Leading Traction Motor and MA Set Repairs - Houghton International

Houghton International Rail

Leading Traction Motor and MA Set Repairs

CASE STUDY:

Tyne & Wear Metro Nexus, the operators of the Tyne and Wear Metro approached us as they required the life span of their entire fleet of motors to last until 2023. The decision being whether to buy in new rolling stock or extend the life of the existing fleet.

We offered HiTRAX™, our insulation system proven to life extend DC and AC traction motors for over 10 years as a solution for the debilitated traction motor field systems.

As a result, part of their £60 million reinvigoration process is now dedicated to rewinding the field systems on their entire fleet of motors with the HiTRAX™ system, resulting in their life span being extended to at least 2023 when new rolling stock will be introduced.

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Houghton International Rail Leading Traction Motor and MA Set Repairs

WELCOME Our Rail Division pioneers technical and commercial innovation in the repair, maintenance and life extension of AC & DC traction motors and MA Sets into the UK and global rail markets. We have serviced and repaired over 4,000 individual traction motors ranging from G310s, EE507s, high speed train (HST) motors, both Brush and GEC type, in addition to a broad range of other AC traction motors.

Products and services include; • AC and DC traction motor repairs • coils. The only insulation system in the world developed and marketed specifically into the traction motor market by a traction motor repair company • HiTRANS Our patented (Protected by UK Patent No 2494369) transient dynamic MA Set test process that electrically simulates full load conditions on any type of MA Set, replicating exactly what happens in service • Auxiliary equipment, heavy repairs • Consultancy services; engineering and technical support, development projects, site visits and audits Our vision is to have one of our products improving the performance of every train in the world, and our mission is to be rated the number one supplier into every customer we service.

Our strategy is to develop long-term partnerships with our customers and by listening to our customers needs, understand the markets in which they operate and how they add value to their customers.

Through our commitment to total quality we plan to continue to lead the UK’s traction motor repair market in terms of innovation and customer service through investment in plant, equipment and people.

In 2012 we invested in new facilities and plant including a silicone VPI plant to complement our epoxy capability, along with TIG welding and undercutting equipment enabling us to provide the comprehensive range of operations required for a high quality armature rewind. This has resulted in a 100% increase in both traction motor and MA Set capacity.

We value our independence and work alongside our customers to solve their problems and provide a flexible commercial framework that adds significant value to their businesses. That’s why our customers keep coming back to us.

Please contact us to learn how we can add value in your business.

Michael Mitten Chief Executive Officer Houghton International Rail Leading Traction Motor and MA Set Repairs

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everyone matters

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Houghton International Rail Leading Traction Motor and MA Set Repairs

OUR EXPERTISE OUR PEOPLE OUR QUALITY

OUR EXPERTISE

OUR PEOPLE

We have invested in an AC motor test rig which can dynamically test all AC traction motor specifications and rotor bar crack detection equipment, which is to our knowledge unique in the UK. We are also the UK’s only traction motor repairer with the capability to rewind and vacuum pressure impregnate (VPI) both epoxy and silicone resins.

We employ for attitude and train for skill. We aim to be the employer of choice for talented people and invest in them to ensure that they have the opportunities to develop. In return we expect loyalty, a total focus on our customers’ needs, delivery to deadlines and commitment to our total quality process.

We provide the UK’s highest quality traction motor repair service and our customers trains run on time with the confidence that their traction motors will not fail in service.

At Houghton International ‘everyone matters’.

We understand that our customers are judged by train reliability and punctuality. We work alongside them to solve their problems and provide a flexible commercial framework that adds significant value to their business.

Houghton International operates in sectors where quality procedures and the safety of equipment are critical.

Our quality assurance model is designed around the requirements of each individual motor type meaning we create a dedicated quality management system bespoke to each individual product.

We believe that we are the only UK company with the capability of producing edge wound field and interpole coils for DC traction motors utilising our in-house coil manufacturing facility.

In February 2013 South West Trains were the best performing mid-life operator in the UK.

Houghton International Rail Leading Traction Motor and MA Set Repairs

OUR QUALITY

As such we have developed a rigorous quality policy with processes and procedures to ensure that everything we do is of the highest standard. These policies and procedures are reviewed across all areas of the business on an on-going basis which reflects our culture of continuous improvement.

Our quality management system is accredited to BS EN ISO 9001:2008 and our occupational health and safety management system is accredited to OHSAS 18001; 2007.

We plan to achieve ISO 14001:2004 accreditation.

As part of our commitment to total quality assurance and the development of our supply chain we have established strong relationships with suppliers.

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Houghton International Rail Leading Traction Motor and MA Set Repairs

AC / DC TRACTION MOTOR SERVICES Houghton International offers the broadest scope of services for AC / DC traction motors. Our cradle to grave OEM manufacturing and life cycle management service produces the entire range of original motors to the train OEM’s specification, under licence if required, with options to provide life-cycle or in-warranty service and maintenance. Houghton International are specialists in rewinding and overhauling AC traction motors. Our pioneering HiTRAX™ life extending insulation system was originally designed as an AC solution, and subsequently transferred to DC motors.

We are the UK’s only traction motor repairer with the capability to rewind and vacuum pressure impregnate (VPI) both epoxy and silicone resins. This is complimented by in-house coil manufacturing, rotor bar production and induction braizing technology.

Our aftermarket service is focused on train operators, owners, bogey overhaulers and OEM’s requiring scheduled maintenance, casualty support and in-depot condition monitoring. We have worked on a wide variety of AC traction motors covering fleets across the UK, Scandinavia and Asia. Hong Kong’s MTR Corporation specify our HiTRAX™ system for their AEG AC traction motor rewinds.

Our research and development division works closely with organisations planning to either solve a minor problem, through to exploiting our expertise and academic links to develop new intellectual property rights for commercial exploitation. We have worked with Porterbrook in the UK as life extension consultants for their 458 fleet Juniper AC traction motors in conjunction with Newcastle University.

We work with all the mainline Roscos in the UK as well as rolling stock OEM’s on a project basis, delivering quantified improvements.

All this complements our contracted volume, service, maintenance and manufacturing provision.

TECHNICAL CAPABILITY AND CAPACITY: • •

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Capacity to process 100+ AC traction motors per month VPI facilities: 2 x individual plants processing: Epoxy (Ulitmeg 2002) and Silicone (Wacker H62) resins allowing 160 °C Class F – 220 °C Class C resin impregnation HiTRAX™ insulation system proven over 10 years for both epoxy and silicone systems. The ideal life extension solution providing cutting edge composite insulation technology to maximise life cycle 2 x Schenck balancing machines Separate 11,000 sq. ft. coil manufacturing facilities CAD function Dynamic rotor bar crack detection Induction braizing facilities Load testing facility and capability Winding and insulation system redesign services

Houghton International Rail Leading Traction Motor and MA Set Repairs

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WORK SCOPE TRACTION MOTOR AND MA SETS SERVICED Traction motors and MA sets serviced include; • • • • • •

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Brush EE507 traction motor Brush TM21/41 traction motor Brush MK 7/7A MA Sets Brush MK12/12A MA Sets Brush MK3 MA Set GEC MK1 and MK1A MA Sets. These are also referred to as 313 or 776 MA’s GEC 512 and Brush 1156 G310 traction motors Siemens traction motor

WORK SCOPE - OVERHAUL AND HEAVY REPAIR An overhaul consists of the following work scope; • • • • •

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Receipt of motor into works Dismantle and inspect Remove old bearings Datum all component parts to specification Carry out static tests to field and armature windings against specification requirements Steam clean and stove all windings

• Carry out Non-Destructive Testing (NDT) / Magnetic Particle Inspection (MPI) checks where required by specification • Clean and paint all component parts • Replace / repair all faulty components • Supply and fit new bearings • Assemble motor • Test run motor • Paint motor • Quality assurance check prior to dispatch A heavy repair will consist of the same work scope as above and all or some of the following work scope; •

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Full armature rewind with existing commutator, including the manufacture of new coils and VPI process Full armature rewind with new commutator, including the manufacture of new coils and VPI process Full field and interpole rewind, including the manufacture of new coils and VPI process Full field and interpole re-insulation and VPI process Supply and fit of new armature shaft Weld repairs from failed NDT / MPI checks Houghton International Rail Leading Traction Motor and MA Set Repairs

MECHANICAL & ELECTRICAL TESTING Traction motors sent to Houghton International for repair undergo a series of mechanical and electrical checks that are governed by the overhaul specifications Houghton International adhere to using a route card system.

Route cards include an initial test and data report, assembly data report and test sheet and are populated at each stage of the repair process which highlights any defects that are present.

Route cards are derived from the traction motor specifications to ensure product output is as required.

The commutator profiles are carried out on receipt of the product, through each stage of the repair and also during the final inspection.

The severity of the repair will determine the checks and tests conducted. For example, if an armature fails an electrical check and is deemed as requiring a full rewind, the new winding fitted will undergo several tests including pressure tests and resistance checks throughout the rewind process.

An overhauled armature will not need to undergo the same checks as a fully rewound one as the checks that are specific to this situation are different.

Route cards have specific job numbers and are cross referenced with product serial numbers to identify each product.

Houghton International Rail Leading Traction Motor and MA Set Repairs

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CASE STUDY: “This was a great example of FCC, Unipart Rail and Houghton International staff working together to understand the potential effect on our customers and putting together unique robust solutions that averted loss of availability and potential severe disruption to our customers”.

Ian Duncan, Head of Fleet GN

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First Capital Connect In February 2009 the UK witnessed one of its harshest snowfalls in the London region for over 10 years. As a result First Capital Connect (FCC) had over 40 traction motor failures due to earth faults. The implication of this was a shortage of vehicles.

Once the initial impact was assessed, FCC approached Unipart Rail, who immediately involved their partner supplier Houghton International. A triage team was set up to assess the actual damage to each traction motor and the level of work required to bring them back to a serviceable condition. This also included Hornsey Depot’s capacity to remove and refit the units and Houghton International’s ability to individually assess each traction motor to determine whether it required major rework, such as an armature rewind or a light overhaul and dry out.

In a matter of days, full availability of trains for passenger service was achieved.

Within three weeks, quality, cost and delivery had been achieved. All defective motors had been removed, rectified by Houghton International and refitted to the vehicles. The drive, enthusiasm and flexibility of working together by all parties and not compromising any core values were greatly appreciated by FCC.

Houghton International Rail Leading Traction Motor and MA Set Repairs

HiTRANS Our patented transient dynamic MA Set load testing process Many of our customers were experiencing major issues with their MA Sets. MA Sets were being returned from other repairers and failing almost immediately in service. As a result, we were asked to develop a solution that ensured every MA Set we repaired would work under full load conditions first time, every time.

The result is HiTRANS™, our patented (Protected by UK Patent No 2494369) transient dynamic MA Set test process that electrically simulates full load conditions on any type of MA Set. It replicates exactly what happens in service, which means that the unit has been tested at full working load before it leaves our facility.

The Benefits: • Units work first time, every time • Eliminates MA Set related in-service failure • Proven life extension with HiTRAX™ insulation system • Tests each MA Set through a dedicated controller i.e. FM2 Type • Full load testing proves each individual wound component • Reduced ongoing maintenance costs • Reduced life-cycle cost

Our repairs are proven to work first time, every time, and to a life expectation in line with the operating life of the train.

We believe that we are the first company in the world capable of simulating exactly the electrical load conditions both through the MA Set controller and the incoming electrification.

Houghton International Rail Leading Traction Motor and MA Set Repairs

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CASE STUDY:

Porterbrook “Following reliability problems with traction motors, Houghton International were approached and asked to apply their knowledge and experience to fully evaluate the condition of some sample motors.

The professional team at Houghton International assisted in the development of a comprehensive test regime which was augmented with a thorough physical examination of the component parts, drawing on the expertise of their suppliers and industry partners where appropriate. All test results were interpreted and presented in a clear and concise manner that ensured they were understood.

The sound conclusions drawn from this investigation will be used to improve the future maintenance strategy for all Porterbrook traction motors of this type and Houghton International are a key partner in this on-going development work.�

Garry Taylor, Porterbrook Fleet Manager, London & South East

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Houghton International Rail Leading Traction Motor and MA Set Repairs

Our traction motor life extension solution HiTRAX™ is an insulation system proven to extend the life of DC and AC traction motors for over 12 years. It is a combination of both our traction motor and high voltage expertise applied to solve the problem of deteriorating dielectric capability of problematic motors.

Life extension can be required for numerous reasons; from poor original manufacturing processes and / or materials to, most commonly, degradation due to age, environmental exposure and transient voltages from inconsistent electrification.

We understand that traction motors require special attention.

They operate in unique conditions that expose them to heavy ingress of moisture and often corrosive dirt. Ambient running temperatures can range from -40°C to +50°C, and in humidity greater than 95%, providing maintenance issues to train owners and operators. Air intakes are often open to the elements, meaning snow and ice cause problems in winter

Houghton International Rail Leading Traction Motor and MA Set Repairs

periods, as do the leaves in the autumn. All contribute to the deterioration of a motor windings dielectric integrity.

HiTRAX™ combines insulation materials that have the greatest dielectric durability throughout the wide temperature range traction motors are exposed to in their life cycle, with the highest specification VPI resins and stringent process control, tested to extremes. HiTRAX™ is proven to work in conjunction with both epoxy and silicone VPI resins, although we believe epoxy provides the absolute superior lasting protection.

HiTRAX™ is proven because it has been running across the UK’s rail system for longer than 12 years without failure.

However, it is imperative that all elements within our total quality system are followed throughout the manufacturing, rewinding and VPI process for it to be absolutely effective. To date, we have never experienced a motor failure due to its insulation system.

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CASE STUDY:

“I would recommend using Houghton International for any type of electric motor reconditioning.”

Phil Locke, Fleet Procurement Manager, Merseyrail

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Merseyrail Merseyrail were experiencing a 20% in-service failure rate for their G310 traction motor due to lack of product development work and required an urgent solution.

We immediately added significant value by making small initial changes to the specification and introducing our HiTRAX™ system, the only insulation system in the world developed and marketed specifically into the rail traction motor market by a traction repair company.

The improvements have reduced the Merseyrail in-service failure rate to under 0.02% and in 2012 Merseyrail suffered zero warranty failures on Houghton International serviced traction motors.

Houghton International Rail Leading Traction Motor and MA Set Repairs

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IN DEPOT MAINTENANCE Owners and operators share a similar challenge. How to improve the performance of their traction motor fleet.

OUR SOLUTION COMPRISES TWO ELEMENTS: 1. Improve the overhaul process and life extend windings

OUR SPECIALIST ENGINEERS CAN TEST FOR THE FOLLOWING WHILE STILL CONNECTED TO THE TRAIN: • Surge on windings • DC dielectric strength • Insulation resistance (Megger test) • Polarisation Index • 1,2 / 50 pulse

2. Improve in depot maintenance

Our solution covers AC and DC traction motors, MA Sets and transformers combining the highest quality overhaul and life extension schedule when taken out of service, alongside our expert engineers in depots, to support traction motor maintenance programmes.

Houghton International Rail Leading Traction Motor and MA Set Repairs

THE BENEFITS: • Reduced in-service failures • Improved reliability and life cycle management • Identification of vulnerable motors before they fail • Data driven failure mode analysis • Extends time between overhauls • Maintenance can be scheduled more efficiently • The services of a dedicated in depot team or an individual engineer on a per shift basis

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Houghton International Rail

CONTACT Houghton International Riverside Court Fisher Street Newcastle upon Tyne NE6 4LT United Kingdom

T: +44 (0)191 234 3000 E: info@houghton-international.com W: www.houghton-international.com

Due to our policy of continuous improvement Houghton International Electrical Services Ltd reserve the right to modify product specifications without notice. © Houghton International Electrical Services Ltd 2013.

HiTRAX™ and HiTRANS™ are trademarks of Houghton International Electrical Services Ltd.