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lR;eso t;rs

GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

Report on Reliability
of
Transformer of Three Phase Electric Locomotive

Report No.: RDSO/2016/EL/IR/173. Rev ‘0’

Issue Date: September’ 2016

Approved by
EDSE(CO-ORD) Signature

Issued by
Electrical Directorate
Research, Designs and Standards Organisation
Manak Nagar, Lucknow-226011

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Status of Revision

S. No. Date of Revision Page No. Revision Reason of Revision

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Table of contents

S. No. Description Page No.

1. Introduction 4
2. Rating of Three phase Loco transformer 5
3. Different Parts of Three phase Loco transformer 6
4. Background 7
5. General steps to improve reliability of transformer: 7
6. Condition monitoring of traction transformers by 11
Dissolved Gas Analysis (DGA)
7. Specific Steps to improve reliability of Transformer 13
8. Failure mode & Modifications to be carried out by 13
Manufacturers.
9. Oil leakage from the transformer bushings and covers 20
in 3-phase locomotives
10. Conclusion and Recommendations 24
11. Annexure-I 26

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1.0 Introduction:
Initially, 33 Nos. of 3-phase drive (11-WAP5, 22-WAG9) locomotives were imported
from M/s ABB/Switzerland (now M/s. Bombardier Transportation) with transfer of
technology. These locomotives had Secheron make main 7500 / 6500 KVA
transformers. When these locomotives were taken up for indigenous production at
CLW, main transformer was got developed through M/s. BHEL, M/s CGL, M/s
BT/India, M/s NGEF & M/s EMCO based on Transfer of Technology (TOT). Later
on, few more sources obtained TOT from CLW. So far, CLW have manufactured
about 89 WAP-5, 700 WAG-9/WAG9H and 279 WAP-7 (passenger version of WAG9)
locomotives; majority of which have been provided with indigenously manufactured
traction transformers supplied by TOT partners.

A three phase Electric locomotive Traction Transformer consists of one Primary

winding, four Traction windings, one Auxiliary winding (BUR) and two Hotel Load
windings (Originally the transformer of WAP5 loco was provided with only one hotel
load winding). In addition, it has a filter winding which is connected on locomotive
to passive filter. The transformer tank also contains 02 series resonant chokes (one
for each traction converter) & 03 Auxiliary Converter double chokes (one for each of
the 03 auxiliary converters). The Transformer is oil cooled and external cooling of
the oil is designed with two independent oil circuits with cooling units located
within the machine room of locomotives.

Unlike the transformer provided in conventional electric locomotives the

transformer provided in three phase locomotives is equipped with special features
as follows:

• Transformer is mounted under slung on under frame

• Transformer is designed for feeding GTO/IGBT based Power and Auxiliary

converter load.

• It has very high impedance between primary & traction windings to satisfy
operational requirements

• 100% de-couplings between windings

• Use of continuous transposed conductor (CTC) for windings

• Use of disc construction of windings

• Transformer and conservator tank made of Aluminum Alloy.

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2.0 Rating of three phase Locomotive Transformers:

Table1: Rating of Transformer

SN Parameters Values
1 Type LOT-6500/LOT-7500*/LOT-7775**
2 Original Design Secheron SA
3 Windings: Nos.
Traction 4
Auxiliary 1
Filter 1
Hotel Load* 1*/2**
4 Frequency (f nom) 50 Hz
5 Primary Voltage:
Maximum 30.0 kV
Nominal 25.0 kV
Minimum 17.5 kV
6 Voltage Ratings (at 25.0 kV Catenary):
Traction 1269V
Auxiliary 1000V
Filter 1154V
Hotel Load* 750V*/960**V
7 Current Ratings:
HT 261A/299A/311 A
Traction 4 x 1142A
Auxiliary 334A
Filter 347A
Hotel Load* 1X1260A*/2X648A**
8 Thermal Ratings:
Primary 6531 kVA/7500 kVA/7775 kVA
Traction 4 x 1449 kVA
Filter 400 kVA
Hotel Load* 945 kVA*/2X622.5kVA**
9 Winding Data:
Traction 37.0 mΩ, 2.1 mH ± 15%
Auxiliary 60.0 mΩ, 0.43 mH
Filter 19.0 mΩ, 0.29 mH
Hotel Load* 11.0mΩ, 0.37 mH*

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3.0 Different parts of Transformer:

The LOT 6500/7500/7775 transformer has following main parts:

1. Transformer tank:

Transformer tank :
Material : Aluminium
Colour : RAL-7009
Weight : 966 kg

Figure1: Transformer Tank

2. Transformer main winding:

Power (kVA)= 6531/7500/7775

Voltage: 25000 V
Current: 261.25/299/311 Amp
Winding Resistance 489.5 to 585.9 mOhm

Figure 2: Transformer main winding

3. SOD Winding (Series Resonant Choke):

Inductance per choke : 2 x 0.551 mH (±15%)

Linear to I peak = 1391A
ii) Thermal current ITh : 2 x 984A
iii) Resonant frequency : 100 Hz
iv) Voltage stress between
a. terminals max. : 482 VAC
b. to earth max. : 3471 V
v) Separate voltage withstand capability : 10 KV

Figure 3: SOD Winding

4. GOD Winding (Auxiliary Converter Choke):
Current (Amp) Inductance (mH)
0 30
120 30
155 26
190 20
Frequency 100 Hz
Ripple 38% (Nom) 50.2 max
Voltage to earth 1153V (Rated) 2000V
(Max)
Separate voltage 10 kV
withstand capability Figure 4: GOD Winding

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4.0 Background:

Zonal Railways had been reporting increased number of failures/problems in the

indigenously manufactured transformers for 3-phase electric locomotives. Based on
the failure analysis and study of different types of failures, various corrective
actions have been suggested by RDSO to manufacturers and Zonal Railways vide
different letters and MOMs. The general measures required to improve reliability
and other modifications suggested by RDSO from time to time has been compiled in
this report. These measures are divided in two parts i.e. general measures and
special measures. The general measures include condition monitoring of
transformers by various methods such as Dissolved Gas Analysis (DGA) and
benchmarking of abnormal DGA values. The special measure includes the steps to
be taken based on the specific failures reported. Such types of failures includes
core heating, circulating current in earthing shunt or overheating of clamping
structure leading to abnormal DGA. Also, cases of oil leakages had been reported in
transformers and special steps had been suggested by RDSO based on the
discussion with manufacturers.

5.0 General steps to improve reliability of transformer:

In order to ensure reliable performance of a transformer, there are several steps

required from transportation to storage of transformer. These small steps as
detailed below should be taken by Electric Loco sheds/manufacturers to enhance
the reliability of a transformer.

5.1 Transportation of transformer:

The transformer is to be transported duly filled with oil. The conservator is

transported along with the transformer without oil and oil is supplied in separate
drums. The breather should be removed during the installation of the transformer
in the locomotive, and put back as soon as possible. The breather must be filled
with new or dried silica gel.

5.2 Lifting of the Transformer:

The transformer must never be lifted without its lid. Lifting points are welded to the
side of the tank for this purpose. The rope should be attached on these lifting
points as described in figure shown below. The ropes should never make a smaller

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angle than  = 60° with the horizontal, otherwise there is a danger that the tank
will distort.

(a) Correct Method (b) Incorrect Method

Figure 5: Lifting of a Transformer

5.3 Supporting the Transformer on a Point:

If for any reason, the transformer needs to be supported on a point, then it should
only be supported on the indicated areas shown by the arrows in the figure given
below.

Support points of transformer

Figure 6: Supporting of Transformer

5.4 Storage of Transformer:
The transformer can be stored as long as required. However, following points
should be given proper attention while storing a transformer.

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5.4.1 Storing place:

The oil-filled transformer should be stored in covered area. The storing place must
be dry and the transformer must be covered with a loose taped plastic sheet.

Figure 7: Stored TFP

5.4.2 Connecting flanges
All pipes, pumps and blocking valves should be closed off using blanking flanges.

Figure 8: Connecting Flange

5.4.3 Expansion tank
Fix the expansion tanks in vertical position on a higher level than the transformer‟s
lid. Join then with flexible pipes with transformer in the same way as they are
installed in the locomotive. The oil level in the expansion tank should correspond
between the minimum and maximum temperature mark.

Figure 9: Expansion Tank

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5.4.4 Labels:
If stickers need to be added then they should be stuck on separate plates. The
plates should then be tied to the transformer using strings (no wire).

TFP No. 2042130

Make: BHEL
Date of O/H:20/8/16

Figure 10: Labeling

5.4.5 Checks:
After transport and installation at the storing place the transformer should be
checked for any signs of oil leakage.

5.5 Maintenance during Storage:

5.5.1Checks
According to the atmospheric conditions, the oil level and the silica gel in the
breather should be checked every 6 months.

5.5.2 Oil level

If the oil level is lower than the equivalent temperature mark, oil can be added by
the filling cap on the expansion tank with the oil of the same quality. Mixing with
oils which have significantly different parameters should be avoided. If the oil level
is not visible at the expansion tank, the reason for the low oil level must be found.
Oil should not be added by the filling cap of the expansion tank as long as reason
has not been found.

5.5.3 Breather
If more than half of the silica gel is saturated (moisturized), then it must be
completely replaced. The old silica gel may be regenerated. The transformer must
not stay longer than 3 hours without functional breather.

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6.0 Condition monitoring of traction transformers by Dissolved Gas

Analysis (DGA):

In order to detect incipient faults in the transformer and to arrest deterioration

/ damage to the transformer insulation, gases dissolved in the transformer oil
are detected, analysed and preventive measures adopted. Gas Chromatography
Method is used for detection of the dissolved gases and identification of
incipient faults. The most significant gases generated by decomposition of oil
and deterioration of paper insulation on the conductor are hydrogen, methane,
ethane, ethylene and acetylene. The quantities of these gases dissolved in
transformer oil vary depending upon the type and severity of the fault
conditions. The complete details of method of measurement are given in RDSO
SMI No. RDSO/ELRS/SMI/138. However basic details are given below for ready
reference.

Basic diagnosis of DGA is based upon the quantity of gases generated. Types of
gases in excess norms produced by oil decomposition/cellulosic material
depends upon the hot spot temperature produced by faults. Characteristics
gases associated with various faults are as under:-

Table: 2
S. No. Dissolved gases. Associated faults.

i. Methane (CH4) Low temperature hot spot.

ii. Ethane (C2H6) High temperature hot spot.

iii. Ethylene (C2H4) Strong over-heating.
iv. Acetylene (C2H2) Arcing
v. Hydrogen (H2) Partial discharge
vi. Carbon dioxide(CO2) & Carbon Thermal decomposition of
monoxide (CO) paper insulation

The contents of various dissolved gases in the transformer oil vary with design
and operating conditions. It is desirable that the values of concentration of
gases of healthy transformers of different age groups are to be gathered by the
Railways concerned to evolve suitable norms. However, as a starting point, the
permissible concentrations of dissolved gases in the oil of a healthy transformer
are given below as guidelines:

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6.1Permissible concentrations of dissolved gases in the oil of a healthy

transformer:

Table: 3
Gas Less than 4 years 4-10 years in More than 10 years
in service (ppm) service (ppm) in service (ppm)

Hydrogen (H2) 100/150 200/300 200/300

Methane (CH4) 50/70 100/150 200/300
Acetylene(C2H2) 20/30 30/50 100/150
Ethylene (C2H4) 100/150 150/200 200/400
Ethane (C2H6) 30/50 100/150 800/1000
Carbon dioxide 3000/3500 4000/5000 9000/12000
(CO2)

6.2 Purification of Transformer Oil:

The object of oil purification is to remove all contaminants such as water,

carbon deposits, dirt, sludge, dissolved moisture and gases. The most important
quality to be preserved is the di-electric strength, which is affected by the
presence of moisture. The insulating materials used in the winding are
hygroscopic by nature and therefore moisture is absorbed through defective
breathers, gaskets and addition of untreated make up oil. It is essential to
remove these impurities by purifying the oil when the dielectric strength goes
below the permissible limits (50 kv for in service oil and 60 kV for new oil ).

The purification plant should be capable of removing dissolved air/ moisture in

the form of free and finely dispersed water vapour and moisture in solution,
sludge and fibers, gases, carbonaceous products formed due to arcing and
drum scale or any other solid particles from insulating oil. The switching ON &
OFF of the heater groups should be thermostatically controlled so that the
temperature of the oil during treatment is not be permitted to rise above 60°C.
Operating vacuum should be better than 1 torr.

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7.0 Specific Steps to improve reliability of Transformer:

7.1 Failure of transformers on account of abnormal DGA- Design issues:

In spite of predictive maintenance actions taken by electric Loco sheds, the

problems in 3-Ph locomotive transformers on account of abnormal DGA which
was reported high due to one or more reasons of has been observed. The failed
transformers were opened at the works of M/s BHEL and M/s ABB in presence
of RDSO representatives and found overheating/flashing marks observed on
the guide pin of the clamping fixture of centre tie rod. 01 No. LOT 7500 KVA
transformer of M/s CGL was also reported with abnormal DGA. The
transformer was opened at CGL‟s Works at Mandideep in presence of RDSO
representative where overheating marks observed on the centre tie rod.

Based on the failure analysis and discussion with M/s ABB and M/s BHEL, it
was concluded that DGA was found high due to reasons of core heating,
circulating current in earthing shunt or overheating of clamping structure. In
order to eliminate these failures, following modifications had been identified for
implementation. Further based on the positive results of these modifications, it
was decided to implement these modifications in all the transformers
supplied/repaired by the manufacturers. The details of modifications are given
below:

7.2 Failure mode and modifications to be carried out by manufacturers:

7.2.1 Due to less cooling of outer (last) core packet, heating marks had been
observed as shown in figure-11 leading to abnormal DGA cases.

Figure 11: Heating mark observed on the core due to less cooling.

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In order to improve cooling, it was decided to remove the side wedges of outer
(last) core packet in all the transformers to be manufactured/repaired.
Following Figure-12 shows the details of modification to be carried out. After
implementing this modification, such type of cases has not been reported.

Wedges provided

Figure 12: Removal of side wedge of outer (last) core packet

7.2.2 In addition to above, it was decided to introduce (2 x 15 mm) slot in the

existing 5 x 30 mm rectangular outer core wedge as per details given in
Figure-13 for improving the core cooling. Earlier, RDSO had permitted M/s
BHEL to use existing rectangular wedge 5 x 30 mm with slot dimension as 2
x 10 mm.

Figure 13: Introduction of slot (2 x 15 mm) in the existing 5

x 30 mm rectangular outer core wedge

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7.2.3 In order to block the circulating current between reactive active part and
tank it was decided to use of insulating washer as per details given in Figure
14 in the fixation of reactor and tank to improve isolation between reactor
active part & tank.

Figure 14: Use of insulating washer

7.2.4 The circulation of induced current in the centre tie rod had resulted into
heating of the centre tie rod as well as centering pin of the transformer
leading to abnormal DGA cases. The failure mode is shown in following
figure-15.
Sign of overheating

Figure15: Circulating path of induced currents in centre tie rod and

overheated centre tie rod.

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In order to eliminate such cases following modification has been suggested.

(a) Use of 2 mm fibre glass insulating tube on the centering pin and 2 mm
insulation sheet of pre-compressed board/Nomex board between the
centering pin and tank bottom as per details given in figure 16. For this,
existing diameter of centering pin is to be reduced from 45 mm to 41 mm.
Detail procedure is explained as follows:

Step 1 Reduce the diameter of the insert pin to 41mm by machining the
existing pin:

Figure 16

Step2: Insulating tube to be introduced at bottom pin

Figure 17

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Step3: Nomex paper introduced to insulate the bottom part of the pin in addition
to fibre glass tube to insulate the pin.

Figure 18

Figure19 Complete figure showing the modification

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7.3 Clamping studs fitted in the bottom side of transformer (GOD/SOD Reactor
side) has two earthing leads going from the clamps - one to bottom side tie-
rod and the other to top side tie-rod. It was noticed that overheating of the
stud (M16 x 160) due to circulating current passing through the stud.
Hence, it was decided to change the location of both the earthings to one
(single) clamp only. This had ensured proper earthing and avoid chances of
current flowing through the stud.

Figure 20: Single clamp earthing

All the earthing connection shall have provision of crimping along with
brazing for jointing of cable lugs with earthing cables.

Figure 21: Crimping along with brazing for jointing of cable lugs with
earthing cables.

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7.4 Additional issues: It has also been found that abnormal DGA is caused
due to looseness of earthing connected to the centre tie rod of the clamping
arrangement. Hence care should be taken to properly tighten the earthing
connection.

Figure 22

Figure 23
7.5 It has also been noticed that if proper earthing externally to the tank (see
below) is not ensured then circulating current inside the transformer will
find a path and shall lead to failure hence proper earthing external to the
transformer also needs to be ensured. Also, it may be noted that where ever
any paint is applied at the point of earthing, same should be removed by
proper cleaning before making earth connection because it acts as insulation
while flowing earth current.

Figure 24

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7.6 Oil leakage from the transformer bushings and covers in 3-phase
locomotives

While the traction transformers imported from OEM had given satisfactory
service, the indigenous transformers supplied by ToT partners had given
problem of oil leakage from the transformer bushings and cover. Problem
was studied and it was noted to be due to non-standard type of gaskets / „O‟
rings used by manufacturers in assembly. To prevent the problem, a
Technical Circular No. ELRS/TC/0076, Rev’0’ was issued by RDSO
specifying the manufactures and type of gaskets to be provided on bushings,
, top cover and bushing plates of transformers.

However, the problem of oil leakage had been again reported by Railways.
The matter was investigated by RDSO and the majority cases of oil leakage
reported were due to

1. Use of non specified gaskets/‟O‟ rings by the manufactures. Quality of

gasket / „O‟ ring is important and therefore specification and vendors of
these was examined; and
2. Also, oil leakage cases were on account of bushing gaskets at location* „B‟
& „C‟ (SKEL-4663) which was of NEBAR and supplied by M/s James
Walker, UK. NEBAR gaskets were made of a blend of rubber and cork
material. Equivalent material of NEBAR developed by M/s Nu-Cork and
supplied by M/s CGL had also reported failed by some of the Railways.
Based on above following remedial action suggested:

7.6.1 Oil Leakage from bushing Gasket:

On the subject issue, RDSO had interacted with M/s ABB, India and M/s
ABB/Secheron, the OEM of these transformers who had conducted a quality
audit of their unit at Vadodara. Based on their global experience, ABB
Secheron had recommended the use of NBR (Nitrile) gaskets at location* B &
C (SKEL-4663, Alt.1 placed at page 22 of this report) in place of NEBAR
gaskets. RDSO had further discussed the matter with all the transformer
manufacturers including M/s ABB and it had been considered to use NBR
(Nitrile) gasket for bushing gaskets at location „B‟ and HNBR gasket for
bushing gaskets at location „C‟ with high temperature withstand capacity in
place of existing NEBAR gaskets. Accordingly, the requisite changes have

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been incorporated in Technical Circular No. ELRS/TC/0076, Rev‟0‟ and Rev

„1‟ had been issued. The salient technical details of Technical Circular are as
follows:

The bushings used for different applications in the transformers for 3-phase
locomotives are given in Table-4 as follows:-

Table 4
TYPE OF BUSHING APPLICATION TERMINALS
DT 3/2000 Traction Bushings 2u1-2v1, 2u2-2v2, 2u3-2v3, 2u4-
2v4,
SOD Bushings X11-X12, X21-X22

DT 1/250 GOD Bushings XB11-XB12, XB13-XB14,XB21-

XB22, XB23-XB24, XB31-XB32,
XB33-XB34.
DT 3/630 Filter/BUR/Earth 2UF-2VF, 2UB-2VB, 1V
Bushings
DT 1/2000 Hotel Load Bushings 2UH -2VH

In order to prevent oil leakage from the bushing gaskets, it is necessary to

use gaskets at different locations in the bushings as per details given in the
Table-5 below:-

Table 5
Bushing Location
Type A B C D E
DT NITRILE NITRILE HNBR NBC NBC
1/250 Ø 22/12x11 Ø 29/14x3 Ø 50/28x4 Ø 50/28x2 Ø 45/25x2
DT NITRILE NITRILE HNBR NBC NBC
1/2000 Ø 59/42x18 Ø 76/44x3 Ø 104/70x4 Ø 104/70x3 Ø 90/63x3
DT NITRILE NITRILE HNBR NBC NBC
3/630 Ø 32/20x13 Ø 41/22x3 Ø 70/45x4 Ø 70/45x2 Ø 63/40x2
DT NITRILE NITRILE HNBR NBC NBC
3/2000 Ø 59/42x18 Ø 76/44x3 Ø 104/70x4 Ø 104/70x3 Ø 90/63x3

The Locations A, B, C, D & E of the gaskets are indicated in the RDSO

drawing SKEL No.4663, Alt.1 (Figure 25 on page 22) which is given below for
ready reference. The details of the above gasket material, the governing
Specifications and Source of supply has been given in Technical Circular No.
ELRS/TC/0076, Rev‟1‟ . It may be noted that HNBR is a hydrogenated nitrile
compound of standard quality for use in the transformer gaskets. This
exhibits good chemical and mechanical properties at high temperature.

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RDSO Drawing No. SKEL 4663, Alt-1

Figure 25: Location of various gaskets

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7.6.2 Oil Leakage from Cover Gaskets:

In order to prevent oil leakage from transformer cover gaskets as well as from the
two bushing plate gaskets, it is necessary to use joint less gaskets as per details
given in Table-6 Below. The sources of supply are indicated in Technical Circular
No. ELRS/TC/0076, Rev‟1‟.
Table: 6
Location Qty. Material Single With overlap Dia. Ref. IS /
piece joint  ‘S’ BS
Tank 01 Nitrile 8035 ± 8035 ± 10 + 16mm BS : 2751-
Cover (nitrile 10 mm „C’ (44) mm = 2001
rubber 8079 ± 10
vulcanized mm
butadiene)
Bushing 02 Nitrile 3930 ± 3930 ± 10 + 07mm BS : 2751-
Covers (nitrile 10 mm „C’ (20) mm = 2001
rubber 3950 ± 10
vulcanized mm
butadiene)

7.6.3 Crushing of oil Compartment gaskets

The crushing of oil compartment gaskets leads to less cooling of core and winding
as given in figure 25 below:

Figure 27: Crushing of oil compartment gasket.

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In order to avoid crushing of oil compartment gasket, the material of gasket has
been specified and shall be used as per details given in Table-7 below. The sources
of supply are also indicated in Technical Circular No. ELRS/TC/0076, Rev‟1‟.
Table 7: Oil Compartment gaskets
SN Description of Drg. No. Ref. IS/BS/ Unit Qty
gasket Material Per set
1. 450 x 1744 x 6 HSTN104275P0001 FPM (Viton) No. 4
2. 80 x 421 x 6 HSTN424015P0001 Ref. IS:3400 No. 4

3. 100 x 290 x 6 HSTN423988P0001 No. 4

4. 80 x 409 x 6 HSTN423987P0001 No. 4

5. 80 x 414 x 6 HSTN423986P0001 No. 4

6. 10 mm Dia. HSTN003296P0010 mm 8150
Round cord

8.0 Conclusion and Recommendations:

(i) The transformer of a three phase electric Locomotive is a very vital

component. The failures of a transformer cause detention of locomotive for
considerable time and all the care should be taken to avoid failures. Though,
all the topics related with reliability of three phase transformer such as its
schedule maintenance part and other maintenance aspect has not been
covered in this report due to focus of the report being on the specific steps
taken by RDSO. In this connection, a “Maintenance Handbook on
Transformer of 3 Phase Electric Locomotives has already been issued by
CAMTECH, Gwalior” covering the relevant details. Some of the important
points have been included in this report from this maintenance handbook.
Zonal Railways are requested to go through this maintenance handbook.

(ii) All the failed transformers, whether under warranty or not, should be
inspected jointly by manufacturer and the concerned Railways and joint
note made in each case. This will help in analyzing the type wise failures
leading to identification of remedial measures.

(iii) The instructions elaborated in clause 7.0 have already been issued by RDSO
to manufacturers, however, Zonal Railways should closely monitor the
progress of implementation and the performance of the modified

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transformers. Zonal Railways should ensure that these steps are being taken
by manufacturers during repair of transformers as well. This may be verified
during consignee inspection.

(iv) These modification needs to be implemented during POH of transformers of

three phase locomotives. Workshops are required to plan accordingly.

(v) Proper records regarding cut in serial no. of a transformer with certain
improvement measures, affect of change in manufacturing process etc.
should be maintained to ensure traceability.

(vi) Performance of NBR/HNBR/Viton based gaskets of M/s Nu-Cork & M/s

BOSCO to be monitored closely and any abnormality observed in the same
should be reported to RDSO so that further corrective action can be taken.

(vii) Performance of NBC gaskets of different suppliers shall also be monitored

and any abnormality observed in the same should be reported to RDSO for
taking further corrective action.

(viii) It may be noted that special facilities are required to be developed for
storage of the nitrile gaskets by manufacturers in consultation with M/s
Nu-cork/M/s Bosco, the supplier of gaskets/‟O‟ rings of 3-ph transformers.
It shall also be ensured by manufacturers that the gaskets/‟0‟ rings
procured should be used well within the expiry date of these gaskets so that
their properties do not change with the passage of time.

(ix) In order to improve quality, it is recommended that CLW should verify the
availability of M&P and Testing facilities as stipulated in Schedule of
Technical Requirement (STR). At the same time Quality Assurance Plan may
also be verified ensuring that the actions suggested in this report have been
included in the QAP.

(x) It should be ensured that the manufacturing area of 3-phase locomotive

transformer is segregated from other activities and it should be dust free
and under air conditioned/temperature controlled environment to prevent
any foreign ingress of material.

(xi) All the materials/sub-component used in manufacturing of the

transformer should be as approved in Bill of Material (BOM) or as
specified/stipulated by competent authority from time to time.

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Annexure-I
1. Special Maintenance Instructions:
S. No. SMI No. Title Date of
issue
1. ELRS/SMI/0228 Assembly of electrical terminations of 06.08.02
traction winding bushings 2u1_2v1,
2u2_2v2, 2u2_2v3, 2u4_2v4 in
indigenously
manufactured transformers type
lot_6500/lot_7500 used in 3phase drive
locomotives type WAG9/WAP5
2. SMI/249 Rev ‟0‟ Test procedure, Lower limit and process 28.11.07
of adding inhibitor in transformer oil of
inservice traction transformer

2. Modification Sheets:
S. No. MS No. Title Date of
issue
1. RDSO/2014/EL/MS/043 Removal of shorting link provided at c- 12.03.14
2/Rev‟0‟ d terminal of over current relay of 3-
ph locomotives.

3. Technical Circulars:

S. No. TC No. Title Date of

issue
1. ELRS/TC-0076-2002 Oil leakage from the transformer 17.9.02,
Rev.‟0‟, bushings and covers in 3 phase
locomotive
2. ELRS/TC-0076 Rev‟1‟ Oil leakage from the transformer 22.02.13
bushings and covers in 3 phase
locomotive

REFERENCES:

1. “Maintenance Handbook on Transformer of 3 Phase Electric Locomotives

issued by CAMTECH, Gwalior”

2. Quality Audit of manufacturing of 6500/7500 LOT transformers for

3- phase electric locomotives produced by M/s BHEL, Jhansi on 18.05.2012.

3. MOM conducted at various forums with manufacturers by RDSO on 26-3-

14, 22-4-14, 11-6-14, 5-9-14, 3-2-15 & 3-5-16 and Presentations given by
manufacturers.

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