Handbook On Oil Cooling Blower (OCB) of Three Phase Eelectric Locomotive-May 2018

(For Official Use Only)
Hkkjr ljdkj GOVERNMENT OF INDIA

jsy ea=ky; MINISTRY OF RAILWAYS
End User : Maintenance Staff of 3 Phase

Electric Locomotives
CAMTECH/E/18-19/EP-2/OCB/Rev.0
May, 2018
egkjktiqj, Xokfy;j & 474 005

Maharajpur, GWALIOR - 474 005
HANDBOOK ON
OIL COOLING BLOWER (OCB) OF
THREE PHASE ELECTRIC
LOCOMOTIVE
QUALITY POLICY
“To develop safe, modern and

cost effective Railway
Technology complying with
Statutory and Regulatory
requirements, through
excellence in Research, Designs
and Standards and Continual
improvements in Quality
Management System to cater to
growing demand of passenger and
freight traffic on the railways”.
FOREWORD
During operation of the locomotive, the traction converter

and transformer assemblies produce a considerable amount of
heat. As excess heat adversely affects the performance of these
units, cooling is required to keep them operating at optimal
performance levels. Oil cooling blower supplies air to heat
exchanger unit to remove this excess heat from oil circulating
through the traction converter and transformer assemblies.
CAMTECH has prepared this hand book on Oil Cooling

Blower (OCB) of three phase electric locomotive to cover
general description and maintenance activities along with
testing with the objective to create awareness among the
maintenance personnel.
I hope this handbook will prove to be useful for the

staff working in electric loco sheds/ workshops maintaining
three phase locomotives.
CAMTECH, Gwalior Executive Director

Date : May, 2018
PREFACE
The traction converter and transformer assemblies of three

phase electric locomotive are cooled by circulating the oil
through heat exchanger unit and forced air is supplied by oil
cooling blower through heat exchanger unit to remove this
excess heat.
The continuous working of oil cooling blower is necessary for
safe and efficient running of locomotive which can be ensured
by proper maintenance.
CAMTECH has prepared this handbook on “Oil Cooling
Blower (OCB) of three phase electric locomotive” to
disseminate the knowledge among the maintenance personnel.
This handbook comprises technical data of OCB,
maintenance activities, and testing along with MUST CHECK
POINTS with useful standards.
It is clarified that this handbook does not supersede any
existing provisions laid down by Railway Board, RDSO or
Zonal Railways. This hand book is for guidance only and it is
not a statutory document.
I am sincerely thankful to all field personnel who helped us in
preparing this handbook.
Technological up-gradation & learning is a continuous
process. Please feel free to write to us for any addition/
modification in this handbook. We shall highly appreciate your
contribution in this direction.
CAMTECH, Gwalior (Peeyoosh Gupta)

Date: 24 May, 2018 Director/ Electrical
e-mailid: direlcamtech@gmail.com
CONTENTS
Sr.No. Description Page No.
Foreword iii
Preface iv
Content v
Correction Slip vii
1. INTRODUCTION 01
1.1 Technical Data 01
1.2 Tools & Special Tools 02
2. BEFORE-REMOVAL OF OCB FROM OPERATION 03
3. SPECIAL CHECK POINTS FOR O/H OF OCB 07
4. OPERATION CHART FOR OVERHAULING 11
i. Incoming testing. 11
ii. Remove the extended lead with flexible pipe 12
iii. Remove the impeller 13
iv. Remove the motor from dome 14
v. Remove terminal box 14
vi. Stripping of motor 14
vii. Stripping of rotor 14
viii. Clean the following parts 15
ix. Checking and attending of various part 16
x. Rotor balancing. 18
xi. Stator varnishing. 19
xii. Fitting of terminal box. 20
xiii. Testing of stator. 20
xiv. Motor assembly. 21
xv. Light run test 22
Sr.No. Description Page No.
xvi. Assembly of blower. 22

xvii. Load testing. 23
5. CHECK POINTS 25
6. RELIABILITY ACTION PLAN 29
FOR 3-PHASE LOCOMOTIVES
(Rev. ‘10’, May.’14)
7. MODEL QUESTIONS 33
8. ANSWERS 41
9. AN APPROACH TO EQUIPMENT FAILURE
INVESTIGATION 42
REFERENCE 44
ISSUE OF CORRECTION SLIP
The correction slips to be issued in future for this

handbook will be numbered as follows:
CAMTECH/E/18-19/EP-2/OCB /1.0/ C.S. # XX date---
Where “XX” is the serial number of the concerned

correction slip (starting from 01 onwards).
CORRECTION SLIPS ISSUED
Sr.No. Date of Page no. & Item Remarks

Issue no. modified
CAMTECH/E/18-19/ Loco OCB 1
1. INTRODUCTION
During operation of the locomotive, the traction

converter and transformer assemblies produce a
considerable amount of heat. As excess heat adversely
affects the performance of these units, cooling is
required to keep them operating at optimal performance
levels. To remove this heat, cooling oil is circulated
through the traction converter and transformer
assemblies. This oil is then passed through a heat
exchanger which removes excess heat. This oil cooling
unit draws air in through filter panels located in the
pantograph roof hatch. These filters remove impurities
and debris from the air. This debris is then removed
from the filter panels by the scavenge system.
1.1 TECHNICAL DATA
Oil Cooling Unit
Oil volume total 150L

Volume converter oil 78L
Volume transformer oil 72L
Weight empty 840kg
Painting Topcoat RAL 7030
stone gray silky 45±
5%
Test excess pressure 4 bar
converter oil
Test excess pressure 4 bar
transformer oil
Handbook on Oil Cooling Blower (OCB) May, 2018

of 3  Electric Locomotive
2 CAMTECH/E/18-19/3  Loco OCB
Oil Cooler Blower Fan Electric Meter

Type Three phase squirrel-cage motor
Motor model 200L55-RH2A
Voltage 3 x 415V ± 10%
Current 43A
Power supply Square wave (inverter operated)
Degree of protection IP54
Frequency 50Hz
Normal speed 2,930rpm
Output 25kW
Insulation class F
Weight 265kg
1.2 TOOLS & SPECIAL TOOLS

In addition to conventional railways workshop
tools and equipment, the following are also required for
the maintenance of oil cooling blower procedures
described in this chapter.
Cleaning grate, part 04.882.30.500, BHER Industrie

technik. Required for Oil Cooler Blower, refer to
Chapter 5, Oil Blower of Volume F10, and Suppliers
Documentation.
 A high pressure cleaner capable of delivering water
at 80 bar at 70 °C.
 An industrial grade vacuum cleaner.
 An external compressed air supply capable of
delivering air at 6 bar.
May, 2018 Handbook on Oil Cooling Blower (OCB)
 A suitable heating oven capable of fitting the oil

cooler and heating to 105-110°C.
 A fluid cleaning system with a filter with a mesh
size of 25 microns.
 A lifting eye-bolt suitable for attachment and lifting
of the fan wheel and motor.
1.3 BEFORE-REMOVAL OF OCB FROM

OPERATION
General
Isolate the locomotive electrical systems. Set the

„Oil Cooling‟ circuit breaker to the Off position. Circuit
breaker for the No.1 End is situated auxiliary circuits
cubicle-1(HB1) and circuit breaker for the No.2 End is
situated in auxiliary circuits cubicle-2 (HB2).
Set the “Traction Motor Blower and oil cooling

unit scavenge blower” circuit breaker to the Off
position. Circuit breaker for the No.1 End situated
auxiliary circuits cubicle-1 (HB1) and circuit breaker
for the No.2 End is situated in auxiliary circuits cubicle-
2 (HB2).
Set the “Oil pump converter” circuit breaker to

the Off position. Circuit breaker for the No.1 End
situated auxiliary circuits cubicle-1 (HB1) and circuit
breaker for the No.2 End is situated in auxiliary circuits
cubicle-2 (HB2).
Set the “Transformer oil pump” circuit breaker

to the Off position. Circuit breaker for the No.1 End is
situated auxiliary circuits cubicle-1 (HB1) and circuit
breaker for the No.2 End is situated in auxiliary circuits

cubicle-2 (HB2).
Oil cooler assembly

First drain the oil from the system. Disconnect
the oil cooling piping from between the transformer and
the oil cooler.
Disconnect the oil cooling piping from between
the traction converter and the oil cooler.
Removed oil cooler and blower assembly
 If necessary, remove the traction converter oil pump

from the cooler assembly.
 If necessary, remove the transformer oil expansion
tank from the cooler assembly.
 Disconnect the electrical harness from the outside of
the oil cooling unit.
 Unbolt the earth lead to the cooling unit

 Cut the cable ties securing the wiring to the looming

bar, then move cabling out of the way.
 Unbolt and remove the looming bar, if necessary.
 Remove the three bolts, spring and plain washers
along each side of the cooling assembly.
NOTE:
The oil must be sealed to prevent damage from

foreign materials. Seal the oil cooler opening using a
clean cardboard sheet and masking tape.
All oil flanges must be sealed with dummy
flanges before the oil cooler is moved to prevent the
ingress materials and any possible outflow of oil.
Lift the oil cooling unit from the locomotive
using suitable lifting equipment attached to the lifting
lugs. Take care not to damage any part of the assembly
or other machine room components during the removal
of the cooling unit assembly.
Blower fan and motor
The blower fan and motor may be removed

from the oil cooling assembly without removing the
assembly from the locomotive. Once the filter has been
removed, the fan and motor can be removed.

Oil cooler assembly
Oil cooler
may be unbolted and
removed from oil
cooler assembly if
required. This may
be required for the
oil cooler cleaning
procedures described
in section inspection
and repair.
 Remove the looming bars (3) if not removed

previously
 Attach suitable lifting equipment to the lifting lugs
(4)
 Remove the eight bolts, spring washers and
washers (5,6,7) securing the oil cooler assembly (1)
to the oil cooler (2)
 Lift the oil cooler assembly (1) from the oil cooler
(2)

2. SPECIAL CHECK POINTS FOR O/H OF OCB
Sr. Check point Standard

*. Incoming Sr.No./Make record
*. Outgoing Sr.No./Make record
1. Incoming test
a. IR value with 1 KV Meggar record
b. Check the bearing noise record
c. Any abnormality record
d. Vibration record
e. Any abnormal noise normal
f. Incoming run test parameter of VVVF
test plant at full speed for 10 minutes
a. Voltage record
b. Current record
c. Frequency record
d. Direction OK
2. a. Check the condition of terminal block OK
and connecting leads, overheating/
breakage of lugs & breakage of stand
near crimped portion.
Provision of transparent heat shrink
sleeve near lug.
3. Measure the shaft dia at bearing seat DE record
NDE
4. Measure the end cover bearing housing record
dia
DE,
NDE


5. Check the rotor bars and short circuiting done
end rings for any crack by means of
growler test as per SMI-163 & rotor
body looseness at shaft by sound test for
healthiness/ dullness.
6. Condition of key, keyway & shaft good/
threaded portion to be checked damage
7. I.R. value of stator with 1 KV meggar 10M
after baking (min.)
8. Baking of stator to be done before done
varnishing & after anti track
9. perform dielectric test on stator by stand for 1
applying 1.5 KV AC supply for 1 minute
minute
10. Measure the winding resistance between record
the phases
a. UV
b. VW
c. WV
11. Surge comparison test on stator at 2KV Wave form
for old, SKV for new matched
12. Bearing details:-
a. Check the bearing as per SMI- done
16,23,79 & 148
b. SPM reading to be recorded as per record
SMI-58
c. New bearing provided Monthly/ done
year should be inscribed
d. Detail of the grease used in bearing GHY-72
e. Record bearing make DE & NDE record
side


13. Light run test parameter at VVVF test
plant at full speed for 10 minute
a. Voltage record
b. Current record
c. Frequency record
d. Speed record
e. Direction OK
f. Bearing Noise DE record
NDE
g. Check for free run No abnormality
14. a. Check visually dome for any crack No crack
& damage No damage
No deformation
b. Check impeller for any crack by No crack healthy
RDPT test & also check the sound
impeller blades for any dull sound
by ring test
15. Check the alignment of impeller with Alignment is
respect to cone poor
16. Check the tightness of locking bolt & Properly
plate securing the impeller tightened/ locked
17. Check for any abnormal noise during Normal noise.
starting & running
18. RTV compound is to be applied at Applied
every joint & terminal connection box
19. Load run test parameter at VVVF test
plant at 3 stages
a. Voltage record
b. Current record
c. Frequency record
d. Speed record
e. Direction OK
f. Bearing Noise Normal

20. a. Check the blower assembly for Balancing done
balancing by portable balancer (Limit 40 cu/sec.)
21. Check the blower assembly 5mm/ sec (Max.)

vibration level by SKF vibration
pen
22. Winding scheme for oil cooling Followed

blower of 3 phase loco as per SMI -
0239
23. Any other remarks

3. OPERATION CHART FOR OVERHAULING
i. Incoming testing.
a. Shift the OCB from pallet to

the working place.
b. Remove OCB dome

inspection cover
c. Remove terminal box cover

from OCB dome.
d. Test winding insulation resistance both.
i. In between windings and
ii. Between earlier body and winding by 1 KV
meggar.
e. Check the free movement of impeller by hand.

f. Put OCB on test bench
g. Connect the 3 phase VVVF supply to terminal and

start from zero speed and check the
h. Check the equipment various parameters at different

stages of speed like frequency, current, voltage,
bearing noise, vibration and any other abnormalities.
i. Check visually for any defects and deficiencies.
j. Remove 3-phase supply.

ii. Remove the extended lead with flexible pipe
a. Remove extended lead

connection from dome
terminal box.
b. Remove dome terminal box.

c. Remove clamp from flexible pipe.
d. Remove extended lead connection from motor terminal

box.
e. Remove motor terminal box cover.
iii. Remove the impeller.
a. Put the OCB from test bench to working place.

b. Remove the top cone.
c. Remove the bottom cone.
d. Put the OCB in horizontal condition with the help of
crane.
e. Remove the locking bolt with locking plate of impeller.
f. Fit the hydraulic puller and remove the impeller with
key

iv. Remove the motor from dome
a. Unscrew the 4 nos. bolt with

washer of motor foundation.
b. Remove the motor from
dome by crane.
v. Remove terminal box
a. Remove the lead connection

b. Remove the SB
c. Remove terminal box
vi. Stripping of motor
a. Place the motor in horizontal

condition
b. Unscrew the hex. hd. Screw

of end cover of DE side.
c. Remove DE side end cover.
d. Unscrew the hex. hd. Screw of end cover of NDE side.
e. Remove NDE side end cover.
vii. Stripping of rotor

a. Remove circlip from NDE side rotor shaft.
b. Remove bearing from both sides by 3 leg puller.
c. Remove inside grease cap from both sides.
d. Remove rotor from stator
viii. Clean the following parts
a) Dome b) Cone
c) Dome Impeller
d) Rotor

e) Stator
f) End covers
g) Terminal box and other parts.
ix. Checking and attending of various part
a. Check the dome for any

defect and damages and
repaired if required.
b. Check the cone for any

defect and damages and
repaired if required.
c. Checking and repairing of

dome inspection cover.
d. Measure the shaft dia of

bearing seat.
e. Measure the bearing housing dia of end covers.
f. Checking attending/ replacement of damage parts of

terminal box.
g. Prepare the rubber gasket.

h. Check attending/replacement of damaged part of terminal

box.
i. Replace rubber gasket of

various part
j. Check the impeller after cleaning for DPT and MPT test.
k. Paint the following parts.
a) Dome
b) Cone
c) Stator from out side
d) End covers
e) Terminal box and other parts.

x. Rotor balancing.
a. Check the rotor bars for any crack with the help of
growler test.
b. Fit the impeller on shaft.
c. Fit the attachment to the shaft for making it suitable

to fit on the balancing machine.
d. Send rotor with impeller for balancing.

e. Load the impeller on balancing machine with the
help of crane.
f. Rotate at specified speed.
g. Note the balancing weight value and location.
h. Repair the balancing weight and fit the balancing
weight at appropriate location.
i. Re-rotate and check the balancing position.
j. Repeat the above process if required.
k. Get it certified by inspection and unloaded it from
balancing machine.
l. Bring in assembly shop.
m. Remove attachment from shaft.
n. Remove impeller.
o. Paint the impeller.
xi. Stator varnishing.

a. Put stator into oven for
backing.
b. Remove stator after

backing.
c. Apply varnish to stator
winding.

d. Put stator into oven for backing.

e. Remove stator after backing.
f. Clean extra varnish.
g. Clean the threaded portion of stator.
xii. Fitting of terminal box.

a. Fitting of terminal box with backside gasket.
b. Fitting of SB.
c. Tinning of short link and lugs.
d. Connection of connecting lead on SB.
xiii. Testing of stator.
a. Bring the stator and do connection for HV test.
b. Remove connection after HV test.
c. Bring stator in surge testing both and connect the
leads to do surge testing.
d. Disconnect the connection and shift the stator on
work bench.
e. Measure the winding resistance of all 3-phase with
the help of W stone bridge.
f. Measure the insulation resistance with 1 KV
megger.

xiv. Motor assembly.
a. Insert the rotor into the stator.
b. Check the bearing clearance.

c. Inscribed the date on new bearing.
d. Heat the bearings by induction heating.
e. Fit the bearings on both side of shaft with shims.
f. Provide the specific quantity of grease into the
bearing.
g. Provide the circlip to the

shaft in front of bearing.
h. Fit both side end covers.

i. Fit grease nipples.
xv. Light run test.
a. Check the insulation resistance by 1 KV meggar.

b. Connect the 3-phase VVVF supply to motor
terminal.
c. Run the motor at various speeds and record the
parameters.
d. Check for any abnormal noise.
e. Check the vibration.
f. Measure the bearing noise by dBN meter.
g. Check the bearing temp. rise.
xvi. Assembly of blower.

a. Place the dome in vertical position.

b. Place the motor in the bracket in dome with the
help of crane.
c. Fit the motor in dome.
d. Fit the key on shaft.
e. Fit the impeller duly balanced on motor shaft if
crank fit new impeller.
f. Fit the locking bolt with locking plate.
g. Fit both the cranes.

h. Fit the flexible pipe with extended loads.
i. Clamp the flexible pipe.
j. Fit the insp. cover of dome with gasket.
xvii. Load testing.
a. Lift the blower assembly and

put on test bench.
b. Connect the 3-phase VVVF
supply to the motor terminal.
c. Run the motor at full speed.
d. Check the bearing noise by
SPM.

e. Check the following parameters at different speed

i.e. 1000, 2000 & full speed.
a) Voltage b) Current c) Frequency, air flow
by anemometer.
f. Check the temperature rise of bearing after 2 hrs.

load run test.
g. Check the vibration by portable balancing machine.
h. Check for any

abnormal noise &
vibration.
i. Offer the inspection staff for checking.

j. Attend the bookings offered by inspection staff.
k. Disconnect the power supply from terminal box.
l. Fit the terminal box cover.
m. Fit the extended leads on dome with terminal box.
n. Write the equipment No. Loco No. and location of
equipment on blower assembly.

4. CHECK POINTS :
Auxiliary Rewinding of all auxiliary motors except

motors MRB/SCMRB by corona resistant wire. (Ref.
EL/2.2.8/17 dt 14/08/08)
All new motors procurement except
MRB/SCMRB from indigenous sources must
be with corona resistant wire only. ( Ref.
Amendment 3 to spec no E-10/3/09 (motor)-
Aug‟ 1997 issued vide EL/3.2.176/1 dt
28/1/09)
Replace MS impeller with Aluminum impeller.(
Ref. CLW‟s letter no ELDD/3743/CRH dated
08/05/09. For OCB).
Replacement of 10 mm2 cable type 4GKW-AX
(cable no.1147,1148 & 1149) of oil cooling unit
with 16 mm2 cable type 4GKW-AX to improve
the reliability of three phase loco.
(RDSO/2011/EL/MS/0395, Rev.‟0‟ dated
28.02.2011)
Other Air delivery measurement in 3-phase electric
locomotive to ascertain proper cooling and
pressurization of machine room .(EL/SMI
/0255 Rev.-0 date 06.05.2009)
Motors Ensure replacement of all must change items
during MOH, IOH & POH as per guidelines.(
Ref. EL/3.1.35/16 dated 30/03/2007).
Procedure for rewinding of auxiliary motors.(
Ref. RDSO/ELRS/ SMI/3 (Rev.‟1‟) issued
vide letter no. EL/3.2.70 dated 30.11.2000).

Procedure for connecting the lead wire with the

stator winding wires of auxiliary motors.( Ref.
RDSO/ELRS/ SMI/5 issued vide letter no.
EL/3.2.70/D4 dated 21.12.1977).
Fits and limits on bearings Of auxiliary motors
used on Electric locomotives. (Ref.
RDSO/ELRS/SMI/16 issued vide letter no.
EL/2.2.48/J2 dated 3.5.1978).
Procedure for measuring the bearing clearances
of a “free bearing” that is a bearing off the
machine( Ref. RDSO/ELRS/SMI/23 issued
vide letter no. EL/2.2.48/J2 dated 7.5.1978).
Procedure for fixing the socket with the lead
wires of auxiliary motor stator Winding. (Ref.
EL/3.2.70/J2 dated 21.11.1978).
Conditioning monitoring of bearing.( Ref.
SMI/58 issued vide letter no. EL/8.11.12/DB3,
dated 20.07.1979).
Fitment of outer race of bearing in the bearing
housing.(Ref. RDSO/ELRS/SMI/78 issued vide
letter no. EL/2.2.48 dated 2.5.1981).
Testing/checking of new bearings for Auxiliary
motors .( Ref. RDSO/ELRS/SMI/79 issued vide
Procedure for impregnation of stator auxiliary
motors.( Ref. RDSO/ELRS/SMI/86 (Rev.1)
issued vide letter no. EL/3.2.70 dated
29.11.2000).

Hard chrome plating of bearing/housing shafts

of auxiliary machines.( Ref. SMI/94 issued vide
letter no. EL/3.2.48/JTMU, dated 15.10.1982).
Use of button type of grease nipple on auxiliary
motors fitted on Electric loco. (Ref.
EL/3.2.70/J3 dated 30.10.1992).
Guidelines to identify genuine and spurious/
reconditioned bearings.( Ref.
EL/2.2.48 dated 21.10.1992).
Special instruction for surge test on 3 phase AC
auxiliary motors.( Ref. RDSO/ELRS/SMI/149
issued vide letter no. EL/3.2.70 dated
Oct.‟92).
General guidelines to follow for balancing of
rotor and blower impellers.( Ref.
EL/3.2.70/J3 dated 15.12.1992).
Characteristic properties of enamel used on
enameled winding wires.(Ref.
RDSO/ELRS/SMI/153 (Revised April‟98)
issued vide letter no. EL/2.2.8/4 dated
20.04.1998).
Special instructions for essential requirements
of facilities to rewind 3 phase AC auxiliary
motors in loco sheds and rewinding shops.( Ref.
EL/3.2.70 dated 22.04.1993.

Rewinding material for auxiliary motors.( Ref.

RDSO/ELRS/ SMI/185(Rev. „1‟) with Amend
1 &2 issued vide letter no. EL/3.2.70
30/10/2000, 28/12/2000, 15/03/2001).
General guidelines to follow for balancing of
rotors and cooling blower impellers in
position.( Ref. RDSO/ELRS/SMI/199 issued
vide letter no. EL/3.2.70 dated 01.04.1998).
Characteristic properties of impregnating resins
and insulating varnishes (Superseding SMI154).
(Ref. RDSO/ELRS/SMI/200 (Revised) issued
vide letter no. EL/2.2.8.4 dated 30.12.1999).
Special Instruction for essential requirements of
facilities to rewind 3-Phase AC Auxiliary
Motors used in Electric Locomotives in Loco
Sheds and rewinding shops. ( Ref.
RDSO/ELRS/SMI/222, Rev.„0‟ issued vide

5. RELIABILITY ACTION PLAN

FOR 3-PHASE LOCOMOTIVES (Rev. ‘10’, May.’14)
a All Auxiliary Blower and Motors- Visually check

the oil cooler radiator for any oil leakage/external
damage.
i. Check all the auxiliary motors for any abnormal
sound and proper functioning.
ii. Measure the current of all auxiliary motors
iii. Visual examination / RDPT of impeller of OCB.
iv. Check tightness of foundation bolts of all
auxiliary motors.
v. Check the electrical connections of all auxiliary
motors.
vi. Check the condition of all flexible hoses
connected with various auxiliary blowers and
replace, if required.
vii. Check tightness of SB and cable connections at
terminal box.
viii. Greasing of all motors with recommended grease
ix. Ensure that the terminal covers of various
auxiliary motors are intact and water tight.
Special attention needs to be given to main
compressor motor cable layout and water
tightness of its entry point into the motor terminal.

b. Oil Cooling Piping

Replace the 'O' rings in the main transformer and main
converter oil pipes.
c. Oil Cooler Radiator
Examine flange joint for sign of cracks, oil leakage and
loose/missing screws.
Vacuum clean the radiator chamber via the machine
room access cover and then clean the radiator by high
pressure hot water jet. Check that the radiator is not
blocked.
d. Oil Cooler Blower
Remove and clean the oil cooler blower filter duct.
Remove all traces of dirt, duct and debris.
Clean the oil cooler blower fan impeller. Remove all
traces of dirt, dust and debris.
Remove the air cone from the oil cooler blower filter
panel. Remove all dirt, debris and obstructions.
Check for abnormal noise and measure vibration level
on OCB before and after inspection.
Air velocity measurement of OCB to be taken before
and after inspection.
Conduct RDPT of Impeller and check for unbalancing
Replace the Impeller of oil cooler blower
Check the condition of Rubber bellows of OCB duct to
TM Scavenger Blower. If damaged, replace it.

Check the condition of roof filter & OCB duct gasket

if damaged - replaced
Check the condition of rubber hosepipe and clamps.

Replace if damaged. Check the tightness of clamps.
Check the condition of the filter screen, inspect for

cracks or damage. Rectify any faults found.
Check the security of the bolts around the duct flanges.

Check all flanges on the ducting for cracks around the
hoses. Rectify any fault found.
Remove any build up of dirt and foreign material from

around the filter screen.
e. Oil Cooler Blower Motor
Checking of bearing condition by SPM/Noise and

changing on condition basis
Overhaul the oil cooler blower motor. Replace the

bearings along with associate components & grease.
Remove all dust and dirt from motor body using a

vacuum cleaner and soft non- metallic brush.
Conduct RDPT of motor foundation brackets.
Securing of motors cables.
Check Current & Voltage of OCB Motor

f. Oil Cooler Blower Seals
Replace the seals between the oil cooler blower & the
filter duct, between the oil cooler blower filter & the
pantograph roof hatch on the oil cooler blower unit,
between the oil cooler blower & machine room floor,
on the oil cooler blower filter & ducting and on the oil
cooler blower inspection door (WAP5/WAP7)
Replace the seals between the oil cooler blower & the
filter duct, between the oil cooler blower filter & the
pantograph roof hatch on the oil cooler blower unit,
between the oil cooler blower & machine room floor,
on the oil cooler blower filter & ducting and on the oil
cooler blower inspection door (WAG9/ WAG9H)
Check the seal between the filter screen and

pantograph roof hatch. If necessary conduct a water
test. Replace the seal if any leakage occurs.

6. MODEL QUESTIONS
OBJECTIVE
1. Before starting work on faulty circuit it should be ensured
that
a. The faulty circuit has been isolated from power supply
and earthed.
b. The worker is capable to do the work.
c. The connections are not approachable.
d. None of the above.
2. One can protect himself from electric shock by wearing

hand gloves of good.
a. Conducting material
b. Insulating material
c. Semiconductor material
d. Any of the above.
3. Which of the following are safety precautions?

a. Don‟t touch live wire or equipment with bare hands.
b. Before switching on DJ, see no one is working inside
loco.
c. Use insulated meting and hand gloves.
d. All of the above.

4. Which material is recommended as fire extinguisher in

electrical cases?
a. Carbon tetra chloride
b. Carbon dioxide
c. Sulphur hexafluoride
d. Any of the above.
5. The BDV of transformer oil should be

a. 20kV
b. 30kV
c. 40kV
d. 50kV
6. The colour of moisturized silica gel is
a. Pink
b. Blue
c. Yellow
d. Green
7. Which of the following is not the function of transformer
oil
a. Cooling of winding and core.
b. Providing additional insulation
c. Media for are quenching
d. Provides inducting coupling
8. Transformer oil should be free from

a. Odour
b. Gases
c. Temperature
d. Moisture

9. Dielectric strength of oil should be performed using

12.5 mm ball electrodes with a gap of-
a. 04mm
b. 05mm
c. 2.5mm
d. 03mm
FILL IN THE BLANKS
1. Transformer is a ………….device
2. WAG-9 Loco transformer has…………….windings
3. WAG-9 Loco transformer has………………..tank
4. WAG-9 Loco Required variable voltage is achieved by
the use of ……….………….
5. An emf induced in a coil due to variation of flux in
another coil is called……
6. The coils of a transformer are wound on a …………core
of ………….material
7. The conductors used in HV and LV windings of loco
transformer are…………
8. In WAG-9 Loco The primary side is protected from the
voltage surges by means of ………….placed on the roof
of the locomotive.
9. The auxiliary winding is protected from sudden rises in
voltage by means of ………………connected across the
winding.

10. Ingress of moisture is prevented by means of

…………….
11. The complete cooling arrangement includes………..,
………..and…………..
12. The oil pump and the cooler are connected to the
conservator and radiator by…………………
13. The breather is attached to ………………and
contains……………
14. Pink colour of silica gel indicates……………..
15. The colour of transformer oil become dark brown, it
indicates presence of …… ……
16. Operating vacuum of transformer oil purification plant
should be ………….
17. DGA stands for …………………..
18. Transformer must never be lift without its……………….
19. Oil BDV Test six consecutive reading should not lie
more than……
20. The lifting ropes should not make a smaller angle
then….with the horizontal.
SAY ‘TRUE’ OR ‘FALSE’
1. Transformer transforms power from one AC circuit to

another AC circuit, at same frequency.
2. Transformer can raise or lower the voltage.
3. Transformer can raise or lower the frequency.
4. Two circuits in a transformer linked by a common

magnetic flux through a path of low reluctance.
5. In case of step up transformer, the transformation ratio
will be more than one.
6. Constructional features of a loco transformer are more or
less same other power transformer.
7. 25 kV condenser/ cable head bushing is mounted on the
top of the tank cover.
8. The cooling arrangement of the loco transformer is
force oil forced air type.
9. In G-9 Loco the complete cooling equipment is
mounted on the cover of the loco transformer.
10. In G-9 Loco spring-loaded safety valve is fitted to the
top of the conservator.
11. Presence of moisture in transformer oil is highly
desirable.
12. The oxygen present in transformer reacts with
insulation and forms an organic acid.
13. The solid impurities present in insulation oil strengthen
its dielectric strength as well as insulation of windings.
14. The slackness of winding is desirable factor to create
electrical and magnetic unbalance of the coils.
15. Meggering is done to check the insulation resistance of
the windings.
16. The tightening torque of the bolts of tank and lid must
be 70 Nm.
17. To arrest the oil leakage from bushing RDSO has
recommended to use ISI make gaskets.
18. Bushing gaskets to be replaced as per TC- 076.
19. New M.S. hardware may be used in transformer flange

joints fitting.
20. Periodic maintenance of transformer is essential to
ensure safety, reliability and trouble free operation of
Locomotives.

Electrical GK QB
21. For the protection of single-phase 1.5 kW motor, a MCB of
____ rating should be provided
(a) 10 A (b) 16 A (c) 32 A (d) 63 A
22. The low power factor results in
(a) Increased losses
(b) Decreased losses
(c) No effect on losses
(d) Better generating efficiency
23. Low power factor
(a) Aids the voltage regulation
(b) Increase the voltage regulation
(c) Decrease the voltage regulation
(d) None of the above
24. The power factor of the AC supply can be improved by using
(a) Synchronous generator
(b) Universal motor
(c) Synchronous condenser
(d) SCR
25. A distribution line of 440 V is classified as
(a) LV (b) MV (c) HV (d) EHV
26. Which of the following reduces the power factor
(a) Motor on no load
(b) Tube lights
(c) Fans
(d) All of the above
27. Unit of energy is
a) Kilo volt hours
b) Kilo watt hours
c) Kilo watt
28. As per Ohm‟s law
a) V= IR
b) V= I/R
c) R= VxI
29. Unit of resistance is
a) Ampere
b) Volts
c) Ohm
30. In three phase 415 volts 50 Hz supply, the phase to phase

voltage is
a) 220 Volts
b) 415 volts
c) 440 volts
31. In three phase 415 volts 50 Hz supply, the phase to neutral

voltage is
a) 220 volts b) 230 volts c) 440 volts
32. In 4 sq. mm PVC wire, 4 sq. mm stand for
a) Thickness of wire
b) Length of wire
c) The area of thickness of wire
33. 10 hours use of 500 watt Motor will consume the energy
a) 10 units b) 20 units c) 5 units
34. No. of poles in MCB/TPN is
a) 2 poles b) 4 poles c) 3 poles

7. ANSWERS
Model Question
1 (a), 2 (b), 3 (d), 4 (b), 5 (d), 6 (a), 7 (d), 8 (a), 9 (c).
Fill In the Blanks
1. Static, 2. 04,
3. Aluminium Alloy, 4. GTO or IGBT,
5. Metual Induction, 6. Laminated, Silicon Steel,
7. Continuous Transposed Cu Conductor,
8. Lightening arrester, 9. RCL Damping,
10. Air dehumidifire, 11. Radiator & Blower,
12. Oil Pipe, 13. Conservator, Silicagel,
14. Humid 15. Acid & Impurties,
16. 1Torr, 17. Incipien fault,
18. Lid, 19. 15%,
20. 60°.
True or False
(1)-T, (2)-T, (3)-F, (4)-T, (5)-T, (6)-T, (7)-T,
(8)-T, (9)-F, (10)-F, (11)-F, (12)-T, (13)-F, (14)-T,
(15)-T, (16)-T, (17)-F, (18)-T, (19)-F, (20)-T.
Electrical (G.K.)
21-a, 22-a, 23-c, 24-c, 25-a 26-d, 27-b, 28-a,
29-c, 30-b, 31-a, 32-c, 33-c, 34-b,

8. AN APPROACH TO EQUIPMENT
FAILURE INVESTIGATION
A. On Failure Aspects
1. Occurrence
2. Date of occurrence
3. Past similar occurrences if any
4. Analysis of failure i.e. why did it happen?
5. Whether the rate of failure is worse than other
installations?
B. On Maintenance Aspects
1. Whether schedule maintenance & required testing
have been carried out on the failed equipment as
per norms stipulated?
2. Does the frequency of maintenance require
change?
3. Was the work properly supervised?
4. Was any RDSO modification required to be done?
5. Is any modification possible to avoid failure?
C. About Staff
1. Is the quality of work done satisfactorily?
2. Is the skilled staff properly trained to carry out the
work?
3. Is the SMI available with them?
4. Are proper tools available with the staff?

D. About Material
1. Is the material received from approved source?
2. Whether the material is as per approved
specification?
3. Can a better material be used?
E. About Testing
1. Is the testing equipment available?
2. Could testing procedure be improved to weed out the
failures?
3. Whether testing equipment are calibrated?
F. General Points
Whether following points were checked / performed
properly?
1. Proper contact
2. Clearances
3. Capacity
4. Proper contact pressure
5. Crack detections
6. Cleaning
7. Proper connections/alignment
8. Cross checks/super checks

REFERENCE
1. ABB Maintenance manual.
2. Electrical Technology Books.
3. RDSO/SMI-
3,5,16,23,32,58,78,79,86,94,147,148,149,152,
153,155,163,185,199,200,222,239,255.
4. RDSO MS 0360,395.
5. Details collected from various field units (Shed

and workshop).
6. Suggestions received during the seminar held

on 23.04.2018 organised by CAMTECH/
Gwalior.

OUR OBJECTIVE
To upgrade maintenance technologies and
methodologies and achieve improvement in
productivity and performance of all Railway assets
and manpower which inter-alia would cover
reliability, availability, utilisation and efficiency.
CAMTECH is continuing its efforts in the documentation and up-gradation

of information on maintenance practices of electrical assets. Over the years
a large number of publications on electrical assets have been prepared in the
form of handbooks, pockets books, pamphlets & video films etc. These
publications have been uploaded on the internet as well as rail net.
For downloading these publications please do following:
1. On internet visit : www.rdso.indianrailways.gov.in
Go to Directorates  CAMTECH  Publications for download
Electrical Engineering
2. On Railnet visit RDSO website at 10.100.2.19
Go to Directorates  CAMTECH  Publications for download 
Electrical Engineering Year wise/ Subject wise
For any further information regarding publications please contact:
Director (Elect.) – 0751- 2470740 (O) BSNL, 9752447030 (CUG)
SSE/Electrical - 9755549297 (CUG)
E-mail at direlcamtech@gmail.com
Fax to 0751- 2470841
Write at : Director (Electrical)
Indian Railways
Centre for Advanced Maintenance technology,
In front of Hotel Adityaz,
Airport Road, Maharajpur,
Gwalior, Pin code – 474 005


Handbook On Oil Cooling Blower (OCB) of Three Phase Eelectric Locomotive-May 2018

Uploaded by

Copyright:

Available Formats

Handbook On Oil Cooling Blower (OCB) of Three Phase Eelectric Locomotive-May 2018

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Handbook On Oil Cooling Blower (OCB) of Three Phase Eelectric Locomotive-May 2018

Uploaded by

Copyright:

Available Formats

(For Official Use Only)

Hkkjr ljdkj GOVERNMENT OF INDIA

End User : Maintenance Staff of 3 Phase

egkjktiqj, Xokfy;j & 474 005

“To develop safe, modern and

During operation of the locomotive, the traction converter

CAMTECH has prepared this hand book on Oil Cooling

I hope this handbook will prove to be useful for the

CAMTECH, Gwalior Executive Director

The traction converter and transformer assemblies of three

CAMTECH, Gwalior (Peeyoosh Gupta)

xvi. Assembly of blower. 22

The correction slips to be issued in future for this

CAMTECH/E/18-19/EP-2/OCB /1.0/ C.S. # XX date---

Where “XX” is the serial number of the concerned

CORRECTION SLIPS ISSUED

Sr.No. Date of Page no. & Item Remarks

During operation of the locomotive, the traction

1.1 TECHNICAL DATA

Oil Cooling Unit

Oil volume total 150L

Handbook on Oil Cooling Blower (OCB) May, 2018

Oil Cooler Blower Fan Electric Meter

1.2 TOOLS & SPECIAL TOOLS

Cleaning grate, part 04.882.30.500, BHER Industrie

 A suitable heating oven capable of fitting the oil

1.3 BEFORE-REMOVAL OF OCB FROM

Isolate the locomotive electrical systems. Set the

Set the “Traction Motor Blower and oil cooling

Set the “Oil pump converter” circuit breaker to

Set the “Transformer oil pump” circuit breaker

breaker for the No.2 End is situated in auxiliary circuits

Oil cooler assembly

 If necessary, remove the traction converter oil pump

May, 2018 Handbook on Oil Cooling Blower (OCB)

 Cut the cable ties securing the wiring to the looming

The oil must be sealed to prevent damage from

Blower fan and motor

The blower fan and motor may be removed

Handbook on Oil Cooling Blower (OCB) May, 2018

Oil cooler assembly

 Remove the looming bars (3) if not removed

May, 2018 Handbook on Oil Cooling Blower (OCB)

2. SPECIAL CHECK POINTS FOR O/H OF OCB

Sr. Check point Standard

Handbook on Oil Cooling Blower (OCB) May, 2018

Sr. Check point Standard

May, 2018 Handbook on Oil Cooling Blower (OCB)

Sr. Check point Standard

Sr. Check point Standard

21. Check the blower assembly 5mm/ sec (Max.)

22. Winding scheme for oil cooling Followed

23. Any other remarks

May, 2018 Handbook on Oil Cooling Blower (OCB)

3. OPERATION CHART FOR OVERHAULING

a. Shift the OCB from pallet to

b. Remove OCB dome

c. Remove terminal box cover