www.rdso.indianrailways.gov.in A

N

N

U

A

L

R

E

P

O

R

T

2

0

1

2

-

2

0

1

317

ELECTRICAL

RESEARCH, DESIGN & DEVELOPMENTSafety Device for Aluminium Gearcases used in WAP5 Locomotives

Trouble Shooting Instructions for QLM Target Relay Operation Along with other Target Relays

Issue of Guidelines to Zonal Railways for Design, Development and Manufacturing of Developing Infrastructure to Home 200 Electric Remote Monitoring and Analysis for Electric Locomotives in ShedLocomotives (REMAN-EL) for 25 KV Electric Locomotives

Development of High Capacity Compressors for WAP-4 to Address the Problem of Low MR Air Pressure while Hauling Duranto Trains

Controllers. This will help in taking corrective action at right opportunity, in the event of any abnormality, before it can convert into major failure, disrupting the traffic. Such real-time monitoring of locomotives will

To avoid the risk of falling of bottom half of involve decision making at appropriate level of aluminum gear case online in the event of breakage of expertise, thereby, achieving above objectives.mounting lug in WAP5 class of locomotives due to

For locomotives, fitted with Ver.2 of MPCS, sudden impulse loading, a safety device has been ESMON and VCD, Remote Monitoring and Analysis developed and a modification sheet no RDSO/2013/ for Electric Locomotives (REMAN-EL) has been MS/0424 Rev ‘0’ has been issued for use of safety conceived to get the data stored in MPCS on line device as an emergency support to prevent falling of through internet along with signal from pulse aluminum gear case in WAP5 class of locomotives .generator of ESMON and status of working of VCD. So far this concept has been tried in three locomotives with MPCSs of three different makes. All these systems are working satisfactory, till date. RDSO has prepared a FRS no. RDSO/EL/ 4.2.15/FRS/REMAN-EL Rev.0, dt. 18.01.2013 for meeting the above requirements as per RDSO’s Work Instructions, after considering the suggestions and comments received from all existing approved sources of MPCS.

In compliance with Railway Board’s letter No.2012/Elect(TRS)/115/1 dated 20.3.12 & 06.06.12, RDSO has analysed 71 cases of QLM experienced by IR during 2011-12 and troubleshooting instructions of the Railways. RDSO vide letter No.EL/3.2.10/Gen dated 01.8.2012 has examined the cases and issued guidelines of QLM operation to all Railways and advised to revise Loco Trouble Shooting Directory (TSD) accordingly.

Based on the acceptance of Committee’s Report No.RDSO/2012/EL/RM/ 0158 on requirement

Tap changer electric locomotives working on of infrastructural facilities to home 200 electric Indian Railways are provided with control based on locomotives in shed by Railway Board, RDSO has electromechanical and Electro-pneumatic relays/ prepared a Technical Circular No. RDSO/2012/EL/ contactors. Microprocessor-based control system TC/0121, Rev.’0’ dated 14.12.2012 for developing (MPCS) was provided in the existing electric infrastructural requirement for homing 200 electric locomotives as per specification no. ELRS/SPEC/ locos in shed and issued for the guidance of Railways. MPC-FDS/0001 Rev. ‘2’. Although benefits such as It is expected that these guidelines will facilitate Zonal improvement of reliability of locomotives has been Railways in planning for creation of new sheds and reaped , but issues like real-time monitoring of expansion of existing sheds.locomotives to provide assistance to crew as well as locomotives are yet to be addressed.

For improving the utilization of locomotives, its unscheduled withdrawal from traffic, monitoring of

Railways have been reporting problem of MR working of safety equipment, prevention of accident

pressure drop on line ever since ‘Duranto’ train was like situation, such as signal passing at danger

introduced on Indian Railways while working with (SPAD), etc, real-time monitoring of locomotives is

WAP-1/WAP-4 locomotives due to use of air springs required at Electric Loco Sheds and Traction Loco

SAFETY DEVICE

Failure Management of Aluminum Gearcases of WAP5 Locomotives

www.rdso.indianrailways.gov.inA

N

N

U

A

L

R

E

P

O

R

T

2

0

1

2

-

2

0

1

318

ElectricalElectrical

and control toilet discharge system in these trains. loss of MR air pressure. Hence for setting of SIV, a WAP-4 Locomotives are equipped with 02 units of separate push button type SIV reset switch has 1000LPM compressors, which are adequate enough already been provided on the SIV panel by all the to meet out the compressed air requirement of train manufacturers as per RDSO’s standardization brake and auxiliary pneumatic systems of scheme in all the units (except older version TCD, Kit-2 locomotives. In the conventional rake since control & Kit-3, which are less than 10% of total population). toilet discharge system and air springs are not Vide RDSO’s letter no EL/1.2.9.1, Railways have been available, therefore, this type of problem is not advised that Loco pilots may be counseled to press observed while working the train with WAP-1/4. SIV reset switch provided on the panel for resetting of

SIV instead of HBA “OFF/ON’.There is additional load of around 33 lpm per LHB coach on the locomotive air supply circuit (FP There have been few cases of tripping of SIV circuit) with introduction of LHB rakes. It, therefore, due to input voltage out of range. It has been observed has become necessary to increase the capacity of that during tripping on account of input over voltage, compressor in WAP-4 locomotives to 3500 LPM. sometime loco pilots get confused that whether it is Fitment trails of high capacity oil free compressors due to high OHE voltage or due to malfunctions of have been carried out as on-board (08 nos) as well as input voltage sensor. Technical Circular no. under-slung (02 nos) in WAP-4 locomotives. Railways RDSO/2012/EL/TC/0115, Rev ‘0’ Dated 11.07.2012 have reported satisfactorily field performance of these have been issued on verification of OHE voltage on compressors. In view of enhanced air requirement of Electric locomotives by loco pilot for cross check the Duranto trains, a proposal for provision of higher voltage displayed on SIV panel by the reading of UA capacity oil free compressors (2* 1750 lpm) in new meter provided on Driver desk, fitted with 180 KVA SIV.WAP-4 locomotives being manufactured by CLW has Recently there have been few punctuality loss cases been sent to Railway board. Railway Board has on account of improper trouble shooting by loco pilots approved the proposal for provision of high capacity oil for segregation of faults of 180 KVA static converters. free compressor (2x1750 lpm) as under-slung for all In this connection, instructions for segregation of future manufacture of WAP-4 locos by CLW and on- internal & external faults and working in earth fault board fitment of high capacity oil free compressor bypass mode has been reiterated to Railways vide (2*1750 lpm) during major schedule by zonal RDSO’s letter no EL/1.2.9.1 dated 10.12.2012.Railways. CLW has been advised to make provision of high capacity oil free compressor (2*1750 lpm) as

Failure of E-70 brake system causing non-under-slung in all future manufacture of WAP-4 application of brakes in loco no 30011 & 30208 of locomotives. ELS/GZB has been investigated. During investigation of brake electronic rack of locomotives 30011 & 30208, it has been noticed that solder joint of signal connector pin carrying transducer signal was found crack and

RDSO has finalised the specification of guiding strips were not intact. To avoid such failures Distributed Power Wireless Control System (DPWCS) and to further improve the reliability of E-70 brake with braking features from remote loco for Electric system, action plan has been formulated in locomotives. Type tests have been carried out at firms consultation with OEM and minutes of meeting premises and the material is under extended field trials incorporating agreed upon action plan has been at Electric Loco Sheds at NGP, TATA,BIA, Kazipet circulated vide RDSO’s letter no. EL 3.2.19/3-Phase

dated 19.10.12. Reliability action plan to be implemented by Railways/ Firm has been circulated vide RDSO’s letter no. EL/3.2.19/3-Phase dated Recently there have been few cases of 15.10.2012 & 06.11.2012. punctuality loss on account of intermittent tripping of

180 KVA SIV. Loco pilot generally put HBA ‘OFF’ Detailed investigation on the “Brake Electronics position and then in ‘ON’ position for resetting of SIV in Failure” messages appearing on DDS of 3-phase case of intermittent tripping and after putting HBA locos (30251, 30244 and 30036) of ELS/GZB has OFF/ON, fault get vanished and SIV re-energized & been carried out jointly by M/s FTRTIL, Northern worked. However the process of putting HBA OFF & Railway & RDSO from 24.10.2012 to 27.10.2012. To ON generally takes 05-15 minutes because by avoid generation of spurious messages and to further keeping HBA ‘OFF’ position, it will not only lower the improve the reliability of E-70 brake system, action pantograph but also de-energies IP magnet valve plan has been formulated in consultation with OEM provided in brake panel for DBR/ VCD. De- and minutes of meeting incorporating action plan has energisation of IP magnet valve results in application been circulated vide RDSO’s letter no. EL 3.2.19/3-of emergency brake through E-3 emergency valve and Phase dated 01.11.12.

Reliability Improvements of E-70 Brake System

Development of Distributed Multiple Unit Coupler System (DPWCS) for Convention Electric Locomotives

Instructions For Loco Pilots in Locomotives Fitted with 180 KVA SIV

www.rdso.indianrailways.gov.in A

N

N

U

A

L

R

E

P

O

R

T

2

0

1

2

-

2

0

1

319

ElectricalElectrical

ON LINE Updating of Trouble Shooting Directory for 3 Phase Electric Locos

accordingly. Therefore, the updated RAP and TSD has been uploaded on RDSO website from time to time under the head “important letters / documents of 3-RDSO had issued Reliability Action Plans phase locos” in Electric Loco Directorate of RDSO (RAPs) and Trouble Shooting Directory (TSD) for loco Website rdso.indianrailways.gov.in. Alternatively, pilots of three phase locomotives to Zonal Railways. R a i l w a y s c a n f o l l o w t h e l i n k As reliability measures are being identified regularly to “ht tp ; / / rdso . ind ianra i lways .gov. in /v iew improve the reliability of 3-phase locomotives and section.jsp?lang=0,2,344,1060”. Railways have troubleshooting Directory is also required to be been advised to refer the latest version of these changed with implementations of new modifications, it documents. is important to update the list of RAPs and TSD

Loco performance Simulation Software

Insulation Scheme for Rewinding of 3 Phase Traction Motor Used in AC/DC EMUs in Mumbai

RDSO is developing Loco performance Simulation software in association with IIT Kanpur. This software will help Railways in simulating the various conditions available in Railways and assessing train performance. The Specifications have been firmed up and order placed on IIT Kanpur. The software has been developed and is under trial.

electrics supplied to CR and WR against GP-194 and MRVC projects since 2007 onwards. Similarly, TM type DMKT 53/42 have been working on AC/DC EMU rakes with BHEL electrics on CR for more than one decade.

Large number of traction motors are waiting for repair and rewinding. For repair and rewinding of these motors, necessity of a comprehensive insulation scheme has been felt. Only limited information regarding these TMs is available in ROSO as there was no transfer of technology for these traction Traction motors type ITB 2022-0T A03 have motors. CR has sent a reference in this regard, vide been working on AC/DC EMUs with SIEMENS letter no .NK.TMW.PR.482,dt. 04.04.2012.

www.rdso.indianrailways.gov.inA

N

N

U

A

L

R

E

P

O

R

T

2

0

1

2

-

2

0

1

320

ElectricalElectrical

In turn, the insulation schemes for both types of traction motor have been studied and rewinding schemes have been finalized in line with Insulation scheme of traction motor type 6FRA6068, in order to use a universal Insulation scheme for rewinding of three phase traction motors of EMU/MEMUs, etc.

Major benefits of these insulation schemes are as under :

Universal Impregnating Resin for all types of three phases TMs of Electric Locos/EMUs.Use of established insulating materials.

Requirement of VPI plant limited to just one.

Availability of materials from approved vendors

Lower cost of inventory.

n

Cross-wind Stability of Pantographsn

n

n

Indigenisation and Cost Cutting

Railway Board vide letter No. 2004/ Elect. 2004(TRS)/441/12 dated 06.03.2013 advised to examine the issues related with wind tunnel test of pantographs as brought out by Northern Railway.

Based on the designs and drawings submitted RDSO has carried out wind tunnel test of pantograph by M/s Medha Servo Drives Ltd for IGBT based for two additional cross wind configurations, namely

0 0Propulsion system for three phase locomotives wind incidence angle of 45 & 90 , in addition to normal against CLW P.O. 70/12/1134/08209 dtd. 07.05.2012, configuration as specified in IEC. These tests have RDSO has successfully completed the type tests and been performed at IIT/ Kanpur to evaluate cross wind routine tests on Vehicle Control Unit, Traction effect on pantograph. The up lift force for cross wind at

0 0Converters and Auxiliary Converters of Propulsion 45 & 90 (lateral direction) at wind speed up to 200 system of M/s Medha. Based on the test results, kmph was observed well within the limits specified in dispatch clearance for one set of IGBT based IEC standard. From the wind tunnel test report of Propulsion system for three phase locomotives has IIT/Kanpur, it has been concluded that pantograph is been given by RDSO. This development is totally stable at speed up to 200 kmph for entire configuration indigenous development for three phase electric of wind incidence angles i.e. longitudinal and lateral locomotive without any foreign collaboration. The direction of wind. Railway board has been advised system is under commissioning at CLW/Chittaranjan. accordingly vide RDSO’s letter no EL/2.2.1 dated

04.04.2013.