date: 20-02-2019 · c-dac will study the issues 6-11 and propose solution by 20.03.2019. 12....
TRANSCRIPT
Fax : (0522)-2452581 Telephone: (0522)·2450374 Email: dsetpgroupl@gmai l. com
No. EL/11.5.5/21
Principal Chief Electrical Engineer,
1ffi"'ff mct>R - ~~ ~ ~QA ~ ~ lJAif) WrcR ~- 226011
Govt. of India · Ministry of Railways Research, Designs &. Standards Organization,
LUCKNOW - 226011
Date: 20-02-2019
• Central Railway, HQs Office, 2"d floor, Parcel Office Bldg., Mumbai - 400 001
• East Central Railway, Hajipur (Bihar) - 844 101
• Eastern Railway, Fairlie Place, Kolkata- 700 001
• East Coast Railway, Railway Complex, Bhuvneshwar- 751 023
• Northern Railway, Baroda House, New Delhi- 110 001
• North Central Railway, Allahabad- 211 001
• South East Central Railway, Bilaspur - 495 004
• South Central Railway, HQs Office, Rail Nilayam, Secunderabad- 500 071
• South Eastern Railway, Garden Reach, Kolkata - 700 043
• Southern Railway, Park Town, Chennai- 600 003
• West Central Railway, HQs Office, Opp. Indira Market, Jabal pur - 482 001
• Western Railway, Churchgate, Mumbai- 400 020
Sub: Minutes of the Meeting held at ELS/HWH/ER on 14-15.02.19 on reliability of
Propulsion Equipments of IGBT based 3-phase locomotives.
A meeting on reliability of Propulsion Equipments (Traction converter, Auxiliary converter &
VCU) of 3-phase loco was held at ELS/HWH/ER on 14-15.02.19.
Minutes of the meeting of the same is enclosed herewith for kind information and necessary
action please.
~~0\ {Suresh Kumar)
Encl: As above For Director General/Elect.
Copy to:
1. Secretary (Eiec. Engg./RS), Railway Board, Rail Bhawan, New Delhi-110 001. For kind information. (Kind Attn.: Shri A.K. Goswami, DEE/RS)
2. Principal CEE, Chittaranjan Locomotive Works, Chittaranjan - 713 331(WB): for kind information and necessary action please
3. M/s ABB Limited, Survey No. 88/3-4, Nelamangala Taluk, Bangalore- 562 123
4. M/s. BHEL, EDN, PB.No.2606, Mysore Road, Bangalore-560 026
5. M/s. BTIPL, ERDA Road, Maneja, Vadodara-390 013
Page 1 of 2
6. M/s. CGL, Plot No. 9, New Industrial Area, Mandideep - 462 046.
7. M/s Medha Servo Drives Pvt. ltd., P-4/5 B, Nacharam, Hyderabad- 500076
8. M/s Autometer Alliance limited, C-63, Sector- 57, Noida- 201 307
9. M/s Hind Rectifier limited, Regd. & H.O. Lake Road, Bhandup {W), Mumbai - 400 078
~~\i7 {Suresh Kumar)
End: As above For Director General/Elect.
Page 2 of 2
Minutes of Meeting held at ELS/HWH on 14-15.02.2019 on Reliability of Propulsion equipment of IGBT based of 3 Phase electric locomotives.
Members Present·
RDSO 1. Shri 0. P. Kesari, PEDSE
2. II Suresh Kum ar, DSE/TPS.
3. II Shailendra Kumar Deo, SSE/TPS
Railways 4 . II Gautam Benergy, PCEE/ SER (on 14.02.19) 5. II S.N. Dubey, PCEE/ER
6. II Navin Kuma r, CELE/ER
7. II R.K. Tiwari, CELE/SER {on 15.02.19) 8. II A.M. Chaudhary, CELE/SR
9. II Arvind K. Ray/ Sr DEE/ TRS/RPM
10 . II D.V. Yadav / Sr DEE/TRS/HWH
11. II A. K. GUPTA / Dy. CEE /LOCO/ER
12. II Jeet Ram / Sr DEE/TRS/ SRC
13. II Anant Sadashiv / Sr DEE/TRS/ TATA (on 14.02.19) 14. II Atul Kumar / Sr DEE/TRS/ BNDM
15. II Rahul Pachori / Sr DEE/TRS/ TKD
16. II Manish Pratap Singh / Sr DEE/ TRS/ LDH
17. II J.P. Pal/ DEE/TRS/ HWH
18. II A. Koteswara Rao / DEE/TRS/ LGD
19. II Pawan Kumar Jayant/ DEE/ TRS/AQ
20. II B. Avinash / ADEE/ TRS/ VSKP
21. II Kirtesh Meena / ADEE/TRS/ N KJ
22. II Dinesh Sharma /ADEE/TRS/ GZB
CLW 23. II Pankaj Kumar, ADE/D&D/CLW 24. II Raghavendra /AEE/ Design-11/CLW
M/sABB 25. II Bobin V Zacharias I Se Engr./ABB/BLR
26. II Pradip Savaliya/ Product Manager / ABB/ BLR
27 . II Sutanu Ganguly / ABB/BLR .
M/s Hind Rectifier 28. II Arun mayekar/ AGM/ H. Rect.
29. II Sunil Jadhav/ DGM-Traction R&D.
30. II Shailesh Mehta I DGM-Traction R&D.
M/s Mitsubishi/ Elect. 31. II Pradip Gaur
M/s CGPISL. 32. II Ostw al S.S./ unit Head
33. II M.V. Nagarjuna/ Sr Manager
34. II Sudhir Yadav/ Sr. Executive
35. II Krishan Junwani/ Engineer
M/s BTIL 36. II C. Ramanujam/ Head BD
37. II Ashok Agarwal/ lead Low
M/s Medha 38. II A.N.V. Rao/ Dy Manager
39. II P. Venu I Engineer
M/sAAL 40. II Tapan Das/ Asst. Manager
41. II Dr. Akhter Alam/ Product Head
M/s C DAC 42. II Renji Chacko/ Associate Div. C-DAC
43. II Sigi C Joseph/ Scientist/ C-DAC
M/s BHEL 44. II I. H. Ansari/ Sr. Engineer
1.0 The meeting was convened to address the reliability issues of IGBT based traction converters, Auxiliary converters, TCN based Vehicle Control Units (TCN-VCU) and the status of the points discussed in
various meeting held in some last months.
Page 1 of 24
2.0 PCEE/ER welcomed all the participants in the meeting and wishes for the meeting to be fruitf ul in concern of reliability of the 3-phase locomotives.
3.0 PEDSE expressed his concern on the poor reliability and high failure raisings of traction & Auxiliary converters and stressed upon the various failures on account of software malfunctioning, failure of IGBT Power Modules and premature failure of electronic cards. Reliability improvement of 3-phase locomotive can be only achieved with team work by Industry and Railways. All stakeholders were requested to make their effort in this direction. As the population of 3-phase locomotives is increasing day by day, Railways have to improve their maintenance practices for better equipment reliability and OEMs to improve their design and manufacturing quality.
4 .0 M/s BHEL did not depute their technical representative for the meeting. The representative deputed to attend the meeting was not fully prepared to discuss technical issues. OSE/TPS/RDSO gave a presentation on reliability issues of converters of all makes. Brief of the detailed deliberations and action plan as discussed and decided during the meeting are as under:
5.0 Performance of C-DAC make TCN VCU
5.1 Performance of M/s. ABB make C-DAC VCU
SN
1.
2.
3.
Item
S/w mismatch &
Life sign missing
Cab redundancy
issue
Display issue
Action plan
C-DAC has informed that 9 locos out of 17 of ELS/RPM are running with modified software ver. 1010.
ELS/RPM has stated that issue of 'Software mismatch' is not fully resolved yet.
M/s C-DAC has reiterated that this message is com ing from redundant processor card; hence all processo r cards should be uploaded with modified software.
It has been decided that modified software shall be downloaded in balance locos of ELS/RPM and 20 locos of ELS/LDH by 25.02.2019.
CLW shall issue necessary instruction to the sheds. Performance of the locomotives with modified software shall be monitored.
• Cab redundancy in C-DAC based VCU to be provided in line with MICAS VCU.
• M/s C-DAC stated that system level correction as well application level correction is required to be done to implement the cab redundancy in line with MICAS-VCU. C-DAC shall make ready a prototype unit of VCU having cab redundancy features. PDC -20.05.2019.
• It has been decided that CLW/RDSO shall amend the specification that VCU having provision of cab redundancy sha ll only be procured.
• Aux. Converter failure data doesn't get displayed in DDU due to issue in ABB PDA syst em. 2 locos of ELS/RPM have been modified and performance is satisfactory. All the locomotive of ELS/RPM shall be modified by M/s ABB. PDC -15.03.2019.
• ELS/RPM reported that after complete charging of battery, 'BA Charger Overcurrent' message in display are coming. This issue is because of absent of MCB-100 which has not been provided by M/s ABB. M/s ABB shall provide MCB-100 in place of fuse. M/s
Page 2 of24
4.
5.
Error messages
Unreliable
indication
ABB stated that they will revert back by 25.02.2019 with a proposal for the same.
• Following error messages getting logged in C-DAC VCU on regular basis (&sometimes bogie gets isolated): (i) SLG1:0137-MC2 Boggie-11solated (ii) SLG2:0129-Dist In speed sensor Motor-3 (iii) SLG1:0017-Conv Coolant flow< Limit (iv) SLG1:0107-Dist. ln speed sensor Motor-1 (v) SLG1:0118-Dist In speed sensor Motor-2 (vi) SLG1:0136-MC1 Boggie-llsolated.
• These issues are related to Traction Converter of M/s ABB. M/s ABB stated that these issues will get eliminated in trial s/w version 96.
• PDC -15.04.2019.
Trafo, SR & AUX CON parameter (voltage, current, frequency &
pressure) displayed in DDU are inconsistent & unreliable for trouble
shooting & indication point of view.
This issue was due to calibration error. Corrected software has been
given and demonstrated in the shed.
ABB shall provide training to maintenance people of loco sheds
regarding exploration of background data.
5.2 Performance of M/s. CGL make C-DAC VCU
SN Item Action plan
1. Software issues Issues yet to be resolved 1. Wrong sensing of Speed:
At present there is no wheel diameter feature available. To be
implemented.
2. FLG1:0020- Emergency Vigi lance Brake - Loco not moving due to TE/BE reads "ZERO":
To be investigated this issue by C-DAC in TKO/RPM.
3. Issues with MU operation (i) Non formation of multiple unit with same cab i.e. cabl to cabl
and cab2 to cab2: This is because of non-availability of signals. (ii) Wrong panto sequence while activating locomotive from Cab-
2 (Pantograph of unoccupied cab of both the locos rising), while it was normal from cab-1.
For (i) & (ii) above, new software shall be downloaded by 22.02.2019 and C-DAC will join the trial.
4. Non- display of Node information of Master loco in the DDU of slave loco:
This is an issue of synchronisation of timings of BUR & SR. C-OAC will study and propose solution by 20.03.2019.
5. Non-display of Primary current {lpri) in DDU.
lpri signal is not available in MVB. To be looked into and C-DAC will study and proposed solution by 20.03.2019.
Page 3 of24
2. AF L not working.
3. VCB stuck-up.
4. MCB-100 trip
message not Pop-
up on DDU
6. Message "earth
fault trafo or
motor" logged in
data w ith Traction
Bogie isolated.
7. Message display
on DDU
6. Display of spurious messages in the DDU-'Angle Transmitter fail, More than one cab occupied, Emergency stop- shut down, Train bus disturbance slave, Simulation fault etc.
7. Tripping of DJ and simultaneous dropping of pantograph in case of 'Low/No OHE voltage' or isolation of any subsystem.
8. In fault messages, Date & Time of some messages get reset (i.e. 1.1.1970).
9. In error log some fault messages logged as error undefined.
10. Individual TM isolation is not addressed properly.
11. Wrong display of value (20%) of 0101-XangTrans (FLG-1) at '0' position of Throttle.
C-DAC will study the issues 6-11 and propose solution by 20.03.2019.
12. Non-working of Unloader valves of Main compressor during closing of DJ, in case of MR pressure < 8 kg/cm2 caused excess current drawn by the main compressor thereby sometimes L tripping of MCBs of Main compressor.
C-DAC to study the standard unloader cycle and implement the same as below:
AFL not working in standstill condition and also in running condition in some locos. M/s CGL and C-DAC shall take corrective action to eliminate the same.
The logic as per RDSO letter no. EL/ 4.2.17 dtd. 19.12.2018.
PDC- 20.03.2019.
Messages come after passing neutral section.
C-DAC will study the issues propose solution by 20.03.2019.
C-DAC will study the issues propose solution by 20.03.2019.
C-DAC will study the issues and propose solution by 20.03.2019.
Motor isolation popup message & BUR failure data is logged in DDS
but not displayed on DDU.
C-DAC will identify such messages and propose solution by 20.03.2019.
Page 4 of 24
5.3 Performance of M/s. BHEL make VCU
SN Item Action plan
1. TM isolation from • In BHEL TCN Locos, TM isolation from DDU is possible only from
DDU is possible CAB-1. From CAB-2 TM isolation not possible from DDU.
only from CAB-1 • BHEL has stated that they will study the issue and revert back by 28.02.2018.
2. Frequent failure of • Frequent failure of train bus communication in MU operation of
train bus MICAS based system with IGBT BHEL traction converter. The
communication in failures are transient but repetitive in nature.
MU operation • MU operation with C-DAC & BHEL make VCU has not been done yet.
• BHEL to give action plan by 28.02.2019 .
3. Multi operation • Multi operation failure in BHEL TCN loco due to reasons like
failure tripping of slave loco & panto lowered, traction not allowed in master & slave loco.
• BHEL state that trials in different combinations of MU gateway successful in ELS/VSKP.
4. Harmonic current • Trial has been conducted at ELS/VSKP in loco no. 31967 on
high. 24.01.19.
• Performance under watch .
5.4 C-DAC has been advised to review the manufacturing process of PCB cards of M/s ABB and CGL.
6.0 Performance of M/s. BTIPL make Converters (IGBT)
6.1 Make wise failure details M/s BTIPL make Traction Converter
No. of failures SN Cause of Failure
2016-17 2017-18 2018-19
(Apr-Jun) (Jui-Sept) (Oct-Dec)
1 Power Module 25 35 15 19 13
2 Software Malfunctioning 28 44 17 12 21
3 GDU/DCU card 7 22 2 8 6
4 Cooling blower 10 17 3 1 1
5 Others 8 37 19 23 32
Total Failures 78 155 56 63 73
Total Population 108 231 246 271 349
FRPCPY 72 67 91 93 84
Page 5 of 24
6.2 Shed wise failure details M/s BTIPL make Traction Converter
2018-19 (Oct-Dec)
SN Cause of Failure AQ BIA BRC CNB GMO G2B HWH KYN LDH LGD NKJ RPM TKO VSKP Total
1 Power Module 2 0 3 0 1 0 1 1 0 2 0 0 3 0 13
2 Software Malfunctioning 1 2 0 0 2 2 6 1 0 3 0 0 4 0 21
3 GDU/DCU card 1 1 0 0 3 1 0 0 0 0 0 0 0 0 6
4 Cooling blowe r 0 1 0 0 0 0 0 0 0 0 0 0 0 0 1
5 Others 4 5 1 0 5 6 1 1 1 1 6 0 0 1 32
Total Failures 8 9 4 0 11 9 8 3 1 6 6 0 7 1 73
Total Population (loco set ) 16 32 18 22 71 5 30 34 17 7 12 5 24 56 349
FRPCPY 200 113 89 0 62 720 107 35 24 343 200 0 117 7 84
6.3 Following deliberation done to improve the reliability of M/s BTIPL make converters:
SN Item
1. Fai lures of Power Modules
2.
3.
Main power OFF due to 'FLG-1 time out DC link circuit charge'
DC link overvoltage during regeneration.
Details and Action Plan
1. Release of new SW version 218T01BT & 318T01BT that limits the max allowed current when the coolant flow is suboptimal during the ramp up of the aux converter. • Modified software installed in- 127 locos out of 272 locos. • Balance locos in which mod. s/w to be installed - 145
• PDC -15.03.19.
2. Further, M/s BTIPL has proposed to replace a pipe in the converter cooling circuit that has an orifice of 18mm diameter with one that uses a larger orifice with 21.5.mm diameter to increase the coolant flow rate from 176 LPM to 237 LPM.
• RDSO has given approval to replace the cooling circuit with increased orifice of 21.5 mm in 25 locomotives vide letter no. EL/11.5.5/1/IGBT dtd. 12.02.2019.
• The performance test of the cooling efficacy shall be carried out in presence of RDSO engineers in March' 19 before starting up of summer season.
BTIPL has intimated that after the above mod ification, the failures of IGBTs shall
reduce considerably.
• BTIPL has stated that this issue has been addressed in new SW version 218T01BT & 318T01BT.
•
•
•
Balance locos - 145. PDC- 15.03.2019 .
Railways have reported that the issue of 'DC link overvoltage' has been increased and there was burning smell from MUB resistors.
M/s BTIPL stated that during regeneration, OHE is not accepting the regenerative voltage and current. Hence, there is more power dissipation in MUB resistors causing smell.
• BTIPLwas requested to study if the rating of MUB resistor can be increased.
Page 6 of 24
4.
5.
Logging
spurious
messages
of ELS/BRC reported following spurious messages:
Corruption of
wheel
diameter due
• CONl: 311 Trac. Mot.2 Temp. Implausible. CON 1/2: PSU for DCUM implausible.
• "CON1:204 A627 PSU for DCUM3 implausible", "CON1:203 A625 PSU for DCUM2 implausible", "CON1:202 A623 PSU for DCUM1 implausible", "CON1:201 A621 PSU for PCUL implausible"
• TM2 Bogie-1 isolate without any failure message
• con1 M2 pulsing not started
• DCUM1 or cabling faulty • DCUM3 or cabling faulty- Bogie 1 got isolated
• Main power got off without any message
• bogie isolated due to following messages
• CON2: comm. Loss to DCUM1, DCUM2, DCUM3 & DCUL. • CON2: PSU OFF relay feedback fault.
• Dist. Redundant VC12
• Dist. Comm. CON2 VCI
• VCI2 : Amp2 isolate
Above spurious messages come during cab changing. These messages do not come online. BTIPL to study and propose solution by 28.02.2019.
As per M/s BT, the wheel diameter data is being stored in Non-Volatile memory
which gets corrupted very easily. M/s BTIPL shall move this data to internal
memory of DCU cards. BTIPL sha ll try this in ELS/RPM by 25.02.2019 .. Based on the
to software outcome, decision for final cut-in shall be taken.
problem.
6. Catenary The propulsion software has been drawn as per old MICAS software. The changes
voltage out of related to OHE voltage limit need to be implemented by 28.02.2019.
limits.
7. Main power CCUO: 0231-UPRIM Sensing Ckt Fit SPIF11ogged and subsequently main power off.
8.
9.
off
Relevant
variables
always
M/s BTIPL has stated that they are investigating the cause and revert back by
28.02.2019.
In DDS environment data, relevant variables always are missing. i.e. in error log
pertaining to OHE voltage, OHE voltage field is missing and same in the case with
are other error messages.
missing in DDS
data. M/s BTIPL has stated that they are investigating the cause and revert back by
28.02.2019.
Issues
propulsion
system
in Following are the issues faced by ELS/HWH in BTIPL make propulsion system:
(i) Motors are getting isolated frequently with message 'speed sensor single channel faulty & M1/M2/M3 switching command feedback failure.
(ii) Messages are being logged, 'L: Pantograph bouncing' then all BUR remains idle or in recovery stage which leads sensing 'low coo lant pressure' by both traction converters.
(iii) During self-testing sometimes Traction bogie getting isolated without any
Page 7 of 24
message.
(iv) Protective shut down due to 'MVB pull wire from other DCU active'.
(v) TMs are getting isolated without sufficient back ground data in DDS.
M/s BTIPL has ensured that they will revert back by 28.02.2019 with the solution.
10. Other Issues Following other issues have been noticed in Propulsion system.
1. Sometimes even in shed during loco checking suddenly VCB tripped, PT got down & after some time PT got raised by itself & following distu rbance messages logged.
CCU0:0198- Catenary Voltage out of Limits. CCU0:0183-Power reduction line voltage L: Power limitation 1 active (Pline) L: Pantograph bouncing
2. In Aux. Converter, data most of the time no fault is getting logged.
3. Traction converter is getting isolated without any message and with message 'L charging resistor too hot'.
4. When any fault occurs dds is showing only the latest instant of fault occurrence and older ones are storing as counts. So Lp is unable to check the sequence of fault occurrence.
5. When ZTEL is operated Traction is limited to only 84 KN.
M/s BTIPL shall revert back by 28.02.2019 with the solution.
6.4 Performance of M/s. BTIL make TCN VCU
SN Item Action Plan
1. Shunting mode message is logging only for the first These issues have been reported by
instant. ELS/RPM. M/s BTIPL shall submit the action
2. Traction not allowed with applied brakes messages plan to RDSO by 28.02.2019.
logging even at throttle 'O'position. These issues have been reported by
3. Shunting speed is available up to 20 kmph but usually it ELS/RPM . M/s BTIPL shall submit the action
is 15 kmph. plan to RDSO by 28.02.2019.
4. Filter contactors are not operated when note is shifted
from 596 o 590. Also when throttle is 0 but speed is
not 0, loco shows node 590.
Page 8 of 24
7.0 Performance of M/s. ABB make Converters (IGBT)
7.1 Make wise failure details M/s ABB make Traction Converter
No. of Failures
SN Cause of Failure 2018-19 2018-19 2018-19 2015-16 2016-17 2017-18
(Apr-Jun) (Jul- Sep) (Oct-Dec)
1 Duagon Card defective 10 4 4 0 0 1 2 Software Malfunctioning (TE
becoming zero, LC & MC cu rrent high) 44 43 46 17 26 26
3 PEC (controller ca rd) defective 11 11 12 4 8 6 4 Gate Driver Unit (GDU) ca rds 14 15 16 1 3 5 5 Pump Fai lure I Fan Fai lure 2 7 12 0 2 1 6 Loose connector/OFC/ Cable
defective 6 4 3 2 3 1
7 PEBB (Power Module) Fa ilure 12 20 24 12 8 13
8 Others (transient , contactor stuck up,
MCB t rip) 52 42 34 28 20 22
TOTAL 151 146 151 64 70 75 Total Population 115 156 220 236 252 258
FRPCPY 131 94 69 108 111 116
7.2 Shed wise failure details M/s ABB make Traction Converter
2018-19 (Oct-Dec)
SN Cause of Failure AQ BIA BRC GZB HWH NKJ RPM TATA TKO VSKP Total
1 Duagon Ca rd defect ive 0 0 0 0 0 0 1 0 0 0 1
2 Software Ma lfunctioning (Time out initialization, harmonic filter current high, etc) 8 5 0 9 0 2 0 0 2 0 26
3 PEC (controller ca rd) defective 1 1 0 3 0 0 1 0 0 0 6
4 Gate Driver Unit (GDU) cards 3 0 0 1 0 0 0 0 0 1 5
5 Pump Fai lure I Fan Failure 0 0 0 0 0 1 0 0 0 0 1
6 Loose connector/ OFC/ Cable defective 1 0 0 0 0 0 0 0 0 0 1
7 PEBB (Power M odule) Failure 1 1 0 0 0 0 0 2 7 2 13
8 Others (transient, contactor stuck up, MCB
trip etc) 4 1 0 9 0 1 0 3 4 0 22
9 TOTAL 18 8 0 22 0 4 2 5 13 3 75
10 Total Population ( loco set) 45 24 10 20 1 7 10 52 44 45 258
11 FRPCPY 160 133 0 440 0 229 80 38 118 27 116
7.3 Following deliberation done to improve the reliability of M/s ABB make Traction converters:
SN Item Action Plan
1. Failure of PEBB 1. ABB has indicated that some issues for failure of IGBT modules software
modu le malfunctioning have been identified and reso lved in SW ver-40.
• Regular use of Software ver-40 has been accorded in WAP-5 locos . 2. Software • Software downloaded in 4 locos out of 5 in GZB and 2 locos out of 8 in
malfunctioning, BRC. TE becomes 0. Perfo rmance under watch.
3. New software Maximum issues are reported of LC and MC Overcurrent. Issues are particularly
Issues: with 1500 Amp IGBT. Firm carrying trial w ith version - 40.
Issue of 'LC Software shall be ready by 28.02.2018.
Overcu rrent '
Page 9 of 24
4. Coolant Coolant of bad qualities has to be replaced as per RDSO SMI-325.
replacement • Total locos to be modified: 70
activities • Locos modified: 56
• Locos to be modified: 14
PDC- 28.02.19.
5. Loco resetting When loco reset using VCU reset then Traction will resume only after speed
issue becomes zero.
M/s ABB shall take corrective action and action plan shall be submitted by 28.02.2019
6. Issue with The first loco with composite converter is running only up to 130 kmph.
composite Beyond 130 kmph, jerks are coming. ABB may look in to and take necessary
converter action in this regard.
7.4 Make wise failure details M/s ABB make Auxiliary Converter
No. of Failures
SN Cause of Failure 2018-19 2018-19 2018-19 2015-16 2016-17 2017-18
(Apr-Jun) (Jul- Sep) (Oct-Dec)
1 IGBT burst (inverter module) 2 3 5 1 2 2
2 Converter module 0 1 1 0 0 1
3 PCB ca rds 5 6 3 1 1 7
4 Battery charger module 0 1 10 2 3 9 s Software malfunctioning 4 13 2 2 2 2
6 Misc. 6 11 4 2 4 2
TOTAL 17 35 25 8 12 23
Total Population 21 29 42 49 65 74 FRPCPY 81 121 60 65 74 124
7.5 Shed wise failure details M/s ABB make Auxiliary Converter
2018-19 (Oct-Dec)
SN Cause of Failure PD. BIA BNDM GZB KYN LDH LGD NKJ RPM TATA TKO VSKP Total 1 IGBT burst (inverter module) 0 0 0 0 0 0 0 0 0 0 1 1 2
2 Rectifier module 0 0 0 0 0 0 0 0 0 1 0 0 1
3 PCB cards 1 0 0 0 0 0 0 0 0 0 6 0 7
4 Batterv charqer module 3 0 0 0 0 1 0 1 1 1 2 0 9
5 Software malfunctioninq 1 1 0 0 0 0 0 0 0 0 0 0 2
6 Misc. 2 0 0 0 0 0 0 0 0 0 0 0 2
7 TOTAL 7 1 0 0 0 1 0 1 1 2 9 1 23
8 Total Population (loco set) 10 7 1 3 2 1 2 1 6 4 21 5 63
9 FRPCPY 280 57 0 0 0 400 0 400 67 200 171 80 146
Page 10 of 24
7.6 Following deliberation done to improve the reliability of M/s ABB make Auxiliary converters:
SN Item Action Plan
1. Failure of IGBT 1. Failure of IGBT modules is a cause of concern and M/s ABB to submit the module action plan to RDSO by 15.03.2019.
2. In other reliability measures, earthing to be done as per GTO locomotives.
• Total locos to be modified: 39
• locos modified: 33
• locos to be modified: 6 (BRC-30076, RPM-30479, TKD-31405, 31406,
31477, 31481)
PDC: 15.03.19.
2. Battery
charger failure
Following measure issues with CHBA modules have been reported:
1. Auxiliary converter failure due to CHBA stops working sometimes & load shifting doesn't take place from BUR-3. ABB has to take corrective action and to submit the action plan at the earliest.
2. Auxiliary converter fai lure due to CHBA DC link capacitor burst/CHBA defective, Chopper circuit burnt & input fuse melt.
3. Battery charger not working at times.
In spite of repeated intimations, M/s ABB has not given due importance to the
above issues. They are requested to study and submit the action plan by
28.02.19 positively
7.7 Railways reported that M/s ABB is using fixing past e to join cold plate & IGBT in shed. This is very sophisticated process and needs to be avoided in sheds.
8.0 Performance of M/s. CGl make Converters (IGBT)
8.1 Make wise failure details M/s CGL make Traction Converter
2018-19 SN Cause of failu re 2016-17 2017-18
(Apr-Jun) (Jui-Sep) (Oct-
Dec)
1 Power m odule 7 20 3 7 8
2 PCB cards 3 4 20 14 11
3 Coolant pump 1 1 0 3 1 4 Software malfunctioning 26 40 16 17 24
5 Ot hers 6 14 19 9 19 Total 43 79 58 so 63
Total Population (Loco) 18 71 80 104 139 FRPCPY 239 111 290 192 181
'--
Page 11 of 24
8.2 Shed wise failure details M/s CGL make Traction Converter
2018-19 (Oct-Dec)
SN Cause of Failure BNDM CNB GMO LDH NKJ RPM Total
1 Power module 1 0 3 4 0 0 8 2 PCB cards 5 0 0 3 0 3 11 3 Coolant pump 0 0 0 1 0 0 1 4 Software malfunctioning 1 0 4 16 3 0 24
5 Others 8 0 3 6 2 0 19 6 Total 15 0 10 30 5 3 63
7 Total Population (loco set) 47 1 33 31 9 18 139 8 FRPCPY 128 0 121 387 222 67 181
8.3 Following deliberation done to improve the reliability of M/s CGL make traction converters:
SN Item Action plan
1. Failure
module
of power CGL has proposed to modify the modules with bus-bar type
& their arrangement in place of existing clip-lam arrangement.
connector
2. PCB card failure
3. Software issues
• Total locos to be modified: 69
• Locos already modified: 42
• Locos still to be modified: 27 (BNDM-8, GM0-10, LDH-01, NKJ-07,
KZJ-01)
The rate of modification is too slow. M/s CGL to expedite the same at
the earliest.
PDC- 31.03.2019
Failures of 45 PCB cards have been reported during year 2018-19 (Apr
Dec) . This is very serious cause of concern and affecting reliability of 3-
phase locomotive.
M/s CGL shall submit the detailed investigation report of each and
every card along with action plan to RDSO by 05.03.2019.
1. Issues with Software version 0023: • Isolation of Traction bogie 1 & 2 with message 'Time out NSC
pulse Bogie1/ Bogie2' . • Some times after MCE OFF/ON isolation of Traction bogie 1
and 2 with message 'Time out ALG test2 end Bogie1/Bogie2'. • Vbus Max
2. Modified software ver. 25 beta 04 provided in locomotive no. 39001, 39002, 39004 & 30680 of ELS/RPM Performance is under monitor.
4. Issues with UTIZEN 1. To reduce the booting time. The problem of isolation of
CPU electronics motors/bogie, non-logging of fault data in line with the VCU data could not be set right so far on converters with UTIZEN electronics. CGPISL is having 14 locomotive converters of UTGEN type (GM0-7, LDH-4, BNDM-3.
2. M/s CGL has been impressed upon to replace the UTIZEN electronics with new VEGA electronics as there are several
Page 12 of 24
software issues which could not be solved.
3. CGL has confirmed that first loco shall be modified by 10.03.2019. Rest of 13 locomotives shall be completed by 30.06.2019.
4. Firm to submit detailed action plan by 28.02.19.
5. IrE/BE reduces to zero For this CGPISL has modified the software and same has been
uploaded in loco nos. 30680, 39001, 39002 & 39004 of ELS/RPM.
Performance is under observation.
6. Failure of modified lnspite of repeated request, no investigation report has been
X24 Card (Analogue submitted. Investigation report along with action plan to be submitted
1/0 card). by 28.02.2019 positively.
7. Repeated failure o 1. The issue is with Kiyosh make resisters. The failure is due to
balancing resistor overheating of resistor and its outer cover is getting cracked. M/s CGL shall replace Kiyosh make resisters with HVR Pentagon make resistors.
2. 10 locos each of ELS/RPM and ELS/BNDM shall be modified as per details given below:
{i) Resistor with increased diameter from 54mm to 80mm shall be provided in 5 locos each of ELS/RPM and ELS/BNDM. The same has been provided in one loco no.
30693 of ELS/RPM yet.
(ii) Two resistors of 1.95K Ohm each in cascaded in place of single resistor (3.91K Ohm) shall be provided in 5 locos each of ELS/RPM and ELS/BNDM. The same has been added in two locos no. 30577 & 39000 of ELS/RPM yet.
It was advised that temperature stickers to be used to access the increase in the temperature of both modified and unmodified
resistors.
PDC- 10.03.2019
3. Further decision will be taken after analysing performance of
above two.
8. Sludge formation • Formation of sludge has been experienced in 3 locomotives (Loco No. 31739, 31742 & 31917) by ELS/ BNDM even after replacement of coolant of M/s Chemtex make with coolant of M/s Clariant make as per RDSO SMI 325.
8.
even after flushing & filling up of coolant as per SMI-0325
•
•
It appears that the procedures as per SMI-325 have not been strictly followed while cleaning the radiators. Also, M/s CGL to inspect the quality of coolant and submit the detailed report in this regard to
RDSO.
Further the pace of replacement of coolant is very slow. In light o upcoming summer, all the locos may be attended by 31.03.19.
Failures of sensors of Jaquet make
Speed Failures of speed sensors of M/s Jaquet & M/s Laxven make are being M/s experienced. M/s Laxven make speed sensors have not been cleared by
RDSO. M/s CGL to submit the investigation report along with action plan to
Page 13 of 24
9. Isolation bogies
10. Other issues
RDSO by 15.03.2019.
of both ELS/RPM has reported that both bogies are getting isolated without fault messages at times . M/s CGL has stated that they have not found any data in DDS. M/s CGL to investigate the same and prepare joint note w ith ELS/RPM.
Software Following are other software issues being faced by maintenance sheds:
• When any motor gets isolated, corresponding popup message of isolation does not get displayed. However, message is logged in DDS.
• Spurious messages of " Info: SLG has received a shutdown command" messages are getting logged in SR data.
• When transformer oil pump MCB is tripped manua lly, then message of oil temperature high appears instantly without increase in oil temperature.
• VCB stuck-up messages are more frequently coming after passing neutral section.
• SR isolation due to multiple life sign missing from MVB is frequent. • Both bogies are getting isolated without fault messages at times.
M/s CGL to submit the action plan by 05.03.2019.
8.4 Make wise failure details M/s CGL make Auxiliary Converter
2018-19 SN Cause of fa ilure 2015-16 2016-17 2017-18
(Apr-Jun) (Jui -Sep) (Oct-Dec)
1 Power supply card (KUC153 A02) 74 106 24 3 3 6
2 BUR processor card {CCPU card) 9 39 49 24 14 10
3 INVCC-01 e lectronic card 21 60 75 29 16 29
4 Inverter module 0 2 18 4 11 9
s Others 0 17 25 14 14 45
Total 104 224 191· 74 58 99 Tot al Population (Loco) 182 217 308 321 349 392
FRPCPY 57 103 62 92 66 101
8.5 Make wise failure details M/s CGL make Auxiliary Converter
2018-19 {Oct-Dec)
AQ BIA BNDM BRC CNB GMO GZB HWH KYN LDH LGD NKJ RPM TATA TKD VSKP Total SN Cause of Failure
1 Power supply card (KUC153 A02) 0 0 0 0 0 1 3 0 0 1 1 0 0 0 0 0 6
2 BUR processor card (CCPU card) 0 0 0 0 0 3 1 1 0 2 2 0 1 0 0 0 10
3 INVCC-01 electronic card 1 0 2 0 0 5 1 6 0 8 0 0 1 0 5 0 29 4 Inverter module 0 0 0 0 0 2 0 1 0 1 1 0 1 1 1 1 9 5 Others 1 2 1 3 0 4 3 1 0 19 1 1 1 4 3 1 45
6 Total Fai lures 2 2 3 3 0 15 8 9 0 31 5 1 4 5 9 2 99
7 Total Population (loco set} 17 11 17 18 5 63 19 14 23 37 19 9 13 38 36 53 392
8 FRPCPY 47 73 71 67 0 95 168 257 0 335 105 44 123 53 100 15 101
Page 14 of 24
8.6 Following deliberation done to improve the reliability of M/s CGL make Auxiliary converters:
SN Item Action plan
1. Modification in the 1. Firm has modified the software and provided modified software in
INVCC and CCPU following locomotives at four locations RPM, TKO, HWH and GMO.
card. • HVVH-30305,30506,30454, 30503, 30455 .
• RPM - 30679, 30680, 39004, 30678, 30675
BUR current greater • GMO- 31267, 37047, 31316, 32153, 32074, 31596, 32152 than max. • TKD - 30653, 30683, 30451, 30637, 32200, 31548 .
Battery charger 2. In spite of above measures, PCB cards failures are still there. The card
current below 10 A. failures are with message 'Battery charger current less than 10 Amp' and 'BUR current greater than maximum' and 'Inverter fault'.
3. M /s CGL shall submit the investigation report along with action plan to this office by 15.03.2019.
2. Auxiliary Converter • After neutral section, the frequency ramps down and takes about 10
over current issue seconds t o reach zero frequency. If driver close DJ within 5· seconds before frequency coming down below 35 Hz, auxiliary converter over current message appears and immediately DJ trips.
• This problem has been raised several t~mes in past but no solution has been given by M/s CGPSIL. CGPSIL is once again requested to study the issue and propose the solution by 28.02.2019.
3. MCB-100 trip • MCB-100 (Battery charger MCB) trips and message not Pop-up on DDU.
message pop-up Due to this battery gets run down on line.
issue • CGL to submit the action plan by 05.03.19 .
4. Other issues 1. High failure rates of the auxiliary machines:
Harmonic contents in output of M/s CGL make Aux. converter fitted in loco No. 30445 of ELS/GZB shall be measured in presence of RDSO representative in first week of March'19.
2. Date and time format & value get s corrupted in fault data of BUR.
3. BUR parameters are either not available or are erratic & unreliable in DDU.
CGL to submit the action plan by 05.03.19.
8.7 A presentation was given by M/s CGIPSL on issue related to Auxiliary converter. M /s CGIPSL is requested to submit the document related to proposed changes in CCPU & INVCC card to RDSO.
Page 15 of 24
9.0 Performance of M/s. Medha make Converters {IGBT)
9.1 Make wise failure details M/s Medha make Propulsion system
No. of failures
SN Cause of Failu re 2017- 2018-19 2016-17
18 (Apr-Jun) (Jui-Sept) (Oct-Dec)
1 Card failure 0 8 3 8 4
2 VCU problem 1 0 2 0 1
3 Software Malfunctioning (Time out
1 9 14 8 14 initialization, Time mis-match etc)
4 Converter contactor 2 1 3 3 0
5 Power Module 3 9 0 4 6
6 TM speed sensors 0 4 1 1 5
7 Loose connector I OFC/ Cable defective 0 0 1 0 1
8 Others/Misc. 5 37 22 16 25
Total 12 68 46 40 56
Population 9 83 88 99 126
FRPCPY 133 82 209 162 178
9.2 Shed wise failure details M/s Medha make Propulsion system
SN Cause of Failure 2018-19 (Oct-Dec)
AQ BIA BRC CNB GZB HWH LDH LGD RPM TATA TKO VSKP Total
1 Card fai lure 0 0 0 0 3 0 0 1 0 0 0 0 4
2 VCU problem 0 0 0 0 1 0 0 0 0 0 0 0 1 3 Software Malfunctioning (Time out
0 ini tial ization, Timemis-matchetc)
0 0 0 10 0 0 1 0 3 0 0 14
4 Converter contactor · 0 0 0 0 0 0 0 0 0 0 0 0 0
5 Power Module 0 0 0 0 4 0 0 2 0 0 0 0 6
6 TM speed sensors 0 0 0 0 2 3 0 0 0 0 0 0 5
7 loose connector I OFC/ Cable
defective 0 0 0 0 1 0 0 0 0 0 0 0 1
8 Others I Misc. 2 0 2 0 19 1 0 0 0 1 0 0 25
9 Total Failures 2 0 2 0 40 4 0 4 0 4 0 0 56
10 Total Population (loco set) 2 5 10 19 26 2 1 21 2 29 2 7 126
11 FRPCPY 400 0 80 0 615 800 0 76 0 55 0 0 178
9.3 Following deliberation done to improve the reliability of M/s CGL make Auxil iary converters:
SN Item Action Plan
1. Bursting of capacitor: M/s Medha stated that they have received Analysis
In locomotive no 30553 at Report from M/s. Electronicon, but not satisfied with
ELS/TATA the DC link capacitor their report. M/s Medha requested Electronicon to re-
burst, which led to failure of examine and submit the root cause analysis. Power module. PDC- 28.02.2019
2. PCB card failure • 15 PCB card fai lu res have been reported during 2018-19 (Apr-Dec).
• So far, no investigation report has been submitted to RDSO or Railways. M/s Medha is once again
Page 16 of 24
3. lnteroperability of MU units
requested to submit the same at the earl iest.
• It has been decided that M/s Medha make voltage sensor may be fitted in 5 locos (WAP7) of ELS/SRC for trial. Further decision shall be taken after performance feedback.
• MU operation between Medha & BHEL loco has been successfully demonstrated. Medha has informed that the MU protocol is as per UIC 556. However, t hey have not submitted details in this regard.
M/s Medha is once again requested to submit the details so that the same can be implemented in other makes MU gateways also so that interoperability among different make ca n be achieved. M/s Medha is once again requested to submit the details by 10.03.19.
• MU operation with C-DAC VCU and M/s Medha make VCUs to be done.
• M/s Medha may carry out the same along with CDAC VCU at ELS/VSKP.
4. Harmonic filter getting isolated • In case of isolation of any Traction converter
5.
6.
automatically I manually, filter current increases and ultimately Harmonic fi lter getting isolated. M/s Medha has modified software to chalk out this issue.
• Software updated in 46 Locos out of 113.
Balance - 67
PDC: 28.02.2019.
• Railways are sti ll reporting t he issue. M/s Medha may look into increasing the delay in monitoring t ime
• The specification mentions the panto bounce of 45 ms. During th is time, traction converter should deliver fu ll power. M/s Medha sha ll submit the detailed report for which duration of panto bounce, their converter gives full power and reduced power.
There are several cases of • isolation and recovery of subsystem automatica lly due to
Updated software have been provided in 10 Locomotives 37001/Ajni, 30547 /SRC, 31930/TATA, 31902/TATA, 31920/TATA, 30558/SRC, 30149/GZB, 30700/SRC, 30595/LGD and 30649/GZB. transient troubles.
M essage "Converter oi l pressure not ok" does not store in DDS and w henever coolant temperature goes out of limit then direct ly "Converter oil temperature too high" message appears and the respective SR or Bogie gets isolated.
• Railways may critical ly analyze the merit/de-merit of the individual mod ificat ion and submit the details to RDSO for further decision on its proliferation.
7. Bogie iso lated on line instead of ELS/BRC reported that bogie isolated on-line after failing
Page 17 of 24
8.
9.
individual TM-4 isolation.
Initial TE of 18% (40KN) observed in WAPS locos.
DC link over voltage
one TM in place of individual TM.
M/s Medha shall study and incorporate the same suitably in software. A joint may be prepared with ELS/BRC.
All locos equipped with M/s MEDHA make propulsion reported with same problem by ELS/BRC.
M/s Medha to submit the action plan by 28.02.2019.
• There are several messages like 'DC link over voltage' which are not available in DDS but available in display unit. There are other such messages.
• M/s Medha to submit the complete list of messages which are not available in DOS but available in display
· unit and submit the action plan.
10. Earth fault sensing ckt. • Extra 'earth fault sensing ckt.' in each Aux. converter is provided which causes protective shut down of Aux. Conv. In case of bonding of Scavenger leading to concerned BUR OFF and automatically transferring load to other BUR which also senses earth fault and
11.
12.
gets isolated and due to isolation of both conv. 'Main L power gets OFF'.
• It has been decided that M/s Medha sha ll remove the 'earth fau lt sensing ckt.' provided in each auxiliary converter.
• An action plan along with time line to remove the same shall be submitted to RDSO by 10.03.2019.
"OHE voltage out of range • message" not appearing in DOS.
•
SR gate unit power supply MCB • (20 amps) tripping
"OHE voltage out of range" message not appearing in DDS and loco does not trip. Due to OHE voltage out of range inverter pulsing stopped and further th rottle not responding.
M/s Medha to look into and submit the action plan to RDSO by 28.02.2019.
SR gate unit power supply MCB (20 amps) tripping causing Traction bogie iso late. The issues is with ABB make MCB.
• Railways reported that this issue is not with Schneider make MCB.
• M/s Medha make take action to replace ABB make MCBs and submit the action plan.
13. Wrong display of energy • In place of Energy consumption, Display showing regeneration Energy regeneration in all newly received WAP7
locomotives. • M/s Medha intimated that this may be due to wrong
wiring. Medha may study the same and take necessary action.
14. Difference in simulation and • Railways have reported that the loco operation in actual values. simulation is different from actual operation. For
example there is contradiction in VCB stuck up message during simulation and actua l operation.
• M/s Medha may study and remove such anomalies. Detailed action plan may be submitted by 15.03.19.
Page 18 of24
9.4 It has been reported by Railways that M/s Medha carries out software/ hardware modifications without clearance from RDSO/ CLW. M /s Medha is requested to take clearance from RDSO/ CLW before implementing the same in locomotives.
9.5 ELS/BNDM & SRC have created harmonic filter contactor testing arrangement. This is very helpfu l in setting the closing/ opening time of the contactors w hich has led to drast ic reduction of failures. SER is requested to submit the details of testing arrangement to RDSO, so that other Rai lways may also be benefited.
9.6 CLW has reported that BHEL, CGL & ABB are following the traction motor cable sequence (sequence 1,2,3,6,5,4) as per specification w hich is same as in GTO locos. There are deviations by M/ s BTIPL & Medha (sequence 1,2,3,4,5,6). Sheds may face issues while changing GTO converte rs w ith M/s BTIPL & Medha make converters. CLW may study the issue and sort with M/s BTIPL & Medha.
9.7 At present, Medha make converters give full power between 22.5 kV to 28.5 kV. Other manufacturers have increased upper OHE voltage limit to 30 kV. Medha may also study this and increase the upper voltage limit.
10.0 Performance of M/s. BHEL make Converters (IGBT)
10.1 Make wise failure details M/s BHEL make Traction Converter
No. of Failures
SN. Cause of Failure 2018-19 2018-19 2018-19 2015-16 2016-17 2017-18
{Apr-Jun) (Jui-Sep) (Oct-Dec)
1 Power Module/PMI/USID 57 90 140 66 136 105
2 VIU/ DCU Card 17 26 55 20 31 26
3 Coolant Pump 1 3 8 4 2 3
4 Software Malfunctioning (Harmonic
filter stuck, ASC pulsing stopped, TFP 10 14 36 20 17 12
oil pressure not OK, etc)
5 Pressure Switch 42 15 29 13 6 6
6 Misc. (Transient /random faults) 16 26 56 50 40 31
Total Failures 143 174 324 173 232 183
Total Population (loco) 140 176 329 348 361 417
FRPCPY 102 99 98 199 257 176
10.2 Shed wise failure details M/s BHEL make Traction Converter
2018-19 (Oct·Dec)
SN Cause of Failure AQ BIA BRC GMO GZB HWH KYN LGD RPM TATA TKO VSKP
1 Power Module/PMI/USID 6 0 2 2 12 7 4 13 2 49 5 3
2 VIU/DCU Card 4 0 2 1 5 1 0 3 1 8 1 0
3 Coolant Pump 0 0 0 0 1 0 0 0 0 0 0 2
Software Malfunctioning (Harmonic filter
4 stuck, ASC pulsing stopped, TFP oil pressure 0 0 0 0 10 1 0 1 0 0 0 0
notOK,etc)
5 Pressure Switch 0 2 0 0 0 0 0 2 0 2 0 0
6 Misc. (Transient / random faults) 0 2 2 1 12 0 8 2 0 3 0 1
7 Total Fai lures 10 4 6 4 40 9 12 21 3 62 6 6
8 Total Population (loco set) 9 19 18 8 48 9 35 21 17 63 32 45
9 FRPCPY 444 84 133 200 333 400 137 400 71 394 75 53
Page 19 of 24
Total
105
26
3
12
6 31
183
324
226
10.3 No technica l representative attended the meeting. The following issues are reported and point wise reply along with PDCs may be submitted by BHEL.
SN Item Action Plan
1.
2.
3.
4 .
5.
Power Module Failures
Fai lure of Pressure Switch
BHEL informed that higher rated MOSFET driver
introduced from Oct 2017 and higher rated MOSFET
introduced in gate drivers from June 2018 in regular
production to improve the reliability of gate driver after
usage in converters at Kazipet.
• Software ver. 774 with increased timing parameter
for SEPL max detection introduced loaded in all347
Locos.
BHEL shou ld look into the problem afresh.
The pressure switch needs to be replaced by Honeywell
make in all the locomotives in phased manner.
Replaced in 263 locos till date.
Remaining 50 Locos of ELS/LGD, KZJ, TATA
PDC 28/02/2019.
Reduction of TE/BE with no DDS (i) Occurring due to loss of Panto contact with OHE for
at higher speed. more than 45ms. This has come to light after ana lyzing
the data of loco 30129 of ELS/GZB where this problem
occurred.
(ii) BHEL was requested to explore the feasibility of
increasing the DC link capacitance to the extent
possible so as to reduce such problems by higher
energy storage capacity. Existing rating 6.75 mF (9x750
uF) .
)> BHEL concluded that the capacitance is adequately
sized for the application. Further BHEL has indicated
increased capacitance is resulting in higher short circuit
current limits which are detrimental for the equipment.
Hence, increase in capacitance is not envisaged.
)> BHEL was once again requested to look into the
possibility to increase the DC link capacitance and
other related aspects. BHEL has to specifically intimate
the solution considering all the parameters.
Failure of Electronic (VIU/DCU)
Cards • 77 cards failed in 2018-19 (Apr-Dec) whereas 55 cards
were failed in year 2017-18.
Reappearing of " Harmonic Filter
contactor (8.1 / 8.2) stuck on"
• In spite of taking various steps, the rate of fai lure is
increasing. It seems that the steps are not effective and
the problem needs to be taken afresh.
• Reappearing of "Harmonic Filter contactor (8.1 /8.2)
stuck on" problem.
• BHEL should re-investigate the prob lem and submit the
investigation report along with action plan to RDSO.
Page 20 of 24
6. Harmonic filter current high. In M/s. BHEL IGBT Traction Converter, Harmonic Filter current is current 300 to 325 amp. Whereas in other make Traction Converter it is 150 to 180 amp.
BHEL may study the logic of filter operation of other make. 7. Issue of "flashing of power cable" This issue has been reported by ELS/ BRC. M/s BHEL to take
at gland area inside converter. corrective action at the ea rliest . 8. Power module Stucchi coupling In all t he cases Power modu le Stucchi spindle found jam
failure due to spring inside got defective.
9. Sludge formation in coo lant circu it Sludge formation in coolant circu it of BHEL make Traction
converter even after flushing and changing the coolant
ca using pressure sw itch chocked.
It appears this is an issue of improper cleaning.
10.4 Make wise failure details M/s BHEl make Auxiliary Converter
No. of Failures SN Cause of Fa ilure 2018-19 2018-19 2018-19
2015-16 2016-17 2017-18 (Apr-Jun) (Jui-Sep) (Oct-Dec)
1 Inverter module 21 35 40 13 13 14 2 Controlled rectif ier module 9 7 22 2 10 10 3 ACI card 11 17 12 11 4 6 4 AMC card 0 8 4 2 1 0
5 MVB Fibre interface (MFI ca rd) 3 4 3 2 2 0 6 Battery Charger 12 11 13 4 1 1
7 Software malfunctioning 7 7 8 4 1 2 8 Misc. 9 11 20 13 4 33
Total Failures 72 100 122 51 36 66 Total Population (loco) 93 180 328 347 360 406
FRPCPY 77 56 37 59 40 65
10.5 Make wise failure details M/s BHEL make Auxiliary Converter
2018·19 (Oct-Dec) SN Cause of Failure AQ BIA BRC GMO GZB HWH KYN LDH LGD NKJ RPM TATA TKO VSKP 1 Inverter module 1 0 0 0 2 1 1 0 2 0 0 2 2 3
2 Controlled rectifier module 0 0 0 0 1 1 0 0 1 0 1 2 3 1
3 ACI card 1 0 0 0 1 2 0 0 0 0 1 1 0 0 4 AMC card 0 0 0 0 0 0 0 0 0 0 0 0 0 0 5 MVBFibreinterface (MFI card) 0 0 0 0 0 0 0 0 0 0 0 0 0 0 6 Battery Charger 0 0 0 0 1 0 0 0 0 0 0 0 0 0
7 Software malfunctioning 0 0 0 0 2 0 0 0 0 0 0 0 0 0
8 Mise 2 0 0 0 0 0 0 0 0 1 0 0 5 1
9 Total Failures 4 0 0 0 7 4 1 0 3 1 2 5 10 5
10 Total Population (loco set) 20 28 23 11 37 13 32 8 40 4 18 60 32 48
11 FRPCPY 80 0 0 0 76 123 13 0 30 100 44 33 125 42
10.6 No technical representative attended the meeting. The fo llowing issues are reported and point wise reply along with PDCs may be submitted by BHEL:
SN Item Action Plan
1. Inverter module failure SW ver. 188.1 w ith less sensit ive di/dt monitoring (2 to 3
~s) has been uploaded and regular cut-in since Jan'2018.
Power up issue in AMC module: Resistor va lue modif ied to
Page 21 of 24
Total
14
10
6
0 0 1 2
33
66
374
71
2. Control rectifier module failure optimize the initializing current and same implemented
from May 2016.
No improvement in the performance.
..
3. No DDS of BUR with BT make No DDS of BUR is being recorded other than life sign missing
4.
5.
6.
7.
8.
9.
traction converter.
Low BUR-2 frequency
Main power off
in Locos equipped with BT make Traction Converters.
• Compatibility issue with BT make SR.
• BT and BHEL has modified the software to address the issue.
• Tested in loco no. 31943 at ELS/Katni.
• Firmware was updated and message getting logged.
• However, BHEL has not still started downloading the updated firmware.
• Firm has indicated they have addressed the issue in
software version -188.1.
• Railways to indicate if the problem is resolved in \....._
software version -188.1.
Isolation of BUR1,2 & 3 due to Low/No OHE followed by
Main power off as compared to other make Auxiliary
converter.
BHEL to take corrective action and inform RDSO the same.
Overheating of power cable • terminal lug supporting stud
Firm has stated that Brass studs have been made ava ilable to loco sheds.
Mismatch of Ramp up time
Contactor logic neither recorded in DDS nor in Aux. ACI card.
BUR 3 input current is having a
variation of upto 20A between
phases when Battery charger is
in service.
• Very poor response of firm in BRC. Only 03 nos. locos out of 22 locos.
Mismatch of Ramp up time (16 sec) of BHEL make auxiliary converter with monitoring time (15 Sec) of BT make Traction Converter even in latest software version R-1240 causing several time message of 'TFP oil pressure not OK' and after 3 times this leads to" Main Power Off'. BHEL to solve the issue at the earliest.
Isolation of Aux. Converter due to contactor logic neither recorded in DDS nor in Aux. ACI card. Only pop up message shown, so isolation of Aux. converter due to contactor mal operation cou ld not be identified at shed
M/s BHEL to investigate the cause and take corrective
action at the earliest.
10. There is power supply breaker to M/s BHEL to investigate the cause and take corrective
battery charger processor card action at the earliest.
and when it fails loco shut down
with message battery voltage
less than 82 V.
Page 22 of 24
11.0 Performance of M/s. AAl make Auxiliary Converters (IGBT)
11.1 Make wise failure details M/s AAl make Auxiliary Converter
2018-19 2018-19 2018-19
SN Cause of Failure 2017-18 (Apr-Jun) (Jui-Sep) (Oct-Dec) 1 Inverter module 6 0 2 1 2 Rectifier module 1 0 1 1 3 PCB cards 5 6 6 3 4 Battery charger module 1 0 1 0 5 Software ma lfuncti oni ng 8 2 0 4 6 Misc. 17 5 8 4
TOTAL 38 13 18 13 Total Population (loco set) 134 134 134 148 FRPCPY 28 39 54 35
11.2 Shed wise failure details M/s AAl make Auxiliary Converter
2018-19 (Oct-Dec) SN Cause of Failure AQ BIA BNDM BRC GMO GZB HWH LDH NKJ RPM TATA TKO VSKP Total 1 Inverter module 0 0 0 0 0 0 0 0 0 0 0 0 1 1 2 Rectifier module 0 0 0 0 0 1 0 0 0 0 0 0 0 1 3 PCB cards 0 0 1 1 0 0 0 0 0 1 0 0 0 3 4 Batterv charoer module 0 0 0 0 0 0 0 0 0 0 0 0 0 0 5 Software malfunctioning 0 0 0 0 0 4 0 0 0 0 0 0 0 4 6 Misc. 0 0 0 0 1 0 1 0 0 0 0 1 1 4
TOTAL 0 0 1 1 1 5 1 0 0 1 0 1 2 13 Total Population (loco set) 5 22 21 8 17 11 3 4 6 3 9 9 30 148 FRPCPY 0 0 19 50 24 182 133 0 0 133 0 44 27 35
11.3 Following deliberation done to improve the reliability of M/s AAl make Auxiliary converters:
SN Item Action plan
1. Failure of PCB cards In spite of issue raised in previous MoM, no investigation report has been submitted. It is once again request ed that investigation report of each ca rd may be submitted to RDSO and concern shed.
2. Issue with cab ELS/VSKP has reported that whenever the control is shifted f rom redundancy software FLG1 to FLG2 in ca b redundancy software, the contactor sequence of
BUR malfunction. M/s AAL to requested to study the issue with ELS/VSKP and submit the action plan by 10.03.19.
3. Compatibility of the Issue to message incompatibility with BTIPL make tract ion converter. messages w ith other Regular cut in of the Version 54 has been done. make converters
4. Software Software malfunctioning cases increased. Fi rm to submit the action malfunctioning plan.
12.0 Other issues
12.1 IGBT power module should be replaced in fully assembled form only by OEM.
12.2 All OEMs are requested to submit the proposal t o control the junction temperature in IGBT in line w ith efforts made by M /s BTl PL.
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12.3 Formation of sludge even after flushing & filling up was reported by Railways. Further some Railways reported about Tmax message even after cleaning the radiators. It is once again advised that the procedures as per SMI-325 should strictly be followed while cleaning the radiators by manufacturers. Manufacturers are also requested to inspect the quality of coolant.
12.4 C-DAC should ensure compliance of all the logics as existing in MICAS VCU while carrying out software modification in their VCU. CLW/RDSO to ensure while testing.
12.5 It is desirable that CLW should take control of C-DAC VCU software after resolving all the pending issues. To achieve this, C-DAC should impart training to CLW/RDSO and submit all the related documents.
12.6 CLW will conduct training on C-DAC VCU involving engineers from C-DAC, ABB, BHEL & CGL. Railways shall also depute their technical representatives.
12.7 Railways have been apprised about need to make WAPS & WAP7 locos Push-Pull compliant. Urgent action needs to be taken by concern Railways.
12.8 Upgradation of WAPS loco to 6000 hp: Status is as follows:
Loco type GZB BRC Total GTOSR Population 43 40 83
Upgraded 43 35 78 BHEL SR Population 32 17 49
Upgraded 2 0 2 ABBSR Population 6 8 14
Upgraded 5 2 7 BTIPLSR Population 1 0 1
Upgraded 1 0 1
Medha SR Population 11 3 14
Upgraded 8 0 8 CGLSR Population 0 0 0
Upgraded 0 0 0 Total Population 93 68 161
Upgraded 59 37 96
BHEL is requested to complete the trials early and carry out modifications in all the locos at the earliest.
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