Hydraulic Retrofit of Locomotive Generator and Electric Motor Drive System Saves Over $1,000,000 Annually
New hydraulic system design and retrofit dramatically improves manufacturing operations, while reducing maintenance and replacement part costs.
Customer:
Midwest ManufacturerIndustry:
Industrial ManufacturingEquipment:
Locomotive Generator and Electric Motor Drive SystemServices Provided:
Trouble Shooting, Hydraulic System Design, and RetrofitResults:
Cost of equipment, and replacement parts, reduced from $1,000,000+ per year to under $150,000 per year.
Summary (Problem)
A Midwestern manufacturer was using a locomotive to transfer a highly conductive material in an environment where ambient temperatures commonly reached 130+ F. The average duty cycle of the generator and drive motors was 4-6 hours. The customer was spending over $1,000,000 / year in replacement generator and drive motor parts alone.
A crew of three worked 7 days a week, 10-12 hours per day, removing and replacing failed components. The environment was such that a hydraulic drive system was considered as an option, but the duty cycle was still a concern due to the environment.
Process and Outcome
The equipment was observed by IRG in operation and production and maintenance personnel were consulted. A hydraulic system design was then submitted and approved.
- Total Turnkey cost < $200,000
- We consulted with customer maintenance personnel during installation and emphasized proper maintenance and troubleshooting of the system.
Results:
The main drive components have now been in operation for over 25,000 (twenty-five thousand) hours of operation without replacement. The total maintenance cost of equipment is now under $150,000 / year.