Reliability issues of M/s BHEL at ELS/BRC

1. Problem of intermittent “Harmonic Filter contactor 8.1/8.2 stuck ON/OFF fatal” and Main power OFF
on-line. (Total cases in 2018-19: 18 no.s & in 2019-20 : 26 no.s).

2. VCU reset operation is not working in all locos equipped with M/s BHEL IGBT complete propulsion
system and M/s BHEL IGBT traction converter with MICAS VCU. Whenever VCU reset is done on-line
during coasting then messages of “dist. In speed sensor” arises from all TMs and main power gets
OFF

3. M/s BHEL has not provided any software for push-pull operation.

4. Overheating of power cable terminal lug supporting stud in Aux Converter. M/s BHEL replaced steel
studs with brass stud in only 02 nos. locos out of 39 locos till date.

5. Loose connection of male & female SUB-D connectors at VCU (M/s BHEL IGBT propulsion system
TCN) interface plate.

6. High Failure of Power module of M/s BHEL make IGBT traction converter:
Defect type 2018-19 2019-20 (Till Dec.)
USID_low 04 05
SEPL_Max 07 03
TMax 10 02
Status error 04 03
Coolant leakage - 04
Earth fault - 01
Fitment issue - 01
Misc. - 02
Total 25 21

7. High failure rate of BHEL TCN VCU , RDD & RBU cards:

Item 2018-19 (POP-9 locos) 2019-20 (till Dec.) POP-21* locos Total
RBU 04 24 28
RDD 03 11 14

There has been increasing trend of failures of RBU and RDD-R cards and due to non availability UES,
downtime of locos equipped with M/s BHEL TCN VCU is very high.

8. High failure rate of Inverter module of aux converter ( in 2019-20 : 9 cases)

Issues of Hotel load converters(PoP : 6 locos)

1. Poor quality of blowers fans provided in Hotel load converter (till now total 7 defective blower fans
got replaced in 4 locos).

2. Poor performance of inductor in loco no 30719. Earlier choke failed on 08/9/19 & same replaced on
13.11.19. On date 28/12/19, again same inductor failed and loco is running in non hog link.

3. LSHO lamp is not glowing in WAP7 locos implemented with RDSO modification No.
RDSO/2018/EL/MS/0468 (Rev-0) dt. 06.02.18. This issue pertains due to VCU not receiving
“Feedback signal” from Hotel Load converter.

4. No service engineer is being deputed to attend line failures of HOG converters in Mumbai/ADI
division.
 Detention of locos in shed on BHEL account

1. Loco no 30598 is in shed since 28/12/19 due to following fault messages

a. RBU 2 RIOM extension fault with “MCB tripping message of OCB,MRB,TMB1, Converter pump1,
Transformer pump 1” arising.
b. RBU 4 RIOM extension fault With “Emergency brake vigilance” & emergency brake gets applied.

2. Loco no. 30173 is in shed since 10/01/19 due to 3 no.s power module burst and awaiting for material.

3. Loco no 30719 is not utilized in hog link trains as awaiting for inductor since 28/12/19.

High all time pending warranty of M/s BHEL:

GTO based items

IGBT/Propulsion based items
1 Gate Unit 03
DDU
2 GUSP 01 1 01
(Gersys)
3 PPA988B01 03
Power
4 PPB622B01 04 2 09
module
5 UAB630A93 01
Inverter
6 UFB660A01 02 3 02
Module
7 PPB908A01 02
Power
8 URB512D15 06 4 02
Supply
Valve Set 5 RBU 03
9 01
(ZV-ZV)
6 RDD 04
10 Cooling Fan 07
TOTAL 21
Total 30