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Performance Review
Static converter (SIV)
Meeting at Railway Board
On 12.05.2017
1
Agenda
Performance Review
Root cause analysis of failures.
Status of reliability action plan
Status of AMC by Zonal Railways
2
FRPCPY AT A GLANCE (ALL FIRMS)
Make Population 2016-17
upto DEC
16
2015-16 2014-15
2013-
14
2012-13
AAL 960 11.39 % 13.49% 15.56% 32 % 27.5 %
Siemens 905 4.27% 5.36 % 9.0 % 10.9 % 10.3%
Medha 337 16.62% 11.19 % 9.44 % 12.5 % 9.7%
Hind 310 22.37% 18.64 % 35.79 % 18.7 % 16.9%
ABB 116 22.22% 13.16 % 35.06 % 22.2 % 26.5%
BT 53 25.16% 25.49 % 29.41 % 88.8 % 73.4%
3
SIV AAL MAKE
PERFORMANCE OF M/s. AAL MAKE SIV
4
FRPCPY AT A GLANCE (AAL)
Firm Population 2016-17
upto DEC 16
2015-16 2014-15
2013-14
2012-13
Autometers 960 11.39% 13.49% 15.56 % 32 % 27.5%
5
FRPCPY M/s. Autometers Year wise
6
72.4
41.5
32.4
38.8
23.0
27.5
32.0
15.6 13.5
11.4
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 (DEC)
Series1
Major Cause/component wise failure analysis (AAL)
SN Year Component
2010-
11
2011-
12
2012-
13
2013-
14
2014-
15
2015-
16
2016-17
1 MCU 15 18 49 56 22 18 12
2 Cooling Fan 31 38 55 57 65 21 16
3 ZCT 18 16 21 25 15 9 2
4 DCCT / CHCT 2 2 9 11 4 5 8
5 GDU card of CHBA
24 18 19 17 13 5 16
6 Misc 10 11 7 5 10 8 8
7
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.
3. Firm carried out modification in
3 units per loco shed and also
impart training to shed officials
for carrying out the modification
in the remaining units
Completed in all units.
Failures of this card has
reduced in last 3 years.
Further performance is
under watch .
8
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
4. Cooling fan bearing of ZIEHL-
ABEGG is to be replaced in 18
months and full unit is to be
replaced after a service of 6 years.
No failures of modified
cooling fan has been
reported .
ELS/BZA modified cooling
fan as per RDSO
modification sheet in 60
SIVs. Performance
reported satisfactory.
Zonal railways to complete
the modification.
Performance of modified
cooling fan is under
watch.
9
Cooling Fan Failure (AAL make )
Cooling failure ( AAL)
10
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.
There are two ZCTs for sensing internal and external earth faults.
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. Rly.
will replace remaining ZCTs of
DEESYS make by M/s. Broycee
Control make and till date Rly.
replaced 118 units. There is
reduction in failures of ZCT’s.
Further performance is under
watch.
11
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.
Total 130 no.’s replaced .
Failures have reduced and
further performance is under
watch. Firm advised to
replaced remaining with LEM
make CT.
12
Charger/ Chopper CT failures of AAL
GDU card of Battery charger are failing due to decrease in winding
resistance& voltage range of Pulse transformer particularly after 5
years of service.
Action plan Status
1
2
3
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.
Old cards (> 09 years service of
KIT -3 ) to be replaced by modified
card.
Performance of replaced
pulse transformer is under
watch.
Modified cards in Kit –3
fitted in 30 locos ( CNB – 12
& KZJ- 18). Performance is
satisfactory.
13
GDU card failures of AAL
SIV HIND RECTIFIER MAKE
PERFORMANCE OF M/s. HIND RECTIFIER SUPPLIED 180
KVA STATIC CONVERTER
14
FRPCPY AT A GLANCE ( HIND)
Firm Population 2016-17
up to Dec
16
2015-16 2014-15
2013-14
2012-13
Hind
310 22.37 % 18.64% 35.79 % 18.7% 16.9%
15
FRPCPY M/s. HIND YEAR WISE
16
109.9
58.0
80.0
44.0
26.7
16.9 18.7
35.8
18.6 22.4
0.0
20.0
40.0
60.0
80.0
100.0
120.0
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 (DEC)
Series1
Major Component-wise year wise failure analysis HIND
SN Year
Component
2012-13 2013-14 2014-15 2015-16 2016-17
1 QCON timer
card
07 01 07 06 09
2 Crow bar
thyristor
01 04 02 03 01
3 Cooling Fan 00 00 08 03 11
4 Snubber
Capacitor
01 01 04 03 06
5 Control card
A703 &
A704
01 03 (2+1) 04 ( 1+3) 06 ( 2+4) 05 ( 3+2)
6 Fuse 02 04 07 02 10
17
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 20 units
and after satisfactory
performance , firm has been
permitted to modify all the
units.
Fitment feed back along with
performance is under watch .
18
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 06
locos an energy absorption
unit (04 no ET, 01 CNB
01 JHS). 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.
19
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
and not dry type and the life of oil filled type capacitor is less than Dry
type.
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 have
also been requested to check
the value of capacitors during
maintenance and replace if
required. This has been
communicated to all railways.
20
Snubber Capacitor problem of M/s HIND
The basic problem is bearing failure. All the bearing failures are after a
service period of 4 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 .
21
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.
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
22
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.
23
Fuse failures in Battery Charger out put
SIV SIEMENS MAKE
PERFORMANCE OF M/s. SIEMENS SUPPLIED 180 KVA
STATIC CONVERTER
24
FRPCPY AT A GLANCE (SIEMENS)
Firm Populatio
n
2016-17
upto DEC
16
2015-16 2014-15
2013-14
2012-13
Siemens
905 4.27% 5.36 % 9.0 % 10.9% 10.3 %
25
FRPCPY M/s. SIEMENS YEARWISE
26
37.4
28.1
19.8
17.5
14.5
10.3 10.9
9.0
5.4 4.3
0.0
5.0
10.0
15.0
20.0
25.0
30.0
35.0
40.0
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 (DEC)
Series1
Major Component-wise year wise failure analysis SIEMENS
SN Year
Component
2012-13 2013-14 2014-15 2015-16 2016-17
1 Battery
Charger
9 21 22 3 4
2 Cooling Fan 15 19 18 10 10
3 Inverter 16 20 05 6 6
27
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 260 units
has been modified by the
firm.
Firm has been advised to
modify balance 26 units
within 30.06.2017.
28
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
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 performance in Zonal railways
is under watch
29
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.
30
Inverter failures of Siemens
SIV MEDHA MAKE
PERFORMANCE OF M/s. MEDHA SERVO DRIVE
SUPPLIED 180 KVA STATIC CONVERTER
31
FRPCPY AT A GLANCE (MEDHA)
Firm Population 2016-17
upto Dec
2015-16 2014-15
2013-14
2012-13
MEDHA
337 16.62% 11.19% 9.44 % 12.5% 9.7%
32
FRPCPY M/s. MEDHA YEARWISE
33
137.5
80.9
67.0
32.9
27.0
9.7 12.5
9.4 11.2
16.6
0.0
20.0
40.0
60.0
80.0
100.0
120.0
140.0
160.0
2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 (DEC)
Series1
Series2
Major Component-wise year wise failure analysis MEDHA
SN Year
Component
2013-14 2014-15 2015-16 2016-17
1 Main
control card
07 01 01 05
2 TDC-IF 01 17 05 07
3 Battery
Charger
03 01 02 04
34
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.
35
TDC-IF & MCU card failure of M/s Medha SIV
The fuse failure took place due to cable contact loose (voltage feed
back circuit).
Action plan Status
1. Firm advised to ensure proper
quality of crimping / soldering
of the contact.
2. Checking the contacts in
schedule maintenance as
specified in SMI.
(i) Two cases failed after a
service period of 05 years.
(ii) Two cases failed after a
service period of 08 years.
36
Battery charger fuse failure of M/s Medha SIV
SIV ABB MAKE
PERFORMANCE OF M/s. ABB SUPPLIED 180 KVA STATIC
CONVERTER
37
FRPCPY AT A GLANCE (ABB)
Firm Population 2016-17
upto Dec
16
2015-16 2014-15
2013-14
2012-13
ABB
116 22.22% 13.16 % 35.06 % 22.2% 26.5%
38
FRPCPY M/s. ABB YEARWISE
39
350.0
700.0
70.0 50.4 43.0
26.5 22.2 35.1
13.2 22.2 0
100
200
300
400
500
600
700
800
ABB 2007-08 2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15 2015-16 2016-17 (DEC)
Chart Title
FRPCPY
FRPCPY
Major Component-wise year wise failure analysis ABB
SN Year
Component
2015-16 2016-17
1 PEC card 01 05
2 Cooling Fan 02 06
40
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 .
41
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 assembly replaced
No failures reported till then.
42
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.
43
Maintenance practices adopted by ELS/ BZA & ED
ELS/ ED has repaired 83 Nos. of cards till date .
ELS/ BZA investigated the failures of GDU card and found
that 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.
44
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.
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). No Railways has floated any tender.
Hirect • Firm has given budgetary quotations. • Tender has been invited for 06 units by ELS/BSL/CR which is under TC.
Siemens • Firm has given budgetary quotations. • Tender has been invited for 41 units by ELS/BSL/CR, 29 units by
ELS/HWH/ER & 09 units ELS/ASN/ER
Medha • Firm has given budgetary quotations. • LOA awarded for 06 units by ELS/ASN/ER on 21.04.2017. • LOA awarded for 02 units by ELS/BRC/WR on 27.04.2017. • Tender has been invited for 04 units by ELS/HWH/ER opened on
24.04.17 & 07 units by ELS/AJJ/SR which is under TC. Opened on 08.03.17.
• Tender will be opened for 60 units by SCRly on 19.05.2017.
ABB • Firm has given budgetary quotations. 45
THANKS
46
