18 January 2006
Update on number of cracked equipment found on East Rail trains and new improvement measures
 
The Kowloon-Canton Railway Corporation (KCRC) today continues to conduct non-destructive test (NDT) on the welding of mounting brackets of East Rail trains underframe components. As of noon today, among the 33 major components checked in the past day, cracks were found on 1 more battery box. (Please refer to attachment for details).
Earlier today, in the special meeting of Legislative Council Subcommittee on matters relating to railways of the Panel on Transport, Mr Michael Tien, KCRC Chairman, stated that KCRC would take a series of measures to resolve the crack problem on the welding of underframe mounting brackets.
 
MEASURE TARGET COMPLETION DATE
To re-design the mounting method of a total of 8,000 underframe components of 23 categories, in order to reinforce the integrity of all components. The measures include:
Depend less on welding, and to use more nuts and bolts, as well as to use supporting brackets for secondary support
Design new mounting method for all the 8,000 components
Design work will be completed in February; Reinforcement work will be completed within one year.
 
KCRC has also taken the following immediate measures, including:
(1) To use non-destructive testing (NDT) on examination
(2) To closely monitor the crack situation, KCRC will record the crack situation in detail on all the 8,000 components and liaise with the Railway Inspectorate and the Review Panel to apply the same standard to conduct inspection of
Components with no crack : Inspect every 3 months
Components with crack that is less than 14mm : Inspect every 2 months
Components with crack that is between 14mm and 40mm : Inspect every month
Components with crack that is between 40mm and 50mm : Inspect every week
Components with crack that is between 50mm and 68mm : Inspect every two days
Components with crack that is more than 68mm : Remove the components at once and stop operating till completion of maintenance. Maintenance works include re-welding, adding mounting bracket or replacing the components as required
 
Mr Tien said that the current measures and the new measures will ensure the safe operation of the railway.
 
AS AT 18 JAN NOON TOTAL NO. OF CRACKED EQUIPMENT FOUND AFTER NDT PROGRESS OF APPLYING NYLONS PROGRESS OF INSTALLING SECONDARY SUPPORT
MAJOR ITEM NO. OF EQUIPMENT INSPECTED NO. OF EQUIPMENT WITH CRACK FOUND
DC Equipment Case 59 17 2 59 0
Main Equipment Case 57 57 18 57 12 out of 18
Main Compressor 116 116 10 N/A Completed
MA Set 116 116 31 116 0
MA Converter Case 116 97 15 116 81 out of 84
Auxilliary Equipment Case 116 116 72 116 (5 repaired)
Main Transformer 116 37 <2> 116 0
Battery Charger 84 24 2 84 0
Battery Box 336 92 2 336 0
Cab Air Conditioning Unit 58 10 3 58 0
Compressor Choke 116 116 8 116 0
MA Choke 116 38 0 116 0
Smoothing Inductor 59 25 0 59 0
Total 1465 861 163 1349  
Non-major item          
Traction Motor Mounting 464 24 0 ---  
Brake Unit 348 27 1 ---  
Main Reservoir 792 54 12 By 31/1  
Auxiliary Reservoir 116 38 1 ---  
Surge Suppression Reservoir 1392 90 23 ---  
Wheel Slide Unit 348 27 1 ---  
Brake Caliper 2784 144 0 ---  
APC Antennae 116 12 1 ---  
Resistor Case 116 5 0 ---  
Rectifier Case 59 7 1 59  
Total 6535 428 40 59  
Remark:
<> Represents upper mounting bracket.