Vehicle Flange Lubrication
Synopsis
Our client had experienced difficulties with their vehicle mounted flange lubrication system. Blockage of the lubrication nozzle was a common occurrence, rendering the system ineffective. This was not always detected during normal service. The problem was commonly identified during routine fortnightly maintenance. In service, the lubrication pump activated for 7 of every 120 seconds, so there was also concern whether lubricant was applied where most needed. A review of lubricant types and techniques for control of lubricant application was needed.
Key Client Issues
The client required a fully functional, reliable and lower maintenance lubrication system. The key issues arising were the risk of non-application of lubricant, and lubricant potentially being applied at the wrong time and location on the network, giving rise to:
- Flange and rail wear.
- An increased derailment risk.
- Increased noise.
Tata Steel was appointed to investigate alternative lubricant options, and how to improve application in terms of time and location on the network.
Solutions
Tata Steel investigated the performance of alternative lubricants, and concluded that the existing flange mounted system could be restored to full working order using a different lubricant without the risk of intermittently blocking the applicator nozzle.
To ensure lubricant application at the right time and place, a Global Positioning System (GPS) was recommended. This solution can ensure effective control of the process of lubricant application, optimise lubricant consumption, and mitigate all the client's concerns in relation to derailment risk, wheel/rail wear and noise.
Client Benefits
The conclusions of Tata Steel's investigations enabled the client to:
- Ensure consistent lubricant application and reduce lubricant system maintenance.
- Apply lubricant in the optimum locations on the network.
- Mitigate the derailment risk.
- Reduce noise.
- Increase running distance between wheel flange re-profiling, and correspondingly increase wheelset service life.
- Reduce rail wear.
