Latest Flir ThermaCAM in use on UK Bullet train

Hitachi Rail Maintenance is investing in the latest technology with a ThermaCAM T400 for use in their workshops, maintaining the trains on the Channel Tunnel Rail Link

The build quality of the new Hitachi train that will serve the Channel Tunnel Rail Link is superb.

Travelling at speeds of up to 140mph it will cut the journey time from Ashford to St Pancras to just 37minutes.

Based on the iconic Shinkansen or Bullet Train it has 24 wheel-sets, 16 of which are driven.

This ensures exceptional power and the ability to meet timetables even with 25% of the traction equipment isolated.

The first consignment of the planned 29 trains is now in the UK and the focus is on building the support and maintenance structure to ensure these quality trains provide a quality service.

Central to this is a young and enthusiastic maintenance team headed by the Hitachi Rail Maintenance Engineering Manager, Dan Barrett.

It is his job to oversee the development of the maintenance programme, as the team's knowledge of on-board systems develops.

And Hitachi Rail Maintenance is certainly investing in the latest technology to complement the programme.

Non-intrusive condition monitoring is a very important element of this.

For example at the company engineering depot at Ashford, an MRX system has been installed that will automatically measure wheel profiles and shoe gear thickness.

Thermography was another 'must have' as far as Dan was concerned and as a result Hitachi Rail Maintenance has recently taken delivery of a Flir Systems ThermaCAM T400.

"I've worked for other organisations that have not used thermography and have suffered repeat failures as a result," Dan explains.

He cites checking the integrity of cable fixings on high voltage jumper cables as typical examples.

These inter-vehicle cables from the secondary windings of the transformer terminate in sealed and watertight junction boxes.

"Having to undo those boxes just to check the fixings are torqued to the correct value is time-consuming and often fault inducing," Dan adds: "Without thermography there is no alternative as if a bad termination isn't rectified the contact will burn out and that will incur significant parts and labour cost.

Using the ThermaCAM T400 this job will take seconds.

All we need do is look at the thermographic image of cable for tell-tale signs of a loose connection - it's such an effective technology".

The inspection of high voltage connectors is another early application for the camera.

Traditionally contactor tips would be replaced, regardless of their condition, every six months.

"It's an arbitrary task," Dan continues: "Using thermography we can actually see if the replacement is necessary and we don't need to disturb a system if it's working fine".

Other planned applications include checking for loose connections and intermittent faults on relay panels and terminal bars; monitoring motor temperatures - specifically around bearings casings on blowers and HVAC fans; and checking high resistance contacts on third rail shoe gear cabling to prevent 'burn-up'.

Naturally the portfolio of thermographic applications at Hitachi Rail Maintenance will grow as the team becomes fully conversant with the technology.

The camera has been purchased for the maintenance facility and as a result a programme is now in place to train all technicians to use the camera and most importantly, to interpret its findings against benchmarks.

"As we learn more about the technology, we will apply it to more tasks," Dan continues.

"At Hitachi Rail Maintenance we will maintain our trains in the most effective way possible and that means spotting problems early.

This camera is a very effective tool and if it saves us just one cable burn-up, it's paid for itself".

The Flir Systems camera was Dan's first choice.

He had seen other ThermaCAM models in action and was impressed with their performance.

The ThermaCAM T400 is the very latest model in this predictive maintenance range.

Launched in the UK only a matter of months ago this mid-range camera is designed for the advanced and frequent user of infrared.

The integration of thermal and visual imaging has been perfected in this model and it also introduces a clever overlaying facility called thermal fusion.

This allows the automatic and seamless transition of images from thermal to visual and vice versa whilst retaining all measurement functions in both view modes.

In addition to thermal and visual imaging Hitachi Rail Maintenance was also attracted by the large touch screen on the camera, an industry first.

This allows sketching via stylus and speedy text entry via the touch screen QWERTY keyboard enabling the vehicle car identification number to be embedded on the infrared image.

This ensures all the information is to hand for report generation.

"We are really looking to this investment to help us maximise equipment life, drive reliability and reduce unit downtime" Dan concludes: "We want our service to be second to none and thermal imaging has an important part to play in helping us achieve this".

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