_a,aId
File No.RDSO-MPOLKO(EM)/1 1/2019-O/o JD/EM/MP/RDSO
811(d d++1{ _ hr Hdldq Government of India - Ministry of
Railways
3TqTRITH3Tt&q@T3ikl Research Designs & Standards
Organisation B3fg Tii©
HaaS - 226 011 LUCKNOW - 226 011 icT 3Elqg TrunsR irl
EPBX +91 (522) 2451200 DID +91 (522) 2450115
FAX +91 (522) 2458500 DID +91 (522) 2450110
No. SD. Aux. EMD.FP Motor Date: As Signed
8 q+6itftvnnMhF/gtqv
1. xu bIt, gmt+ fgmit q€Ntv afBni, Tq+ 400 o01
2. IfH, +TTft qT, +hrq;TaT- 700 OOI
3. aT+T+, TT-TRT€MR, dfHI-
110 o01
4. VITT tHI, TtIW- 273 OOI
5. TInT%f+:R\M, qRfhTTT, IqT§Tft- 781 011
8
6. qfIPTbT+, gMt, TT#ZT3m, ++- 600 O03
7. qfDpT TET tnt, tv f+TPIT, fRFaTTVTR- 500 071
e 8. qfBpT if bt, =TT+TftV, #bTqTtfT- 700 043
9. qfeFT tnt, #ItT, W{- 400020
IO. an TEXt;It, TTFRIT - 211 033
11. TV qf#m Hi, WIJT- 302 o06
12. If VET ba, ITdtV- 844 IOI
8 13. T+ Tan, tnt viET+Hr, VtTt- 751 023
14. qfepr qf8H tnt, Sdlt- 580 023
15. qfMT TERM, qVljT- 482 OOI
16. qfhT it TERM, fbnTIT- 495 o04
SUB: Modification on Fuel Pump of HHP Loco.
Ref: Railway Board Letter No. 2022/M(L)/466/23 dated 04.01.2023
RDSO had issued the Mod sheet no. MP.MOD.EM.02.08.15 dt. 27.11.2015 for providIng
standby inverter in 25 locos preferably on locos for passenger service each by diesel loco
sheds GY, SGUJ, BGKT, and KJM for trials purpose. Further, RDSO vjde letter no.
SD. Aux.EMD.FP Motor dated 11-02-2019 issued advisory to undertake additional modification
in which an air gap is to be created by providing shim for improved cooling of inverter in
existing FPM inverter fitted with Fuel Pump Motor.
As per above referred MOM on HHP locomotives held at NR on 08.12.22 , RDSO was requested
to advise technical instructions to ZRs on the failures of Fuel Pump Motor.
RDSO collected feedback against trials mod sheet and advisory on the FPM inverter failure.
in
Based on data collected, RDSO reviewed the modification and the Mod sheet has been revised
8
for provision of standby inverter and shim (in existing inverter fitted with 0.75 HP FPM) for
implementation in HHP Diesel Locomotives.
Revised Mod sheet no. MP.MOD.EM.02.08.15 (Rev-01) is enclosed herewith for kind
information and implementation. JP
B
:HI&
i's--&d++
File No.RDSO-MPOLKO(EM)/11/2019-O/o JD/EM/MP/RDSO
8
Railways are requested to furnish the status of implementation and performance
feedback as per format given below on monthly basis for evaluation.
Status of implementation of Mod Sheet no. MP.MOD. EM.02.08.15 (Rev-01 ) 8
S SHE 1 LOC 1 DATE OF 1 DATE I MAKE I DATEOF I DATE WHETH E REMAR
N D 10 OF
MODIFICAT I 1OF FAILURE OF R KS
NO ION OF I FITMEN t STAND OF MAIN FAILUR SWITCH WITH
SHIM AS ITOF I BY INVERTER E OF OVER TO FAILUR
PER MOD F STAND INVERT IN FPM STAND STANDBY E
SHEET 1BY ER AFrER BY INVERTE DETAIL
INVERT SHIM INVERT R S, IF
ER AS MODIFICAT ER PREVENT ANY
8
PER ION AS PER ED LINE
MOD MOD SHEET FAILURE
SHE Fr
e
8
• in case, modification is yet to be carried out, “NIL” may be indicated.
• in case, no failure after modification, “NO FAILURE” may be indicated.
8
The status in the given format may be sent at email id
adeecmp®rdso.railnet.gov.in, ancha.0191 @gov.in.
qr
DA: Mod Sheet No. MP.MOD. EM.02.08.15 (Rev-01). Digitally Signed by Vikas
Verma
Date: 24-05-2023 16:03:48
8
R®qldpqqW
f+Ign/{oqqo/vrqT gnr
Copy to :
1. CWMs, Jamalpur, Parel, Ajmer, Charbagh, New Bongaigaon, Golden rock : For kind 8
information and necessary action.
2. CDE/Dsl, BLW, Varanasi : For kind information
3 DME/Traction, Railway Board, New Delhi : For kInd information.
8
File No.RDSO-MPOLKO(EM)/1 1/2019-O/o JD/EM/MP/RDSO
Document No MP.MOD.EM.02.08.15 Revision No: 01 Date Issued: 18.05.2023
Modification Sheet Title: Provision of standby inverter and shim (in existing inverter fitted with FPM) on
fuel pumps motors of HHP locomotives
HT{a TTHTT/Government of India,
tH +7THT/Ministry of Railways
aq+IITa 3TfitWT vd HTHH +TaR/Research Designs & Standard Organization
8 HTaIF RIN, aaH/Manak Nagar, Lucknow – 226011.
Document No.MP.MOD.EM.02.08.15 (Rev-01) 18-05-2023
Document Title
Provision of standby inverter and shim (in existing inverter fitted
e with FPM) on fuel pump motors of HHP Locomotives
8 Amendment History:
r ldment Date Revisi Reasons for Amendment
on No
1. 27.11.2015 00 Provision of standby inverter for fuel
pump motor of HHP Locomotives.
8
2. 18.05.2023 01 Provisions of standby inverter and
e shim (in existing inverter fitted with
FPM) for fuel pump motors of HHP
Locomotives .
Technical Specification of Standby
8
Inverter and Tests elaborated.
Page 1 of 11
8
File No.RDSO-MPOLKO(EM)/1 1/2019-O/o JD/EM/MP/RDSO
Document No MP.MOD.EM.02.08.15 Revision No: 01 Date Issued: 18.05.2023
standby inverter and shim (in existing inverter fitted with FPM) on
fuel pumps motors of HHP locomotives
1) Title:
Mod sheet for Provision of standby inverter and shim (in existing inverter fitted with 8
FPM) for fuel pump motors on HHP locomotives.
2) Background:
A. Railways have been reporting high rate of failures of AC Fuel Pump motors of
HHP locomotives. Majority of the failures are attributed to the inverter failures.
B. During the CMPE’s conference held at NDLS on 11th & 12th August’2015, GY shed
shared 3 months trial report on modification carried out in 14 locos by providing a
standby inverter. Accordingly, Mod sheet no. MP.MOD.EM.02.08.15 dt. 27.11.2015
was issued on standby inverter for implementing modification in 25 locos preferably on
locos for passenger service each by diesel loco sheds GY, SGU J, BGKT, and KJM.
Further, sheds have also undertaken additional modification in which an air gap has
been created by providing shim for improved cooling of inverter. The advisory for
provision of shims was also circulated by RDSO vide letter no. SD.Aux.EMD.FP Motor
dated 11-02-2019
RDSO collected feedback against mod sheet and advisory issued on the FPM inverter
failure. As per data collected, it is observed that this modification has reduced the
online failure of locomotives and the reliability of the locos have improved with standby
inverter
8
Accordingly, RDSO reviewed the modification and the Mod sheet has been revised for
provision of standby inverter and shim (in existing inverter fitted with FPM) for
implementation in HHP Diesel Locomotives.
e
3) Object;
Provision of standby inverter and shims (in existing inverter fitted with FPM) for fuel
S
pumps motors (0.75 HP) on HHP locomotives.
4) Application to class of locomotives:
BG Diesel electric HHP locomotives equipped with AC Fuel Pump motors (0.75 HP).
5) Brief modification content:
8
a) Provision of additional inverter to be provided at equipment rack (lube oil cooler
mounting channel).Ref. Fig-1
Page 2 of 11
8
File No.RDSC)-MPOLKO(EM)/1 1/2019-O/o JD/EM/MP/RDSO
Document No MP.MOD.EM.02.08.15 Revision No: 01 Date Issued: 18.05.2023
Modification Sheet Title: Provision of standby inverter and shim (in existing inverter fitted with FPM) on
fuel pumps motors of HHP locomotives
b) Provision of selector switch (Rotary switch 30A, 6NC-6NO interlocks) fitted to a wooden
box shall be located near water tank to select existing inverter and standby inverter.
B
Refer fig-1 & fig-4.
c) Provision for maintaining gap between motor and inverter by providing 5mm thick
aluminum shims (2no’s) with heat sink compound to enhance the cooling efficiency of
existing inverter fitted with Fuel Pump Motor (Which is beyond warranty) as shown in
fig .2
Rotary SwiIch StandbyJnverter
8
lb
e
8
Fig. 1 Location of fitment of inverter and selector switch
Shims
e
8
Fig.2. Motor with shims
Page 3 of 11
8
File No.RDSO-MPOLKO(EM)/1 1/2019-O/o JD/EM/MP/RDSO
ocument No MP.MOD.EM.02.08.15 Revision No: 01 Date Issued: 18.05.2023
Modification Sheet Title: Provision of standby inverter and shim (in existing inverter fitted with FPM) on
fuel pumps motors of HHP locomotives 8
Fig.3. Motor without shims 8
OUqCFOR£R
SW :lOt
8
Page 4 of 11
8
8
Document No
File No.RDSO-MPOLKO(EM)/1 1/2019-O/o JD/EM/MP/RDSO
MP.MOD.EM.02.08.15 Revision No: 01 Date Issued: 18.05.2023
ILI
standby inverter and shim (in existing inverter fitted with FPM) on
fuel pumps motors of HHP locomotives
Fig.4. Connection diagram for fitment of inverter and Rotary Switch
6) Materials required:
A. Following materials required for standby inverter for fuel pump motor which is located near
8 lube oil filter drum (On equipment rack):
S. No. Description Qty/ loco
1 Terminal lug to EMD pt.no:8210498 14 nos.
e 2
3
Flexible pipe 1 ” dia
14 AWG wire
1 % mtrs.
16 mtrs.
8
4 Butt connector 2 way pt.no: 8200891 02 nos.
5 M12 x 1.75 -30mm bolt with nut 02 nos.
6 Wooden box of size 150x150x150mm –10mm thick 01 no
7 Rotary switch 30A 01 no
8
8 Ultra-fast fully insulated terminal lug EMD pt.no: 4-521098-2 03 nos.
9 Ultra-fast fully insulated terminal lug EMD pt.no: 4-520448-2 03 nos.
10 M5 x 0.8 x 25mm bolts with nuts 04 nos.
11 Metal plate (140mmx110mmx3mm) 01 no
12 Inverter 01 no
B. The material required for standby inverter for fuel pump motor which is
located underneath the frame:
Description CIty/loco
Terminal lug to EMD pt. no: 8210498 14 nos
Flexible pipe 1 ” dia 41/; mtrs
14AWG wire 35 mtrs
Page 5 of 11
8
File No.RDSO-MPOLKO(EM)/1 1/2019-O/o JD/EM/MP/RDSO
Document No MP.MOD.EM.02.08.15 Revision No: 01 Date Issued: 18.05.2023
Modification Sheet Title: Provision of standby inverter and shim (in existing inverter fitted with FPM) on
fuel pumps motors of HHP locomotives
8
4 Butt connector 2 way pt.no: 8200891 02 nos.
5 M12 x 1.75 -3C)mm bolt with nut 02 nos.
6 Wooden box of size 150x150x150mm – 10mm thick 01 no
7 Rotary switch 30A 01 no
8 Ultra-fast fully insulated terminal lug EMD pt.no: 4-521098-2 03 nos. 8
9 Ultra-fast fully insulated terminal lug EMD pt.no: 4-520448-2 03 nos.
10 M5 x 0.8 x 25mm bolts with nuts 04 nos.
11 1 Metal plate (140mmx110mmx3mm) 01 no
12 1 Inverter 01 no
The above mentioned auxiliaries are for guidance purpose and may vary at the time of
actual fitment as per convenience at the diesel shed.
7) Technical Specification of inverter:
Power Capacity: Continuous-800W Peak-1500W
Nominal Voltage 74 VDC
Input Current 7.5-8A @74 VDC with 4Kg/crn2 pressure 8
Output Frequency 3 Phase, 50-60 Hz
Output wave form Quasi-Sine wave
THD <5%
Input Voltage Range 50 V to 90 V DC with 15% ripple. Effect of inverter switching on
input DC should not cause ripple current more than 5% at full
load. 70% torque should be delivered at 17v DC input voltage.
During cranking of loco voltage may dip to 17 V for a short
duration. Inverter should not trip during this duration
,e
Short time rating Minimum 10 sec duration at 1 .5 times the rated current
Input over voltage 100 V DC input
rotection
Output over load 1.5 times the rated current
rotection
o
r 8
o
r
o
Note: The Supplier shall furnish Datasheet and Undertaking that the Inverter is complying the
vibration and shock tests as per IEC 61373 or its equivalent and the inverter is also
complying other environmental test conditions required for Rolling Stock application.
Page 6 of 11
8
File No.RDSO-MPOLKO(EM)/11/2019-O/o JD/EM/MP/RDSO
Document No MP.MOD.EM.02.08.15 Revision No: 01 Date Issued: 18.05.2023
Modification Sheet Title: Provision of standby inverter and shim (in existing inverter fitted with FPM) on
fuel pumps motors of HHP locomotives
8) Acceptance Tests may be carried out by the firm on the sample size as defined
by the Zonal Railway as per Annexure-1 as tabulated below:
Tests Remarks
Preliminary Checking Pass/Fail
Temperature Rise Test (Measurement by thermometer) Pass/Fail
Over Voltage Protection Test Pass/Fail
e Pass/Fail
Dielectric Test Pass/Fail
IR Test after Dielectric Test Pass/Fail
Reverse Polarity Test Pass/Fail
Short Circuit Test Pass/Fail
V/f Control Test Pass/Fail
Performance Test Pass/Fail
9) Sources of supply:
Based on the supply of fuel pump inverter in Diesel Loco (HHP & ALco)1 following firms
may be considered as likely source of supply.
8 i) Greentech Labs
#140, Kalmane, 2nd Cross, 1 st Phase,
Reliable Residency
Harlur, HSR Layout, Banglore-560102
ii) Progress Rail innovations Pvt. Ltd
D-149 to 153 & 178 to 182,
Hosiery Complex Noida Phase-II Extn Noida,
Uttar Pradesh - 201305
B
e iii) Signotron (India) Pvt. Ltd.
Plot Jl-6, Block-EP.
Sector-V Salt Lake Electronic Complex
Kolkata, West Bengal – 700091
iv) Elixir Engineering
No 6 SFHS Shopping Area
8 Nandini Layout Bangalore,
Karnataka – 560096
V) Medha Servo Drives Pvt. Ltd
Jodimetla Cross Road,
Korremula Village, Ghatkesar Mandal
Hyderabad,Telangana – 500088
8
Page 7 of 11
8
File No.RDSO-MPOLKO(EM)/1 1/2019-O/o JD/EM/MP/RDSO
8
'&v
Document No MP.MOD.EM.02.08.15 Revision No: 01 Date Issued: 18.05.2023
Modification Sheet Title: Provision of standby inverter and shim (in existing inverter fitted with FPM) on
fuel pumps motors of HHP locomotives
vi) M/s Auto Industries India
Plot no. 209, Sector Udyog Kendra Ext-II,
Ecotech-III, Gautam Budh Nagar,
Greater Noida UP. 8
However, Railways may at their own discretion, procure these items for subject
modification from any suitable firm complying the technical specification of the inverter as
given at Para-7 above.
10) Additional information:
8
The selector switch should be set at existing Inverter fitted with Fuel Pump Motor in default
mode .
11 ) Agency and schedule of implementation: •
Diesel Sheds and Diesel Workshop.
12) Distribution:
As per enclosed list.
13) References :
A) BLW letter No. 2016/SPC/13/13.1 dated 28.05.2022 regarding minutes of CMPE’s,
8
CWM’s, BLW, RDSO and Railway board officers held at BLW/BSB on 06.05.2022 to
07.05.2022. (Point no 6.7 of Discussion of Agenda items).
B) Minutes of meeting of CMPE’s, RDSO, BLW, PLW and Workshop’s held on 08.12.2022
at Railway Board New Delhi. (Point no 3.2 & 6.2 of Discussion of Agenda items).
C) This office letters no SD.Aux.EMD.FP Motor dated 11.02.2019 & 13.12.2022.
e
8
Page 8 of 11
8
File No.RDSO-MPOLKO tEM)/1 1/2019-0/o JD/EM/MP/RDSO
Document No MP.MOD.EM.02.08.15 Revision No: 01 Date Issued: 18.05.2023
rmTitle: naGa–if–War an=MiliJM invertMMTilii Don
fuel pumps motors of HHP locomotives P
NNE
1. Preliminary Checking:
8
a. Inverter shall be checked properly for the loose connections of the leads, heat
sink and other visible defects.
b. All fasteners shall be checked for tightness.
C. Physical dimensions of the inverters shall be checked in accordance with the
approved drawings.
d. Equipment no. plate to be verified.
e. Power ON check is to ensure that the system is working normal when the rated input
B
voltage is connected to the system
2. Temperature Rise Test (Measurement by thermometer):
e Heat Run Test:
The inverter shall be allowed to run at 74 V DC input and at full load till the temperature
is stabilized. Following parameters shall be recorded after every 15 minutes during the
8 run
Ambient temperature before start-––----
Time Ambienttemp, Temp. Riseof Body
B Manufacturer shall provide the device junction temperature calculations due to temperature
rise and the value of device junction temperature obtained by calculation shall be 25 deg C
less than the designed value of device junction temperature of device manufacturer.
e 3. Over Voltage Protection Test:
The inverter shall trip at 100 V DC input voltage. The unit shall work satisfactorily after
completion of this test.
8
4. Insulation Resistance (IR) Test before Dielectric Test:
Insulation resistance value of the inverter shall be measured at 500 V DC and recorded. It
should not be less than 10 mega ohms.
5. Dielectric Test:
8 This test shall be carried out on inverter separately. The test voltage shall be alternating sine
wave, frequency being 50 Hz to 60 Hz. For inverter a test voltage of RMS value of 1.2 KV
shall be applied for a period of one minute between shorted connections and frame.
Page 9 of 11
8
File No.RDSO-MPOLKO(EM)/1 1/2019-O/o JD/EM/MP/RDSO
Document No MP.MOD.EM.02.08.15 Revision No: 01 Date Issued: 18.05.2023
Modification Sheet Title: Provision of standby inverter and shim (in existing inverter fitted with FPM) on
fuel pumps motors of HHP locomotives
The inverter shall be connected at a voltage of less than one third of test voltage and shall
be increased gradually to the full test voltage. The test shall be considered satisfactory if
neither a disruptive discharge nor a flash over occurs.
6. IR Test after Dielectric Test:
8
Insulation resistance of the inverter shall be measured after the dielectric test and there shall
be no appreciable difference between the two values, one before the test and one after the
test
7. Reverse Polarity Test:
The inverter shall be connected to 74 volts DC input supply in reverse polarity for a period of
8
2 minutes. At the end of the test, the inverter shall work satisfactorily when the connections
at the input are restored to correct polarity. e
8. Short Circuit Test:
The fault current shall be detected and cleared by the protective circuit of inverter. Inverter
shall work satisfactorily after this test.
8
9. V/f Control Test:
The inverter shall be mechanically loaded with Fuel Pump Motor according to its rating.
The voltage shall be varied from 20V to 65v (17 V to 65 V for AC Fuel Pump Motor) in steps
of 10 Volts. The following parameters shall be recorded:-
a. Output AC volts of inverter (Vac).
b RPM 8
C. Output frequency of inverter in Hz.
d Torque in Kgm (Desirable)
e. Current in Amp. e
The ratio Vac/f shall be calculated. The values so obtained shall be within +20% of nominal
value. The torque measured shall not be less than 70 % of full load torque.
10. Performance Test: 8
The inverter shall be loaded with Fuel Pump Motor according to its rating. The performance
characteristics shall be observed at 65 V, 72V and 90 V DC input to inverter. The following
parameters shall be recorded:-
b) Input DC voltage to inverter (Vdc).
c) Input DC current to inverter (Idc).
8
d) Output AC volts of inverter (Vac).
e) Output AC current of inverter (lac).
Page 10 of 11
8
File No.RDSO-MPOLKO(EM)/1 1/2019-0/o JD/EM/MP/RDSO
Document No MP.MOD.EM.02.08.15 Revision No: 01 Date Issued: 18.05.2023
Modification Sheet Title: Provision of standby inverter and shim (in existing inverter fitted with FPM) 9
fuel pumps motors of HHP locomotives
F
8 f) Input frequency in Hz.
g) Power factor
h) Inverter efficiency = V3Vac X lac X Power factor
Vdc X Idc
The output AC volts of inverter, input frequency, power factor recorded at 65 V, 72V and 90
V DC input to inverter shall be within the design limits. Inverter efficiency calculated at 65 V,
72V and 90 V DC input to inverter shall not be less than the design values. Wave form of
8 Inverter output should also be captured.
e
8
Page 11 of 11
8
