reliability improvement of the KTX Mu-Jeong, SON Manager, KORAIL, - - PowerPoint PPT Presentation

Contributing factors in reliability improvement of the KTX

Mu-Jeong, SON Manager, KORAIL, KOREA Tuesday, 7th July, 2015 Session : 2B - Technical Specifications -

Content

• Ⅰ. General information of Korea high-speed railway
• Ⅱ. Factors in reliability improvement of the KTX
• Upgrading the maintenance technique
• Utilization of the cutting-edge IT infra
• Engineering modifications and revision of the manuals
• Ⅲ. The effect of reliability improvement of the KTX
• Ⅳ. Conclusion

2 Mu-Jeong, SON Manager, KORAIL, KOREA Tuesday, 7th July, 2015, Session : 2B - Technical Specifications –

High-speed railway network(KOREA)

• Gyeongbu High-Speed Line
• Route : Seoul-Busan
• Length : 423.8 km
• Travel time : 2h30m
• Commencement : 2004.04.01.

3

• Honam High-Speed Line
• Route : Osong-Gwangjusongjeong
• Length : 183.8 km
• Travel time : 1h 5m
• Commencement : 2015.04.02.

Mu-Jeong, SON Manager, KORAIL, KOREA Tuesday, 7th July, 2015, Session : 2B - Technical Specifications –

Type of high-speed trains in Korea

4

Classification KTX KTX-Sanchoen(Ⅰ) KTX-Sanchoen(Ⅱ)

Appearance Manufacturer

ALSTOM(France) Hyundai-Rotem(Korea) Hyundai-Rotem(Korea)

Maximum Speed(km/h)

300 300 300

Number of trainset

46 24 22

Number of seats

931 363 410

In operation since(year)

2004 2010 2015

Gauge(mm)

1435 1435 1435

Body material

Mild steel Aluminum Aluminum

signal

ATC/ATP/ATS ATC/ATP/ATS ATC/ATP/ATS

Unit composition

Power car : 2 Passenger car(motorized) : 2 Passenger car : 16 Total : 20 cars Power car : 2 Passenger car : 8 Total : 10 cars Power car : 2 Passenger car : 8 Total : 10 cars

Mu-Jeong, SON Manager, KORAIL, KOREA Tuesday, 7th July, 2015, Session : 2B - Technical Specifications –

Annual KTX failure rate

5

0,3 0,6 0,9 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014

KTX KTX-Sancheon

(Case/1million Car-km)

• What is the major factors in the reliability improvement of KTX

and KTX-Sancheon?

Mu-Jeong, SON Manager, KORAIL, KOREA Tuesday, 7th July, 2015, Session : 2B - Technical Specifications –

Upgrading the maintenance technique

• Using the Electronic Endoscope

6 Mu-Jeong, Son - Manager, KORAIL, KOREA - 7 July - Session: Technical Specifications No.203

Check the Gear Surface Check the wiring Equipment setting Verifying surface Equipment setting Finding disconnection

• Using X-ray spectrometer
• Check the amount of iron in gear oil
• Determine when to replace the gear oil
• Determine when to replace the gear box

Mu-Jeong, SON Manager, KORAIL, KOREA Tuesday, 7th July, 2015, Session : 2B - Technical Specifications –

Upgrading the maintenance technique

• Expand the Ultrasonic Inspection
• Result : Prevent the Tripod and Cooling fan shaft breakage in operating

7 Mu-Jeong, Son - Manager, KORAIL, KOREA - 7 July - Session: Technical Specifications No.203

BEFORE(ONLY 2 POINT) NOW(ADD 2 POINT) axle wheel Tripod transmission Cooling fan shaft

• Application of cooling fan vibration measurement
• Problems : service failure increased because of defect of cooling fan
• Solution : monitoring condition of all the cooling fans from the result of

vibration measurement data

Mu-Jeong, SON Manager, KORAIL, KOREA Tuesday, 7th July, 2015, Session : 2B - Technical Specifications –

Upgrading the maintenance technique

• Improve trouble shooting ability of electronic control unit
• Expand Investment for ECU maintenance infra
• Detect the root cause of malfunction
• Design new PCB for discontinued components
• Up-grade the quality of repaired ECU
• Prevent service failures caused by ECU

in operation

8

• KTX-sancheon

Electron microscope Coating removing machine Temperature test chamber Logic analyzer

Mu-Jeong, SON Manager, KORAIL, KOREA Tuesday, 7th July, 2015, Session : 2B - Technical Specifications –

Utilization of the cutting-edge IT infra

• Development of a wireless fault code transmission device
• System diagram

9

DMZ Internal users

KOVIS system

Wireless base

station

CDM A

Exclusive line Communication company

rout uter

destination location information

• Real-time fault code monitoring
• Diagnosis train condition remotely
• Collecting fault code automatically
• Analysis of fault code before

entering the KTX depot -> Prepare tools and manpower in advance

Mu-Jeong, SON Manager, KORAIL, KOREA Tuesday, 7th July, 2015, Session : 2B - Technical Specifications –

Utilization of the cutting-edge IT infra

10

• Developing the Monitoring program of Axle bearing temperature
• Replacement prioritization of axle bearings and wheelsets
• Major information offered by program
• 1. Showing the ranking of bearing heating
• 2. Temperature distribution graph about each trainset
• 4. Temperature changes of bearings in a certain period
• 3. Temperature distribution about each trainset

Mu-Jeong, SON Manager, KORAIL, KOREA Tuesday, 7th July, 2015, Session : 2B - Technical Specifications –

Engineering modifications and revision of the manuals

• KTX
• 2,127 Engineering modifications by ALSTOM(During warranty)
• 222 Engineering modifications by KORAIL(After warranty)
• Revise 182 maintenance manuals
• Establish 79 maintenance manuals
• Optimize TBO(time between overhaul) of major components

11

• KTX-sancheon
• 656 Engineering modifications by KORAIL and Hyundai-Rotem
• Overcome initial imperfections on in the trainset by upgrading train

diagnosis system software and signal system

Mu-Jeong, SON Manager, KORAIL, KOREA Tuesday, 7th July, 2015, Session : 2B - Technical Specifications –

The effect of reliability improvement of the KTX

12

• Basic inspection(KTX-sancheon)

2004(at first) 2005(1st change) 2010(2nd change) 1day / 2,500km 3day / 3,500km 5,000km

• Extending preventive maintenance cycle
• Basic inspection(KTX)
• Running gear inspection(KTX)

2004(at first) 2005(1st change) 9 day / 15,000km 14 day / 20,000km 2010(at first) 2014(1st change) 3,500km 5,000km

• Improving availability
• Increasing customer satisfaction by preventing failures in operation

Mu-Jeong, SON Manager, KORAIL, KOREA Tuesday, 7th July, 2015, Session : 2B - Technical Specifications –

Conclusion

• Key success factor of KTX and KTX-sancheon
• Development and Implementation of advanced maintenance technique
• Optimization of maintenance policy based on RCM(reliability-centered

maintenance)

• Constant supplementation of the maintenance manuals and the emergency

response plans

• Unceasing effort to make high-speed train percfect through engineering

modification

• Accumulation of operation data and utilization of the data for decision

making

13

Korail has accomplished the reliability improvement of the KTX by enhancing predictive maintenance and

• ptimization of the maintenance plan

Mu-Jeong, SON Manager, KORAIL, KOREA Tuesday, 7th July, 2015, Session : 2B - Technical Specifications –

...Thank you

for your kind attention