Reliability Issues of IGBT based Converters...Performance of M/s. BHEL make Traction Converter SN...
Transcript of Reliability Issues of IGBT based Converters...Performance of M/s. BHEL make Traction Converter SN...
Reliability Issues of
IGBT based Converters
19.04.2018
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Performance of M/s. BHEL make Converters (IGBT)
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SN. Cause of Failure
No. of Failures
2015-16 2016-17 2017-18
(Dec) 2017-18
1 Power Module/PMI/USID 57 90 104 140
2 VIU/DCU Card 17 26 45 55
3 Coolant Pump 1 3 6 8
4
Software Malfunctioning
(Harmonic filter stuck, ASC
pulsing stopped, TFP oil
pressure not OK, etc)
10 14 28
(22-GZB) 36
5 Pressure Switch 42 15 20 29
6 Misc. (Transient /random faults) 16 26 45 56
7 Total Failures 143 174 248 324
8 Total Population (loco) 140 176 284 329
9 FRPCPY 112 99 116.4 98.5
Performance of M/s. BHEL make Traction Converter
Performance of M/s. BHEL make Traction Converter SN Item Action plan Remark 1 Harmonic
Filter
contactor
stuck on/off
Modified software (ver. 373)
by increasing the feedback
time of the auxiliary signal to
2.0 sec.
Downloaded in 5 locos each
at ELS/LGD, ELS/KYN and
ELS/BIA and two locos at
ELS/RPM.
Software version 373
addresses this problem.
RDSO approval has been
given for regular use of
software version 373 in all
BHEL make SR vide letter
No. EL/3.1.35.17 (BHEL)
dtd. 25.09.2017.
Position of Ver-373:
LGD – 16, KZJ – 9, AQ – 8,
BIA – 30, GZB – 19, BRC –
15, TKD – 21, KYN – 33.
Total – 151 out of 284
locos.
Performance of M/s. BHEL make Traction Converter SN Item Action plan Remark 2 Power
Module
Failure
Protection level shall be
modified for short
circuit current time from
existing 600 ns to 750ns.
The vulnerable
component shall be
replaced with improved
rating components.
This will be
implemented in two
locomotives for trial.
(i) Timing parameter for generation of
SEPL_MAX error increased in software on
trial basis. Downloaded in loco no. 31604
of ELS/LGD and loco is under observation
since 31/8/17. SW loaded in LGD (
31248, 30563, 31492, 31347, 31345,
30625), KZP (31604) and WAT (30152).
Asked to implement in at KYN, RPM &
TATA.
(ii) 18 nos. of upgraded IGBT Power Modules
dispatched to CLW in Aug’17 which are in
loco no. 31970 & 31975 of ELS/Kazipet.
(iii)BHEL has still not submitted the details of
the modification carried out. BHEL has
been instructed to submit the complete
document on reliability actions taken.
SN Item Action plan Remark 3 Failure of
Pressure
Switch
The pressure switch
needs to be replaced by
Honeywell make in all
the locomotives in
phased manner.
Honeywell make pressure switch is
dispatched to following sheds
a) ELS/TATA -8 Nos
b) ELS/LGD - 7 Nos
c) ELS/BIA - 4 Nos
d) ELS/KYN - 6 Nos
e) ELS/BRC - 3 Nos
f) ELS/TKD - 3 Nos
g) ELS/WAT - 2 Nos.
h) ELS/HWH – 2Nos.
i) ELS/GMO - 1 No
Firm has scheduled replacements in
phased manner.
The progress is very slow. Firm need to
expedite.
Earlier PDC was – 31.03.2018.
Performance of M/s. BHEL make Traction Converter
SN Item Action plan Remark 4 Formation of
multiple consist of 3 locomotives
Railways in process of running the Multi consist with three locomotives (1 master and 2 slaves). BHEL needs to make the necessary changed in the software/firmware and demonstrate the operation in ELS/LGD by 20.07.2017.
The testing conducted in ELS/VSKP and successful.
5 Reduction of TE/BE with no DDS.
TE/BE suddenly comes to ‘zero’ on run. No fault message is stored in DDS. No firm action plan could be told.
Problem has also been reported by ELS/GZB and HWH. BHEL to visit ELS/HWH & resolve the issue with intimation to RDSO. Firm has not given any satisfactory reason for this problem.
Performance of M/s. BHEL make Traction Converter
Performance of M/s. BHEL make Traction Converter
SN Item Action plan Remark 6. Failure of
Electronic
Cards
(VIU/DCU/
ACI)
VIU: BHEL has
increased the relay
setting to 8A along
with modified
snubber circuit.
2 Nos. modified cards installed in loco
31683 (LGD) and 1 No. installed in
loco 31535 (KYN).
1 No. yet to be dispatched to ELS/BIA.
Firm still to submit the details of
modification and ratings of new
components to RDSO and CLW.
Earlier the firm had confirmed that
they have implemented the
modification in all new supplies. Now
they have confirmed that the
modified components shall be
populated wef Apri’18.
Performance of M/s. BHEL make Traction Converter
SN Item Action plan Remark 7. Simulation
of DC link
capacitor on
MATLAB
BHEL was to carry out the
simulation study on the
adequacy of the DC link
capacitor on MATLAB.
Report to be submitted
by 15.07.2017.
In spite of several PDCs, the report
is still awaited.
BHEL was requested to submit the
report by 05.11.17 positively.
Report not yet submitted.
8. Simulator for
the software
validation
BHEL was to create the
loco modeling on the
simulator so that the
software validation can
be done on the simulator
instead of locomotive.
BHEL has informed that Simulator
lab has been established in BHEL
and future validation will be done
through simulator in lab.
Performance of M/s. BHEL make Traction Converter
SN Item Action plan Remark 7. Coolant
pump failure
The pump failure rate is
on rise. firm to submit
the failure investigation
report.
Approval for alternate
make of Flowell has been
given. Firm has been
advised to install the
same for early trial.
Firm has not submitted any failure
investigation report.
Firm has given a target of 31.01.18
for installation of Flowell make
pump for field trial. Still no
confirmation from BHEL.
Failures - BHEL make Auxiliary Converter
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SN Cause of Failure
No. of Failures
2015-16 2016-17 2017-18
(Dec) 2017-18
1 Inverter module 21 35 37 40
2 Controlled rectifier
module 9 7
17 22
3 ACI card 11 17 7 12
4 AMC card 0 8 2 4
5 MVB Fibre interface (MFI
card) 3 4
2 3
6 Battery Charger 12 11 11 13
7 Software malfunctioning 7 7 11 8
8 Misc 9 11 18 20
Total Failures 94 100 105 122
Total Population (loco) 93 180 293 328
FRPCPY 102 61 53 37
Performance of M/s. BHEL make Aux. Converter SN Item Action plan Remark 1. Inverter module
failure of Auxiliary converter
• Assembly process reviewed to prevent damage of IGBT terminals in the module. • Further, power-up issue in the AMC module shall be addressed with increased initializing current.
SW ver187.2 (addressing di/dt issue) implemented. Performance under watch.
Failures in control electronics are very high. Modification in the existing AMC card installed in running locos to be taken in phased manner. In spite of repeated assurances schedule for replacement of AMC card has not been submitted.
2 Control
Rectifier
Module
The failures of the
Controlled rectifier modules
have increased. Firm has
not given the details of the
cause.
As per BHEL, the failures are due
to problem in AMC card for which
action of replacement is
underway. However, firm has not
submitted any progress report.
Performance of M/s. BHEL make Aux. Converter
SN Item Action plan Remark 3. Low BUR-2
frequency Frequency of message TR-1 & 2 oil pressure not OK & Converter-1 & 2 Coolant pressure not OK are abnormally high. BUR-2 frequency at that moment is found 15 to 20 Hz. whereas, frequency of BUR-3 is 50 Hz in the back ground data.
BHEL informed that software issues have been addressed in software release 188.1 with BUR-2 frequency set at 50 Hz. Firm to indicate the nos. of locos downloaded with latest software.
4. No DDS of BUR with BT make traction converter
No DDS of BUR is being recorded other than life sign missing in Locos equipped with BT make Traction Converters.
Issue with the compatibility with BT make SR. BT has informed that the issue has been resolved with their latest software version 1235. Railways to give feedback to RDSO.
Performance of M/s. BHEL make Aux. Converter
SN Item Action plan Remark
3. Overheating of
power cable
terminal lug
supporting stud
Overheating of power cable
terminal lug supporting stud
inside the BUR Box-1 & 2 due
to bad conductivity between
stud and hexagonal socket
reported by ELS/GMO and
ELS/BRC
Firm has indicated that
they have sent spare
brass studs to Railways.
Railways to indicate
the number of locos
modified.
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Performance of M/s. CGL make Converters (IGBT)
Performance of M/s. CGL make Traction Converter
SN Cause of failure 2016-17 2017-18
(Dec)
2017-18
1 Power module 7 16 20
2 PCB cards 3 2 4
3 Coolant pump 1 1 1
4 Software malfunctioning 26 29 40
5 Others 6 12 14
Total 43 60 79
Total Population (Loco) 18 68 71
FRPCPY 238 118 111
Performance of M/s. CGL make Traction Converter
SN Item Action plan Remark 1 Replacement of
temperature sensor in IGBT modules.
SCL (Spain) make temperature sensors need to be replaced with Floricon make temperature sensors.
All the locomotives have been modified. Performance under watch.
2 IGBT module failure
CGL to propose the solution to provide bus-bar connections in place of cliplam arrangement.
CGL has proposed to modify the
modules with bus-bar type
arrangement. Firm has confirmed the
conversion rate of 5-6 loco per month.
Performance of M/s. CGL make Traction Converter SN Item Action plan Remark 3 Harmonic filter
isolation
Filter current greater than
max. Issue resolved by
changing the PWM reference
& control strategy.
All the locomotives have been
downloaded with the modified
software. Performance under
watch.
4 Bogie isolation in WAP-7 at high speed
Timing & Synchronization issue between TCU & RCU in low level software
Firm has indicated they have resolved the issue in software ver-13. Downloaded in all 8 WAP7. Performance is under watch.
5 Problem in formation of Multi-loco
CG loco work will other manufacture in multi , but filter current greater than max. Issue is there with multi CG to CG combination
Firm has indicated that 3 pairs are running satisfactorily at BNDM. Performance under watch.
6 Increase of OHE voltage out of limit
Software limits modified & implemented in WAP7
CGL has raised the upper limit to 30 kV as has been done in the other make converters.
Performance of M/s. CGL make Traction Converter SN Item Action plan Remark 7 TM isolation Non display of TM isolation
status on DDU once fault is
acknowledged.
Firm has been advised to
provide status of TM isolation
on display.
8 Main power off In case of failure of FLG-1,
Main power becomes Off.
Firm has intimated that the
software has been modified.
Firm has been advised to make
joint note with ELS/TATA.
9 Monitoring tool There is no snapshot in log
viewer file due to which it is
not possible to monitor
electrical parameters at any
particular time of fault.
Monitoring tool is required to
be modified and shall be
provided to user Railways.
Firm has intimated that they
are providing latest monitoring
tool.
Firm has to carry out trainings
for different sheds/CLW/RDSO.
User manuals to be submitted
to CLW/RDSO/Railways.
Performance of M/s. CGL make Traction Converter SN Item Action plan Remark 10 Discoloration of
SR coolant with
bad smell
Discoloration of SR coolant with bad
smell in machine room. In some
converter black/brown turbidity is also
being found. Firm indicated that this
may be due to mixing of oil during OCB
testing.
All locomotives have
been cleaned. Under
watch.
ELS/BNDM informed
about discoloration in
one loco.
11 Software
malfunction:
Whenever harmonic filter current>
maximum and bogie is isolated,
sometimes in background inverter
over current messages appears.
Firm intimated that
they have resolved the
issue.
Joint note to be
submitted with
ELS/TATA.
Performance of M/s. CGL make Traction Converter SN Item Action plan Remark 12 Sudden increase
of the
frequency.
Performance of M/s. CGL make Aux. Converter
SN Cause of failure 2015-16 2016-17 2017-18
(Dec)
2017-18
1 Power supply card (KUC153
A02) 74 106 22 24
2 BUR processor card (CCPU
card) 9 39 44 49
3 INVCC-01 electronic card 21 60 57 75
4 Inverter module 0 2 10 18
5 Others 0 17 25 25
Total 104 224 158 191
Total Population (Loco) 182 217 274 308
FRPCPY 57 103 76.9 62
Performance of M/s. CGL make Aux. Converter
SN Item Action plan Remark
1. Failure of PS card
(KUC153A02)
In place of KUC153A02 card, firm
modified KUB921 card of VCU and
made it suitable for auxiliary
converter.
Seventeen
locomotives of ELS/
Gomoh,
Royapuram & VSKP
are still remaining.
Material is
available in the
shed.
From the above, it
appears that failure
of INVCC cards are
still there.
2. Failure of BUR
processor card (CCPU)
Failure was due to over sensitively
of input channel. Sensing voltage
has been modified from 10 V to 36
V.
3. Failure of INVCC card The failure is due to spurious
inverter fault message in INVCC
card. To resolve this problem the
resistance to sense the over
current has been increased in gate
driver and corresponding software
modification in INVCC card.
Performance of M/s. CGL make Aux. Converter
SN Item Action plan Remark
4. Wrong generation of
fault message, BA
charger current < 10
Amp.
Problem raised by ELS/TATA in loco
no. 31436, 31487 & 31429 and by
ELS/BNDM in loco 31869.
Firm was advised
to resolve the issue
by 15.01.18. No
progress yet.
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Performance of M/s. ABB make Converters (IGBT)
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Performance of M/s. ABB make Traction Converter
SN Cause of Failure
No. of Failures
2015-16 2016-17 2017-18
(Dec)
2017-18
1 Duagon Card defective 10 4 1 4
2 Software Malfunctioning (Time out
initialization, harmonic filter current
high, etc)
44 43 37 46
3 PEC (controller card) defective 11 11 10 12
4 Gate Driver Unit (GDU) cards 14 15 10 16
5 Pump Failure / Fan Failure 2 7 7 12
6 Loose connector/OFC/ Cable
defective 6 4
3 3
7 PEBB (Power Module) Failure 12 20 21 24
8 Others (transient, contactor stuck up,
MCB trip) 52 42 27
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TOTAL 151 146 116 151
Total Population 115 156 194 220
FRPCPY 131 93.5 79.7 68.6
Performance of M/s. ABB make Traction Converter
SN Item Action plan Remark 1 i. Harmonic Filter Over
current. ii. Time out release shut down
due to non-availability of timely signal from converter to VCU (within 150 ms) for DC link voltage discharge. iii. Loco going into simulation mode with throttle not responding.
These software issues resolved in Verson-38 (417T38AB). Instructions have been issued for regular use of software version-38 vide RDSO letter No. EL/11.5.5/1/IGBT/ABB dtd. 19.06.17.
All the locos except of ELS/TATA have been provided with Ver-38. Performance under watch. About 15 locos of ELS/TATA still running with Ver-37.
2 Failure of PEBB module Investigation reports of recent failures still awaited.
ABB has indicated that most of PEBB module analysis is inconclusive since failures are blast cases.
Performance of M/s. ABB make Traction Converter SN Item Action plan Remark 3 Timing issue in
PEC Card Firm has proposed following two solutions: •Old version PEC-2 card
(presently in about 75 locos) have high booting time of 67 sec. Booting timing has to set as per the latest specification of the traction converter. • Proposed solution: (i) Software optimization in
existing PEC-2 card
ABB Remark:
At present, 8 locomotives have been
loaded with optimized software for
reduction of booting time and the
entire fleet will be covered by Feb-
2018.
ELS/ AQ : 31477, 31403, 31536,
31560
ELS/ TKD : 31358, 31545
ELS/ BIA : 30385
ELS VSKP : 31501
Firm need to expedite the
modification work and complete the
same by 28.02.18.
Performance of M/s. ABB make Traction Converter SN Item Action plan Remark 4 Gate Driver
Unit (GDU) cards
Cases of communication failure between GDU and PEC card Resolved. M/s ABB has been advised to submit detailed investigation analysis for the cases of component failure in GDU card.
ABB Remark: Firm has informed about providing tolerance limit for generation of GD link error in Ver-38. The failure incident in last quarter are 6. Firm need to submit the RCA.
5 Failure of
door guide
pin
Failure of door guide pin which
leads to transfer of weight on
the door latch. This problem is
arising after 2-3 years of service.
12 locos (TKD-2, GZB-2, BRC-5, TATA-
1 & VSKP-2) have been modified so
far. The progress is very slow.
ABB to identify and rectify the locos
early. Action plan yet to be
submitted. 6 Software
malfunctioni
ng, TE
becomes 0.
In WAP5 locomotive, TE
suddenly becomes 0 and jerk is
observing at that time.
Jerk observed in Loco 30114 of ELS
BRC during high variation in OHE
voltage. ABB had indicated that they
will submit investigation report with
corrective action plan by 20th Feb.
However, no report submitted.
Performance of M/s. ABB make Traction Converter SN Item Action plan Remark 7 Bogie
isolation due
to Pinion
fault & TM
earth fault
Reported by ELS/HWH. Complete
bogie is being isolated in spite of
faulty TM due to Pinion fault & TM
earth fault.
ABB has indicated that they
are analyzing and evaluating
to understand the adoption
such case (pinion failure) in
software and will submit
findings and solution by
20th Feb.
No Solution has been
proposed by the firm. 8 Optical fiber
issue
Communication between one
traction converter to other is with
optical fiber cable. In case of lifting
of converter, fiber optic cable is
forced to cut. Suitable connector is
required to be used to facilitate
lifting of converters without cutting
the fiber optic cable.
M/s ABB to yet to submit
the action plan.
Performance of M/s. ABB make Traction Converter SN Item Action plan Remark 9 Mismatch of
Ventilation
signal timing
Reported by ELS/RPM. This issue is
reported in 2 locomotives of the
shed. The firm needs to find the
cause of ventilation mismatch in
the affected locomotives.
M/s ABB to yet to submit
the action plan.
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SN Cause of Failure No. of Failures
2015-16 2016-17 2017-18
1 IGBT burst (inverter module) 2 3 5
2 Converter module 0 1 1
3 PCB cards 5 6 3
4 Battery charger module 0 1 10
5 Software malfunctioning 4 13 2
6 Misc. 6 11 4
7 TOTAL 24 35 25
8 Total Population 21 29 42
9 FRPCPY 114 120 59.5
Performance of M/s. ABB make Aux. Converter
Performance of M/s. ABB make Traction Converter SN Item Action plan Remark 1 IGBT burst
(inverter
module)
The Earthing circuit was proposed
to be modified.
RDSO has given approval to
modification in the earth
sensing circuit. The same
need to be implemented.
Firm need to give the time
line. 2 Battery
charger
module
Action plan to be submitted. Action plan to be submitted.
34
Performance of M/s. BTIL make Converters (IGBT)
SN Cause of Failure No. of failures
2016-17 2017-18
(Dec) 2017-18
1 Power Module 25 28 35
2 Software
Malfunctioning 28 30 44
4 GDU/DCU card 7 17 22
5 Cooling blower 10 14 17
6 Others 8 29 37
Total Failures 78 118 155
Total Population 108 206 231
FRPCPY 78 76 67
Performance of M/s. BTIL make Traction Converter
Performance of M/s. BTIL make Traction Converter
SN Item Action plan Remark 1 Failures of Power
Modules Presently 2 IGBT being used in parallel combination (4.5 kV, 900 Amp. Rating). To avoid mismatch in paralleling, single IGBT of higher rating (4.5 kV, 1500 Amp, Hitachi make).
BT Remark:
Based on the discussion of
software expert, BT has
improved the software for
over current protection in
software version
317T01BT/217T01BT and
modified software has been
uploaded in 188
locomotives.
Performance is still not
satisfactory.
Performance of M/s. BTIL make Traction Converter
SN Item Action plan Remark 2 Software problems:
i. Protective action not allowing DJ to reclose if OHE voltage >29 kV (Particularly after crossing NS).
Modified software addressing issue I & ii has been uploaded.
BT Remark: Both issue has been addressed in software version 317T01BT/21701BT. Modified software has been uploaded in 188 locomotives. Performance under watch.
ii. Issue of limitation of the TE in case module of other converter isolated.
Performance of M/s. BTIL make Traction Converter SN Item Action plan Remark 3 Isolation of
healthy TM instead of faulty one in case of TM/Penion failure.
In case of TM/Pinion failure, healthy motor gets isolated and at last affected bogie gets isolated instead of isolation of faulty TM with DDS message Speed Sensor Signal missing. Faulty TM should get isolated by stopping firing with appropriate Message
BT Remark: As per preliminary analysis, Event of pinion failure speed data from faulty Axel difference shows erratic behavior compared to healthy speed sensor - data goes beyond allowed range and traction interlock get applicable. BT is studying diagnostics data of pinion failure cases and look into possibility to do improvement in the Software to identify such cases and isolate TM. Investigation needs to be completed early.
Performance of M/s. BTIL make Traction Converter SN Item Action plan Remark 4 Phase fault in
TM In case of Phase fault in TM, bogie isolation takes place. Repeated rebooting will cause module failure. Faulty TM should get isolated by stopping firing with appropriate Message. Firm will examine & give feedback.
BT Remark:
In case of single earth fault in phase of traction motor, converter will work without any trouble. More than one earth fault will create, DC-link short circuit fault causing shutdown of traction converter. It’s not suggested to attempt to reboot the Electronics as phase short circuit and maintenance can happen at shed only.
Performance of M/s. BTIL make Traction Converter
SN Item Action plan Remark 5 Main power OFF
due to FLG-1 time out DC link circuit charge
BT is still working on this issue. BT to revert back at the earliest. Root cause not established by firm. Firm requested shed to send DDS data for further investigation. BTIPL has to provide data logger in all locomotives of ELS/HWH in 10 days.
Addressed in the software version 317T02BT & 217T02BT. RDSO has given approval for regular use. Performance under watch.
Performance of M/s. BTIL make Traction Converter
SN Item Action plan Remark
6 False message “VCB stuck off”
False message “VCB stuck off” in case of catenary voltage out of limit has not been solved. BT is still working on this issue and promised feedback in 10 days. Feedback awaited.
BT Remark: We had discussed with ELS/HWH and ELS/BRC regarding the “VCB stuck off” message in case of catenary voltage goes beyond the limit and they do not found any VCB stuck off messages in new released software 317T01BT/217T01BT. Railways to comment.
Performance of M/s. BTIL make Traction Converter SN Item Action plan Remark 7 Harmonic Filter
Current > Max
Harmonic Filter Current >
Max, leads to MCE OFF.
Normally with Speed
Restriction of 40 KMPH,
after Bogie Isolation, loco
should run normal with Half
Traction.
BT remarks:
Problem reported only in 2
locomotives and problem
under investigation.
No findings yet shared by BT.
8 No regeneration in
rear loco in MU
operation.
There is no regeneration in
rear locomotive in MU with
BTIPL make traction
converter. This is software
issue.
Firm has indicated that they
are studying the issue and
propose solution by 15.02.18.
Solution still awaited.
9 Isolating cock in
cooling circuit
Isolating cock has not been
provided in cooling circuit of
traction converter. Required
to incorporate the same.
Firm to study and suggest
modification by 15.02.18.
Solution still awaited.
Performance of M/s. BTIL make Traction Converter
SN Item Action plan Remark 10 False message
display of “Traction may not be available on this Loco or Slave Loco, Bring throttle to ‘0’ position and set again” in place of “coolant pressure not OK”
Whenever converter-1/2 pump MCB trips, concerned Bogie is getting isolated with display message “Traction may not be available on this Loco or Slave Loco, Bring throttle to ‘0’ position and set again” in place of “coolant pressure not OK” , thus confusion LP.
BT remark: Whenever converter-1/2 pump MCB trips concerned bogie isolated with display message "Auxiliaries HB2 - MCB(s) open in Aux Cubicle1/2, traction power may get reduced". Loco pilot Check MCBs in Auxiliary cubicle. ELS/HWH to comment.
11 Integration issue of
BT SR with BHEL &
AAL make BUR.
DDS messages regarding fault of
IGBT Auxiliary converter of
BHEL, AAL make (except life sign
missing) is not recorded in DDS
with BT make IGBT traction
Converters.
The software has been
modified as some of the
messages were wrongly
configured.
Railways to comment.
Performance of M/s. BTIL make Traction Converter SN Item Action plan Remark 12
Problem with
new software
version 3500:
(i) If FLG-1 fails, all
BURs stop working
BT remarks:
It is expected that in the event of FLG1
failure BUR should stop working until
FLG2 take over the vehicle control. Same
has been demonstrated to locomotive in
31619 at Kalyan Shed.
(ii) If Cont. 8.1 or
8.2 stuck off, H/filter
gets isolated
without tripping of
VCB.
BT remarks:
As per implemented Logic VCB will open
in the event of 8.1 or 8.2 contactor
stuck-off.
We request Shed to share diagnostics
data.
(iii) It is not possible
to troubleshoot
TM/Converter
isolation from DDS.
BT remarks:
We have feature of online investigation
of any TM isolation/converter isolation
at shed using BT Tool DCUTERM and
easily identify cause of failure.
45
Performance of M/s. Medha make Propulsion system
Performance of M/s. Medha make Propulsion
SN Cause of Failure
No. of failures
2016-17 2017-18
(Dec)
2017-18
1 Card failure 0 7 8
2 VCU problem 1 0 0
3 Software Malfunctioning (Time out
initialization, Time mis-match etc) 1 9 9
4 Converter contactor 2 1 1
5 Power Module 3 6 9
6 TM speed sensors 0 4 4
7 Loose connector / OFC/ Cable defective 0 0 0
8 Others / Misc. 5 16 37
Total 12 43 68
Population 9 76 83
FRPCPY 150 75.4 82
Performance of M/s. Medha make Propulsion system
SN Item Action plan Remark
1. Comprehensive
maintenance
tool
As per the PO condition firm
needs to submit the
comprehensive maintenance
tool.
Firm has said that only two
nos. comprehensive tools to
TATA-1, CNB-1 & LGD-1 have
been given.
Firm to submit the
details/user manual of
comprehensive maintenance
tool to Railways, CLW and
RDSO.
Performance of M/s. Medha make Propulsion system SN Item Action plan Remark
2. Bursting of
capacitor
Bursting of capacitor:
In locomotive no 30553 at
ELS/TATA the DC link capacitor
burst, which led to failure of Power
module. The capacitor of
Electronicon has failed twice in the
same locomotive. Firm to
investigate the failure with
capacitor manufacturer and
submit the detailed investigation
report to RDSO and CLW.
Firm advised to replace the
traction converter as complete unit
by 31 Jan-18 and take it to firm
premises for detailed investigation.
Medha Remark:
We have sent the failed DC
link capacitor to Electronicon
(Italy) and waiting for detailed
investigation report.
Performance of M/s. Medha make Propulsion system SN Item Action plan Remark
3. Mapping and
logging of fault
messages in
DDS:
Instances of failure have been
reported form sheds, ELS/TATA
and ELS/LGD where it has
been observed that either
non-logging of fault messages
in case of failure or logging of
wrong messages taking place.
Firm has been advised to
ensure proper logging of fault
messages in case of
failure/fault and submit the
fault list and diagnostic data list
to CLW and RDSO. The
compliance is pending. Firm to
expedite. PDC 31/01/18
Medha Remark:
As per the trouble shooting
directory for three Phase
Locomotive Rev.8 dated Jan'14
we have implemented the
fault messages.
We once again submitting
fault messages list for your
reference.
ELS to confirm.
Performance of M/s. Medha make Propulsion system SN Item Action plan Remark
4. Interoperability
of MU units:
Multi-operation of locomotive
of MEDHA with propulsion of
BHEL is pending. Many attempts
has been made at ELS/LGD to
resolve the issue.
However, the firm indicated that
the primary communication over
WTB has been established
successfully and application level
integration is required for
seamless transfer of messages
and consequently successful
multi-formation/operation.
Firm advised to visit the
ELS/LGD with M/s BHEL and
test the Multi-
operation at the earliest.
Medha Remark:
We have configured Multi Unit
operation with Bhel make
Propulsion system on 31-10-
2017. As per the Joint note
(enclosed) it is mentioned to
provide the feature to show
the DDS messages of Slave loco
on DDS of Master loco during
MU operation for smooth
performance of the system.
Firm has been advised to
demonstrate the MU operation
at ELS/VSKP.
Performance of M/s. Medha make Propulsion system SN Item Action plan Remark
5. Failure of MTCN
Card:
Cases reported of failure of
MTCN cards during multi
formation of locomotive, firm
introduced surge protection in
cards 8 locos in ELS/TATA.
Performance under watch, firm to
submit the failure report.
Medha Remark:
We have added surge protection
device in TCN card, and we have
modified all Locomotives (8 nos)
running MU and modifying
remaining Locos also with surge
protected cards.
1) Modified MTCN cards has
provided in 09 locomotives.
(31920,31926,31927,31980,31
904,31915,31937,31902,3054
9)
2) Firm to give the current
position.
3) Details of modification to be
submitted to RDSO for formal
approval.
Performance of M/s. Medha make Propulsion system SN Item Action plan Remark
6. ELS/TATA has
reported
isolation of Aux
converter
ELS/TATA has reported
isolation of Aux converter
with fault message “AC input
frequency disturbance” and
“DC link voltage high”. The
firm has modified the
software and uploaded in 20
locomotives. Performance
under observation.
Medha Remark:
Improved software has been
provided in 20 locomotives, (
31906,31920,31926,31927,3
1898,30547,31930,31952,31
953,31955,31904,30553,
30558,30564,31937,30566,3
0549,31962,30601,30600 )
Firm to indicated the current
position and action plan for
remaining locomotives.
Details of the software
modification to submitted to
CLW/RDSO for formal
approval.
Performance of M/s. Medha make Propulsion system SN Item Action plan Remark
7. High ramp-
up/ramp-down
High ramp-up/ramp-down of
26 seconds to be reduced to
15 seconds as per existing
MICAS logic and provided in
20 loco for trial, performance
is under observation.
Medha Remark:
Software improvements done in
Auxiliary converter to decrease the soft
start time to below 20 sec by modifying
ramp up time to 5Hz/sec earlier it was
2.5Hz/Sec.
Improved software has been provided
in 20 locomotives
(31906,31920,31926,31927,31898,3054
7,31930, 31952, 31953, 31955, 31904,
30553, 30558, 30564, 30566, 31937,
30549, 31962, 30601, 30600 )
Ramp up time further to be reduced to
15 sec which is under testing and same
will be provided in locomotive once it
has proven in lab.
Performance of M/s. Medha make Propulsion system SN Item Action plan Remark
8. Training Firm to impart training at
sheds for diagnostic tool as
the population of propulsion
system is increasing and
sheds are facing difficulty in
operation of diagnostic tool
and Fault downloading
analysis. Firm advised to
submit the operational
manual/ procedure of
Diagnostic tool to CLW and
RDSO for distribution to
sheds.
Medha Remark:
We are already providing
training at various sheds
wherever our locomotives
are present.
We have enclosed the
details of training arranged
in last year for your
reference.
Firm to conduct training on
diagnostic tools in different
sheds.
Performance of M/s. Medha make Propulsion system SN Item Action plan Remark
9. Issues of
Throttle not
responding
Issues of Throttle not
responding was resolved
through Plausibility check
error recalibrated as per
MICAS logic, Trial and testing
under observation at
ELS/TATA.
Medha Remark:
Logic to declare the "Angle
transmitter failed" message
is if difference between
reading value and actual
value is more than 40% of
1/3 scale.
We have implemented the
logic as per existing Loco
logic i.e full scale error 40%
of full scale at all 3 positions
of as per shed advice.
In-house testing is going on.
Current position?
Performance of M/s. Medha make Propulsion system SN Item Action plan Remark
10.
Failure of
radiator
Zonal railway reported
several cases of failure of
radiator unit only in MEDHA
make propulsion system.
Firm advised to investigate
and discuss the observation
with RDSO for further action.
Firm need to submit the
action plan.
Performance of M/s. Medha make Propulsion system SN Item Action plan Remark
11.
Draining of
battery
Northern railway reported
fast rate of draining of
battery causing fatal error
of the locomotive. It was
observed that the some of
the sub-system such as DDU
keep on in standby mode
even after BL key is in off
position. Firm advised to
review the design to address
the issue as this is not
required.
Medha Remark:
Changes done to switch OFF
DDU when BL Key OFF
condition. And also the
power consumption of DDU
is 15W. As Loco battery 190
AH rated and with 15W
power consumption up to 30
days battery should not
drain.
Firm need to submit the
action plan.
58
Performance of M/s. AAL make Aux. Converter
Performance of M/s. AAL make Aux. Converter
SN Cause of Failure 2017-18
1 Inverter module 6
2 Rectifier module 1
3 PCB cards 5
4 Battery charger module 1
5 Software malfunctioning 8
6 Misc. 17
TOTAL 38
Total Population (loco set) 134
FRPCPY 28
Performance of M/s. AAL make Propulsion system
SN Item Action plan Remark 1 Use of Gateway
card Firm has not given the type of gateway card used. The details of the card to be given.
Details yet to be submitted.
2. Failures of Rectifier module and BA charger module.
Failure investigation reports of rectifier module and BA charger module to be submitted.
Firm yet to submit the reports.
3. Compatibility of the messages with other make converters
Railways to indication the compatibility issues.
61
Performance of M/s. Hirect make Aux. Converter
Performance of M/s. Hirect make Propulsion system ELS/GMO
Isolation of BUR-2 during Stuck ON of contactor 52/4.
Without downloading the registration of Aux. Converter no Trouble
shooting is possible on DDS of Loco.
If input voltage is not OK other than fuse fault/failures, in this case
neither BUR starts nor it gets isolated.
ELS/BIA
Two times Battery Charger faulty in one loco. Battery charger
control card, gate driver card & cables changed.
Inverter fault due to IGDU fault and DC-DC converter fault.
Detail investigation report yet to be submitted.
ELS/VSKP
Replaced BUR in one loco due to compatibility with the BTIPL make
SR.
Thanks !
63