reliability issues of igbt based converters...performance of m/s. bhel make traction converter sn...

Reliability Issues of

IGBT based Converters

19.04.2018

1

2

Performance of M/s. BHEL make Converters (IGBT)

3

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.


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.



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.


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.


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

11

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.

15

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



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.



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.

25

Performance of M/s. ABB make Converters (IGBT)

26

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

34

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.

32

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


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.


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.


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.



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.


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


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.


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.


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.


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.


demonstrate the MU operation

at ELS/VSKP.


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.


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.


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.


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.


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?


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.


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

reliability issues of igbt based converters...performance of m/s. bhel make traction converter sn...

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