ABB Relay

Relay Position:-

• As per Rate contract No.KR/RN/SG/5/CONTRACT/03/2014-15

Dtd:-22/12/2014
“The work of Repair of Defective IHC Make relays of panel
Interlocking in KRCL on Rate contract basis for 3 years on
Konkan Railway.”
o Repaired through M/s.IHC/Baroda Relay Repaired on first RA-I
for the year 2014-15
o Total Relays Repaired =394 Nos.
o Under Repaired.=369+37nos for the year 2015-16
o The detailed brake up attached .These relays are repaired and
ready for inspection.
 Types of Failure
The existing Relays in most of the station completed more than 15 years.
as per product manual of MHC.

LIFE EXPECTENCY : 1 Million Switching Cycle or 10 Year whichever earlier.

Following failure are noticed in relays. 

o Coil open:-Maximum relays are found coil open. The same is attended by sending
to OEM and replaced the same. i.e.M/s.IHC.

o Interlocked Relays are found mechanical adjustment disturbed . Hence relays may
be chances of mechanically stuck up. Such relays checked by 0.1mm test is used
for “Go gauge” and 0.2mm test is used for “No Go Gauge “ test, If the relay found
gap setting disturbed then developed mechanical failure.

o Such type of relays are collected from section and send to OEM for re-setting the
gap and other parameters of that particular relays. The defective relays attend by
OEM and mark the same to identified some body disturbed or tamper the same
and put their sealed.
 Cont…
o High contact Resistance always Relay contact Resistance
required less than 50 ohm. If the contact resistance more
reduce by using contact cleaner and rectify the same.

o Current Regulator defective, such type of failure are

observed in “ECR”.

o Most of the “ECR Relays” are failed during the lightening. In

this relays only CT found defective. By replacing the “CT”
ECR relays are rectified. Such relays are more chances of
repeated failure.
 
Following Equipments are used for Relay
Testing indoor at M/s.IHC/BRC
o Micro OHM Meter – Agronic -54C
o Regulated DC power supply –Aplab 7191M.
o Power supply 0 to 120 VDC 1A max.
o Coil Resistance 25°C Temperature 0.98073
o Mechanical Interlocked Relays Gauge Test
• 0.1mm for Go gauge Test.
• 0.2mm for No Go gauge Test.
o Weight used to test contact Test Load.
• 27 gms+ 4 gms .
o As per RDSO Specification = 20 gms LED Lit..
o As per IHC/BRC practices =27 gms LED Lit. =31
gms Indication closed.
 Cont…
o For One contact weight used =10gms.
o For Two contacts weight used =20 gms. As per RDSO recommendation.
o As per IHC Contact adjustment gap = 1.8 mm gauge.
o As per RDSO Contact adjustment gap = 1.5 mm gauge.
o Relay contact Resistance less than 50 ohm.
o For cleaning of contact CTC spray is used.
o Coil Resistance is 1070 ohm at 20° c
o As per IHC practice =1070 +/- 8%.
o As per RDSO =1070 +/- 10%.
 
1070 1070
o At 25° c Middle value = ------------------------- = ------------= 1071
Conversion factor (0.98073) 
 Sub:-“The work of Repair of Defective IHC Make relays of panel
Interlocking in KRCL on Rate contract basis for 3 years on Konkan
Railway.”

• Ref:-per Rate contract No.KR/RN/SG/5/CONTRACT/03/2014-15 Dtd:-

22/12/2014
1st Lot send on 26/09/2014
Qty Balance 1st Lot send on 01/11/2014
Qty send to Qty Received with firm Qty send to firm Qty Received Qty Balance
Sr.
Item Description firm M/s.IHC form M/s.IHC M/s.IHC on M/s.IHC for form M/s.IHC with firm Inspecte Not
No.
for Repair on 04.12.14 reason Not Repair on 23.02.15 M/s.IHC on d Repairable
after Repair Repairable. after Repair reason Not
1 ECR SHUNT RELAYS. 16 0 16 19 14 Repairable. 5 0 21
2 ECR ON/OFF RELAYS. 83 68 15 43 1 42 37 20
3 2F/4B NEUTRAL RELAYS 5 2 3 6 5 1 0 4
4 5F/3B NEUTRAL RELAYS 42 24 18 27 35 -8 0 10
5 4F/4B NEUTRAL RELAYS 77 59 18 0 3 -3 0 15
6 6F/2B NEUTRAL RELAYS 98 62 36 3 2 1 0 37
5F/3B:5F/3B INTERLOCK
7 RELAYS 13 9 4 0 4 -4 0 0
3F/5B:3F/5B INTERLOCK
8 RELAYS 17 9 8 0 4 -4 0 4
5F/3B:4F/4B INTERLOCK
9 RELAYS 31 13 18 0 5 -5 0 13
4F/4B:4F/4B INTERLOCK
10 RELAYS 37 25 12 46 50 -4 0 8
11 KLCR-24V 6 0 6 6 0 6 0 12
Total 425 271 154 150 123 27 37 144
Total Repaired Relays
271+123=394
Received for the year 2014-15
Amount Claimed (16.03.15) 8,46,561=00
Numbers of Relay Beyond
144
Repair.(Non Repairable)
Pending for Dispatch from
37
M/s.IHC
 3rd Lot
Qtysend on 29/06/2015
Received
Sr. Qty send to form M/s.IHC Qty Balance
Item Description
No. firm M/s.IHC on …. after with firm
for Repair Repair M/s.IHC
1 ECR SHUNT RELAYS. 9 0 9
2 ECR ON/OFF RELAYS. 164 0 164
3 2F/4B NEUTRAL RELAYS 2 0 2
4 5F/3B NEUTRAL RELAYS 66 0 66
5 4F/4B NEUTRAL RELAYS 15 0 15
6 6F/2B NEUTRAL RELAYS 14 0 14
5F/3B:5F/3B INTERLOCK
7 RELAYS 2 0 2

8 3F/5B:4F/4B INTERLOCK RELAYS 1 0 1

9 5F/3B:4F/4B INTERLOCK RELAYS 5 0 5

10 4F/4B:4F/4B INTERLOCK RELAYS 91 0 91

11 KLCR-24V 0 0 0
Total 369 0 369

These Relays are repaired and pending for Inspection with M/s.IHC/BRC.
 No.KR/RN/S&T/SOC/KKW Date:-11/07/2014
NOTE
Sub:-Investigation of Defective QB3 Relay of HNA station of SE/S&T/BTJL section
 
01 nos Defective QB3 Relay of TLBI at HNA station failed on 09.07.2014. The same is received on 11.07.2014
The Relay Details is under.
Sr.No.4242
Type:-QB3 Q-style
Relay used at place:-CRR(R)
Mfd:-Not visual
 
The visual checked found PTJ make and sealed. The same relay fixed in BI at SOC and try for line cleared
found Relay not pick up. Checked the coil found coil is open. Inform to SE/BTJL keep the line current both side
equal between 60-70ma)
 
This is for your kind information pl.
 
 
SE/SOC/KKW
 
Copy to:-RSTE/KAWR for kind information pl.
ASTE/UD -----do---
SE/S&T/BTJL info.& to take na accordingly.
SNTCTRL for kind info.pl.
 
• Date:-30.11.2015
• Sub:- Relay failure Analysis
• Relay failure detected during investigation.
• Netural Relays
• Normally coil opens (Chance of coil weak, ageing problem ,power supply problem)
• Relay contact pressure disturb, due to number of operation more.
• Due to ageing (Maximum relay are failed more than 15 years.
•  
• Interlocked Relays
• Normally coil open (chance of coil weak, due to ageing power supply problem)
• Relay contact pressure disturbed, due to number of operation more.
• Mechanical latch gap disturbed, due to number of operation more.
• Due to ageing (Relay are more than 15 years)
•  
• ECR Relays
• Maximum current regulator failed due to lightening.
• Coil open due to power supply problem, lightening.
• Contact problem not detected during investigation.
• 4.Heavy Duty Contractor Relay (WR,RXR &NXR)
• Maximum coil open failure detect –Nil.
• Contact problem –Due to greenish fungus cleaned and rectified.
• 5.Track Relay
• Found base contact problem –Greenish fungus cleaned and rectified.
• Coil open –Nil .
• Relay base problem- Required to replace.
•  
• SE/SOC/KKW
•  
•  
•