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Performance Review
Static converter (SIV)
Meeting at RDSO
On 11.07.2017
1
Agenda
Review Of Failures of year 2016-17
Punctuality loss cases 2016-17
Status of reliability action plan
Compliance of meeting at RB
Issues reported by Railways
Status of AMC
2
POPULATION (ALL FIRMS)
3
AAL Total population 960 Units
K -2 Model - 60 Units.
K-3 Model – 87 Units
GC Model – 813 Units
SIEMENS Total population 906 Units
TCD units - 44 units at ELS/ CNB, AQ & BNDM
SCD units – 861 no.
Medha -- SCD units – 337 no.
Hind -- SCD units – 310 no
ABB -- SCD units – 108 no
BT -- SCD units – 53 no
CODAL LIFE
4
As per railway board’s letter no. 2002/AC-II/I/10
dated 24.05.2006 the codal life of auxiliary converter
/Devices for single phase to 3 phase converter is 18
years .
Population details
5
Year wise population of static converter
Year Firm
AAL SIEMENS MEDHA HIND ABB BT TOTAL
0-3 Yrs 123 72 37 81 24 0 337
3-5 Yrs 82 188 157 112 30 28 597
5-7 Yrs 94 225 105 62 45 25 556
7-9 Yrs 453 182 15 34 8 0 692
9-12 Yrs 169 134 13 21 0 0 337
12-15
Yrs
31 49 0 0 0 0 80
> 15 yrs 8 11 0 0 0 0 18
Total 960 861 327 310 107 53 2618
Performance of SIV – a comparision between all
make
6
The detail data on failures from NR, SR, BKSC of SER & SCR (except
KZJ) awaited.
Year 2014-15 2015-16 2016-17
Make Total
pop
Pop
as
recd
Failur
es
FRPC
PY
Pop
as
recd
Failur
es
FRP
CPY
Pop
as
recd
Failur
es
FRP
CPY
AAL 960 479 220 45.93 553 263 47.56 557 281 50.45
SIE 905 438 98 22.37 516 108 20.93 528 89 16.86
MED 337 134 31 23.00 168 49 29.17 173 50 28.9
HIND 310 128 131 102.3 185 114 61.62 206 133 64.36
ABB 105 63 32 50.79 82 33 40.24 78 30 39.46
SIV AAL MAKE
PERFORMANCE OF M/s. AAL MAKE SIV
7
Major Cause/component wise failure analysis (AAL)
SN Year
Component
2014-15 2015- 16 2016-17
1 MCU 31 29 28
2 Cooling Fan
(Bearing + motor)
46 (40+6) 54 (42+12) 29 (21+8)
3 ZCT 19 19 24
4 DCCT / CHCT 03 (3+0) 03 (1+0) 03 (3+0)
5 GDU card inv &
of CHBA
36 (28+8) 55 (41+14) 82 (67+15)
6 Misc 35 34 46
Misc - Transient, RTC, Choke and any other fault having 01 or 02
failure during year
8
Sudden voltage changes across QCON relay contact which
leads to stucking up of QCON relay contact, hence MCU
failure.
Action plan Status
1. Providing RC damping network
across Q-CON relay.
2. Increasing higher rating of Reed
relay with 2 Amps & 5 lacs
operations in place of earlier
one with 1 Amp & 1 lac
operations.
Completed in all units.
The performance is under
watch.
Failure reduced in
modified units as reported
by railways.
9
Main control unit (MCU) AAL make
Reasons of cooling fan failure were mainly due to bearing failures,
loose fitment in Aluminum housing and burning of motor winding .
Action plan Status
1. Diameter of bearing increased and
housing changed to Mild steel and
capacity of fan increased from
500W to 1.5 kW.
2. Design of Fan has been modified
and validated in field trials.
(Havells make).
3.RDSO also issued modification
sheet no RDSO/ 2016/EL/MS
/0449 Rev 0 dated 30.03.2016 for
the same
1.No such failures on (Havells
make) cooling fan has been
reported by railways .
2. Firm has been advised to
submit the maintenance
procedure of modified cooling
fan.
3.Some Sheds implemented
modified cooling fan as per
RDSO modification sheet no
0449 and performance
reported satisfactory.
10
Cooling Fan Failure (AAL make)
Cooling failure ( AAL)
11
Cable of AC choke was passing just beneath the ZCT leading to erratic operation
of ZCT due to variation in impedance value. Also, mechanical stresses developed
on the core of ZCT which leads to its failure.
Action plan Status
1
AAL has been advised to replace
ZCTs of M/s. DEESYS make of Korea
by M/s. Broycee Control of England.
Firm has replaced 100 units.
Railways are also replacing ZCTs of
DEESYS make by M/s. Broycee
Control, England make during
failures of ZCTs.
12
Failure of ZCT AAL
There have been frequent failures of Battery Charger and chopper CT.
All failures were of ABB make CTs. There was a loose connection in
power supply terminals due to wrong position of screw.
Action plan Status
1 Firm have sent failed DCCT/CHCT
to OEM (ABB) for investigation and
reported failures were due to
defective batch of 180 no.’s. Firm
has been advised to replace ABB
make CT by LEM make CT.
Total 130 no.’s replaced.
Firm reported 3 sheds (AQ, ET &
NKJ) denied to accept new ABB
make CT for replacement, as firm
replaces ABB make CT by ABB
make CTs,
13
Charger/ Chopper CT failures of AAL
GDU card failures of Inverter & Battery charger section are failing due
to decrease in winding resistance & voltage range of Pulse transformer
and reducing value of capacitor in GDU card after 5 to 6 years of
service.
Action plan Status
1
2
Winding resistance and voltage
range of pulse transformer
measurement is to be done by
Sheds and to be replaced on
condition basis.
BZA shed carried out rewinding of
defective pulse transformer.
Performance reported by shed as
satisfactory of such transformers.
Performance of replaced
pulse transformer is under
watch.
The performance of re-winded
pulse transformer in GDU
card awaited.
14
GDU card failures of AAL
GDU card failures of Inverter & Battery charger section are failing due
to decrease in winding resistance & voltage range of Pulse transformer
and reducing value of capacitor in GDU card after 5 to 6 years of
service.
Action plan Status
1
2
The second reason of GDU card
failures are due to detoriating of
capacitors value. The detoriating
capacitor cannot block DC voltage
which create DC offset in
transformer leading to heating of
transformer hence, interrupted
pulse to Gate.
The winding resistance, voltage
range of pulse transformer and
capacitance value of capacitor are
also to be measured.
ELS/ED and ELS/BZA have
carried out rewinding of
defective pulse transformer.
Performance reported by shed
as satisfactory.
Further performance to be
monitored.
Other shed can obtain the
process.
15
GDU card failures of AAL Cont
Maintenance practices adopted by ELS/ BZA & ED
ELS/ ED has repaired 83 Nos. of cards.
ELS/ BZA investigated the failures of GDU card,
found GDU card was failing due to failure of Pulse
transformer. Shed has developed an In-house test
bench and re-wind the Pulse transformer. They
achieved the same voltage range of pulse of +16 V to -
11 V and winding resistance of 0.2 to 0.3 Ω.
ELS/BNDM stated resistance is 0.017 to 0.023 Ω.
16
Till now shed has provided 12
no.’s of such re-winded Pulse
transformers and all are
working satisfactorily. In this
way they have saved purchase
of complete GDU card which
costs 2.2 lakhs.
SIV SIEMENS MAKE
PERFORMANCE OF M/s. SIEMENS SUPPLIED 180 KVA
STATIC CONVERTER
17
Major Component-wise year wise failure analysis SIEMENS
SN Year
Component
2014-15 2015-16 2016-17
1 Battery Charger 22 18 11
2 Cooling Fan
bearing + motor +
churning fan
22 (11+11) 22 (7+13+2) 34 (22+10+2)
3 Inverter (1+ 2) 03 (1+2)
8 (3+5)
8 (5+3)
4 M 1300 & M
2100
06 (6+0) 4 (1+3) 7 (3+4)
5 Misc. 32 39 18
Misc --- Transient, RTC, Choke and any other fault having 01 or 02
failure during year.
18
Indigenized Battery charger failed due to failure of rectifier module due
to Diode getting open circuit.
Action plan Status
1 Firm has to modify rectifier section
in their Indigenized Battery
charger.
Amongst 286 units 276 units
has been modified by the
firm.
Firm has been advised to
modify balance 10 units
early. (Modification pending
in MGS -05, LDH –03, TATA-
01, BKSC – 01 )
Performance is to be
monitored
19
Failure of Battery charger
The cooling fan of M/s Siemens failed due to bearing failures and Jam.
Firm stated the major failure of cooling fan bearing is due to either
improper mounting of cooling fan or improper maintenance . Total
cooling fan failures are 34 no.= Motor jam 10 & bearing problem 22 no )
in the year 2016-17
Action plan Status
1
2
As per firm’s advice the
bearing of cooling fan is to be
replaced after a service period
4.5 years.
RDSO has issued guideline
vide RDSO letter no
EL/1.2.9.1 dated 29.04.2016
Zonal railways to replace bearing
as per OEM recommendation.
The guide line is to be followed also
requested to replace bearing as per
OEM recommendation.
20
Cooling fan failure M/s. Siemens
The failures of inverter module are repetitive due to various reasons like
component failures, IGBT failure etc. During previous meeting firm has
been advised to draw action plan of Inverter failure.
Action plan Status
1 There are two cases of warranty
failures of Inverter . Loco no 28726
and loco no 27263 of ELS/AQ and
ELS/BSL respectively
Firm stated the causes of
failures along with action
plan is to be submitted to
RDSO.
Firm also stated that no clear
trend has been noticed for
the failures.
The investigation of Inverter
failures under warranty is
awaited.
21
Inverter failures of Siemens
SIV HIND RECTIFIER MAKE
PERFORMANCE OF M/s. HIND RECTIFIER SUPPLIED 180
KVA STATIC CONVERTER
22
Major Component-wise year wise failure analysis HIND
SN Year
Component 2014-15 2015-16 2016-17
1 QCON timer card 09 9 10
2 Crow bar section 09 09 9
3 Cooling Fan
bearing + motor)
14 (5+9) 5 (3+2) 7 (3+4)
4 Snubber
Capacitor
01 08 8
5 Control card A
703 & A704
10 ( 8+2) 25 (19+6) 11 (10+1)
6 Fuse 06 07 5
Misc 50 28 33
Misc --- Transient, cable looseness, sensors, software and any other
fault having 01 or 02 failure during year
23
Initially wiring of delay timer was tapped from secondary of Auto
transformer at 380 ± 5% V but the voltage spikes were the cause of
melting the fuses failures.
Action plan Status
1
2
The firm proposed to change the
secondary tap point taken from
380 ± 5% V to 110 ± 5% since at
low voltage spikes will be less
Use of 110 V timer
Firm has modified 34 units
and after satisfactory
performance , firm has been
permitted to modify all the
units.
Fitment feed back along with
performance is under watch .
24
QCON TIMER CARD OF M/s HIND
The problem was unwanted firing pulse to crow bar thyristor for
protection of DC link over voltage.
Action plan Status
1 To prevent unwanted firing of
crow bar thyristor an energy
absorption unit is being
introduce by firm.
Firm has introduced in 07 locos
an energy absorption unit (04 no
ET, 01 CNB 01 JHS & 01 NKJ).
which reduces the excess energy
generated due to unwanted firing
of crow bar thyristor and thereby
preventing the melting of fuse.
Another 50 units has been
permitted & to be done within 02
(two) months. Fitment feed back
along with performance is under
watch.
25
CROW BAR THYRISTOR OF M/s HIND
The capacitance value (0.47 mF) of Snubber capacitors are deteriorating
after a service period of 3 to 4 years of service. The value is deteriorating
from 0.47 micro farad to 0.5 nano farad. The capacitors are Oil filled.
Capacitors are to be replaced by dry type only.
Action plan Status
1 Firm has been asked to make a
cycle check on the value of
snubber capacitors and if the value
deteriorates they have to replace
with new Capacitors of Dry Type.
One cycle checking done.
Firm has replaced snubber
capacitors in 26 locos with
dry type. Total 247 unit have
been checked. Sheds are
being requested to check the
value of capacitors during
maintenance and replace if
required. This has been
communicated to all railways.
26
Snubber Capacitor problem of M/s HIND
The basic problem is bearing failure. All the bearing failures are after a
service Failures of cooling fan increased . Mainly due to ageing of more
than 04 years.
Action plan Status
1 Zonal railways are advised to
replace bearing after a service
period of 04 years. .
Zonal railways have to replace
the bearing after a service
period of 04 years.
27
Cooling Fan failures of M/s HIND
There are failures of Control Cards A 704 (Chopper) & A 703 (Inverter) .
VD-9 diode failed and Programmable logic device damaged.
The failure of inverter control card ( A 703) increased
Action plan Status
1 The failed control cards were sent
to M/s. Transtanik/ Germany for
investigation by firm. It was
reported by the firm that diode
(VD-9) and PLD (Programmable
logic device) of SCR board
damaged and these were replaced
by the firm.
The performance of control card
failures is under watch.
Detailed action plan awaited.
Advised to submit action plan on
inverter control card ( A 703)
28
Control card failures of M/s HIND
25 Amps rating fuse in Battery charger out put failed make EATON and
FERRAZ.
Action plan Status
1 The 25 Amps rating fuse in
Battery charger out put failed.
Replacement of fuse by 35 Amps.
The fuse of M/s EATON and
FERRAZ are replaced by 35
amps. All fuse replaced. The
performance is under watch.
29
Fuse failures in Battery Charger out put
SIV MEDHA MAKE
PERFORMANCE OF M/s. MEDHA SERVO DRIVE
SUPPLIED 180 KVA STATIC CONVERTER
30
Major Component-wise year wise failure analysis MEDHA
SN Year
Component 2014-15 2015-16 2016-17
1 Main control
card
0 0 4
2 TDC-IF 9 6 8
3 dv/dt capacitor 0 0 1
4 Battery
Charger
4 6 5
5 Cooling Fan 0 0 1
6 Misc 8 21 17
Misc ---Transient, volt free contact, power supply card and any
other fault having 01 or 02 failure during year
31
The tripping of SIV occurred due to sensing over voltage of OHE though
OHE voltage was below specified limit.
Action plan Status
1. The case has been studied by the
firm and found that heat generated
in TDC-IF card which leads to
opening of solder joint of a resistor
in RC circuit. The firm has now
provided RC network in place of
resistor.
2. On further study the limit of OHE
sensor of SIV is being increased
from 500 ms to 1 sec. by software
modification vide letter dated
5.4.2017
3. Average time increased from 200ms
to 500ms
1. Problem occurred again in
the locos where modification in
RC network of TDC-IF card was
carried out. .
2. Software modification in 20
locos in ELS/CNB and KZJ.
The performance is satisfactory.
Firm has been advised to
implement the modification in
all units.
32
TDC-IF & MCU card failure of M/s Medha SIV
There are failures of dv/dt capacitor . This is a new trend of failures.
Action plan Status
1. Firm has been asked to submit the
investigation report on failures of
dv/dt capacitor. Also advised to
submit action plan to be adopted .
1. The investigation report
awaited .
33
dv/dt capacitor failures of M/s Medha SIV
SIV ABB MAKE
PERFORMANCE OF M/s. ABB SUPPLIED 180 KVA STATIC
CONVERTER
34
Major Component-wise year wise failure analysis ABB
SN Year
Component
2014-15 2015-16 2016-17
1 PEC card 00 03 05
Battery charger 01 03 01
2 Cooling Fan 12 07 11
Misc 10 10 06
Misc ---Transient, micro switch, power module, and any other fault having
01 or 02 failure during year
35
Cooling fan getting jammed after a service period of 4 to 5 years
Action plan Status
1
The cooling fan bearing is to be
replaced after a service period of 04
years.
Zonal Railways advised
accordingly .
36
Cooling fan failures M/s ABB SIV
Problem was due to loose connection between male & female connectors
of PEC due to which fuse of input/output also melting.
Action plan Status
1
The power supply card connection
with junction box was not proper
which causes these failures.
PEC card failure increased
PEC card assembly replaced
No failures reported till then.
37
PEC card failures M/s ABB SIV
OPEN POINT
Problem of booting time
Action plan Status
1
The booting time on PEC 80 is 55
secs.
If loco pilot made HBA off/on then
booting time takes 55 sec other
competitor is 10 to 15 sec.
Software modification required as
made in 3 phase system
Already discussed in
previous meeting but firm
refused that time but Firm is
again advised to make the
improvement as done in has
been advised in different 3
phase system
38
PEC card failures M/s ABB SIV
Maintenance practices adopted by ELS/ BZA & ED
ELS/ ED & ELS/ BZA have developed Electronic Lab for
testing of various Electronics cards of 180 KVA Static
Converter.
39
Status of AMC of SIV
Firm Status
AAL • Firm has given two types of budgetary quotations. (SIV older than
06 years & SIV less than 06 years). Railways have not floated any
tender.
Hirect • Firm has given budgetary quotations.
• LOA awarded for 06 units by ELS/BSL/CR on 07.06.2017.
• Tender has been invited for 06 units by ELS/BSL/CR which is
under TC.
Siemens • Firm has given budgetary quotations.
• LOA awarded for 29 units by ELS/HWH/ER on 11.05.2017.
• Expected LOA from ELS/ASN /ER
• Tender has been invited for 43 units by ELS/BSL/CR, & 57 units
ELS/RPM/SR
Medha • Firm has given budgetary quotations.
• LOA awarded for 06 units by ELS/ASN/ER on 21.04.2017.
• LOA awarded for 01 units by ELS/BRC/WR on 27.04.2017.
• LOA awarded for 06 units by ELS/HWH/ER on 21.04.2017.
• LOA awarded for 07 units by ELS/AJJ/SR on 21.07.2017.
• Tender will be opened for 60 units by SCRly on 19.05.2017.
ABB • Firm has given budgetary quotations.
40
41
Month
Total
punctu
ality
loss in
Electric
locos
Total
failures
for which
SIV has
been
marked
SIV
failures
External Failures
Problem at
Load side/
loco item like
MCP/ MPCS/
present
Relays and
fuse etc.
Maintenance
lapses/ loose
connection/
control
cable/loose
connectors
Transient
(Succeeded
on HBA
OFF/ON)/
Found Normal
Cooling
Fan
Apr-16 132 12 06 02 00 02 02
May-16 191 15 10 02 01 00 02
Jun-16 183 09 05 02 02 00 00
Jul-16 167 13 03 04 05 00 01
Aug-16 171 17 05 07 05 00 00
Sep-16 129 09 04 03 01 00 01
Oct-16 171 19 09 08 01 00 01
Nov-16 144 21 10 04 05 00 02
Dec-16 140 15 07 04 03 00 01
Jan-16 142 18 10 03 02 00 03
Feb-16 134 14 07 03 01 00 03
Mar-16 166 18 10 04 01 01 02
Totals 1870 180 86 46 27 03 18
Punctuality cases of elocos for SIV (2016-17)
42
Month
Total
punctu
ality
loss in
Electric
locos
Total
failures
for which
SIV has
been
marked
SIV
failures
External Failures
Problem at
Load side/
loco item like
MCP/ MPCS/
present
Relays and
fuse etc.
Maintenance
lapses/ loose
connection/
control
cable/loose
connectors
Transient
(Succeeded
on HBA
OFF/ON)/
Found Normal
Cooling
fan
Apr-15 168 17 10 6 0 1 0
May-15 206 15 04 4 3 3 1
Jun-15 308 16 04 4 4 2 2
Jul-15 Aug-15 Sep-15 Oct-15 Nov-15 Dec-15 Jan-16 Feb-16 Mar-16 Totals 682 48 18 14 7 6 3
Punctuality cases of elocos for SIV (2017-18)
THANKS
43
