■

+N(t)k— ci Government of India - Ministry of

3.3Rrwr atl R +11 1ct?
- - ,
ol Railways Research, Designs & Standards
rK.q •-1 226011 Organization, LUCKNOW — 226011
e-mail: Telex: 0535-2424 RDSO-IN
dsetm@rdso.raiMet.gov.in Fax: 91-0522-2465716
■'-1M4)c1 WZT. Telephone : 0522-Z465716

No. EL/4.2.15/AMC Dated: 21.06.2016

SPECIAL MAINTENANCE INSTRUCTION NO. RDSO/2016/EL/SMI/0288 (REV. '0') 1.0

Title:

Technical Scope of work for Annual Maintenance Contract (AMC) of Microprocessor

based Control & fault diagnostic System (MPCS)
2.0 Brief History:
2.1 Tap changer electric locomotives working on Indian Railways are provided with control
based on electromechanical and Electro-pneumatic relays/ contactors. Microprocessor-
based control system (MPCS) was provided in conventional electric locomotives
(approximately 2000 locomotives) as per specification no. ELRS/SPEC/MPC-FDS/0001
Rev. '2' 86 Rev. '3' by procuring MPCS from M/s Medha/Hyderabad, M/s
Ste salit/ Kolkata, M/s ICECPL/Haridwar, M/s SIL/Kolkata, and M/s
Laxven/Hyderabad.

2.2 As most of the MPCS units (about 85.6%) are beyond warranty, a need is felt to provide
a uniform technical scope of work for Annual Maintenance Contract (AMC) of MPCS.
Zonal Railways have also requested from to time for uniform technical guidelines in this
respect

2.3 Total population of MPCS V2 and V3 as on 31.12.2015 is given below:

SN Name of supplier V2 V3 Total Out of
population population warranty
1 M/s. Medha Servo Drive/ 1110 32 1164 921
Hyderabad
2 M/s. SIL/ Kolkata 72 2 74 40
3 M/s. ICECPL/ HW 91 7 98 62
4 M/s. Laxven/ Hydera ba d 4 4 4
5 M/s. Steaslit/ Kolkata 703 _ 703 703
6. M/s Transtel 2 -- 2 2
Total 1982 41 2023 1732

3.0 DEFINITIONS
Throughout this document, the t e rm s:
a)'MPCS' means Microprocessor based control 86 fault diagnostic system.
b)`VCD' means Vigilance Control Device.

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c) 'LED' means Light Emitting Diode used for signal indication purpose in MPCS.
d) 'LCD' means Liquid Crystal Display used in display unit of MPCS.
e) ‘ S C U ' m e a n s S i g n a l C o n d i t i o n i n g U n i t f o r m e a s u r i n g a n a l o g p a r a m e t e r s o f
locomotives like voltages, speed and pneumatic pressures.
f) `ISCU' means Intelligent Signal Conditioning Unit used for measuring traction
motor currents.
g)'DJ' means Main circuit breaker of locomotive .
h) m e a n s l o w v o l t a g e t e s t i n g o f l o c o m o t i v e o n b a t t e r y s u p p l y
i)'HT' means high voltage testing of locomotive on OHE supply
j)'TM' means Traction Motor of locomotive.
k)'Railways' means Government of India, Ministry of Railways, Railway Board,
Zonal Railways, loco shed or its nominees.
1) 'AMC' means the Annual Maintenance Contract.
m)'Contract' means the contract for annual maintenance of MPCS fitted on
Conventional tap changer Electric locomotives
n)'Contractor' means the firm / company on whom the order for annual
maintenance of MPCS fitted on Conventional tap changer Electric locomotives is
to be placed.
o ) `RDS0' shall mean Research, Design and Standards Organization/Lucknow.
p ) `Minor Schedule' means the inspection schedule IA, IB, IC and ICO
q ) `Major Schedule' means the schedule AOH/TOH, IOH and POH
r ) 'OEM' means Original Equipment Manufacturer

4.0 Object:

To provide technical scope of work for Annual Maintenance Contract (AMC) of

Microprocessor based Control 85 fault diagnostic System (MPCS).

5.0 Scope of work of AMC:

5.1 This is a comprehensive Annual Maintenance Contract for MPCS where Original
Equipment Manufacturer (OEM) /contractor shall at its own cost and expense attend,
replace and install materials which get consumed, wear out due to ageing /use in the
normal course of operation as well as attend failures/breakdowns /out of course repairs
of MPCS including components, assembly/ sub-assembly, electronic cards etc. for
efficient and reliable operation of equipment under AMC. During the maintenance
period OEM/contractor shall arra nge t ra nsport of m a n a nd m a t e ri a l a t i t s own c ost a s
and when required for maintenance of the equipment.

5.2 The contract shall be comprehensive in nature wherein preventive as well as Breakdown
Maintenance of MPCS shall be carried out by the contractor including the arrangement
of spares, tools, consumables, technical expertise, man power and replacement of
defective cards/equipment etc. The released defective cards, consumables, tools, items
etc. will be contractor's property. C ont ra c t or sha l l re m ove t he sa m e from t he she d's
premises with due authority/proce dure s.

5.3 Railways will enter into AMC for MPCS with manufacturers of MPCS for their own make
of MPCS units or with sources approved for repair of MPCS of a particular make.

5.4 MPCS units under warranty shall not be included in scope of AMC. MPCS units beyond
manufacturer's warranty shall only be included in scope of AMC. However, Railways

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 may enter in to AMC contract for MPCS units covered under warranty, but in such
cases, AMC for units still covered under warranty shall commence from the next day of
completion of warranty period.

5.5 AMC will be entered by Railways for MPCS units beyond warranty up to codal life of
MPCS unit.

5.6 AMC will be carried out for MPCS units in working condition.

5.7 The maintenance and support by the contractor shall consist of periodical preventive
checks as per the maintenance schedule of MPCS for trouble free operation of the
equipment as well as attending the failures/breakdown/out of course repair etc.

5.8 Contractor shall ensure that AMC maintenance schedule should match with the loco
inspection schedules. i.e. IA, IB, IC, AOH/TOH, IOH, POH etc. The scope of maintenance
by the contractor shall be largely as per preventive maintenance schedule of the
equipment, but shall include out of course attentions including breakdown, if any
required, to ensure trouble free operation of the locomotive.

5.9 AMC shall not cover the MPCS failures due to circumstances such as fire in
locomotives, accident, earth quake, floods etc. However, in such circumstances payment
for spares to be replaced by the tenderer will be made extra as per the price list of OEM
submitted along with their offer.

5.10 All maintenance activities shall be carried out as per the schedule approved by
Railways. In case of any abnormalities found during minor/major schedules, associated
component/subassemblies shall be replaced/repaired by the contractor. The activities
to be covered under scope of work of AMC of MPCS are given below:

5.10.1 Works to be done during Minor Schedules (IA/IB/IC/ICO)

S.N. DESCRIPTION OF WORK

1.0 Fault Data

1.1 Download fault log da t a t hrough l a pt op/ Pe n dri ve a nd c he c k
for any abnormal messages. Necessary corrective/preventive
action to be taken on the abnormal messages. Record of loco
wise fault data should be kept.

1.2 Verification of driver log Book: verify drivers log book and
record bookings related to MPCS functionality.

1.3 Verification of Remote Monitoring Data from website for MPCS

version-3 for proper working of remote monitoring module.

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S.N. DESCRIPTION OF WORK

2.0 Visual inspection

2.1
Clean the dust with a dry cloth or vacuum cleaner on all sub -
assemblies of MPCS like control unit, display units, PT, SCU
and ISCUs etc.
2.2 Check all cards/cables/units/connectors/couplers/bolts etc.
for proper tightness/se c uri ng/ fi t m e nt .
2.3 Check proper earthing of all subassemblies like main unit,
SCU, ISCU, display unit etc. to locomotive body.

3.0 Functionality check

3.1 Control card (CPU c ar d) Re dundanc y c he c k: obse rve t he
control card change over with DJ opening by observing
blinking of LED on working CPU card.
3.2 Digital input check: Observe simultaneous glowing of LEDs
110V (Green) and 5V (Yellow) on Fascia of all digital input
cards.
3.3 Digital output check: Observe simultaneous glowing of LEDs
110V (Green) and 5V (Yellow) Fascia of all digital output cards.
3.4 Power supply card test: check all LEDs on Fascia of the both
power supply module glowing.
3.5 Communication Check: C he c k t he he a l t h st a t us of a l l sub -
assemblies in test mode on display.
3.6 Check functionality of VCD in MPCS version-3 including foot
switch, bypass switch etc.
3.7 Check functionality of Remote monitoring module (including
antenna) in MPCS version-3.

3.8 Check the Date, time and loco no. for proper entry.
3.9 Check both the display units and buzzer for proper
functioning.
3.10 Check healthiness of spare and redundant input 86 output
cards of MPCS

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5.10.2 Works to be done during major schedules (AOH/TOH/IOH/POH)
During major schedules, following additional activities over and above the activities specified for
minor schedules will be carried out:

S.N. DESCRIPTION OF WORK

1.0
Digital input/output Redundancy checks: Check the
input/output status of main input/output cards and
redundant input/output cards on display unit at power on
and after closing DJ on HT testing mode. Ensure both main
and redundant card input/output status are same.

2.0 Display unit Check:

2.1. LCD Check: Display units in both cabs and its operation,
through menu driven keys.
2.2 Notch Indicator Check: In MPCS version-2, check the working
of seven segment display of notch indicator
2.3 Buzzer Check: Verify buzzer is working or not by simulating
any fault.

3.0 SCU Unit Check:

3.1 Check the voltage of auxiliary supply and redundant auxiliary
supply, Arno/Static Inverter voltage are available when loco is
in energized condition.
3.2 Observe the Battery Charger (CHBA) voltage on display unit in
LT and HT testing mode.
3.3 Observe the TM voltage on display unit by increasing the
Notches in LT and HT testing mode.

4.0 ISCU Unit Check:

4.1 Working of QD-1 and QD-2 functionality.

4.2 Observe the TM currents on display unit.

5.0 All rubber gaskets and grommets to be replaced.

6.0 Check the condition of Real Time Clock (RTC) battery and
replace if required. RTC battery should be replaced before
completion of its codal life as prescribed by respective OEM.
7.0 M othe r B oar d Check: C h e c k t h e c o n t r o l u n i t m o t h e r b o a r d
for formation of dust a nd a l so obse rve t he t ra c ks on m ot he r
board for any abnormality. Abnormalities of mother board
tracks to be attended or mother board to be changed if
necessary.

8.0 Check calibration of all analog parameters like voltage, current

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 S.N. DESCRIPTION OF WORK
and pressure etc.
9.0 Check buzzer functionality for three different frequency used
in MPCS version-3
10.0 Checking proper working of notch encoder for notch indicator
fitted with SMGR in MPCS Version-3.
11.0 Check for proper se t t i ng of all eliminated relays like Q20,
Q30, QF, QD etc.
12.0 Checking Uniformity of configuration parameters in both CPU
cards.
13.0 Check the condition of lock in front door of main control panel
and replace if required.
14.0 Checking of all types of sensors used in MPCS like hall effect,
pressure etc.

15.0 Replacement of VCD foot switch in MPCS V3

16.0 Check for proper functionality of VCD Bypass switch

5.10.3 In addition to above, modifications/reliability improvement measures/instructions

related to MPCS issued by Railway Board/RDSO/Manufacturers from time to time
shall be considered as part of scope of AMC. The cost of modification (material portion)
will be borne by either Contra c t or or R a i l wa ys a s pe r R DSO gui de l i ne s. Howe ve r,
labour portion including provision 86 testing is to be done at free of cost by the
Contractor. Contractor will carry out the required modifications and inform Railways
and RDSO.
5.10.4 Above scope of works is for guidance. Railways may include any additional
activities/works deemed necessary to ensure proper maintenance.

5.11 Responsibilities of Railways

5.11.1 The Railway authority shall permit the contractor to work on MPCS fitted on
conventional tap changer electric locomotives under preventive maintenance or break
down.
5.11.2 Railways shall nominate the Officer/ Supervisor for supervision of the work done by
the contractor under the contra c t .
5.11.3 The necessary space, electricity, and water connection shall be provided by Railway
free of cost at the nearest possible point of the site. In addition, a suitable covered
space to store the tools and tackles shall be provided free of cost by the IR to the
contractor in the shed.
5.11.4 Railway shall mention the details of the equipment under AMC including the
locomotive numbers covered under Annual Maintenance Contract. In case the home
shed of the locomotive is shifted to any other location, the scope of AMC shall shift to
new home shed of the locomotive.

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 5.11.5 Railways and the Contractor shall jointly arrive at the number of locomotives that are
under AMC at the start of contract and a record shall be kept for this purpose.
5.11.6 Railways shall inform in advanc e (pre fe ra bl y 24 hours i n a dva nc e or a t l e a st 12 hours
in advance) the contractor regarding locomotives planned for scheduled repairs (i.e.
IA/IB/IC/ICO/AOH/TOH/IOH/POH) so that contractor can also plan and carry out
the activities as per scope of work of AMC.
5.11.7 Railways shall also inform the contractor regarding any line failures/breakdown of the
locomotive and likely place (trip shed/ loco shed) and date where locomotive needs to
be attended by the contractor.

5.12 Responsibilities of contractor

5.12.1 The contractor shall post adequate no. of qualified service engineers and arrange
required materials exclusively for the execution of this contract at the Loco shed.
5.12.2 Service Engineer shall carryout preventive maintenance on locos at all days and times
including Sundays and Gazetted holidays depending upon availability of locomotive in
the shed. Preventive maintenance will be carried out in shadow of scheduled
maintenance of the locomotives.
5.12.3 Normally Service engineer shall be a va i l a bl e i n t he she d duri ng norm a l worki ng hours
to attend breakdown calls/ preventive maintenance. A backup service engineer shall
be located at one of the contractor's office and shall be available at the designated
shed if required to attend the complaints in case of absence of service engineer at the
designated shed.
5.12.4 The service engineer carrying out repair in the shed shall observe all safety and
security rules prevailing at the place of work.
5.12.5 The contractor shall keep adequate number of spare cards/ components etc. to ensure
timely replacement of defective cards/components. Failed cards/components are to be
replaced with new/repaired cards/components.
5.12.6 Firm shall make Joint Note along with shed staff for each and every line failure and
shed detection cases duly indicating the root cause of failure and corrective measures
to be taken in the format as prescribed by RDSO. Investigation report in each case
along with remedial action taken/to be taken shall be submitted to Railways 86 RDSO.
5.12.7 In no case loco will be given fit without intactness of all good spare input /output
cards, redundant cards, both CPUs etc.
5.12.8 In case of any MPCS card found malfunctioning / behaving erratically showing fault
intermittently (not permanent) it must be replaced by firm.
5.12.9 In some cases, the actual problem is not established and in these cases, loco is
required to be escorted by the m a i nt e na nc e pe rsonne l . He nc e , i n suc h c a se s e sc ort i ng
of loco by the contractor's service engineer for finding the trouble to be ensured.
5.12.10 Firm service engineer should maintain MPCS unit wise history of failure and other
details and checks performed during the minor schedule in the form of check sheets
which will be made as per RDSO guidelines and got approved from Railway
Representative.
5.12.11 Scheduled work and testing if required should be carried out during the schedule and
testing hours as specified by Railways
'2

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5.12.12 After every attention to the MPCS, contractor will give a report to the Railways giving
details of activities carried out including details of components/subassemblies
replaced.
5.12.13 The contractor shall quote the rates for comprehensive AMC (as specified in clause
5.1) considering both the break down & preventive maintenance (including spare
materials, components, assemblies, labour, manpower, service, transportation etc.).

5.13 Place of work:

5.13.1 Minor schedule activities (IA/IB/IC/ICO) will be carried out at the home shed of the
locomotive.
5.13.2 Major schedule activities (AOH/TOH/IOH) will be carried out at the home shed of the
locomotive.
5.13.3 Major schedule activities (POH) will be carried out at the POH shop where locomotive
is undergoing POH as decided by the Railways.
5.13.4 Breakdown maintenance will normally be carried out at the nearest trip shed/loco
shed where loco is sent after failure. If the locomotive cannot be attended at out
stations, locomotive may be called to home shed.

5.14 Penalty Clause for AMC:

5.14.1 As soon as failure of equipment under AMC takes place, the same shall be informed to
Contractor by Shed/Railway authority. Contractor shall attend the defects as early as
possible but not exceeding 24 hours after the placement of locomotive in shed/trip
shed covered under contract mutually agreed between parties (Railways and
contractors).
5.14.2 For smooth execution of AMC by contractor, Zonal Railways may include suitable
penalty clause as special condition of contract for AMC. However sample penalty
clauses are given as under for guidance of Zonal Railways.

5.14.3 Downtime penalty for fleet of locomotives

a) Downtime on account of online failures of equipment under AMC shall be from the
time the locomotive fails on line and reported to the contractor till the loco is g i v e n
ready for service.
b) T h e c o n t r a c t o r s h a l l e n s u r e t h a t d u r i n g t h e b i l l i n g p e r i o d ( t h r e e m o n t h s ) ,
combined downtimes of all the locomotives covered under AMC, on account of
out of course repair and online failures of equipment under AMC does not exceed
1.5% of total loco hours for the locomotives covered in the AMC. Penalty for
Downtime for the fleet of the locomotive shall be as under:

Down time Penalty

1.5 % or less NIL
1.5% to 5% 2% of the total monthly proportional bill
5% to 10% 5% of the total monthly proportional bill
More than 10 % 10% of the total monthly proportional bill

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5.14.4 Downtime penalty for individual locomotive
a) Downtime on account of online failures of equipment under AMC shall be from the
time the locomotive fails on line and reported to the contractor till the loco is given
ready for service.
b) T h e c o n t r a c t o r s h a l l e n s u r e t h a t d u r i n g t h e b i l l i n g p e r i o d ( t h r e e m o n t h s ) ,
individual downtime of all the locomotives covered under AMC, on account of out
of course repair and online failures of equipment under AMC does not exceed 5%
of loco hours for the locomotive covered in the AMC. Penalty for Downtime of the
individual locomotive shall be as under:
Individual Loco Penalty
Down time
5 % or less NIL
> 5% 5% of the individual loco's monthly proportional bill

5.14.5 Overall liability in any case shall not exceed 10% of the contract value

6.0 Application to the Class of Locomotives:

MPCS fitted tap changer 25 KV AC conventional electric locomotives.

-

7.0 Agency of Implementation:

All Electric Loco Sheds.

8.0 Periodicity of Implementation:

Minor schedule inspections (IA/IB/IC/IC0), TOH (Earlier AOH), IOH, POH overhauling
schedules and any other unscheduled maintenance.

4916
(P.K. Saraswat)
for Director General (Elect.)
Enclosures: Nil

Copy to: As per standard Mailing List No EL-M-4.2.3--19 (latest revision).

Cc"

(P.K. Saraswat)
for Director General (Elect.)

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