03.05.2020 - SR, Sensor (3 PH) RAP Gap Analysis ELS-HWH - AEE-I-HWH - PPSX

GAP ANALYSIS
REPORT
RAP on Traction Converter

Ref. TC No. RDSO/2017/EL/TC/0142 (Rev. ‘0’), dt. 09.01.2018
ELECTRIC LOCO SHED / HWH

ELECTRIC LOCO-SHED / HOWRAH
ELECTRIC LOCO-SHED / HOWRAH
LOCO Holding 173
WAP 4 Conventional 73
WAP7 3 – phase 86
WAP 5 3 – phase 14
Traction Converter (SR) 100 Auxiliary Converter (BUR) 100

GTO 16 GTO 17
IGBT 84 IGBT 83
IGBT/BT (Stand-alone) ALT - C 11 IGBT/ABB 1
IGBT/BT (Stand-alone) ALT - D 7 IGBT/AAL 6
IGBT/BT (Stand-alone) ALT - E 6 IGBT/CGL 17
IGBT/BT (Propulsion) 19 IGBT/HIRECT (Stand-alone) 3
IGBT/BT(HIRECT) (Propulsion) 19
IGBT/BHEL (Stand-alone) 16 IGBT/BHEL (Stand-alone) 12
IGBT/BHEL (Propulsion) 17 IGBT/BHEL (Propulsion) 17
IGBT/MEDHA (Propulsion) 8 IGBT/MEDHA (Propulsion) 8
HOG 59
Siemens 27
Medha 30
2
BHEL 2
As on Mar’ 2020
Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH
AN OVERVIEW OF 3 – Ø LOCO
AN OVERVIEW OF 3 – Ø LOCO

POWER
POWERCKT.
CKT.DIAGRAM
DIAGRAMOF
OFTRACTION
TRACTION
CONVERTER
CONVERTER

AN OVERVIEW OF TRACTION CONVERTER
Line – Side DC - Link Driver – Side

Converter Converter

PC
Vehicle Control (VCU – 1) Vehicle Control (VCU – 2)

Central Electronics -1 (CEL – 1) [SB1 – 411] Central Electronics -2 (CEL – 2) [SB2 – 412]
Redundant MVB fibre optics
Processor Cards Processor Cards
PP B622 B01 – 3 Nos. (FLG-1, STB-1, HBB-1) PP B622 B01 – 3 Nos. (FLG-2, STB-2, HBB-2)
PP B908 A01 – 1 No. (DDA-1) PP B908 A01 – 1 No. (DDA-2)
PP B626 B01 – 1 No. (FBV-1) PP B626 B01 – 1 No. (FBV-2)
PP A425 B01 – 1 No. (ZBV-1) PP B624 B01 – 1 No. (DIA-1)
Traction Converter Control – 1 (SR – 1) [415/1] Traction Converter Control – 2 (SR – 2) [415/2]
Non - Redundant MVB fibre optics

Converter Control Unit (CCU-1) Converter Control Unit (CCU-2)
Non - Redundant MVB fibre optics
Processor Cards : PP B622 B01 – 1 No. (SLG – 1) Processor Cards : PP B622 B01 – 1 No. (SLG – 2)
Driver Control Unit (DCU-1) Driver Control Unit (DCU-2)
Line Converter Control (LCC-1) Motor Converter Control (MCC-1) Line Converter Control (LCC-2) Motor Converter Control (MCC-2)
Processor Cards Processor Cards Processor Cards Processor Cards
PP A988 B02 – 1 No. (NSC-1) PP A988 B02 – 1 No. (ASC-1) PP A988 B02 – 1 No. (NSC-2) PP A988 B02 – 1 No. (ASC-2)
Auxiliary Converter - 1 (BUR – 1) Auxiliary Converter - 2 (BUR – 2)

Processor Cards Processor Cards
PP B471 A02 – 1 No. PP B471 A02 – 1 No.
UIC-1
Auxiliary Converter - 3 (BUR – 3)
Processor Cards
TRAIN – BUS Communication PP B471 A02 – 1 No.
(WTB)
6
UIC-2

CURRENT AND VOLTAGE WAVEFORM OF MOTOR PHASE
CURRENT AND VOLTAGE WAVEFORM OF MOTOR PHASE
WINDING
WINDING

RAP ON 3 – Ø TRACTION CONVERTER
In TC – 142 to improve the reliability of 3 – Phase Traction Converter the following
points are considered :-
Installation and implementation of testing set up of gate unit of Traction Converter for 3-Phase electric
locomotives. (RDSO/2010/EL/SMI/0263, Rev.’0’ dtd. 27.07.2010)
Checking of waveforms of gate unit of converter with the help of GUSET in case of valve set failure /
false alarm of GBC as per SMI-263.
 Testing Set Up:

 Gate Unit Transmitter Receiver Test Set (GUSET)
 Four Channel Oscilloscope
 Current Prove (100 A DC).
 Optic fibre cable (20 cm) with connector at both ends (2 nos.)
 Gate Unit Power Supply (GUSP)
 110 V DC Supply Source
8
 dB Meter.

GUSP
GUSET OSC
Ga
Voltage te
Un
Source it
Current
Probe
Optic
Fibre
dB Meter
9
Gate Unit Testing Set Up
Amit Kumar Guin, AEE/I/TRS/HWH
Sunday, May 3, 2020
Optic Fibre Cable
SS RM
110 V DC SS RM
Gate G
Power 110 V GUSP 48 V GUSET
Unit K
Supply
230 V ac
Connection Diagram of Gate Unit testing Setup
10
Amit Kumar Guin, AEE/I/TRS/HWH

Sunday, May 3, 2020
Wave Form of Healthy Gate Unit
No Distortion in waveform SS & RM Pulse Opposite each other
Minimum On time 85 μS +/- 5% Dead time 25 μS (Min.)

11
 Being Followed in ELS/HWH.

Checking of Gate Unit cards by measuring dBm level of QFBR-1478C transmitter

(component no.151).
(RDSO/2009/EL/SMI/0257,dated 22.05.09)
Checking of gate unit GK cable, optic fibre cable losses, downloading of software PPA
988 card in case of GTO failure.
 To improve the reliability of Gate Unit Cards of SR of 3 Ø locos.
 To prevent failure of SR Gate Unit (GVA 587 A01) by measure dBm level of Optical
Transmitter (QFBR – 1478C).
12

dBm loss level Action to be taken
Greater than - 18 dBm Transmitter Fail - replace
In between -16 & -18 dBm Measurement Repeat after 6 months – if

dBm loss more than -1 dBm than previous – replace.
less than - 16 dBm Measurement Repeat after 1 Year –
if dBm loss more than -1 dBm than previous –
replace.
dB
Meter
RM SS
110 V DC SS RM
Gate
Power 110 V GUSP 48 V GUSET
Supply Unit
230 V ac
13
Testing Set up of Transmission loss Measurement

dBm Loss Measurement
 Being Followed in ELS/HWH. 14

Improvement of reliability of LWL cards (AFB635A01) and bus coupler cards (UFB 660
A01 & UFB 701A01) of three phase locomotives by testing QFBR 1478 C and 2478C
transmitter & receivers as per SMI/258.
 LWL card – AFB 635 B08 provides Fibre Optical connection between Bus Station and Gate Unit.
 There are Two cards in each SR rack in 1-2, 3-4 Slots.
 The Fibre Optical Transmitter / Receiver in (LWL) AF 635 B08 card converts the electrical firing
pulses received from AS & NS controller into corresponding light pulses for potential free and
interference free transfer to the Gate Unit.
 The feedback signal also transferred optically is converted into electrical impulses.
 There are 8 Channels each for transmitter and receiver.
 For Transmitter –
 Optical logic ‘0’ – for Signal level < - 40 dB
 Optical logic ‘1’ – for Signal level > - 20 dB
 For Receiver –
 Optical logic ‘0’ – for Signal level < - 40 dB 15
 Optical logic ‘1’ – for Signal level – in between – 24 dB to 12 dB
Converter Rack
16
LWL Card

Testing of LWL Card – AFB 635 B08
Testing of Transmitter –
 Connect 8 Specified pins (1c6, 1c8, 1c10, 1c12, 2c6, 2c8, 2c10, 2c12).
 Insert Power supply card and LWL card inside the rack.
 Switch on 110 V power supply to the rack.
 Inject – 13 dB optical power from dBm Transmitter at the Receiver of LWL card and
measure the optical power at Transmitter by dB.
 The value of optical power should be as given below -
dB loss level Action to be taken

Greater than - 18 dB Transmitter Fail - replace
In between -16 & -18 dB Measurement Repeat after 6 months – if

dBm loss more than -1 dBm than previous – replace.
less than - 16 dB Measurement Repeat next AOH
– if dBm loss more than -1 dBm than previous –
replace.
17

Testing of LWL Card – AFB 635 B08
Testing of Receiver –
 Same setup has to be used however remove the looping back of pins in the back plane.
 Connect dBm Transmitter to Receiver of LWL card.
 Connect Multi-meter on the receiver test point.
 Measure the Output signal amplitude on Multi-meter.
 It should be greater than 4.1 V.
18

Testing of MVB Card – UFB 660 A01 & BUS Coupler Card - UFB 701 A01
Testing of Transmitter –
 Insert Power supply card and MVB card inside the CEL.
 Apply + 5 Volt on Test Point from REGA pin 28.
 Measure dB value at optical power receiver meter.
 The value of optical power should be in between -12 dB to -16 dB.
 If less than – 16 dB : a balancing resistor 70 Ω soldered in between point T1 & T2.
 If greater than -12 dB : the resistor must be unsoldered.
 If not possible to bring the dBm level within specified limits through balancing resistor, transmitter
considered as defective and should be replaced.
Testing of Receiver –
o Carried out the same procedure with Optical signal is injected to the receiver and
corresponding electrical signal is measured at REGA pin 3.
o The voltage should be + 5 Volt in Optical signal switched ON condition
o The voltage in between 0 to 0.08 V if Optical signal switch OFF condition.
19
 Being Followed in ELS/HWH.
Replacement of ECSX make 24 MHz crystals by FOX make crystals in electronic
cards of three phase electric locomotives (MS no. RDSO/2010/EL/MS/0391
(Rev.0), Dated 04.02.2011) PPA 988, PPB471 & PPB622.
Replacement of 1mW crystal of 24 MHz by Zauch make 0.5 mW in PPA988 cards

and PPB622 cards (RDSO’s letter no. EL/11.5.5/5 dtd. 13.04.12).
Replacement of 1mW crystal of 24 MHz by Jauch make 0.5 mW in PPA988 cards

and PPB622 cards having indigenised BAP ASIC during major schedule or
whenever card is taken out (RDSO’s letter no. EL/11.5.5/5 dtd. 26.03.13).
On 23.07.2010 Reliability meeting held on RDSO M/s BTIL informed FOX make crystal
(24 MHz) works perfectly with indigenized BAP ASIC.
20

This crystal (24 MHz) and BAP ASIC used in the following cards –
SL No. Type of Card Name & Function of the Card
(Controller Board)
1 PPB 471 A02
BUR PROCESSOR
(Drive/Line side Controller Card)
2 PPA 998 B02
NSC/ASC PROCESSOR
(Single Board Computer)
3 PPB 622 B01
SLG/FLG/STB/HBB PROCESSOR
(Diagnostic Computer)
4 PPB 624 A01
DIA DDS CARD
(BUS Administrator)
5 PPB 626 B01
FBV PROCESSOR
(Display Computer)
6 PPB 908 A01
DDA PROCESSOR
 It is advised to phase out FOX make crystal from the above cards. Type of massages
which may be encountered are also given.
21

Replacement of 24 MHz Crystal
 Completed. 22

Installation and implementation test set up for SAP cards and sensors
(SMI 260).
 There are three Signal Conditioning Card (SAP) provided in traction converter electronics.
These are UAB 630 A36, UAB 630 A91, UAB 630 A93. each of them processed / conditioned
six analog values in converter electronics.
 This instruction issued for development of testing set up of SAP cards and sensors for three
phase electric locomotives.
23

Different Analog Values in SAP cards
Signal name Slot Signal name Slot

I prime (Primary Current) A/A U prime (Primary Voltage) B/A
I bur (Auxiliary winding Current) A/C GU PF (Gate Unit Power supply Fail) B/C
I filter (Filter winding Current) A/E I q 2.2 [Traction winding 2 (lower) Current] B/E
I ZSS-AC (Train power supply Current) A/G I q 2.1 [Traction winding 2 (upper) Current] B/G
P trafo (Oil pressure Transformer) A/I I q 2.2 [Traction winding 2 (lower) Current] B/I
U ez (Earth Fault detection Current) A/K I q 2.1 [Traction winding 2 (upper) Current] B/K
UBF 630 A36 UBF 630 A91
Signal name Slot

I r (Inverter Current Phase R) B/A
I s (Inverter Current Phase S) B/C
I T (Inverter Current Phase T) B/E
U d1 [DC Link Voltage] B/I
U d2 [DC Link Voltage] B/K
24
UBF 630 A93
 Followed in ELS/HWH.
Calibration & Testing of Wandler module as per SMI 260.
 Wandler Module checked separately for various inputs with the help of voltage Source.
 Table for checking Voltage ratio (50 : 1) of Wandler Module –
Input Voltage Output Voltage Wandler

Module
50 V 1V
100 V 2V
150 V 3V
200 V 4V
250 V 5V
25
 Followed in ELS/ HWH.

Testing of URB512 D15 (Digital I/O Board Computer) and URB177 D15 (Digital I/O
Board Computer) used in VCU & SR (SMI no. RDSO/2013/El/SMI/0277, Rv. 0 Dated
02.01.14.
A Functional setup to Check the healthiness of URB 512 D15 & URB 177 D15 (Digital
I/O Board Computer) and to find the defective reed relay with intermittent problem.
Input Channels Checking:

 Connect LDS, VCU with test Card in Q – Slot.
 Connect Sub D – ‘A’ & ‘D’ of test kit at QA & QD location respectively.
 Switch ON the toggle Switch – 1 of test kit and observe the signal by glowing.
 By Switch OFF the toggle Switch – 1 see the signal is off.
 Repeat this test for 5 to 6 times.
 Similar check carried for all channels signal status (1 to 16).
26

U 512
B
A S1
F
7
D
0
1
VCU Rack
L1
F ST 177 H F U L2
S 19
L B B B B
G 2 A B V F
S 20 L2
1 2 2 6
D 6
0
S 16
SR Rack
I/O Test Kit
110 V DC
LDS Supply
27
Testing Setup for Card UBF 512 D15 & UBF 177 D15

Output Channels Checking:
 For checking O/P channels i.e. 15 reed relays insert the test card in J – slot.
 Connect Sub D – ‘G’ & ‘J’ of test kit at QA & QD location respectively.
 Switch ON the toggle Switch – 1 of test kit and observe the signal by glowing.
 By Switch OFF the toggle Switch – 1 see the signal is off.
 Repeat this test for 5 to 6 times.
 Similar check carried for all channels signal status(1 to 17).
28
Testing of Card UBF 512 D15 (Digital I/O card)

Load testing of Reed Relay –
 To test reed relay on 50% load condition (240mA) switch on S – 19.
 All lamps (L – 1, L – 2) will glow if contact of reed relay is OK.
 To test reed relay on 100% load condition (500mA) switch on S – 20 including S – 19.
 All lamps (L – 1, L – 2, L – 3) will glow if contact of reed relay is OK.
 If found fault replace by Good one which are pretested and carried out the same test.
K 248
K 252
Testing of Reed Relay
 FOLLOWED in ELS / HWH. 29

Improved Grounding of ALG rack in Traction Converter of 3phase electric
locomotives as per MS/365.
 To reduce EMI effects / interferences in ALG rack as these results sometimes in mis-fire of GTO
(i.e. Shoot through failures) proper Grounding is essential.
 With the implementation of improved shielding / Grounding, shoot through failures of valve sets
shall be arrested.
Arrangement to be done :
 An additional earthing cable from ALG rack to converter body earthing terminal has to be
provided with 4 GKW, 6 Sq. mm. cable.
 The cable should be routed along the existing cables and shall be terminated at the converter
earthing terminal where the main earthing cable is terminated.
30

Grounding of ALG rack in Traction Converter
Grounding on ALG rack Grounding of ALG rack with Main earth
 COMPLETED. 31

Working of churning fans of traction converter, Aux converter and VCU
electronics racks to be ensured in every schedule.
3 Nos. of Churning Fan

in each
Converter rack.
The capacitance of combined DC link capacitor as well as combined resonant capacitor

should be measured in every TOH. In case of abnormal variance in the combined
capacitance value identify the faulty capacitor by measuring the capacitance value of
individual capacitor and change the capacitor accordingly as per RDSO Letter No.
EL/3.1.35/17 (BHEL) dt.16.12.16.
 Followed in ELS / HWH. 32

Repair and maintenance instructions of GTO valve sets as per RDSO Technical report No.
RDSO/2016/EL/IR/0176 (Rev’0’), Oct’2016.
Following Precautions to be taken to prevent Valve sets failures :-

 To prevent the dust ingress the converter oil should be drained and filtered in every MOH.
DGA of SR oil should be carried out after Filtration.
 Valve sets should always be filled with Oil / Nitrogen & stored in dust free chamber.
 Testing of LWL (AFB 635 A01) card carried out as per SMI/258. New and repaired LWL cards
should be tested according SMI/258.
 Optical fibre cables should be checked for dB loss which should not be more than 16 dB.
 SR gate Unit (GVA 587 A01) optical transmitter (QFBR-1478C) should be checked during every
IOH as per SMI/257.
 New and repaired Gate Unit should be tested as per SMI/263 & TC/135 and should be done for
a sufficiently long time with continuous monitoring of signal to arrest transient malfunctioning.
 Special precaution should be taken during disconnection & connection of G-K cable. It Should
be replace in every POH.
33
 Followed in ELS / HWH.
Sunday, May 3, 2020 A mit Kumar Guin, AEE/I/TRS/HWH

Modification in cooling circuit of M/s BHEL make IGBT based traction converter to
prevent air locking, spillage of coolant and fluctuating in coolant level as per RDSO/MS
457 Rev'0' dt:12.01.17.
 Coolant level fluctuation and overflow problem observed in M/s BHEL make IGBT based
SR due to entrapped air in the coolant circuit.
 Existing Arrangement –
Air is extracted by making part of the coolant flow though the Expansion Tank where air
and coolant gets separated. Air will be exhausted through the breather mounted in the
Tank.
 Modified Arrangement –
Modification in the cooling circuit ensures continuous removal of air from the coolant.
Air which gets collected at vent Plug-A shall be drained into the expansion Tank along
with coolant (Y). Air gets separated in the expansion tank.
34
The bypass line (Z) ensures positive pressure in suction line.
Sunday, May 3, 2020 A mit Kumar Guin, AEE/I/TRS/HWH

 Exist in 4 Nos. Locos (WAP 7).

 Also exist in 10 Nos. (WAP 5) – onwards Nov’2019 - transferred from BRC to ELS/Hwh .
 Action taken – for Previous 4 Nos. (WAP 7) letter issued to M/s BHEL. 35

SR oil DGA, BDV checking in IA, IB, IC & major schedules as per SMI
No.138, 158.
 SMI – 127 : Characteristics of Transformer Oil as per IS : 335 – 83

 SMI – 158 : Different check of Transformer oil in IA, IB, IC and Major Schedules.
 SMI – 138 : DGA analysis of Transformer Oil as per IS : 10593 – 1983 & IS : 9434 – 1979.
 BDV value of Tr. Oil – for 2.5 mm gap - 30 kV (rms) per min.
 DGA permissible values –
SL. Gas Less than 4 Yrs. 4 - 10 Yrs. in More than 10 Yrs.
No. in Service (ppm) Service (ppm) in Service (ppm)
1 Hydrogen 100 – 150 200 - 300 200 – 300
2 Methane 50 – 70 100 – 150 200 – 300
3 Acetylene 20 -30 30 – 50 100 – 150
4 Ethylene 100 -150 150 – 200 200 – 400
5 Ethane 30 – 50 100 – 150 800 – 1000
6 Carbon dioxide 3000 - 3500 4000 – 5000 9000 - 10000
36

Observation and action –
 If the colour of the oil has become dark brown which is indicative of presence of dissolved copper.
Change the oil with new filtered oil.
 Interpret the faults according DGA result.
 IF BDV and water content and DGA result are beyond the permissible limits, should be filtered
under vacuum as per IS : 10028 (ii) 1981.
 Filtration should continue till such time the oil is completely dried.
 Check the filtered oil sample foe electric strength and water content and DGA, whether these
parameter are within the limits.
 If not within permissible limit continue filtration till recovery.
37
 FOLLOWED in ELS / HWH.

No valve set should be kept without oil either in the locomotive or as a spare
unit.
Dust removal from Machine Room by Industrial Vacuum Cleaner in each schedule.
Checking of valve set GTO values in MOH with multi-meter and in IOH schedule
with IC variable meter as per SMI-247.
Draining of traction converter oil in GTO based loco and filtration of oil to be done
in TOH.
 Being Followed in ELS / HWH. 38

By PUs: Earthing of screening of TM temperature sensors to avoid spurious message of
“Error PS hardware” (MS-347)
By Shed: Earthing of temp sensor shielding with end-bell at both ends.
Ensure proper crimping of temperature measurement cable with temperature sensor

resistance element cable inside Aluminium ferrule & its covering with heat shrinkable
sleeve during TOH/IOH or change of temperature sensor.
Ensuring proper shielding of TFP/SR/TM temperature sensors cables at SR rack.
 Being Followed in ELS / HWH.
39

RAP ON SENSORS OF 3 – Ø LOCO
RAP ON SENSORS OF 3 – Ø LOCO
Pre-testing of speed sensor as per SMI-252.
 “Weigand” speed sensor not exist in ELS/HWH base loco.

 IGBT 5+3 Pin speed sensor testing done.
Speed Sensor Signal

of
IGBT Converter
40

RAP ON SENSOR OF 3 – Ø LOCO
Adoption of IGBT type speed sensors in locomotives with GTO based traction
converter as per RDSO MS 0458.
 GTO locomotives and IGBT locomotives have different type of speed sensors.
 In GTO locomotives, in order to resolve the direction of motion the signal is inverted.
 In case of IGBT locomotives, the direction is resolved by the shifting the signal by 90 degree.
41

 Type of Speed Sensors –
SL. No. of Teeth on pulse No of
TYPE of Speed Sensor Make of Converter
No. generating ring PIN
1 “Weigand” speed sensor Fiber ring 5+5 GTO base Locomotives
2 GTO locomotives 120 5+5+3 GTO base Locomotives
3 GTO locomotives But IGBT speed sensor 120 5+3 GTO base Locomotives
4 IGBT locomotives 120 5+3 BHEL / MEDHA / ABB
5 IGBT locomotives 200 5+3 BT
6 IGBT locomotives 200 8 BT
 Make wise Population of speed sensor at

IGBT ARC ELS/HWH
IGBT Leonard - Medha
IGBT IGBT BT IGBT BT
Make Weigand (120 Teeth) Bauer (120 Teeth) (120 Teeth) (Leonard Bauer) (Leonard Bauer)
5+3 Pin 5+3 Pin 5+3 Pin 8 Pin, 200 Teeth 5+3 Pin, 200 Teeth
Population of
speed sensor 0 114 90 48 108 156
( WAP-7)
Population of
speed sensor 36 20
( WAP-5)
42
 IGBT Speed sensor Adoption in GTO based SR Completed.

Pre-testing of Master Controller as per TC-134.
 Apply 24 V in the angle transmitter Sub D Pin No. 3 & 5.

 Measure Current from Pin No. 9 with the different position of TE/BE.
Position of TE/BE Current in mA Master Controller

TE max 20 ± 0.25
Angle
2/3 TE 15.1 ± 0.5 Transmitter
1/3 TE 9.1 ± 0.5
Initial TE 4.4 ± 0.5
0 2 ± 0.25
Initial BE 3.9 ± 0.5
1/3 BE 8.7 ± 0.5
2/3 BE 14.7 ± 0.5
BE max 20 ± 0.25
43
 Current Measurement Followed in ELS/ HWH.

2019-20 (Apr-Feb)
SL. BTIPL BHEL CGL TOTAL
Defects
No.
F D F D F D F D
1 SR GATE UNIT 0 0 0 0 2 0 2 0
2 SLG CARD 2 0 0 0 0 0 2 0
3 ASC/NSC PROCESSOR 1 0 0 0 2 0 3 0
4 NS-PERI 0 0 0 0 0 0 0 0
5 AS-PERI 0 0 0 0 0 0 0 0
6 LWL CARD 0 0 0 0 0 0 0 0
7 DC-LINK VOLTAGE SENSOR 1 0 0 0 0 0 1 0
8 SAP CARD 1 0 0 0 0 0 1 0
9 POWER SUPPLY CARD 0 0 0 0 0 0 0 0
10 Other/CFN 0 0 0 0 0 0 0 0
TOTAL 5 0 4 9
Population 9 6 2 16
FRPCPY 60.61 0 436.36 60.36
Failure Data of GTO Converter
44

2019 -20 (Up to Feb)
WAP-5 & WAP-7
SL. MAKE CAUSE OF FAILURE
No. BTIPL BHEL MEDHA Total
F D F D F D F D
A1 POWER MODULE 16 0 0 0 0 0 16 0
A2 SOFTWARE MALFUNCTIONING 9 0 0 0 0 0 9 0
BTIPL
A3 GDU/DCU CARD 0 1 0 0 0 0 0 1
A4 COOLING BLOWER 1 0 0 0 0 0 1 0
A5 OTHERS 0 0 0 0 0 0 0 0
B1 POWER MODULE/PMI/USID 0 0 17 0 0 0 17 0
B2 VIU/DCU CARD 0 0 10 0 0 0 10 0
B3 COOLANT PUMP 0 0 0 0 0 0 0 0
BHEL
B4 SOFTWARE MALFUNTIONING (HF STUCK) 0 0 1 0 0 0 1 0

B5 PRESSURE SWITCH 0 0 0 0 0 0 0 0
B6 MISC. (TRANSIENT/RANDOM FAULTS) 0 0 0 0 0 0 0 0
C1 POWER MODULE 0 0 0 0 0 0 0 0
C2 SOFTWARE MALFUNCTIONING 0 0 0 0 0 0 0 0
MEDHA
C3 GDU/DCU CARD 0 0 0 0 0 0 0 0
C4 COOLING BLOWER 0 0 0 0 0 0 0 0
C5 OTHERS 0 0 0 0 0 0 0 0
TOTAL FAILURES 26 1 28 0 0 0 54 1
TOTAL POPULATION 43 33 8 84
FRPCPY 68.50 92.56 0.00 71.43
Failure Data of IGBT Converter 45

Thanking You
Amit Kumar Guin
AEE/TRS-I/HWH
46

03.05.2020 - SR, Sensor (3 PH) RAP Gap Analysis ELS-HWH - AEE-I-HWH - PPSX

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GAP ANALYSIS

RAP on Traction Converter

ELECTRIC LOCO SHED / HWH

Traction Converter (SR) 100 Auxiliary Converter (BUR) 100

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

Line – Side DC - Link Driver – Side

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

Vehicle Control (VCU – 1) Vehicle Control (VCU – 2)

Non - Redundant MVB fibre optics

Auxiliary Converter - 1 (BUR – 1) Auxiliary Converter - 2 (BUR – 2)

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

 Testing Set Up:

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

Optic Fibre Cable

Connection Diagram of Gate Unit testing Setup

Amit Kumar Guin, AEE/I/TRS/HWH

No Distortion in waveform SS & RM Pulse Opposite each other

Minimum On time 85 μS +/- 5% Dead time 25 μS (Min.)

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

Checking of Gate Unit cards by measuring dBm level of QFBR-1478C transmitter

 To improve the reliability of Gate Unit Cards of SR of 3 Ø locos.

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

In between -16 & -18 dBm Measurement Repeat after 6 months – if

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

 Being Followed in ELS/HWH. 14

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

dB loss level Action to be taken

In between -16 & -18 dB Measurement Repeat after 6 months – if

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

Replacement of 1mW crystal of 24 MHz by Zauch make 0.5 mW in PPA988 cards

Replacement of 1mW crystal of 24 MHz by Jauch make 0.5 mW in PPA988 cards

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

Signal name Slot Signal name Slot

UBF 630 A36 UBF 630 A91

Signal name Slot

 Table for checking Voltage ratio (50 : 1) of Wandler Module –

Input Voltage Output Voltage Wandler

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

Input Channels Checking:

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

Grounding on ALG rack Grounding of ALG rack with Main earth

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

3 Nos. of Churning Fan

The capacitance of combined DC link capacitor as well as combined resonant capacitor

 Followed in ELS / HWH. 32

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

Following Precautions to be taken to prevent Valve sets failures :-

Sunday, May 3, 2020 A mit Kumar Guin, AEE/I/TRS/HWH

Sunday, May 3, 2020 A mit Kumar Guin, AEE/I/TRS/HWH

 Exist in 4 Nos. Locos (WAP 7).

Sunday, May 3, 2020 Amit Kumar Guin, AEE/I/TRS/HWH

 SMI – 127 : Characteristics of Transformer Oil as per IS : 335 – 83