctly Release loco for service.
Yellow or Brown colour ----- Damaged dryer -It indicates that desiccant has been contaminated with oil. Replacement of coalescing element and desiccant is required. 3. Check auto drain of main It should function properly. reservoir No.1
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4.
Check electrical connection of air dryer and their tightness.
M-2 SCHEDULE 1. Repeat all the items of T1 schedule. 2. Check cyclic operation of While the dryer is cycling, there should be a slight and air dryer. continuous exhaust from the relevant purge valve. After pre-determined cyclic time, exhaust from the purge valve stops and that of the second tower starts exhausting. This cycle should be reversed after cycle time. The cycle timings of various makes of air dryer are as under: FTIL air dryer - 1 minute drying and -1 minute regeneration Stone India Ltd. air dryer - do - do
Knorr-Bremse air dryer 3. 4. Check Memory Feature
When compressor gets unloaded purging of air should stop and when compressor again gets loaded purging should continue. Examine the drain valve on With the dryer operation, the drain valve must expel a short the sump of pre coalescer burst of air once a minute (each cycle).
M-4 SCHEDULE 1. Repeat all the items of M-2 schedules. 2. Charge the system from Pressure settings of start of cyclic operation are as under: zero pressure and check the FTIL air dryer ----- 7.0 kg/cm2 dryer does not cycle immediately. Note the SIL air dryer ----- 7.0 kg/cm2 pressure when the dryer Knorr-Bremse air dryer ----- 4.6 kg/cm2 starts cycling. M-12 SCHEDULE 1. Repeat all the items of M-4 schedules. 2. Replace consumables as Please see Annexure-III for list of items to be replaced. per respective (in case of KB make air dryers no consumables are to be replaced in M-12) manufacturers recommended replacement kit
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M-24 SCHEDULE 1. Repeat all the items of M-12 schedules. 2. Clean external muffler connected with purge valves. 3. Check condition of each pipe assembly and their tightness. M-48 SCHEDULE 1. Overhaul the complete air dryer and change desiccant. 2. Replace consumables as per respective manufacturers recommended replacement kit. 3. Test each air dryer before putting it back in to service.
In case of KB make air dryers, please see Annexure III for list of items to be replaced. Follow the instructions given in maintenance manual of respective manufacturers. -
For overhauling follow the instructions given in maintenance manual of respective manufacturers. Please see Annexure-III for list of items to be replaced.
Schematic diagram of test bench is given in Annexure-IV List of tests to be conducted and format of record to be maintained is given in Annexure V For further details, specification No. MP.0.01.00.06 may be referred.
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(B) For Electric Locomotives S.N Items to be checked Remarks
TRIP SCHEDULE 1. 2. Open drain cock of final filter to drain off any accumulated water content Check the colour of It indicates condition of air after passing through air humidity indicator dryer. Indication of various colour are as under. Blue colour ---- Dryer is performing correctly Lavender ---- Dryer is suspect - Verify dryer is cycling. - If dryer is cycling correctly and auto drain valve of main reservoir No.1 is operating correctly, release the loco for service White ---- Possible damaged dryer - Verify dryer is cycling. - Remove humidity indicators and look for desiccant dust or residue on inside of manifold and humidity indicators. If desiccant dust or residue is seen Remove dryer for attention. If no desiccant dust or residue is seen on inside of manifold- Install new humidity indicators. Again verify dryer is cycling correctly & No.1 main reservoir drain valve is operating correctly Release loco for service.
3.
Yellow or Brown colour ----- Damaged dryer -It indicates that desiccant has been contaminated with oil. Replacement of coalescing element and desiccant is required. Check auto drain of main It should function properly. reservoir No.1 & main reservoir No.2
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4.
Check electrical connection of air dryer and their tightness. IA/ IB SCHEDULE 1. Repeat all the items of Trip schedule. 2. Check cyclic operation of While the dryer is cycling, there should be a slight and air dryer. continuous exhaust from the relevant purge valve. After pre-determined cyclic time, exhaust from the purge valve stops and that of the second tower starts exhausting. This cycle should be reversed after cycle time. The cycle timings of various makes of air dryer are as under: FTIL air dryer - 1 minute drying and -1 minute regeneration Stone India Ltd. air dryer -do- 2 minute drying and 2 minute regeneration
Knorr-Bremse air dryer 3. Check Memory Feature
When compressor gets unloaded purging of air should stop and when compressor again gets loaded purging should continue. 4. Examine the drain valve on With the dryer operation, the drain valve must expel a the sump of pre coalescer short burst of air once a minute (each cycle). IC - SCHEDULE 1. Repeat all the items of IA/IB schedules. 2. Charge the system from Pressure settings of start of cyclic operation are as under: zero pressure and check the FTIL air dryer ----- 7.0 kg/cm2 dryer does not cycle immediately. Note the SIL air dryer ----- 7.0 kg/cm2 pressure when the dryer Knorr-Bremse air dryer ----- 4.6 kg/cm2 starts cycling. AOH SCHEDULE 1. Repeat all the items of IC schedules. 2. Replace consumables as Please see Annexure-III for list of items to be replaced. per respective (in case of KB make air dryers consumables are to be replaced in alternate AOH) manufacturers recommended replacement kit 3. Clean external muffler Follow the instructions given in maintenance manual of connected with purge respective manufacturers. valves.
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Check condition of each pipe assembly and their tightness. IOH SCHEDULE 1. Overhaul the complete air dryer and change desiccant. 2. Replace consumables as per respective manufacturers recommended replacement kit. 3. Test each air dryer before putting it back in to service.
4.
(C) For EMUs /MEMUs S.N Items to be checked Remarks
TRIP SCHEDULE 1. 2. Open drain cock of final filter to drain off any accumulated water content Check the colour of It indicates condition of air after passing through air humidity indicator dryer. Indication of various colour are as under. Blue colour ---- Dryer is performing correctly Lavender ---- Dryer is suspect - Verify dryer is cycling. - If dryer is cycling correctly and auto drain valve of main reservoir No.1 is operating correctly, release the EMU/MEMU for service White ---- Possible damaged dryer - Verify dryer is cycling. - Remove humidity indicators and look for desiccant dust or residue on inside of manifold and humidity indicators.
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If desiccant dust or residue is seen Remove dryer for attention. If no desiccant dust or residue is seen on inside of manifold- Install new humidity indicators. Again verify dryer is cycling correctly & No.1 main reservoir drain valve is operating correctly Release EMU/MEMU for service.
Yellow or Brown colour ----- Damaged dryer -It indicates that desiccant has been contaminated with oil. Replacement of coalescing element and desiccant is required. 3. Check auto drain of main It should function properly. reservoir No.1 4. Check electrical connection of air dryer and their tightness. IA SCHEDULE 1. Repeat all the items of Trip schedule. 2. Check cyclic operation of While the dryer is cycling, there should be a slight and air dryer. continuous exhaust from the relevant purge valve. After pre-determined cyclic time, exhaust from the purge valve stops and that of the second tower starts exhausting. This cycle should be reversed after cycle time. The cycle timings of various makes of air dryer are as under: FTIL air dryer - 1 minute drying and -1 minute regeneration Stone India Ltd. air dryer -do- 2 minute drying and 2 minute regeneration
Knorr-Bremse air dryer 3. 4. Check Memory Feature
When compressor gets unloaded purging of air should stop and when compressor again gets loaded purging should continue. Examine the drain valve on With the dryer operation, the drain valve must expel a the sump of pre coalescer short burst of air once a minute (each cycle). IA
IC SCHEDULE 1. Repeat all the items of schedules.

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2.
Charge the system from Pressure settings of start of cyclic operation are as under: zero pressure and check the FTIL air dryer ----- 7.0 kg/cm2 dryer does not cycle immediately. Note the SIL air dryer ----- 7.0 kg/cm2 pressure when the dryer Knorr-Bremse air dryer ----- 4.6 kg/cm2 starts cycling.
POH SCHEDULE 1. Repeat all the items of IC schedules. 2. Replace consumables as per respective manufacturers recommended replacement kit 3. Clean external muffler connected with purge valves. 4. Check condition of each pipe assembly and their tightness. Note (a) Overhaul the complete air dryer and change desiccant during alternate POH. (b) Replace consumables as per respective manufacturers recommended replacement kit in every alternate POH. (c) Test each air dryer before putting it back in to service during alternate POH.
Please see Annexure-III for list of items to be replaced.
Follow the instructions given in maintenance manual of respective manufacturers. -
(D) For DEMU S.N Items to be checked Remarks
TRIP SCHEDULE 1. Open drain cock of final filter to drain off any accumulated water content
MP.MI-18 Rev. - 02, April-2008 Page 21 of 40
2.
Check the colour humidity indicator
of It indicates dryer.
condition of air after passing through air
Indication of various colour are as under. Blue colour ---- Dryer is performing correctly Lavender ---- Dryer is suspect - Verify dryer is cycling. - If dryer is cycling correctly and auto drain valve of main reservoir No.1 is operating correctly, release the DEMU for service White ---- Possible damaged dryer - Verify dryer is cycling. -Remove humidity indicators and look for desiccant dust or residue on inside of manifold and humidity indicators. - If desiccant dust or residue is seen Remove dryer for attention. - If no desiccant dust or residue is seen on inside of manifold- Install new humidity indicators. Again verify dryer is cycling correctly & No.1 main reservoir drain valve is operating correctly - Release DEMU for service. Yellow or Brown colour ----- Damaged dryer -It indicates that desiccant has been contaminated with oil. Replacement of coalescing element and desiccant is required. Check auto drain of main It should function properly. reservoir No.1 Check electrical connection of air dryer and their tightness.
3. 4.
Monthly Schedule 1. Repeat all the items of Trip schedule. 2. Check cyclic operation of While the dryer is cycling, there should be a slight and air dryer. continuous exhaust from the relevant purge valve. After pre-determined cyclic time, exhaust from the purge valve stops and that of the second tower starts exhausting. This cycle should be reversed after cycle time. The cycle
timings of various makes of air dryer are as under: FTIL air dryer - 1 minute drying and -1 minute regeneration Stone India Ltd. air dryer -do- 2 minute drying and 2 minute regeneration
Knorr-Bremse air dryer 3. Check Memory Feature
When compressor gets unloaded purging of air should stop and when compressor again gets loaded purging should continue. 4. Examine the drain valve on With the dryer operation, the drain valve must expel a the sump of pre coalescer short burst of air once a minute (each cycle). Quarterly / Half Yearly Schedule 1. Repeat all the items of Monthly schedules. 2. Charge the system from Pressure settings of start of cyclic operation are as under: zero pressure and check the FTIL air dryer ----- 7.0 kg/cm2 dryer does not cycle immediately. Note the SIL air dryer ----- 7.0 kg/cm2 pressure when the dryer Knorr-Bremse air dryer ----- 4.6 kg/cm2 starts cycling. Eighteen Monthly Schedule 1. Repeat all the items of Quarterly/ Half Yearly schedules 2. Replace consumables as Please see Annexure-III for list of items to be replaced. per respective manufacturers recommended replacement kit 3. Clean external muffler Follow the instructions given in maintenance manual of connected with purge respective manufacturers. valves. 4. Check condition of each pipe assembly and their tightness. Note (a) Overhaul the complete air For overhauling follow the instructions given in dryer and change desiccant maintenance manual of respective manufacturers. during alternate Eighteen Monthly Schedule (b) Replace consumables as Please see Annexure-III for list of items to be replaced. per respective manufacturers
(c)
recommended replacement kit in every alternate Eighteen Monthly Schedule Test each air dryer before putting it back in to service during alternate Eighteen Monthly Schedule
6. 6.1 6.2 6.3 6.4 6.5 6.6 6.7
Precautions To Be Taken During Installation, Maintenance And Operation Of Air Dryer Installation of air dryer shall be carried out either by supplier or by the purchaser not by any third party. Air Dryer should be mounted vertically. Desiccant material may be hazardous to health. Direct skin contact with desiccant should be avoided. Auto drain valve of main reservoir tanks should be in working order. If any welding is to be carried out on underframe, ensure the dryer is electrically disconnected from the power supply. For welding, earthing should not be taken through dryer or near to the dryer. On the air dryer, electrical connector has three wires, one for positive, second for intermittent positive for memory circuit only and third wire is for negative connection. While electrical connections of air dryer are made, care should be taken that these connections are properly done after verifying the inscription on electrical connector of air dryer. PCB of air dryer should be isolated when meggering operation is done on Loco./ EMU/MEMU/DEMU Proper conduit and safety straps should be provided on all electrical wiring/ connections involved in dryer installation. Trouble Shooting Of Air Dryer For trouble shooting follow instructions given in maintenance manual of respective manufacturer. However trouble shooting of some of the common problems faced on air dryers are given below :-
6.8 6.9 7.
Page 24 of 40
S.No. 1
SYMPTOM Dryer not cycling.
CORRECTION 1. Make a visual inspection of dryer for damage. 2. Ensure MR air pressure is equivalent to setting pressure of the air dryer. 3. Check supply voltage, it must be in the range of 48-90 V DC for diesel locomotive and 85 to 130 V DC for electric locomotive, EMU/MEMUs & DEMUs. 4. Check electrical connection of air dryer. It should be as per clause5.2. Check circuit board connection. 5. Ensure that solenoid valves are working properly. 6. Inspect control box pressure, check valves, and timer unit and ensure proper working of check valves, magnet valves 7. Ensure all tubing connections to purge and drain valves for. a) Loose connections. b) Check for blockage inside tubing . 8. Inspect and replace circuit board, if necessary 1. Make a visual inspection of dryer for damage. 2. Check outlet valves for debris or damage. 3. Check inlet check valves for debris or damage. 1. Make a visual inspection of dryer for damage. 2. Check double seated drain valve seats for debris or damage. 3. If leakage is occurring for pressure under 70 psi then check control box pressure check valve. 1. Make a visual inspection of dryer for damage. 2. Push clean out plunger on and follow instruction given in maintenance manual.
Excessive air discharge during regeneration. Continuous discharge of main reservoir air from pre coalescer drain valve.
3.
No regenerating air from one or both of the tower purge valves.
5.
1. Make a visual inspection of dryer for damage. One or both humidity indicators are not of correct 2. White Indicators normally turn into proper color after cycling. colour (indication of proper 3. Check for dryer cycling operation. working) 4. Check control box pressure check valve for excessive leakage from vent hole on cap. 5. Check line power to dryer. 6. Check circuit board. 7. Check circuit board connections..
Page 25 of 40
Annexure I
Page 26 of 40
Annexure II
Page 27 of 40
Annexure-III
1. Recommended Spare Parts List For Air Dryer of M/S FTIL (Graham White Design) (A) (Kit for Air Dryer fitted on Diesel Locos including WDP4 & WDG4) Parts to be renewed in M-12 schedule S.N Item 1 Inlet main coalescer kit (AD) 2 Kit for final filter 3 Regenerating orifice kit (AD) FTIL Part No. 790 0291 65 790 0291 25 790 0291 11 D & M Part No. RK-AB787-W27B RK-AB787-W40 RK-AB787-W39 Qty 1 1 1
Parts to be renewed in M-48 schedule S.N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 (B) Item Inlet main coalescer kit (AD) Kit for final filter Regenerating orifice kit (AD) Desiccant canister kit (AD) Inlet check valve kit (AD) Drain valve kit (AD) Outlet check valve kit (AD) Purge valve kit (AD) Solenoid assembly kit (AD) Compactor assembly kit (AD) Humidity indicator kit (AD) O-Ring (ID 1.359x width- 0.139) O-Ring (ID 5.234 x width- 0.139) O-Ring (ID 5.984x width- 0.139) O-Ring (ID 1.734 x width- 0.139) Electric box Gasket Tetra seal for drain valve O-Ring (ID 0.674 x width- 0.103) Gasket for Burndy Connector FTIL Part No. 790 0291 65 790 0291 25 790 0291 11 790 0291 95 790 0291 35 790 0291 75 790 0291 45 790 0291 85 790 0291 55 790 0292 05 790 0291 05 029 7190 00A 029 7150 00 029 7180 00 029 7130 00A 029 7120 00 029 7200 00 029 7015 00 029 7075 00 D & M Part No. RK-AB787-W27B RK-AB787-W40 RK-AB787-W39 RK-AB787-W44 RK-AB787-W27A RK-AB787-W28 RK-AB787-W29 RK-AB787-W36 RK-AB787-W37 RK-AB787-W41 RK-AB787-187 AB787-121 AB787-125 AB787-173 AB787-188 AB787-191 AB787-224 AB787-144 AB787-239 Qty 1 1 1 1 2 1 2 2 2 2 2 8 4 1 2 1 1 1 1
(Kit for Air Dryer fitted on Electric Locos except 3 phase - WAG-9, WAP-7 & WAP-5 Locos.) Parts to be renewed in AOH Schedule FTIL Part No. 790 0291 65 790 0291 25 790 0291 11 D & M Part No. RK-AB787-W27B RK-AB787-W40 RK-AB787-W39 Qty 1 1 1
S.N Item 1 Inlet main coalescer kit (AD) 2 Kit for final filter 3 Regenerating orifice kit (AD)
Page 28 of 40
Parts to be renewed in IOH schedule S.N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Item Inlet main coalescer kit (AD) Kit for final filter Regenerating orifice kit (AD) Kit for Desiccant can (Smaller) Inlet check valve kit (AD) Drain valve kit (AD) Outlet check valve kit (AD) Purge valve kit (AD) Solenoid assembly kit (AD) Compactor assembly kit (AD) Humidity indicator kit (AD) O-Ring (ID 1.359x width- 0.139) O-Ring (ID 5.234 x width- 0.139) O-Ring (ID 5.984x width- 0.139) O-Ring (ID 1.734 x width- 0.139) Electric box Gasket Tetra seal for drain valve O-Ring (ID 0.674 x width- 0.103) Gasket for Burndy Connector FTIL Part No. 790 0291 65 790 0291 25 790 0291 11 790 0291 45 790 0291 35 790 0291 75 790 0291 45 790 0291 85 790 0291 55 790 0292 05 790 0291 05 029 7190 00A 029 7150 00 029 7180 00 029 7130 00A 029 7120 00 029 7200 00 029 7015 00 029 7075 00 D & M Part No. RK-AB787-W27B RK-AB787-W40 RK-AB787-W39 RK-AB787-W27A RK-AB787-W28 RK-AB787-W29 RK-AB787-W36 RK-AB787-W37 RK-AB787-W41 RK-AB787-187 AB787-121 AB787-125 AB787-173 AB787-188 AB787-191 AB787-224 AB787-144 AB787-239 Qty 1 1 1 1 2 1 2 2 2 2 2 8 4 1 2 1 1 1 1
(C) (Kit for Air Dryer fitted on 3 phase - WAG-9, WAP-7 & WAP-5 Electric Locos.) Parts to be renewed in AOH Schedule S.N Item 1 Inlet main coalescer kit (AD) 2 Kit for final filter 3 Regenerating orifice kit (AD) FTIL Part No. 790 0291 65 790 0291 25 790 0291 11 D & M Part No. RK-AB787-W27B RK-AB787-W40 RK-AB787-W39 Qty 1 1 1
Parts to be renewed in IOH Schedule S.N 1 2 3 4 5 6 7 8 9 10 Item Inlet main coalescer kit (AD) Kit for final filter Regenerating orifice kit (AD) Desiccant canister kit (AD) Inlet check valve kit (AD) Drain valve kit (AD) Outlet check valve kit (AD) Purge valve kit (AD) Solenoid assembly kit (AD) Compactor assembly kit (AD) FTIL Part No. 790 0291 65 790 0291 25 790 0291 11 790 0291 95 790 0291 35 790 0291 75 790 0291 45 790 0291 85 790 0291 55 790 0292 05 D & M Part No. RK-AB787-W27B RK-AB787-W40 RK-AB787-W39 RK-AB787-W44 RK-AB787-W27A RK-AB787-W28 RK-AB787-W29 RK-AB787-W36 RK-AB787-W37 RK-AB787-W41 Qty 1 1 1 1 2 1 2 2 2 2
Page 29 of 40
11 12 13 14 15 16 17 18 19
Humidity indicator kit (AD) O-Ring (ID 1.359x width- 0.139) O-Ring (ID 5.234 x width- 0.139) O-Ring (ID 5.984x width- 0.139) O-Ring (ID 1.734 x width- 0.139) Electric box Gasket Tetra seal for drain valve O-Ring (ID 0.674 x width- 0.103) Gasket for Burndy Connector
790 0291 05 029 7190 00A 029 7150 00 029 7180 00 029 7130 00A 029 7120 00 029 7200 00 029 7015 00 029 7075 00
RK-AB787-187 AB787-121 AB787-125 AB787-173 AB787-188 AB787-191 AB787-224 AB787-144 AB787-239
2 8 4 1 2 1 1 1 1
(D) Kit for Air Dryer fitted on EMU/MEMU & DEMU Application Parts to be renewed in POH / Eighteen Monthly Schedule S.N Item 1 Inlet main coalescer kit (AD) 2 Kit for final filter 3 Regenerating orifice kit (AD) FTIL Part No. 790 0291 65 790 0291 25 790 0291 11 D & M Part No. RK-AB787-W27B RK-AB787-W40 RK-AB787-W39 Qty 1 1 1
Parts to be renewed in every alternate POH / Eighteen Monthly Schedule S.N 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Item Inlet main coalescer kit (AD) Kit for final filter Regenerating orifice kit (AD) Kit for Desiccant can (Smaller) Inlet check valve kit (AD) Drain valve kit (AD) Outlet check valve kit (AD) Purge valve kit (AD) Solenoid assembly kit (AD) Compactor assembly kit (AD) Humidity indicator kit (AD) O-Ring (ID 1.359x width- 0.139) O-Ring (ID 5.234 x width- 0.139) O-Ring (ID 5.984x width- 0.139) O-Ring (ID 1.734 x width- 0.139) Electric box Gasket Tetra seal for drain valve O-Ring (ID 0.674 x width- 0.103) Gasket for Burndy Connector FTIL Part No. 790 0291 65 790 0291 25 790 0291 11 790 0291 45 790 0291 35 790 0291 75 790 0291 45 790 0291 85 790 0291 55 790 0292 05 790 0291 05 029 7190 00A 029 7150 00 029 7180 00 029 7130 00A 029 7120 00 029 7200 00 029 7015 00 029 7075 00 D & M Part No. RK-AB787-W27B RK-AB787-W40 RK-AB787-W39 RK-AB787-W27A RK-AB787-W28 RK-AB787-W29 RK-AB787-W36 RK-AB787-W37 RK-AB787-W41 RK-AB787-187 AB787-121 AB787-125 AB787-173 AB787-188 AB787-191 AB787-224 AB787-144 AB787-239 Qty 1 1 1 1 2 1 2 2 2 2 2 8 4 1 2 1 1 1 1
Page 30 of 40
2. Recommended Spare Parts List For Air Dryer of M/S Knorr Bremse (Knorr Design) (A) (Kit for Air Dryer fitted on Diesel & Electric Locomotives) Parts to be renewed in M-24 / Alternate AOH schedule S.N 1 Item Final Filter Element Dwg No I.4.3093 Qty 1
Parts to be renewed in M-48 / IOH schedule S.N Item 1 Desiccant (5.57 Kg/Vessel) POH Kit (55items) 1 Final Filter Element 2 Compression Spring 3 Compression Spring 4 Compression Spring 5 Compression Spring 6 Nut 7 Washer 8 Washer 9 Round Wire Netting 10 Sealing Ring 11 Sealing Ring 12 Sealing Ring 13 Sealing Ring 14 O-Ring 15 Compression Spring 16 Compression Spring 17 O-Ring 18 O-Ring 19 Spring Washer B12 20 Hexagon Nut 21 Spring Washer B06 22 O-Ring 23 Knorr-K-Ring 24 Retaining Ring 25 Washer 26 O-Ring 27 O-Ring 28 Toothed Ring 29 O-Ring 30 Scraper Ring
Part No 503328 I.4.3093 B 80465 C 59204 B 35531 B 82679 B95755/KI A33266 B70469/1/KI B27807 453783 453790 453807 456999 B24036 C65798 B85028 B21928 B21858 466059 468086 466058 A40125/20 454953 467044 450864 A40125/13 A52320 A62331/2 A91453 A97200/5
Qty 2 1 2 1 2 1 2 2 6 4 2 1 2 2 2 1 2 2 6 8 2 2 2 2 2 2 2 1 4 2 2
Page 31 of 40
31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55
O-ring Knorr-K-Ring Sealing Ring O-Ring O-Ring Venting Valve O-Ring O-Ring O-Ring O-Ring O-Ring Gasket Knorr-K-Ring Washer Locking Ring Washer 5.3 Hexagon Nut Locking Ring Washer Scraper Ring Knorr-K-Ring Retaining Ring O-Ring Valve Head Sealing Ring
B44910 462422 459633 A79532 B51209 I46367 A40791 A64261 A83273 B24149 B58177 B70667 462615 450862 466884 462326 466587 468204 468646 A97200/7 458906 464255 B55436 C87786 466686
2 2 1 2 2 1 2 1 1 1 2 1 1 2 4 3 1 3 1 2 2 2 4 2 2
(B) (Kit for Air Dryer fitted on DEMUs Parts to be renewed in Eighteen Monthly Schedule S.N 1 Item Final Filter Element Dwg No I.4.3093 Qty 1
Parts to be renewed in Every Alternate Eighteen Monthly Schedule S.N 1 2 3 4 5 Item Desiccant (5.57 Kg/Vessel) POH Kit (56items) Compression Spring Compression Spring Compression Spring Compression Spring Nut Part No 503328 B 80465 C 59204 B 35531 B 82679 B95755/KI Qty 2 2 1 2 1 2
Page 32 of 40
6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50
Washer Washer Round Wire Netting Sealing Ring Sealing Ring Sealing Ring Sealing Ring O-Ring Compression Spring Compression Spring O-Ring O-Ring Spring Washer B12 Hexagon Nut Spring Washer B06 O-Ring Knorr-K-Ring Retaining Ring Washer O-Ring O-Ring Toothed Ring O-Ring Scraper Ring O-ring Knorr-K-Ring Sealing Ring O-Ring O-Ring Venting Valve O-Ring O-Ring O-Ring O-Ring O-Ring Gasket Knorr-K-Ring Washer Locking Ring Washer 5.3 Hexagon Nut Locking Ring Washer Scraper Ring Knorr-K-Ring
A33266 B70469/1/KI B27807 453783 453790 453807 456999 B24036 C65798 B85028 B21928 B21858 466059 468086 466058 A40125/20 454953 467044 450864 A40125/13 A52320 A62331/2 A91453 A97200/5 B44910 462422 459633 A79532 B51209 I46367 A40791 A64261 A83273 B24149 B58177 B70667 462615 450862 466884 462326 466587 468204 468646 A97200/7 458906
2 6 4 2 1 2 2 2 1 2 2 6 8 2 2 2 2 2 2 2 1 4 2 2 2 2 1 2 2 1 2 1 1 1 2 1 1 2 4 3 1 3 1 2 2
Page 33 of 40
51 52 53 54 55 56
Retaining Ring O-Ring Valve Head Sealing Ring Compression Spring Knorr-K-Ring
464255 B55436 C87786 466686 A57201 454931
2 4 2 2 1 1
(C) (Kit for Air Dryer fitted on EMUs/MEMUs Parts to be renewed in POH schedule S.N 1 Item Final Filter Element Dwg No. I.4.3093 Qty 1
Parts to be renewed in Every Alternate POH schedule S.N Item 1 Desiccant (4 Kg/Vessel) POH Kit (48items) 1 Compression Spring 2 Compression Spring 3 Compression Spring 4 Compression Spring 5 Round Wire Netting 6 Sealing Ring 7 Sealing Ring 8 Sealing Ring 9 Sealing Ring 10 O-Ring 11 Compression Spring 12 Compression Spring 13 O-Ring 14 O-Ring 15 Spring Washer B12 16 Hexagon Nut 17 Spring Washer B06 18 O-Ring 19 Knorr-K-Ring 20 Retaining Ring 21 O-Ring 22 O-Ring 23 Toothed Ring
Part No 503328 B 80465 C 59204 B 35531 B 82679 B27807 453783 453790 453807 456999 B24036 C65798 B85028 B21928 B21858 466059 468086 466058 A40125/20 454953 467044 A40125/13 A52320 A62331/2
Qty 2 2 1 2 1 4 2 1 2 2 2 1 2 2 6 8 2 2 2 2 2 2 2 3
Page 34 of 40
24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
O-Ring Scraper Ring O-ring Knorr-K-Ring Sealing Ring O-Ring O-Ring O-Ring O-Ring O-Ring O-Ring O-Ring Gasket Knorr-K-Ring Locking Ring Locking Ring Scraper Ring Knorr-K-Ring Retaining Ring O-Ring Valve Head Sealing Ring Compression Spring Knorr-K-Ring Toothed Ring
A91453 A97200/5 B44910 462422 459633 A79532 B51209 A40791 A64261 A83273 B24149 B58177 B70667 462615 466884 468204 A97200/7 458906 464255 B55436 C87786 466686 A57201 454931 A62331/2
2 2 2 2 1 2 2 2 1 1 1 2 1 1 4 3 2 2 2 4 2 2 1 1 1
Page 35 of 40
3. Recommended Spare Parts List For Air Dryers of M/s Stone India Limited (Wabtec/Vaporid Design)
(A) (Kit for Air Dryer fitted on Diesel & Electric Locomotives) Parts to be renewed in M-12 / AOH schedule S.N 1 2 3 4 5 Item Filter Coalescing Nut 3/8 16 Hex Lock Washer 3/8 lock Self Sealing O Ring 4.237 I.D Kit Humidity Indicator Rebuild SIL Part No 653298 569374 6401300001 590013 304338 Qty 1 1 1 1 2
3.2 Parts to be renewed in M-48 / IOH schedule S.N 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. Item Filter Coalescing Nut 3/8 16 Hex Lock Washer 3/8 lock Self Sealing O Ring 4.237 I.D Kit Humidity Indicator Rebuild O Ring 2 OD O Ring 1/2 OD Check Valve Seal O Ring 1.739 I D Gasket Flange 1 Gasket Flange 3/8 O Ring 4.487 I.D O Ring 6 O.D Desiccant Element Solenoid Valve Repair Kit Drain Valve Repair Kit Purge Valve SIL Part No 653298 569374 6401300001 590013 304338 536582 524612 653292 593569 93986 93839 593572 304493 653510 653353 309112 309113 Qty 1 1 1 1 2 4 8 4 4 6 3 2 4 2 2 1 2
(B) (Kit for Air Dryer fitted on DEMUs) Parts to be renewed in Eighteen Monthly Schedule S.N 1 2 3 4 5 Item Filter Coalescing Nut 3/8 16 Hex Lock Washer 3/8 lock Self Sealing O Ring 4.237 I.D Kit Humidity Indicator Rebuild SIL Part No 653298 569374 6401300001 590013 304338 Qty 1 1 1 1 2
Page 36 of 40
Parts to be renewed in every alternate Eighteen Monthly Schedule S.N 1 2 3. 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Item Filter Coalescing Nut 3/8 16 Hex Lock Washer 3/8 lock Self Sealing O Ring 4.237 I.D Kit Humidity Indicator Rebuild O Ring 2 OD O Ring 1/2 OD Check Valve Seal O Ring 1.739 I D Gasket Flange 1 Gasket Flange 3/8 O Ring 4.487 I.D O Ring 6 O.D Desiccant Element Solenoid Valve Repair Kit Drain Valve Repair Kit Purge Valve SIL Part No 653298 569374 6401300001 590013 304338 536582 524612 653292 593569 93986 93839 593572 304493 653510 653353 309112 309113 Qty 1 1 1 1 2 4 8 4 4 6 3 2 4 2 2 1 2
(C) (Kit for Air Dryer fitted on EMUs/MEMUs) Parts to be renewed in POH schedule S.N 1 2 3 4 5 Item Filter Coalescing Nut 3/8 16 Hex Lock Washer 3/8 lock Self Sealing O Ring 4.237 I.D Kit Humidity Indicator Rebuild SIL Part No 653298 569374 6401300001 590013 304338 Qty 1 1 1 1 2
Parts to be renewed in every alternate POH schedule S.N 1 2 3. 4 5 6 7 Item Filter Coalescing Nut 3/8 16 Hex Lock Washer 3/8 lock Self Sealing O Ring 4.237 I.D Kit Humidity Indicator Rebuild O Ring 2 OD O Ring 1/2 OD SIL Part No 653298 569374 6401300001 590013 304338 536582 524612 Qty 1 1 1 1 2 4 8
Page 37 of 40
8 9 10 11 12 13 14 15 16 17
Check Valve Seal O Ring 1.739 I D Gasket Flange 1 Gasket Flange 3/8 O Ring 4.487 I.D O Ring 6 O.D Desiccant Element Solenoid Valve Repair Kit Drain Valve Repair Kit Purge Valve
653292 593569 93986 93839 593572 304493 653510 653353 309112 309113
4 4 6 3 2 4 2 2 1 2
Page 38 of 40
Schematic Diagram of Test Rack for testing of Air Dryer
Annexure-IV
dT1
P2
T1
P1
Air Dryer to atmosphere MR-2 with auto drain valve Dew Point Meter F-1 Flow Meter MR-1 with auto drain valve Compressed Air
Legends: F-1 Flow meter up to 6000 l.p.m F-2 Flow meter up to 600 l.p.m T1 Air dryer inlet temperature dT1 Air dryer outlet dew point temperature P1 Inlet pressure Gauge P2 Outlet pressure Gauge
F-2 Flow Meter
Reference: IS-11989-1986 Specification for compressed air dryers
Page 39of 40
Annexure-V
Inspection Report for Air dryer
Air Dryer S.No: Make : Design Air flow rate: 3000 l.p.m for Diesel Locomotives 2000 l.p.m for freight electric locomotive 1500 l.p.m for passenger electric locomotive 1200 l.p.m for EMU/MEMUs 1500 l.p.m for DEMUs Inlet air pressure: 10 kg/cm2 for Locomotives & 8 kg/cm2 for EMU/MEMUs & DEMUs S.No 1 Description Leakage test Soap test exterior surface of the air dryer, purge valve and all tube connections Drying, and regenerative cycle time. Pressure setting at the start of cycling operation of air dyer Pressure drop across the unit. Cyclic operation of air dryer at varying voltage range given below: 48-90 Volt D.C for diesel locomotive 85-130 Volt D.C for Electric locomotive, EMU/MEMUs & DEMUs Dew Point Depression (Inlet air dryer temperatureAir dryer Outlet dew point temperature) Standards No leakage Observation
2 3 4 5
60+5 seconds 7+0.5 kg/cm2 for FTIL& SIL 4.6+0.5 kg/cm2 for KBIL Not more then 3% of working pressure Drying, and regenerative time should be FTIL& SIL 60+5 seconds for diesel and electric locomotive application KBIL 60+5 seconds for diesel locomotive application 120+5 seconds for electric locomotives, EMU/MEMUs & DEMUs application Minimum 30 0C for nominal flow 3000 l.p.m for Diesel Locomotives 2000 l.p.m for freight electric locomotive 1500 l.p.m for passenger electric locomotive 1200 l.p.m for EMU/MEMUs 1500 l.p.m for DEMUs Minimum 15 0C for the worst case of air flow(6000 l.p.m. for diesel locomotives, 2000 l.p.m for passenger electric locomotives, 3000 l.p.m for freight electric locomotive, 2107 l.p.m.for DEMUs & 1320 lpm for EMU/MEMUs) and ambient temperature (up to 700C) Maximum 20% at design capacity
Purge Loss (purge loss measured by flow meter in l.p.m X 100/Design flow in l.p.m)
Page 40 of 40

HKKJR LJDKJ Jsy Ea Ky : Report No. MP - MI-18 REV. - 02, April - 2008

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HKKJR LJDKJ Jsy Ea Ky : Report No. MP - MI-18 REV. - 02, April - 2008

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Hkkjr ljdkj jsy ea=ky; GOVERENMENT OF INDIA MINISTRY OF RAILWAYS

Report No. MP.MI-18 REV. - 02, April - 2008

7. 8. 9. 10. 11. 12.

TROUBLE SHOOTING OF AIR DRYER ANNEXURE-I ANNEXURE-II ANNEXURE-III ANNEXURE-IV ANNEXURE-V

MP.MI-18 Rev. - 02, April-2008

MP.MI-18 Rev. - 02, April-2008

MP.MI-18 Rev. - 02, April-2008

MP.MI-18 Rev. - 02, April-2008

MP.MI-18 Rev. - 02, April-2008

MP.MI-18 Rev. - 02, April-2008

Schematic Diagram of FTIL Make Air Dryer

MP.MI-18 Rev. - 02, April-2008

Schematic Diagram of SIL Make Air Dryer

MP.MI-18 Rev. - 02, April-2008

Knorr-Bremse India, November 2004

Schematic Diagram of Knorr Bramse Make Air Dryer

MP.MI-18 Rev. - 02, April-2008

MP.MI-18 Rev. - 02, April-2008

- Compressor (Load/unload signal) +ve Supply Main - ve Supply

MP.MI-18 Rev. - 02, April-2008

- Compressor (Load/unload signal) +ve Supply Main - ve Supply

M-12 M-24 M-48 -

iii) IB iv) IC v) AOH

MP.MI-18 Rev. - 02, April-2008

Eighteen Monthly 18 months Schedule

MP.MI-18 Rev. - 02, April-2008

Items To Be Checked During Maintenance Schedules

(A) For Diesel Locomotives S.N Items to be checked Remarks

MP.MI-18 Rev. - 02, April-2008

Check electrical connection of air dryer and their tightness.

Knorr-Bremse air dryer 3. 4. Check Memory Feature

MP.MI-18 Rev. - 02, April-2008

MP.MI-18 Rev. - 02, April-2008

(B) For Electric Locomotives S.N Items to be checked Remarks

MP.MI-18 Rev. - 02, April-2008

Knorr-Bremse air dryer 3. Check Memory Feature

MP.MI-18 Rev. - 02, April-2008

(C) For EMUs /MEMUs S.N Items to be checked Remarks

MP.MI-18 Rev. - 02, April-2008

Knorr-Bremse air dryer 3. 4. Check Memory Feature

IC SCHEDULE 1. Repeat all the items of schedules.

Please see Annexure-III for list of items to be replaced.

Follow the instructions given in maintenance manual of respective manufacturers. -

(D) For DEMU S.N Items to be checked Remarks

Check the colour humidity indicator

condition of air after passing through air

Knorr-Bremse air dryer 3. Check Memory Feature

6. 6.1 6.2 6.3 6.4 6.5 6.6 6.7

MP.MI-18 Rev. - 02, April-2008

SYMPTOM Dryer not cycling.

No regenerating air from one or both of the tower purge valves.

MP.MI-18 Rev. - 02, April-2008

MP.MI-18 Rev. - 02, April-2008

MP.MI-18 Rev. - 02, April-2008

MP.MI-18 Rev. - 02, April-2008

MP.MI-18 Rev. - 02, April-2008

RK-AB787-187 AB787-121 AB787-125 AB787-173 AB787-188 AB787-191 AB787-224 AB787-144 AB787-239

MP.MI-18 Rev. - 02, April-2008

MP.MI-18 Rev. - 02, April-2008

MP.MI-18 Rev. - 02, April-2008

464255 B55436 C87786 466686 A57201 454931

MP.MI-18 Rev. - 02, April-2008

MP.MI-18 Rev. - 02, April-2008