As part of a contract with Unipart, IPS carried out an overhaul of traction motors from Merseyrail, helping them to become one of the best performing train operators in the UK.
The challenge
IPS were awarded the contract from Unipart for the overhauling of G310 traction motors from Merseyrail, dating back to 2005. At the time, Merseyrail were the worst performing TOC in the UK with a >20% in-service failure rate.
This was the first major rail contract for IPS.
The solution
Through open, constructive communication with both Unipart and Merseyrail, IPS was able to identify ongoing issues and investigated how best to solve them.
IPS immediately added value by making small initial changes to the specification and introducing the HiTRAX coil insulation system, designed specifically for rail traction motors. 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. In addition, all coils were manufactured in-house by IPS, giving full control over the process and ensuring quality standards are maintained.
The standard specification for the motors required 57 checks to be conducted, but IPS carried out 157 checks, taking a more thorough approach. As a result, the lifespan of the traction motors were significantly extended.
Why IPS
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The Results
The quality of IPS’s overhaul is clearly evident as Merseyrail’s in-service failure rate reduced from over 20% to under 0.02%. This has helped Merseyrail achieve average Public Performance Measure (PPM) results of over 96%, indicating they are amongst the best performing train operators in the UK.
In over 10 years of working together, a positive and collaborative relationship has been forged, an excellent example of a repairer, maintenance provider and end user working together. This has enabled IPS to grow significantly and expand their rail services division, and thus providing the opportunity to innovate several times. With an open, collaborative attitude, a culture of joint learning has provided benefits to Unipart, Merseyrail and IPS.
IPS have now handled around 1500 GEC G310 traction motor repairs, ranging from standard overhauls to full rewinds, and averaging 12 scheduled repairs per month as well as additional in-service failures. With an on-time delivery rate of 100% since the contract began, IPS will continue to service the motors through to the end of their lifespan, providing maintenance and overhaul services until 2021.
I would recommend using IPS for any type of electric motor reconditioning.
Phil Locke, Fleet Procurement Manager, Merseyrail
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