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, 7 th 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 Mu-Jeong, SON Manager, KORAIL, KOREA 2 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.  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 3 Tuesday, 7th July, 2015, Session : 2B - Technical Specifications –

Type of high-speed trains in Korea KTX-Sanchoen( Ⅰ ) KTX-Sanchoen( Ⅱ ) Classification KTX Appearance ALSTOM(France) Hyundai-Rotem(Korea) Hyundai-Rotem(Korea) Manufacturer 300 300 300 Maximum Speed(km/h) 46 24 22 Number of trainset 931 363 410 Number of seats 2004 2010 2015 In operation since(year) Gauge(mm) 1435 1435 1435 Mild steel Aluminum Aluminum Body material signal ATC/ATP/ATS ATC/ATP/ATS ATC/ATP/ATS Power car : 2 Power car : 2 Power car : 2 Passenger car(motorized) : 2 Passenger car : 8 Passenger car : 8 Unit composition Total : 10 cars Passenger car : 16 Total : 10 cars Total : 20 cars Mu-Jeong, SON Manager, KORAIL, KOREA 4 Tuesday, 7th July, 2015, Session : 2B - Technical Specifications –

Annual KTX failure rate (Case/1million Car-km) 0,9 0,6 0,3 0 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 KTX KTX-Sancheon  What is the major factors in the reliability improvement of KTX and KTX-Sancheon? Mu-Jeong, SON Manager, KORAIL, KOREA 5 Tuesday, 7th July, 2015, Session : 2B - Technical Specifications –

Upgrading the maintenance technique  Using the Electronic Endoscope Check the Gear Surface Check the wiring Mu-Jeong, Son - Manager, KORAIL, KOREA - 7 July - Session: Technical Specifications Equipment setting Verifying surface Equipment setting Finding disconnection 6 No.203  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 BEFORE(ONLY 2 POINT) NOW(ADD 2 POINT) Mu-Jeong, Son - Manager, KORAIL, KOREA - 7 July - Session: Technical Specifications axle wheel Tripod transmission Cooling fan shaft 7 No.203 • Result : Prevent the Tripod and Cooling fan shaft breakage in operating  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 Electron microscope Coating removing machine Temperature test chamber Logic analyzer • 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 Mu-Jeong, SON Manager, KORAIL, KOREA 8 Tuesday, 7th July, 2015, Session : 2B - Technical Specifications –  KTX-sancheon

Utilization of the cutting-edge IT infra  Development of a wireless fault code transmission device • System diagram KOVIS system Internal • Real-time fault code monitoring users DMZ • Diagnosis train condition remotely location rout uter information • Collecting fault code automatically • Analysis of fault code before Exclusive destination line entering the KTX depot -> Prepare tools and manpower in advance CDM A Wireless base Communication station company Mu-Jeong, SON Manager, KORAIL, KOREA 9 Tuesday, 7th July, 2015, Session : 2B - Technical Specifications –

Utilization of the cutting-edge IT infra  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 3. Temperature distribution about each trainset 4. Temperature changes of bearings in a certain period Mu-Jeong, SON Manager, KORAIL, KOREA 10 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  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 11 Tuesday, 7th July, 2015, Session : 2B - Technical Specifications –

The effect of reliability improvement of the KTX  Extending preventive maintenance cycle • Basic inspection(KTX) 2005(1 st change) 2010(2 nd change) 2004(at first) 1day / 2,500km 3day / 3,500km 5,000km • Running gear inspection(KTX) 2005(1 st change) 2004(at first) 9 day / 15,000km 14 day / 20,000km • Basic inspection(KTX-sancheon) 2014(1 st change) 2010(at first) 3,500km 5,000km  Improving availability  Increasing customer satisfaction by preventing failures in operation 12 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 Korail has accomplished the reliability improvement of the KTX by enhancing predictive maintenance and optimization of the maintenance plan Mu-Jeong, SON Manager, KORAIL, KOREA 13 Tuesday, 7th July, 2015, Session : 2B - Technical Specifications –

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