Retrofit Locomotive Engine
Problem:
A Midwestern manufacturer was using a locomotive to transfer a highly conductive material in an environment where ambient temperatures commonly reached 130+ F. The average duty cycle of the generator and drive motors was 4-6 hours. The customer was spending over $1,000,000 / year in replacement generator and drive motor parts alone. A crew of three worked 7 days a week 10-12 hours per day removing and replacing failed components. The environment was such that a hydraulic drive system was considered as an option, but duty cycle was still a concern due to the environment.
Process:
- An exhaustive study of the application was done.
- The equipment was observed in operation and production and maintenance personnel were consulted.
- A system design was submitted and approved.
- Total cost < $200,000
- We consulted with customer maintenance personnel during installation and emphasized proper maintenance and troubleshooting of the system.
Results:
- Main drive components have been in operation over 25,000 (twenty-five thousand) hours of operation without replacement.
- Total maintenance cost of equipment is under $150,000 / year.
- There is no longer a dedicated crew of drive motor & generator replacement workers.