CPK Contactor for Compressor Rolling stock O&M and training document CPOCR Over Load Relay for Compressor Rolling stock O&M and training document EF Evaporator Fan Rolling stock O&M and training document EFOCR Over Load Relay for Evaporator Fan Rolling stock O&M and training document HPR Auxiliary Relay for HPS Rolling stock O&M and training document HPS High Pressure Switch Rolling stock O&M and training document INV Inverter Rolling stock O&M and training document IOL Inner Over Load Relay Rolling stock O&M and training document ITH Inner Thermo Relay Rolling stock O&M and training document
IVCB Inverter Circuit Breaker Rolling stock O&M and training document IVFR Auxiliary Relay for INV fault Rolling stock O&M and training document IVK Contactor for Inverter Rolling stock O&M and training document J-TREC Japan Transport Engineering Company (MTJV Subcontractor) General LPR Auxiliary Relay for LPS and ITH Rolling stock O&M and training document LPS Low Pressure Switch Rolling stock O&M and training document Mc Motor driven vehicle with driver’s cab Rolling stock O&M and training document MCB Miniature Circuit Breaker Rolling stock O&M and training document Table 1 – Terms and Definitions Term Definition Scope MRTA The Mass Rapid Transit Authority of Thailand, its successors and assigns. (The Employer) General MTJV MTJV (Thailand) Co., Ltd., (The Sub-Contractor) General
NF Noise Filter Rolling stock O&M and training document NFB No-fuse Breaker Rolling stock O&M and training document NVR No Voltage Detection Relay Rolling stock O&M and training document OCR Over Load Relay Rolling stock O&M and training document R407C A NOT UCzone-depleting blend of three hydro fluorocarbon (HFC) refrigerants. Registered trademark is DuPont “SUVA 9000” Rolling stock O&M and training document TCMS Train Control and Monitor System Rolling stock O&M and training document 5 References 6 MRTA references The following MRTA items are referenced from within this document. Table 2 – MRTA referenced items No. Referenced document [1.01] Contract 4, Annex 4, MRTA’s Requirements, General Specifications C4V4
[1.02] Contract 4, Annex 3, MRTA’s Requirements, O&M Performance Requirements 2.3.4 (K), Appendix B, Appendix C 5.6.1, and Appendix F [1.03] Contract 4, Definitive Design – Ventilation and Air Conditioning unit Specification 7 BMCL references The following BMCL items are referenced from within this document. Table 3 – BMCL referenced items No. Referenced document [2.01] Bangkok Metro Public Company Limited, MRT Purple Line Project, Contract 4, PPP Contract for supply of M&E system and O&M services [2.02] Contract 4, Exhibit II, M&E Systems Subcontract, General Specification, BPL-0003, Clause 1.17, and Clause 9.6 [2.03] Operations Service Plan [2.04] Maintenance Plan [2.05] Contract 4, Exhibit IV, M&E Systems Sub-Contract Technical Specifications, Maintenance for M&E Systems and Track work clause 2.3.1 k, 5.4.1 c, and Appendix F 8 Other references The following other items are referenced from within this document. Table 4 – Other referenced items No. Referenced document [3.01] MT1-PRJ-GNRL-STD-00002, Project Glossary [3.02] MT1-PRJ-GNRL-STD-00001, Document Preparation Standard
[3.03] MT1-PRJ-GNRL-STD-00005, Drawing Preparation Standard [3.04] MT1-PRJ-GNRL-GDE-00006, Operating and Maintenance Manuals Guide [3.05] MT2-MNT-GNRL-PLN-00002, Maintenance Service Plan [3.06] MT1-PRJ-GNRL-FRM-01044, Volume 3 Maintenance Manual Template 9 Operating and maintenance manuals structure The Operating and Maintenance Manuals consists of five (5) major volumes as described in Table 5. This arrangement allows difference users to quickly identify the needed information without having to read through all volumes. Table 5 – Operating and maintenance manuals structure Volume Document Title Key End User One (1) General Information Manual Operations Staff Maintenance Staff Training Staff Two (2) Operation Manual Operations Staff Maintenance Staff Training Staff Three (3) Maintenance Manual Maintenance Staff Training Staff Four (4) Illustrated Parts Catalogue Maintenance Staff Training Staff Five (5) Special Tools and Test Equipment Manual Maintenance Staff Training Staff Readers who wish to understand the overview / general information of the rolling stock, the operation of the ventilation and air condition system via TCMS and air conditioning control panel shall refer to Volume 1 General Information Manual and Volume 3 Train Operation Manual.
The spares, consumable, special maintenance tools and instruments to be used for maintaining the ventilation and air conditioning system are described in Volume 4 Illustrated Part Catalogue and Volume 5 Special Tools and Test Equipment Manual. Users shall make references to the constructed drawings for the wiring and construction details as required. The Rolling Stock is a complex system and as such multiple Volume 3s exist. Table 6 is systematically structured allowing the maintainer to locate the relevant Volume 3 based on subsystems. Table 6 – Rolling Stock Volume 3 maintenance manual structure Document Title / Number Subsystem / equipment covered Carbody MT1-RST-GNRL-MNE00029 Carbody, seats, passenger saloon side window, inter-car gangway, floor, sidewall panels, ceiling, draught screens and partition walls, interior lighting, emergency equipment. Train Cab MT1-RST-GNRL-MNE00030 Driver's console and controls, front display panel, wiper, non-train operator's console, cab doors, cab back panel, driver's seat, cab side wide window, cab lighting. Coupler MT1-RST-GNRL-MNE00031 Automatic coupler, semi-permanent coupler. Passenger Door MT1-RST-GNRL-MNE00032 Door leaf, door control unit, driving unit and rack, door hanging gear, door isolation device, door obstacle detection.
Air Conditioning MT1-RST-GNRL-MNE00033 Saloon air conditioning unit, cab air handling unit, air conditioning control panel. Propulsion MT1-RST-GNRL-MNE00034 Surge arrestor, high speed circuit breaker, main switch box, filter reactor, brake resistor, traction motor, propulsion inverter, master controller and pulse width modulator, wheel slip-slide and jerk control, brake blending, acceleration and braking control. Auxiliary Power Supply MT1-RST-GNRL-MNE00035 Auxiliary converter, rectifier box, main switch (T), fuse box, changeover box. Train Control & Monitoring MT1-RST-GNRL-MNE00036 TCMS train and car computer, display units, OTMR. Brake MT1-RST-GNRL-MNE00037 Service brake, emergency brake, wheel slide protection control, brake caliper unit. Air Supply MT1-RST-GNRL-MNE00038 Compress air supply, air brake equipment Bogie MT1-RST-GNRL-MNE00039 Bogie frame, wheelset and axle box, suspension systems, motor and gear box, bogie mounted brake equipment, bogie piping, flange lubricator, current collection system, earth return device, stone guard
10 Safety information Safety is a primary and utmost important consideration in all railway activities. All activities must work within the constraints of the BMCL Operations Rules and Procedures. Effective safety management for Rolling Stock equipment operation and maintenance requires consideration for all modes of railway operation including, but not limited to, normal operations, degraded operations and emergency operations. For emergency situations, BMCL’s “Operations Rules and Procedures Emergency Operations Manual” on emergency responses, reporting of an incident / emergency, stopping of trains, de-energising of traction power, evacuation of passengers from a train / station, handling of fire emergency, security threats, suspicious objects / persons, etc., must be adhered to strictly. Please refer to the relevant BMCL Operations Rules and Procedures in the applications of any operations and maintenance procedures described in this manual. In addition to BMCL Operations Rules and Procedures, the consideration of safety will be of utmost importance to the maintenance planning and implementation. For example, when using tools and equipment for maintenance purposes, power source for the tools will be restricted to electrical power and diesel fuel power. Petroleum will not be permitted. All systems shall be engineered to ensure that operation and maintenance can be carried out under safe conditions. Safe systems of work will be developed, maintained and enforced to ensure that staff protection is as high as reasonably practical and that risk is as low as reasonably practical. This section states the general safety aspects to be followed when maintaining the air ventilation and air conditioning equipment. Specific details of safety precautions and / or restrictions for the operation and maintenance of the equipment is specified here. Maintenance activities, which impact safety and / or require special qualification and licenses, are highlighted in the relevant maintenance instructions.
Table 7 – Safety Notes 11 Maintenance planning data Maintenance management is an orderly and systematic approach to planning, organising, monitoring and evaluating maintenance activities and their costs. The key to establishing a maintenance management system begins with the initial step of gathering asset inventory data, identifying maintenance activities and tasks on each asset, identifying the frequency (interval) of the task, identifying the skill levels of the maintenance staff in carrying out the tasks, estimating the time required to complete the task, developing a maintenance work flow and schedule, preparing and assigning work orders and determining the costs of all maintenance activities. As such, the establishment of CMMS data driven databases comprising asset inventory register, preventive maintenance task definitions, work flows etc., are of utmost importance in the overall maintenance management. 12 CMMS asset inventory register Appendix 2 outlines all asset inventory register associated with the ventilation and air conditioning system. Each item (LRU) listed in Appendix 2 is assigned with a preventive maintenance task, maintenance interval, estimated manhour, skill level, task description, task reference number, work area, etc., sufficient to for the establishment of the CMMS asset database. The following subsections briefly describe the makeup of the on-board ventilation and air conditioning system.
13 Maintenance task and description Maintenance tasks on the ventilation and air conditioning system can be classified into inspection, checking, cleaning, testing and replacement. 14 Inspection and checking The maintainer shall conduct regular inspection to ensure the system works properly. Abnormal noise and vibration is a good indication of problem with the rotating machines. 15 Cleaning To keep the ventilation and air conditioning system operates effectively, the air filters and the heat exchangers must be cleaned regularly. Blocked filter prevents airflow through the air conditioning unit. Dust covering heat exchangers prevents heat exchange between air and refrigerant. 16 Testing Power supply wiring needs to be checked annually and after replacement of electrical machineries. 17 Replacement Hard time replacement is recommended for major components. Air conditioning unit is suggested returning to workshop for overhaul every six years and refurbishing the refrigerating circuit every fifteen years.
18 Maintenance categories Four types of maintenance activities for the ventilation and air conditioning system need to be performed by the maintenance personnel to fulfil the contract requirements, which are: Level 1, 2 and 3 preventive and corrective maintenance, and Level 4 overhaul. Preventive maintenance is a maintenance activity that is regularly performed on a piece of equipment to lessen the likelihood of failing. Preventative maintenance is performed while the equipment is still working, so that it does not break down unexpectedly. Preventative maintenance is planned so that any required resources are made available beforehand. Maintenance schedule for the ventilation and air conditioning equipment on rolling stock is timebased. Technicians are arranged to inspect and carry out specific tasks on a time based schedule. During the inspection, the technician shall determine if replacement or further investigation is required from observation of physical appearance of parts and detection of abnormal noise and vibration. Hard time replacement is also recommended in this manual to avoid arrangement for unexpected corrective actions. Corrective maintenance is any maintenance performed to return equipment to proper working order. Equipment deteriorate if not detected during preventive maintenance can lead to equipment fault during revenue operation. Corrective actions may involve withdraw the train from service. The cost is much more than planned maintenance hence should be avoided. Overhaul is a comprehensive maintenance task that involves removing and disassembling the ventilation and air conditioning equipment, testing all the components, cleaning and replacing parts as needed and then reassembling the equipment. This is done to improve the ventilation and air conditioning equipment performance and prolong the life of the equipment.
19 Frequency of preventive and overhaul task 20 Every two weeks Part Description Preventative Maintenance Task Task Number ACU Clean return air filters and fresh air filters. Replace filter where needed. VAC_W_0001 CAHU • Check abnormal noise and vibration. • Check fault indication lamp • Check trip of CAHMCB in ACCP VAC_W_0002 21 Monthly task No task. Maintenance Level: 2 Purpose: To check the ventilation and air conditioning system is working properly and to clean / replace the air filter to keep the dust and dirt out. (This period is recommended by the experience of air conditioning unit manufacturer. However, amount of dust accumulation varies according to season and train operation conditions. Please determined the satisfied period in accordance with the check of dirt condition.) Required personnel and competency requirements: Technician Rolling Stock Level 1-3 maintenance training and able to replace filter in a safe manner.
22 Annual task Maintenance Level: 3 Purpose: To check the ventilation and air conditioning system is working properly and to perform comprehensive inspection and cleaning, checking. Required personnel and competency requirements: Technician completed Rolling Stock Level 1-3 maintenance training. Part Description Preventative Maintenance Task Task Number ACU Visual check Spray application for avoiding unpleasant smell VAC_Y_0101 Part Description Preventative Maintenance Task Task Number Cover Removal, check of damage, cleaning and reattachment VAC_Y_0102 Refrigerating circuit Check for leakage VAC_Y_0103 Evaporator drip tray Drain water route Drain pipe and hose Cleaning with pressurised water or steam VAC_Y_0104 Condenser coil Cleaning with pressurised water or steam VAC_Y_0105 Evaporator coil Cleaning with pressurised water or steam VAC_Y_0106 Condenser fan •Remove dust, if dust is accumulated VAC_Y_0107
Evaporator fan • Cleaning the evaporator fan blade if noticeable dirt such as dust and /or grease is observed. Inverter, Noise filter Check and cleaning with pressurized air and vacuum cleaner VAC_Y_0108 F/R air damper Check and cleaning VAC_Y_0109 Emergency damper Check and cleaning VAC_Y_0110 Terminal Check for tightness VAC_Y_0111 Thermal insulator Check and repair VAC_Y_0112 Sealing rubber Check and repair. Replace it, if necessary VAC_Y_0113 Smoke detector • Check the condition of the smoke detector and surroundings, clean if dirty •Test using the test gas •Remove dusts of the smoke detector filter in the cover for smoke detector box VAC_Y_0114 Compressor Condenser fan Evaporator fan Check for abnormal noise / vibration VAC_Y_0115 ACCP •Visual check • Cleaning with pressurised air and vacuum cleaner VAC_Y_0116 CAHU •Removal and reattachment of bottom cover • Check for unusual noise and vibration •Removal of accumulated inside dust by pressurized air and vacuum cleaner. VAC_Y_0117 (not include the ceiling
•Removal of accumulated dust on the axis of damper blade by pressurized air. •Removal of accumulated dust on propeller fan by wet cloth. Check for tightness of bolts and screw. panel removal) Part Description Preventative Maintenance Task Task Number ACU ,ACCP, CAHU Check for insulation* Insulation Resistance Allowable Value Main circuit - Frame More than 5MΩ Control circuit - Frame More than 2MΩ Main – Control circuit More than 5MΩ Note*: Insulation test for annual inspection is required for a car to represent all cars in the system. However, if a car fail the test, all cars in the system shall be conducted the insulation test. VAC_Y_0118 Transformer •Remove dust, if dust is accumulated • Clean if noticeable dirt such as dust, mould and /or grease is observed. 23 Task every three (3) years Maintenance Level: 3
Purpose: To check the ventilation and air conditioning unit is working properly, and to perform detailed inspection and cleaning on connection duct and cover, replacing deteriorated sealing rubber and resilient mount. Required personnel and competency requirements: Technician completed Rolling Stock Level 1-3 maintenance training. Part Description Preventative Maintenance Task Task Number ACU Visual check VAC_Y_0301 Cover •Removal, check of damage, cleaning and reattachment • Check and repair for thermal insulator VAC_Y_0302 Refrigerating circuit Check for leakage VAC_Y_0303 Evaporator drip tray Drain water route Drain pipe and hose Cleaning with pressurised water or steam VAC_Y_0304 Condenser coil Cleaning with pressurised water or steam VAC_Y_0305 Evaporator coil Cleaning with pressurised water or steam VAC_Y_0306 Condenser fan Evaporator fan Remove dust, if dust is accumulated VAC_Y_0307 Part Description Preventative Maintenance Task Task Number
Cleaning the evaporator fan blade if noticeable dirt such as dust and /or grease is observed. Inverter, Noise filter Check and cleaning with pressurized air and vacuum cleaner VAC_Y_0308 Damper Check and cleaning VAC_Y_0309 Emergency damper Check and cleaning VAC_Y_0310 Terminal Check for tightness VAC_Y_0311 Thermal insulator Check and repair VAC_Y_0312 Sealing rubber Check and repair. Replace it, if necessary VAC_Y_0313 Smoke detector • Check the condition of the smoke detector and surroundings, clean if dirty •Test using the test gas •Remove dusts of the smoke detector filter in the cover for smoke detector box VAC_Y_0314 Compressor Check resilient mount. Replace it, if necessary VAC_Y_0315 Condenser fan Repaint it, if necessary. VAC_Y_0316 Evaporator fan • Cleaning for multi-blade fan • Check for abnormal noise / vibration. VAC_Y_0317 Compressor Condenser fan Evaporator fan Check for abnormal noise / vibration VAC_Y_0318 Connection duct Check water leakage and cleaning VAC_Y_0319 Temperature sensor Cleaning VAC_Y_0320
ACCP •Visual check • Cleaning with pressurised air and vacuum cleaner • Check for tightness of terminal screw. VAC_Y_0321 CAHU •Removal and reattachment of bottom cover • Check for unusual noise and vibration •Removal of accumulated inside dust by pressurized air and vacuum cleaner. •Removal of accumulated dust on the axis of damper blade by pressurized air. •Removal of accumulated dust on propeller fan by wet cloth. • Check for tightness of bolts and screw. VAC_Y_0322 (not include the ceiling panel removal) 24 Task every four (4) years Maintenance Level: 3 Purpose: To check the insulation of ACU , ACCP, CAHU. Required personnel and competency requirements: Technician completed Rolling Stock Level 1-3 maintenance training. Part Description Preventative Maintenance Task Task Number VAC_Y_0401
ACU ,ACCP, CAHU Check for insulation* Insulation Resistance Allowable Value Main circuit - Frame More than 5MΩ Control circuit - Frame More than 2MΩ Main – Control circuit More than 5MΩ Note*: In the case that insulation test for a car failed, insulation test of the system shall be conducted. 25 Task every six (6) years Maintenance Level: 4 Purpose: To perform overhaul on the AHU, including comprehensive inspection and checking, deep cleaning and replacing worn parts to ensure the ventilation and air conditioning unit can work properly and prolong the life of the equipment. Required personnel and competency requirements: Technician completed Rolling Stock Level 1-3 and Level 4 maintenance training. Part Description Preventative Maintenance Task Task Number ACU •Replacement of spare ACU for overhaul. •Transportation to workshop VAC_Y_0601
ACU •Visual check • Check for insulation Insulation Resistance Allowable Value Main circuit - Frame More than 5MΩ Control circuit - Frame More than 2MΩ Main – Control circuit More than 5MΩ •Steam cleaning of air conditioning unit included with evaporator drip tray, drain water route, drain pipe. •Remove accumulated dust on surface of thermal insulation • Check for resilient rubbers. Replace, if there is crack and damage. VAC_Y_0602 Cover •Removal, check of damage, cleaning and reattachment •Replacement with new sealing rubber • Check and Repair for thermal insulator, if necessary VAC_Y_0603 Refrigerating circuit Check for leakage VAC_Y_0604 Condenser coil • Dust removal of coil surface • Cleaning with pressurised water or steam •Repair of fin deformation, if necessary VAC_Y_0605 Evaporator coil • Dust removal of coil surface • Cleaning with pressurised water or steam VAC_Y_0606
•Repair of fin deformation, if necessary Piping •Repaint for painted portion •Exchange of rubber plate (except with silicone rubber plate) VAC_Y_0607 Wiring • Check for degraded/damaged cable. Replace, if discoloured, blackened, cracked or damaged. • Check tightness terminal screw. Retighten if loose. •Exchange of rubber plate (except with silicone rubber plate) VAC_Y_0608 Inverter, Noise filter Check and cleaning with pressurized air and vacuum cleaner VAC_Y_0609 F/R air damper Check and cleaning VAC_Y_0610 Emergency damper Check and cleaning VAC_Y_0611 Terminal Check for tightness VAC_Y_0612 Thermal insulator Check and repair VAC_Y_0613 Sealing rubber Check and repair. Replace it, if necessary VAC_Y_0614 Smoke detector •Replace the smoke detector and smoke detector filter with new one •Test using the test gas VAC_Y_0615 Compressor •Replacement of new resilient mount •Repaint, if necessary VAC_Y_0616 Condenser fan • Dismantlement from unit for overhaul • Cleaning •Replacement of new motor bearing. VAC_Y_0617
Part Description Preventative Maintenance Task Task Number Repaint , if necessary Evaporator fan • Dismantlement from unit for overhaul • Cleaning • Replacement of new motor bearing. Repaint , if necessary VAC_Y_0618 Compressor Condenser fan Evaporator fan Check for abnormal noise / vibration VAC_Y_0619 Connection duct Check water leakage and cleaning VAC_Y_0620 Temperature sensor Cleaning VAC_Y_0621 Return and fresh air filter Replacement of new filter VAC_Y_0622 ACCP • Visual check • Cleaning with pressurised air and vacuum cleaner Check for tightness of of terminal screw. • Check for insulation * Insulation Resistance Allowable Value Main circuit - Frame More than 5MΩ Control circuit - Frame More than 2MΩ VAC_Y_0623
Main – Control circuit More than 5MΩ Note*: In the case that insulation test for a car failed, insulation test of the system shall be conducted. CAHU •Removal and reattachment of bottom cover • Check for unusual noise and vibration •Removal of accumulated inside dust by pressurized air and vacuum cleaner. •Removal of accumulated dust on the axis of damper blade by pressurized air. •Removal of accumulated dust on propeller fan by wet cloth. • Check for tightness of bolts and screw. • Check for insulation * Insulation Resistance Allowable Value Main circuit - Frame More than 5MΩ Control circuit - Frame More than 2MΩ Main – Control circuit More than 5MΩ Note*: In the case that insulation test for a car failed, insulation test of the system shall be conducted. VAC_Y_0624 (not include the ceiling panel removal)
26 Task every nine (9) years Maintenance Level: 4 Purpose: To perform the overhaul on inverter and noise filter by comprehensive inspection and checking, deep cleaning, and replacing worn and aged parts to ensure the ventilation and air conditioning unit can work properly and prolong equipment life. Required personnel and competency requirements: Technician completed Rolling Stock Level 1-3 and Level 4 maintenance training. Part Description Preventative Maintenance Task Task Number ACU •Visual check • Check for insulation VAC_Y_0901 Insulation Resistance Allowable Value Main circuit - Frame More than 5MΩ Control circuit - Frame More than 2MΩ Main – Control circuit More than 5MΩ Cover •Removal, check of damage, cleaning and reattachment • Check and repair for thermal insulator VAC_Y_0902 Refrigerating circuit Check for leakage VAC_Y_0903 Evaporator drip tray Drain water route Cleaning with pressurised water or steam VAC_Y_0904
Drain pipe and hose Condenser coil Cleaning with pressurised water or steam VAC_Y_0905 Evaporator coil Cleaning with pressurised water or steam VAC_Y_0906 Condenser fan Evaporator fan Remove dust, if dust is accumulated VAC_Y_0907 Inverter, Noise filter Check and cleaning with pressurized air and vacuum cleaner VAC_Y_0908 F/R air damper • Check and cleaning •Replacement with new geared motor and PCB for F/R air damper VAC_Y_0909 Emergency damper Check and cleaning VAC_Y_0910 Terminal Check for tightness VAC_Y_0911 Thermal insulator Check and repair VAC_Y_0912 Part Description Preventative Maintenance Task Task Number Sealing rubber Check and repair. Replace it, if necessary VAC_Y_0913 Smoke detector • Check the condition of the smoke detector and surroundings, clean if dirty •Test using the test gas •Remove dusts of the smoke detector filter in the cover for smoke detector box VAC_Y_0914 Compressor Check resilient mount. Replace it, if necessary VAC_Y_0915 Condenser fan Repaint it, if necessary. VAC_Y_0916 Evaporator fan • Cleaning for multi-blade fan • Check for abnormal noise / vibration VAC_Y_0917
Compressor Condenser fan Evaporator fan Check for abnormal noise / vibration VAC_Y_0918 Connection duct Check water leakage and cleaning VAC_Y_0919 Temperature sensor Cleaning VAC_Y_0920 ACCP •Visual check • Cleaning with pressurised air and vacuum cleaner • Check for degraded/damaged cable. Replace if there is trace of overheat and damaged. •Replacement of electromagnetic contactor CFCPK11, 12, 21, 22 •Replacement of relay DMCR11,12,21,22 • Check for cracked terminal board. Replace if cracked. • Check tightness terminal screw. Retighten if loose. • Check for tightness of of terminal screw. • Check for insulation * Insulation Resistance Allowable Value Main circuit - Frame More than 5MΩ Control circuit - Frame More than 2M Main – Control circuit More than 5MΩ VAC_Y_0921
Note*: In the case that insulation test for a car failed, insulation test of the system shall be conducted. CAHU •Replacement with spare unit for overhaul • Cleaning of inside • Check and repair of thermal insulator, if necessary • Check for degraded/damaged cable. Replace, if discoloured, blackened, cracked or damaged. • Check tightness terminal screw. Retighten if loose. •Replacement of fans and geared motor of damper Test for function, insulation resistance after overhaul. • Insulation * Insulation Resistance Allowable Value Main circuit - Frame More than 5MΩ Control circuit - Frame More than 2MΩ Main – Control circuit More than 5MΩ VAC_Y_0922 (not include the ceiling panel removal)
Note*: In the case that insulation test for a car failed, insulation test of the system shall be conducted. 27 Task every twelve (12) years Maintenance Level: 4 Purpose: To replace worn and aged parts to ensure the ventilation unit can work properly and prolong equipment life. Required personnel and competency requirements: Technician completed Rolling Stock Level 1-3 and Level 4 maintenance training. Part Description Preventative Maintenance Task Task Number Air conditioning unit •Exchange with spare air conditioning unit for overhaul. •Transportation to workshop VAC_Y_1201
ACU •Visual check • Check for insulation * Insulation Resistance Allowable Value Main circuit - Frame More than 5MΩ Control circuit - Frame More than 2MΩ Main – Control circuit More than 5MΩ Note*: In the case that insulation test for a car failed, insulation test of the system shall be conducted. •Steam cleaning of air conditioning unit included with evaporator drip tray, drain water route, drain pipe. •Remove accumulated dust on surface of thermal insulation • Check for resilient rubbers. Replace, if there is crack and damage. VAC_Y_1202 Cover •Removal, check of damage, cleaning and reattachment •Replacement with new sealing rubber and thermal insulator. VAC_Y_1203 Refrigerating circuit Check for leakage VAC_Y_1204 Condenser coil • Dust removal of coil surface • Cleaning with pressurised water or steam •Repair of fin deformation, if necessary VAC_Y_1205
Evaporator coil • Dust removal of coil surface • Cleaning with pressurised water or steam •Repair of fin deformation, if necessary VAC_Y_1206 Piping •Repaint for painted portion •Exchange of rubber plate (except with silicone rubber plate) VAC_Y_1207 Wiring • Check for degraded/damaged cable. Replace, if discoloured, blackened, cracked or damaged. • Check tightness terminal screw. Retighten if loose. •Exchange of rubber plate (except with silicone rubber plate) VAC_Y_1208 Part Description Preventative Maintenance Task Task Number Inverter, Noise filter Replacement with new one VAC_Y_1209 F/R air damper Check and cleaning VAC_Y_1210 Emergency damper Check and cleaning VAC_Y_1211 Terminal Check for tightness VAC_Y_1212 Thermal insulator Check and repair VAC_Y_1213 Sealing rubber Check and repair. Replace it, if necessary VAC_Y_1214 Smoke detector •Replace the smoke detector and smoke detector filter with new one •Test using the test gas VAC_Y_1215 Compressor •Replacement of new resilient mount VAC_Y_1216
•Repaint, if necessary Condenser fan • Dismantlement from unit for overhaul • Cleaning • Replacement of new motor bearing. Repaint , if necessary VAC_Y_1217 Evaporator fan • Dismantlement from unit for overhaul • Cleaning • Replacement with new motor bearing. Repaint , if necessary VAC_Y_1218 Compressor Condenser fan Evaporator fan Check for abnormal noise / vibration VAC_Y_1219 Connection duct Check water leakage and cleaning VAC_Y_1220 Temperature sensor Cleaning VAC_Y_1221 Return and fresh air filter Replacement with new filter VAC_Y_1222 ACCP •Removal and reinstallation • Cleaning with pressurised air and vacuum cleaner •Replace consumable parts: miniature circuit breaker, relay, electromagnetic contactor and microcomputer control unit with noise filter except with equipment to be replaced every 9 years. • Check for tightness of terminal screw. VAC_Y_1223
• Check for insulation * Insulation Resistance Allowable Value Main circuit - Frame More than 5MΩ Control circuit - Frame More than 2MΩ Main – Control circuit More than 5MΩ Note*: In the case that insulation test for a car failed, insulation test of the system shall be conducted. • Confirmation test for function after installation in car Part Description Preventative Maintenance Task Task Number CAHU •Removal and reattachment of bottom cover • Check for unusual noise and vibration •Removal of accumulated inside dust by pressurized air and vacuum cleaner. •Removal of accumulated dust on the axis of damper blade by pressurized air. •Removal of accumulated dust on propeller fan by wet cloth. • Check for tightness of bolts and screw. • Check for insulation * Insulation Resistance Allowable Value VAC_Y_1224 (not include the ceiling panel removal)
Main circuit - Frame More than 5MΩ Control circuit - Frame More than 2MΩ Main – Control circuit More than 5MΩ Note*: In the case that insulation test for a car failed, insulation test of the system shall be conducted. 28 Task every fifteen (15) years Maintenance Level: 4 Purpose: To perform the overhaul on AHU by comprehensive inspection and checking, deep cleaning, and replacing worn and aged parts to ensure the ventilation and air conditioning unit can work properly and prolong equipment life. Required personnel and competency requirements: Technician completed Rolling Stock Level 1-3 and Level 4 maintenance training Part Description Preventative Maintenance Task Task Number Air conditioning unit •Exchange with spare air conditioning unit for overhaul. •Transportation to workshop VAC_Y_1501 Resilient mount for air conditioning unit Exchange to new one VAC_Y_1502
Cover Removal, check of damage, cleaning and reattachment VAC_Y_1503 Connection duct Replacement with new one VAC_Y_1504 Refrigerating circuit •Recovery of refrigerant •Exchange of worn and aged main parts to new one Compressor, condenser coil, evaporator coil, dryer, capillary tube, high pressure switch, low pressure switch and silicon rubber for pipe fixation. • Check for leakage and enclosing of refrigerant. VAC_Y_1505 Part Description Preventative Maintenance Task Task Number Condenser fan Replacement with new one VAC_Y_1506 Evaporator fan Replacement with new one VAC_Y_1507 Frame Replacement with new thermal insulator VAC_Y_1508 Temperature sensor Replacement with new one. VAC_Y_1509 Evaporator drip tray Drain water route Drain pipe and hose Cleaning with pressurised water or steam VAC_Y_1510 Inverter, Noise filter Check and cleaning with pressurized air and vacuum cleaner VAC_Y_1511 F/R air damper Check and cleaning VAC_Y_1512
Emergency damper •Replacement and reinstallation •Replacement of geared motor VAC_Y_1513 Terminal Check for tightness VAC_Y_1514 Smoke detector • Check the condition of the smoke detector and surroundings, clean if dirty •Test using the test gas •Remove dusts of the smoke detector filter in the cover for smoke detector box VAC_Y_1515 Air conditioning unit •Test for function, insulation resistance after overhaul. • Insulation * Insulation Resistance Allowable Value Main circuit - Frame More than 5MΩ Control circuit - Frame More than 2MΩ Main – Control circuit More than 5MΩ Note*: In the case that insulation test for a car failed, insulation test of the system shall be conducted. VAC_Y_1516 ACCP • Visual check • Cleaning with pressurised air and vacuum cleaner Check for tightness of terminal screw. • Check for insulation * VAC_Y_1517
Insulation Resistance Allowable Value Main circuit - Frame More than 5MΩ Control circuit - Frame More than 2MΩ Main – Control circuit More than 5MΩ Note*: In the case that insulation test for a car failed, insulation test of the system shall be conducted. Part Description Preventative Maintenance Task Task Number CAHU •Removal and reattachment of bottom cover • Check for unusual noise and vibration •Removal of accumulated inside dust by pressurized air and vacuum cleaner. •Removal of accumulated dust on the axis of damper blade by pressurized air. •Removal of accumulated dust on propeller fan by wet cloth. • Check for tightness of bolts and screw. • Check for insulation * Insulation Resistance Allowable Value Main circuit - Frame More than 5MΩ VAC_Y_1517 (not include the ceiling panel removal)
Control circuit - Frame More than 2MΩ Main – Control circuit More than 5MΩ Note*: In the case that insulation test for a car failed, insulation test of the system shall be conducted.
29 Duration of task Table 13 – Duration of task Task Number Time Required (hrs) per train Personnel Required per task Required Man Hours per task per train VAC_W_0001 0.6 2 1.2 VAC_W_0002 0.2 1 0.2 VAC_Y_0101 3.0 2 6.0 VAC_Y_0102 2.0 2 4.0 VAC_Y_0103 1.0 1 1.0 VAC_Y_0104 1.5 2 2.0 VAC_Y_0105 2.0 2 4.0 VAC_Y_0106 1.0 2 2.0 VAC_Y_0107 1.0 2 2.0 VAC_Y_0108 1.0 1 1.0 VAC_Y_0109 1.0 1 1.0 VAC_Y_0110 1.0 1 1.0 VAC_Y_0111 1.5 1 1.5 VAC_Y_0112 0.6 1 0.6 VAC_Y_0113 0.6 1 0.6 VAC_Y_0114 3.0 1 3.0 VAC_Y_0115 1.0 1 3.0 VAC_Y_0116 2.0 2 4.0 VAC_Y_0117 2.0 1 0.6 VAC_Y_0118 3.0 2 6.0
VAC_Y_0301 0.6 1 0.6 VAC_Y_0302 2.0 2 4.0 VAC_Y_0303 1.0 1 1.0 VAC_Y_0304 1.5 2 3.0 VAC_Y_0305 2.0 2 4.0 VAC_Y_0306 1.0 2 2.0 VAC_Y_0307 1.0 2 2.0 VAC_Y_0308 1.0 1 1.0 VAC_Y_0309 1.0 1 1.0 VAC_Y_0310 1.0 1 1.0 VAC_Y_0311 1.5 1 1.5 VAC_Y_0312 0.6 1 0.6 VAC_Y_0313 0.6 1 0.6 VAC_Y_0314 3.0 1 3.0 VAC_Y_0315 1.0 1 1.0 VAC_Y_0316 1.0 1 1.0 VAC_Y_0317 2.0 1 2.0 VAC_Y_0318 1.0 1 1.0 VAC_Y_0319 2.0 1 2.0 Table 13 – Duration of task Task Number Time Required (hrs) per train Personnel Required per task Required Man Hours per task per train VAC_Y_0320 1.0 1 1.0 VAC_Y_0321 2.0 2 4.0
VAC_Y_0322 2.0 1 2.0 VAC_Y_0401 3.0 2 6.0 VAC_Y_0601 8.0 2 16.0 VAC_Y_0602 6.0 2 12.0 VAC_Y_0603 4.0 2 8.0 VAC_Y_0604 2.0 1 2.0 VAC_Y_0605 6.0 1 6.0 VAC_Y_0606 1.5 1 1.5 VAC_Y_0607 2.0 1 2.0 VAC_Y_0608 3.0 1 3.0 VAC_Y_0609 1.0 1 1.0 VAC_Y_0610 1.0 1 1.0 VAC_Y_0611 1.0 1 1.0 VAC_Y_0612 1.5 1 1.5 VAC_Y_0613 0.6 1 0.6 VAC_Y_0614 0.6 1 0.6 VAC_Y_0615 2.0 1 2.0 VAC_Y_0616 3.0 1 3.0 VAC_Y_0617 7.2 1 7.2 VAC_Y_0618 9.6 1 9.6 VAC_Y_0619 1.0 1 1.0 VAC_Y_0620 1.0 1 1.0 VAC_Y_0621 1.0 1 1.0 VAC_Y_0622 0.5 1 0.5
VAC_Y_0623 2.0 2 4.0 VAC_Y_0624 2.0 1 2.0 VAC_Y_0901 3.0 2 6.0 VAC_Y_0902 2.0 2 4.0 VAC_Y_0903 1.0 1 1.0 VAC_Y_0904 1.5 1 1.5 VAC_Y_0905 2.0 2 4.0 VAC_Y_0906 1.0 2 2.0 VAC_Y_0907 1.0 2 2.0 VAC_Y_0908 1.0 1 1.0 VAC_Y_0909 3.0 1 3.0 VAC_Y_0910 0.2 1 0.2 VAC_Y_0911 1.5 1 1.5 VAC_Y_0912 0.6 1 0.6 Table 13 – Duration of task Task Number Time Required (hrs) per train Personnel Required per task Required Man Hours per task per train VAC_Y_0913 0.6 1 0.6 VAC_Y_0914 3.0 1 3.0 VAC_Y_0915 1.0 1 1.0 VAC_Y_0916 1.0 1 1.0 VAC_Y_0917 2.0 1 2.0 VAC_Y_0918 1.0 1 1.0 VAC_Y_0919 1.0 1 1.0
VAC_Y_0920 1.0 1 1.0 VAC_Y_0921 2.5 2 5.0 VAC_Y_0922 2.5 2 5.0 VAC_Y_1201 8.0 2 16.0 VAC_Y_1202 7.0 2 14.0 VAC_Y_1203 4.0 2 8.0 VAC_Y_1204 2.0 1 2.0 VAC_Y_1205 6.0 1 6.0 VAC_Y_1206 1.5 1 1.5 VAC_Y_1207 2.0 1 2.0 VAC_Y_1208 3.0 1 3.0 VAC_Y_1209 1.0 1 1.0 VAC_Y_1210 1.0 1 1.0 VAC_Y_1211 1.0 1 1.0 VAC_Y_1212 1.5 1 1.5 VAC_Y_1213 0.6 1 0.6 VAC_Y_1214 0.6 1 0.6 VAC_Y_1215 2.0 1 2.0 VAC_Y_1216 3.0 1 3.0 VAC_Y_1217 7.2 1 7.2 VAC_Y_1218 9.6 1 9.6 VAC_Y_1219 1.0 1 1.0 VAC_Y_1220 1.0 1 1.0 VAC_Y_1221 1.0 1 1.0 VAC_Y_1222 0.5 1 0.5
VAC_Y_1223 4.0 2 8.0 VAC_Y_1224 2.5 1 2.5 VAC_Y_1501 8.0 2 16.0 VAC_Y_1502 1.2 1 1.2 VAC_Y_1503 2.0 2 4.0 VAC_Y_1504 6.0 1 6.0 VAC_Y_1505 48.0 2 96.0 VAC_Y_1506 4.8 2 9.6 VAC_Y_1507 4.8 2 9.6 Table 13 – Duration of task Task Number Time Required (hrs) per train Personnel Required per task Required Man Hours per task per train VAC_Y_1508 12.0 2 24.0 VAC_Y_1509 2.0 1 2.0 VAC_Y_1510 1.5 2 2.0 VAC_Y_1511 0.6 1 0.6 VAC_Y_1512 2.0 1 2.0 VAC_Y_1513 5.0 1 5.0 VAC_Y_1514 1.5 1 1.5 VAC_Y_1515 3.0 1 3.0 VAC_Y_1516 4.5 1 4.5 VAC_Y_1517 2.0 2 4.0 VAC_Y_1518 2.0 1 2.0
30 Required skill levels and tools 31 Required skills The technicians shall complete relevant system maintenance training on the ventilation and air conditioning system and have following abilities: 1. Fully understand the safety precaution and requirements while performing the maintenance tasks on the ventilation and air conditioning system and equipment in a train or workshop. 2. Able to read and understand the relevant maintenance instruction, drawings and schematic. 3. Able to use the maintenance tools and measuring instruments to perform the assigned maintenance task. 4. Able to follow the step by step maintenance instructions to carry out the regular inspection, cleaning, checking, measurement and adjustment, replacing worn and aged parts and consumables. 5. Able to perform fault diagnosis in a logical and effective, including interpreting the displayed fault information, simulate the trouble mechanically as well as electrically. 6. Carry out on-site and workshop troubleshooting including identifying the root causes, replacing the defective Line Replaceable Unit etc. 7. Perform testing and commissioning to ensure the repaired system / equipment is fit for service. All maintenance staffs who are required to work within MRT Bangkok Purple Line premises shall complete the relevant operations and maintenance rules and procedures from BMCL, MTJV / JTT. They shall adhere and observe to the relevant rules and procedure during the maintenance of ventilation and air conditioning system. 32 Maintenance tools 1. Allen Wrench
2. Bar Extractor for Condenser Fan (MK077-106) 3. Bearing Force-fit Tool 4. Brazing Torch Kit 5. Caps or Plugs for Valve Openings & Refrigerant Lines 6. Clean Water Source 7. Crimping Tool for Terminal 8. Extractor Sleeve (MK092-106) 9. Feeler Gauge 10.Fin Comb Condenser coil: fin pitch: 3mm, thickness t0.18mm Evaporator coil: fin pitch: 2.5mm, thickness t0.18mm 11.Gasket Scraper 12.Gauge Manifold Set 13.Heat Sealing 14.Hex-head Wrench 15.High Pressure Compressed Air Set (30 psig max) 16.Leak Detector (Halide Torch or Electronic Unit) 17.Lubricating Oil for SUS Bolt 18.Needle Nose Pliers 19.Oil Acid Test Kit 20.Overhead Crane (500 lb. Capacity) 21.Padded Sling 22.Press in Sleeve (MK) 23.Pulley Extractor 24.Refrigerant Oil 25.Refrigerant R-407C 26.Refrigerant Recovery Unit 27.Refrigerant Sealant
28.Ring Pliers 29.Screwdriver 30.Sealant (TSE-3925C or equivalent) 31.Soft-faced Hammer 32.Soldering Iron 33.Small Pry bar 34.Torch 35.Torch Wrench 36.Vacuum Cleaner 37.Vacuum Pump 38.Wire Cutter 33 Required personnel For details of the required personnel for different types of preventive and overhaul task, please refer to Section 3.5 - Duration of task. 34 Item failure rate Table 14 – Item failure rate Item Description LRU Functions No. of LRU / train LRU Failure Rate (10-6 hr) Air conditioning unit To supply cooled air and fresh air to maintain the satisfied interior condition 6 3.52
Refrigerating circuit To make the low pressure / temperature liquid refrigerant in order to absorb the heat from the return air and the fresh air 12 6.24 Compressor To supply the high pressure / temperature gas refrigerant to condenser coils by compressing the low pressure / temperature refrigerant from the evaporator coil 12 0.1 Condenser coil To remove the heat from the high pressure / temperature gas refrigerant in order to liquefy the refrigerant 24 0.1 Dryer To remove the moisture which remains in the refrigerating circuit 12 0.033 Capillary tube To reduce the refrigerant pressure in order to facilitate the evaporation process of the refrigerant 12 0.033
Evaporator coil To absorb the heat from the return air and fresh air which is introduced into the air conditioning unit 6 0.1 Accumulator To separate the gas and liquid refrigerant entering to compressor 12 0.033 Condenser fan To supply the air for the cooling of gas refrigerant in the condenser coils 12 0.1 Evaporator fan To induce the return air and the fresh air into the air conditioning unit 6 0.1 High pressure switch To protect compressor from unusual high pressure 12 0.033 Low pressure switch To protect compressor from unusual low pressure 12 0.033 Emergency inverter system To convert the DC power supply to the AC power supply for the evaporator blower drive at AC power loss mode 6 0.75
Transformer To up voltage of AC power supply for evaporator fan from emergency inverter. 6 0.02 F/R air damper To control the mixed ratio of fresh and return air volume based on passenger load for the reduction of heat load. 6 0.167 Table 14 – Item failure rate Item Description LRU Functions No. of LRU / train LRU Failure Rate (10-6 hr) To shut off fresh air or return air in accordance with the outside or inside fire detection Emergency damper To draw more fresh air into the air conditioning unit in case of power loss by making the new route which bypasses the evaporator coil 12 0.084 Filter for mixed air, fresh air To remove the dust and keep the air and system components clean 18 0.033
Over current relay To protect the evaporator fan from over current 24 0.02 Temperature sensor To detect the air temperature at strategic locations 12 0.02 Smoke detector To detect smoke generated at outside of train 6 0.1 Magnetic contactor To open / close the power circuit for motor 10 0.033 Relay To control the electric circuit 4 0.033 Cab air handling unit To feed conditioned air from main duct of air conditioning 2 0.885 Fan To supply conditioned air to cab from main ducts. 4 0.333 Damper To control the supply air volume. 2 0.084 Magnetic contactor To open / close the power circuit for motor 4 0.033 Relay To control the electric circuit 4 0.033 Air conditioning control panel To control the air conditioning system 3