Ul±R _tadt då_Ķ ]2Pa l[Kam 6K

2 mlW^_ Dk^kªa^
Southern Railway Office of Sr. Divisional Electrical Engineer
l[Kam axDx etP _k^Y_n ]
Electric Loco Shed, Royapuram
ItÆWu /D^ ;/^K ϵϬϬϭ͗ϮϬϭϱ͕ /^K ϭϰϬϬϭ͗ϮϬϭϱ Θ
ItÆWu ]2Pa /^K ϰϱϬϬϭ ͗ ϮϬϭϴͿ
Chennai Division Chennai - 600 013
6 ]ta Email : srdeersrpm@mas.railnet.gov.in
g2 No.0 56 530 ,,, ( 2 /Date20.04.2024
lUWkD

M/s. CG power and industrial solutions limited.

Drives & automation division,
Plot no 9, phrase 2, Industrial Area,
Mandideep, Bhopal-462046.

Sub: Issues in CGL IGBT Traction Converters ± Reg

On 15.04.2024 while working with Train No. 12616, loco no.37207 failed
enroute with OCR action and Both bogies also isolated due to Rectifier over current
detected by all the four H-Bridges of both the Traction converters (SLG1 & SLG2). After
resetting the OCR and VCU reset done by LP, both the traction converters (SLG1 & SLG2)
came back to service and the train worked up to destination without any trouble. The
detention/ loss of punctuality featured in Railway Board Punctuality/Asset failure.
On arrival of Loco at ELS/RPM, Loco checked and found normal with both
traction converters in Service. No abnormalities found in the equipment available in HT
circuit and DGA of Transformer Oil found normal. Both the converters are checked
visually and functionally and found normal. MCR relay tested in test bench and found
working normal @ set value of current i.e., 3.3 A.
On analysing DDS data, SR data and LP report the following were observed,
1. After Passing Neutral section LP experienced VCB not closing with Popup Fault
message F0102P1 VCB stuck in OFF position (but DDS record was not available)
and displayed F0108P1 (primary current above maximum).
2. It is noticed that Rectifier Line 1 &2 over current logged from both the SR¶s for
several times during VCB reclosing time. As per SR data at the time of OCR action,
input inrush current has gone beyond 960 A (Figure 2) and rectifier over current
also logged (Figure 3).
3. This is because in CGL Traction Converter¶s (SR¶s), when every time VCB opens,
Line contactors get opened and DC link discharged through MUB resistor (Figure
1) . When VCB is closed again, for immediate charging of DC link capacitor (since
DC link voltage is too low) rectifier draws over current instantaneously (above
2400 A) and causing heavy inrush primary current (above 960 A). This has caused
OCR action in the above failed locomotive.
 VCB opened and DC link started
discharging through MUB and
Line contactors opened

VCB closed and DC link voltage shoot

up instantly from 1650 V to 2450 V

Figure 1: DC-link voltage at the time of OCR action

Input inrush current

raised above 920 A

VCB opened

VCB Closed

Figure 2: Input Current at the time of OCR action

 VCB Closed and rectifier input
current raised above 2400A

Figure 3: Rectifier Current at the time of OCR action

From the above graphs it is inferred that DC link voltage is discharging after opening
the VCB and pulsing of the rectifier H-bridge immediately after closing of the VCB in such a
manner that drawing of inrush current by DC link capacitors (DC link voltage set value 2450 V
± actual DC voltage at the instant of VCB closed 1650 V(Figure 1)). This sudden increase in the
DC link voltage causes over current to flow in the rectifiers of both the Traction converters and
hence the primary circuit. In MICAS and other propulsion DC link voltage is maintained and
Line contactors remain in closed condition during VCB opening and DC link voltage will be
discharged only at the time of protective shutdown.

Hence it is advised to analyse the above issue in the CGL IGBT SR and come up with
suitable changes in the CGL SR software.

Naga Sreenivasu Rongala,

Sr.DEE/RS/RPM
Copy To:
CELE/SR - for kind information
EDSE/RDSO - for kind information
CEE/CLW/CRJ - for kind information
ϴ ZĞƉŽƌƚ
:/Z ŝƐƐƵĞ >t ± ϴϳϰ
ĨƚĞƌͲƐĂůĞƐ ĚĞƉĂƌƚŵĞŶƚ

WƌŽĚƵĐĞĚ ZĞǀŝĞǁĞĚ ƉƉƌŽǀĞĚ

ZĂŵĞƐŚǁĂƌ 'ŽƐǁĂŵŝ WĂƌĂƐŚƵƌĂŵ EĂŐĂŶƵƌ /ŽŶ ^ĂŐĂƌnjĂnjƵ

^ĞƌǀŝĐĞ ŶŐŝŶĞĞƌ ^ĞƌǀŝĐĞ DĂŶĂŐĞƌ ĨƚĞƌ ^ĂůĞƐ ĞŶŐŝŶĞĞƌŝŶŐ
ϮϯͲϬϳͲϮϬϮϰ ϮϯͲϬϳͲϮϬϮϰ ϮϯͲϬϳͲϮϬϮϰ

7KH ODWHVW YHUVLRQ RI WKLV GRFXPHQW LV ILOHG LQ &$) 3RZHU $XWRPDWLRQ VHUYHUV (YHU\ SULQWHG FRS\ LV DQ XQFRQWUROOHG FRS\

Π&$) 3RZHU $XWRPDWLRQ 6 / 8

7KLV GRFXPHQW KDV FRQILGHQWLDO LQIRUPDWLRQ RZQHG E\ &$) 3RZHU $XWRPDWLRQ 6 / 8 DQG LW FDQ RQO\ EH XVHG IRU WKH SXUSRVHV DJUHHG $Q\ UHSURGXFWLRQ WUDQVPLVVLRQ RU XVH RI WKLV GRFXPHQW
RU RI DQ\ RI LWV FRQWHQWV LV SURKLELWHG XQOHVV H[SUHVV ZULWWHQ DXWKRUL]DWLRQ IURP &$) 3RZHU $XWRPDWLRQ 6 / 8 LV REWDLQHG
 ZĞĐƚŝĨŝĞƌ >ŝŶĞ ϭΘϮ KǀĞƌ ƵƌƌĞŶƚ >t ± ϴϳϰ

ŽŶƚĞŶƚƐ
&R Q WU R O RI (GLW LRQ
$FURQ \PV
' 'HI LQ H WKH WHDP
' $Q D O\V LV DQG G HV F U LS W LR Q RI WK H LVVXH
' ,P P HG L D W H F R QW D LQ P H Q W D F W LR QV
' ' HI LQ L W L R Q DQG D Q D O\ V LV RI WKH U RRW FDXVH
' ,G H Q W LI\ F R U U H F W LYH D F W LR Q
' ,P S OHP H QW F R U U HF W LY H DF WLRQ
' $F W LR QV WR S U HY HQW U HF XUU HQF H
' &OR V H WKH LVV XH

^' ϬϬϬϰ ǀϭϱ͘Ϭ WĂŐĞ Ϯ ŽĨ ϴ

 ZĞĐƚŝĨŝĞƌ >ŝŶĞ ϭΘϮ KǀĞƌ ƵƌƌĞŶƚ >t ± ϴϳϰ

ϭ͘ ŽŶƚƌŽů ŽĨ ĚŝƚŝŽŶ
9HUVLRQ 5HDVRQ 'DWH

)LUVW HGLWLRQ

^' ϬϬϬϰ ǀϭϱ͘Ϭ WĂŐĞ ϯ ŽĨ ϴ

 ZĞĐƚŝĨŝĞƌ >ŝŶĞ ϭΘϮ KǀĞƌ ƵƌƌĞŶƚ >t ± ϴϳϰ

Ϯ͘ ĐƌŽŶLJŵƐ
&$) &RQVWUXFFLRQHV $X[LOLDUHV GH )HUURFDUULOHV
&$) 3 $ &$) 3RZHU $XWRPDWLRQ
&*3,6/ &* 3RZHU DQG ,QGXVWULDO 6ROXWLRQV /LPLWHG
&/: &KLWWDUDQMDQ /RFRPRWLYH :RUNV
-,5$ ,VVXH FROOHFWLRQ ZHE DSSOLFDWLRQ
6: 6RIWZDUH
,*%7 ,QVXODWHG *DWH %LSRODU 7UDQVLVWRU
616 6QDSVKRRW
9&% 9DFXXP &LUFXLW %UDNHV +6&%
9(*$ 9HKLFOH (OHFWURQLFV IRU *HQHULF $SSOLFDWLRQV
65 6/* 7UDFWLRQ &RQYHUWHU
+) +LJK )UHTXHQF\
/) /RZ )UHTXHQF\

ϯ͘ ; ϭͿ ĞĨŝŶĞ ƚŚĞ ƚĞĂŵ

&RPSDQ\ 'HSDUWPHQW

&$) $IWHU 6DOHV (QJLQHHULQJ

&*3,6/ $IWHU 6DOHV (QJLQHHULQJ

^' ϬϬϬϰ ǀϭϱ͘Ϭ WĂŐĞ ϰ ŽĨ ϴ

 ZĞĐƚŝĨŝĞƌ >ŝŶĞ ϭΘϮ KǀĞƌ ƵƌƌĞŶƚ >t ± ϴϳϰ

ϰ͘ ; ϮͿ ŶĂůLJƐŝƐ ĂŶĚ ĚĞƐĐƌŝƉƚŝŽŶ ŽĨ ƚŚĞ ŝƐƐƵĞ

7KH LVVXH GHVFULSWLRQ LV WDNHQ IURP WKH -,5$ DSSOLFDWLRQ ZHE VHUYHU

,VVXH WLWOH /2&2

'DWH DQG WLPH

8QLW QXPEHU

6KHG 530 5R\DUSXUDP

.LORPHWHUV

8QLW W\SH :$3

6: 9HUVLRQ Y

$IIHFWV VHUYLFH 6HUYLFH 'HOD\

'HVFULSWLRQ 3ULPDU\ FXUUHQW DERYH PD[LPXP DQG 6/* UHFWLILHU RYHU FXUUHQW
PHVVDJH ORJJHG LQ /LQH

ϱ͘ ; ϯͿ /ŵŵĞĚŝĂƚĞ ĐŽŶƚĂŝŶŵĞŶƚ ĂĐƚŝŽŶƐ

7KH ILUVW LPPHGLDWH DFWLRQ ZDV WR QRWH WKH LQFLGHQW GHWDLOV VR WKDW LW FRXOG EH DQDO\]HG RQFH
WKH ORFRPRWLYH UHDFKHG WKH QHDUHVW VKHG DV ERWK 65 V VKRZHG RYHU FXUUHQWV WKDW ZHUH
UHFRYHUHG ZLWKLQ VHFRQGV ZLWK QR ORVV RI IXOO SRZHU DYDLODELOLW\

R 65 VHULDO QXPEHU &*3, 3

R 65 VHULDO QXPEHU &*3, 3

ϲ͘ ; ϰͿ ĞĨŝŶŝƚŝŽŶ ĂŶĚ ĂŶĂůLJƐŝƐ ŽĨ ƚŚĞ ƌŽŽƚ ĐĂƵƐĞ

$FFRUGLQJ WR WKH 9(*$ 65 ORJV DQG GULYHU FRPSODLQ WKH LQFLGHQW RFFXUUHG RQ 0DUFK
ZKHUH ERWK 6/* WUDFWLRQ FRQYHUWHUV UHSRUWHG D UHFWLILHU OLQH RYHU FXUUHQW RQ WKH ''8
DSSDUHQWO\ DIWHU OHDYLQJ D QHXWUDO ]RQH

^' ϬϬϬϰ ǀϭϱ͘Ϭ WĂŐĞ ϱ ŽĨ ϴ

 ZĞĐƚŝĨŝĞƌ >ŝŶĞ ϭΘϮ KǀĞƌ ƵƌƌĞŶƚ >t ± ϴϳϰ

+HUH LV WKH IXOO VHTXHQFH ZULWWHQ DQG JUDSKHG EHORZ

7KH 6/* UHFHLYHG IURP WKH )/* WKH 09&%B2Q)DVW VLJQDO VR D )DVW2SHQ UHTXHVW
LV VHQW WR WKH 6/* IURP WKH )/*

$IWHU D IHZ PV WKH 6/* UHFHLYHG WKH FRQILUPDWLRQ IURP WKH )/* WKDW WKH 9&% ZDV
RSHQ 09&%B2Q

'HVSLWH RI UHFHLYLQJ WKH 2Q)DVW UHTXHVW DQG WKH FRQILUPDWLRQ IURP WKH )/* WKDW WKH
9&% ZDV RSHQ

)LJXUH 2YHU &XUUHQW /) 616 EDFNJURXQG

:KHQ WKH )/* VHQW WR WKH 6/* D )DVW2SHQ UHTXHVW WKH 6/* SUHSDUHG LWVHOI WR RSHQ WKH
9&% DQG VWDUWHG VWRSSLQJ DOO WKH FRQYHUWHUV VWDUWLQJ IURP WKH LQYHUWHU

$IWHU VHFRQG IURP WKH 2Q)DVW UHTXHVW D FDWHQDU\ UHFWLILHU LQSXW SKDVH RYHUFXUUHQW
VLWXDWLRQ KDSSHQHG ,Q WKDW PRPHQW WKH 6/* 7&8 GHWHFWV WKH RYHU FXUUHQW VLWXDWLRQ
DQG SURWHFWV DV H[SHFWHG

)URP WKH GDWD REWDLQHG IURP WKH KLJK IUHTXHQF\ 616 RI WKH 6/* LW LV REVHUYHG WKDW WKH
FDWHQDU\ RU 2+/ YROWDJH GRHV QRW GURS DW DQ\ WLPH DV LW VKRXOG LQ D QHXWUDO ]RQH QRWLFHG E\
WKH GULYHU )RU WKLV UHDVRQ WKH 5&8 ,*%7 V DUH NHSW VZLWFKLQJ DIWHU 9&% RSHQLQJ 2WKHUZLVH
WKH PRWRU FXUUHQWV DUH VZLWFKHG RII DV VRRQ DV WKH RSHQLQJ VLJQDO LV UHFHLYHG IURP WKH GULYHU

7KH 6/* FRQWDFWRUV DUH NHSW FORVHG PDLQWDLQLQJ WKH '& /LQN YROWDJH ZKLFK LV VWLOO GLVFKDUJLQJ
E\ WKH SHUPDQHQW GLVFKDUJH UHVLVWRUV VDIHW\ SURWHFWLRQ

V DIWHU WKH QHXWUDO ]RQH QRWLFH DQG WKH 9&% FORVXUH ZLWK QR 2+/ ORVV DV WKH UHFWLILHU ,*%7
V DUH VWLOO VZLWFKLQJ WKH XQH[SHFWHG FXUUHQW SHDN DQG LQVWDQWDQHRXV ORVV RI ERWK 6/* V RFFXUV
ZKLFK DUH WKHQ DEOH WR UHFRYHU DQG EHFRPH RSHUDWLRQDO DJDLQ DIWHU D IHZ VHFRQGV

^' ϬϬϬϰ ǀϭϱ͘Ϭ WĂŐĞ ϲ ŽĨ ϴ

 ZĞĐƚŝĨŝĞƌ >ŝŶĞ ϭΘϮ KǀĞƌ ƵƌƌĞŶƚ >t ± ϴϳϰ

)LJXUH 2YHU &XUUHQW +) 616 EDFNJURXQG

9DULDEOHV 'HVFULSWLRQ
YFDWBUDZ 2+/ YROWDJH
YEXVBUDZ '& /LQN YROWDJH
LKE BUDZ + EULGJH FXUUHQW
LKE BUDZ + EULGJH FXUUHQW
DLBJHQHULFB BUDZ 3ULPDU\ &XUUHQW
LQSXWBDLBLX 3KDVH 8 &XUUHQW
LQSXWBDLBLY 3KDVH 9 FXUUHQW

7DEOH )LJXUH YDULDEOH GHVFULSWLRQ

ϳ͘ ; ϱͿ /ĚĞŶƚŝĨLJ ĐŽƌƌĞĐƚŝǀĞ ĂĐƚŝŽŶ

, 1HZ 6/* 6: YHUVLRQ LQ SURJUHVV
R ,Q D QRWLFHG QHXWUDO ]RQH WKH VZLWFKLQJ PDQDJHPHQW RI WKH UHFWLILHU ,*%7 V KDV
EHHQ PRGLILHG VWRSSLQJ WKHP DV VRRQ DV WKH QHXWUDO ]RQH VLJQDO LV UHFHLYHG

R 7KH 6/* PDLQ FRQWDFWRU ZLOO UHPDLQ FORVHG XQWLO WKH '& /LQN YROWDJH GURSV EHORZ
9 ,Q FDVH RI OHDYLQJ WKH QHXWUDO ]RQH EHIRUH WKH YROWDJH GURSV EHORZ 9
WKH 6/* ZLOO EH UHFRYHUHG E\ VWDUWLQJ WR VZLWFK ZLWK WKH PDLQ FRQWDFWRU VWLOO FORVHG

R ,I GXH WR WKH QHXWUDO ]RQH WKH '& /LQN YROWDJH GURSV EHORZ 9 WKH 6/* ZLOO
RSHQ FRQWDFWRUV FRPSOHWHO\ GLVFKDUJLQJ WKH '& /LQN DQG UHTXLULQJ WKH QRUPDO EXV
FKDUJLQJ VHTXHQFH WR EH GRQH

^' ϬϬϬϰ ǀϭϱ͘Ϭ WĂŐĞ ϳ ŽĨ ϴ

 ZĞĐƚŝĨŝĞƌ >ŝŶĞ ϭΘϮ KǀĞƌ ƵƌƌĞŶƚ >t ± ϴϳϰ

ϴ͘ ; ϲͿ /ŵƉůĞŵĞŶƚ ĐŽƌƌĞĐƚŝǀĞ ĂĐƚŝŽŶ

, 9DOLGDWH WKH QHZ 6/* 6: YHUVLRQ WR EH XSORDGHG RQ IOHHW

7KH XSJUDGH WR WKLV 6: YHUVLRQ ZLOO LPSURYH WKH PDQDJHPHQW RI WKH '& OLQN DYRLGLQJ UHFWLILHU
OLQH RYHU FXUUHQWV DIWHU D UHDO RU XQH[SHFWHG QHXWUDO ]RQH

ϵ͘ ; ϳͿ ĐƚŝŽŶƐ ƚŽ ƉƌĞǀĞŶƚ ƌĞĐƵƌƌĞŶĐĞ

7KH SURSRVHG &RUUHFWLYH $FWLRQV SUHYHQW WKH UHFXUUHQFH RI WKH SUREOHP

ϭϬ͘ ; ϴͿ ůŽƐĞ ƚŚĞ ŝƐƐƵĞ

' 3+$6( 67$786

' '(),1( 7+( 7($0 9 FRPSOHWHG

' $1$/<6,6 $1' '(6&5,37,21 2) 7+( ,668( 9 FRPSOHWHG

' ,00(',$7( &217$,10(17 $&7,216 9 FRPSOHWHG

' '(),1,7,21 $1' $1$/<6,6 2) 7+( 5227 &$86( 9 FRPSOHWHG

' ,'(17,)< &255(&7,9( $&7,21 9 FRPSOHWHG

' ,03/(0(17 &255(&7,9( $&7,21 9 RQJRLQJ

' $&7,216 72 35(9(17 5(&855(1&( 9 RQJRLQJ

x 7KH $QDO\VLV DQG $FWLRQ 3ODQ ZLOO EH UHYLHZHG DQG FORVHG WRJHWKHU ZLWK &*

^' ϬϬϬϰ ǀϭϱ͘Ϭ WĂŐĞ ϴ ŽĨ ϴ