Yard Diagram of a Two Road Station

Assets
1.Tracks 2.Signals 3.Points 4.Buttons 5.Axle Counters 6.Crank Handles etc

Track
Tracks may Fail or Bob due to 1. Conductors lying across 2. Improper Ballast 3. Heavy Rain 4. Mischief 5. Relay Problem

Signal
Problems related to Signals

1. Fusing Of signal Lamp

2. Blanking of Signal 3. Signal Raised Up 4. Signal lamp to be replaced for preventive maintenance 5.Conflicting Aspects 6.Signal Passing at danger

Point Machine

1. Friction in movement 2. Loose Packing of Point 3. Point Fail 4. Point not setting due to obstruction 5. Point Button Not Properly Pressed-Premature release 6. Point M/c drawing High Current 7. Relay Bobbing

Point Loose Packing

Obstacle In Point

Button

1. Button Stuck Up 2. Premature Release 3. Unnecessary Pressing of Button 4. Improper Sequence

Circuit

1 Progression Sequence Interrupted

2 Contact offering High Resistance 3 Fuse Blown Off

Analog Voltages & Currents-AC

Analog Voltages & Currents-DC

So what we require may be a Recording System

To Record all the information relating to the yard i.e Data Logger

What Is a Data Logger

A Microprocessor based system to log the changes in the status of Relay contacts & Analog Channels pertaining to a Railway panel interlocking or Route Relay Interlocking (RRI) station.

Computer Connectivity
Single Data-logger can be connected to Computer for storing & processing of the Relay and Voltage information

Computer Connectivity
A Computer can also take data, through an FEP, connected to a network of Data-Loggers.

Computer Memory
In a computer all this data is stored in the Hard Disk. Present Day Hard Disks, of size 40GB can hold nearly 3 years of information of networks, having an average of 30 Data-loggers.

Hard Disk

Computer

 Front End Processor(FEP)

The data of the network is collected by the FEP (Front End Processor), which in turn is transmitted to the computer
FEP acts as a buffer between the Computer and the Network

Information Generation
A data packet is generated whenever a change occurs in a Relay status or a Voltage channel. This packet is stored in the storage space available in the Data logger (Nearly 85,000 packets in 4MB RAM ).
Data Packet DLNo Serial
Type Time Input ID Status

INFORMATION PACKET STRUCTURE

RHNO/DLNO

1BYTE

00

SERL NO
CRC TIME REC ID

2BYTES
1BYTE 4BYTES 1BYTE

01,02
03 04,05,06,07 08

INPUT NO / CHANNEL VALUE STAS/CHANNEL NO.

2 BYTES
1BYTE

09,10
11

DLNo.-Packet Structure

DLNo Serial

Type

Time

Input

Status

Time-Packet Structure
The time is a number which gives an accuracy of 16 milli-seconds.
Relay
On/Off

Tim e

DLNo Serial

Type

Time

Input

Status

Input ID-Packet Structure

Now we need to Know the Relay and its status What about this?
The Input ID i.e the Number of the contact where it is connected to the Data logger, and the change(Status ) are also sent along.
DLNo Serial
Type Time Input ID Status

Input ID-Packet Structure

1. Relay1
On/Off

Time1 Time2 Time3 Time4

2. Relay2 3. Relay 3 4. Analog2

On/Off

On/Off

On/Off

DLNo Serial

Type

Time

Input

Status

Serial Number-Packet Structure

1. 2. 3. 4. Relay1 Relay2 Relay 3 Analog2
On/Off

Time1 Time2 Time3 Time4

On/Off

On/Off

On/Off

DLNo Serial

Type

Time

Input

Status

Record ID -Packet Structure

Record ID : A number indicating the type of information i.e Analog or Digital.
Analog / Digital

DLNo Serial

Record ID

Time

Input

Status

CRC-Packet Structure
The information when passed in a network may be corrupted due to noise etc.How can you identify this ?? CRC : Cyclic redundancy Check- is the best validation algorithm to identify the error, if any in the data packets.This Byte relates to this checking mechanism.

Facilities for viewing information in the Data-logger and printing.

The all Inputs status can be viewed in the Datalogger LCD screen as follows One row at a time Status of all Inputs Signal Name Contact Status

Signal

0001

Occupied

A Printer can be connected to a data-logger to have a hard copy of events recorded

Printout of Status of Relays at Data-Logger Date-Time Relay Status

Relay Information at the Computer

What is the Use of Relay On-Off information

Let us Take an example of a Point M/c working Normal Sequence Failure situation

Nwkr & Rwkr both down for 25 seconds

Point Normal operation

Point Failure condition

18 RCR 18 NCR 18 NWKPR2 18 NCR 18 RCR 18 NWKPR2 18 RCR 18 NCR 18 NWKPR2 18 NCR 18 RCR 18 NWKPR2 18 RCR 18 NCR 18 NCR 18 RCR 18 RCR 18 NCR Down Up Up Down Up Down Down Up Up Down Up Down Down Up Down Up Down Up 03/05/2003 12:43:46:375 03/05/2003 12:43:46:516 03/05/2003 12:43:49:672 03/05/2003 12:43:56:125 03/05/2003 12:43:56:266 03/05/2003 12:43:56:359 03/05/2003 12:44:15:312 03/05/2003 12:44:15:469 03/05/2003 12:44:18:625 03/05/2003 12:44:20:734 03/05/2003 12:44:20:844 03/05/2003 12:44:20:938 03/05/2003 12:45:28:562 03/05/2003 12:45:28:719 03/05/2003 12:45:29:953 03/05/2003 12:45:30:078 03/05/2003 12:47:06:016 03/05/2003 12:47:06:469

made to normal

attempt to make reverse

made to normal Attempt to make reverse

* tried to make normal * 5 attempt to make reverse *** (no fault declar

Loose packing
Failure Condition Normal operation

NWKR status change when TPR Down

Signal blanking
Failure condition Normal operation

All the ECRs Down for 10 seconds

What is the Use of Relay On- Off Information

The correct operation & abnormal operation of all the relays can be understood by analyzing the sequence of relay operations.

No Of Basic Relay Operations

As Train Moves in a station yard an average of 50 Relays operate generating nearly 100 data packets . For a station where some 100 trains pass thru daily the no. rises to 10,000. For a network having some 30 DLs the No. of data Packets on a whole become 3,00,000.

Filtering Relays

Filtered Relay Report

113 Point Relays Operation

Filtering Analog Channels

Selected Analog Channel Report

Analog Channel Graphs

Variations in Supply

Logics In Analysis
How Can You Identify the abnormal sequence of Relay Operation ? An abnormal sequence of relay operation which should be highlighted by the system, as the relays operate is termed as a Fault Logic. A Fault Entry Software gives us the facility to define the sequence of operations. With this Information, NMDL Software , while taking data packets from the all the stations highlights any abnormal sequence of activity .

Block Diagram of the Process Involved - 1

Computer Hard Disk --------------------------------------------------Fault Entry Software

1. 2. 3.

Online Relay Status Online Analog Status Online Simulation

Logic

Fault Files

NMDL Software

Fault Conclusions

Data Packets From Data Loggers

Fault Entry Screen

What are the items you need for analyzing the sequence of an operation???
The operational details of all the Relays connected in a circuit are required, whereas only a few relays are connected to the Datalogger.Due to this and many other factors,the conclusions made from this available information have their own limitations.

Examples of common Logics

TPR Fail
Logic Used IF TPR1, TPR2, TPR3 are in sequence then If TPR1 UP - TPR2 DOWN- TPR3 UP Triggering Relay : TPR2

TPR Bobbing
Logic Used
IF TPR DOWN TO UP OR UP TO DOWN Within the time interval.

Track failure
A36ATpr,A37BTPR,A39ATpr are in sequence Failure Condition Normal operation

Track Dn condition occurring in maintenance of tracks resulted in Track fail Logic wrongly

Cause of common Logic Limitations

Logic Limitation 1. Due to Track maintenance 2. Due to momentary Bobbing of TPR2 3. The POR(Power ON Relay) if not considered in the Logic, Fault may be popped up wrongly

Examples of common Logics

Point Machine
Fail
NWKR is down and RWKR is down for more than given time interval.

Loose packing
When TPR1 is down, then the corresponding NWKR, RWKR should not change their status. Triggering signals are NWKR, RWKR.

Point fail
Failure condition Normal operation

Loose packing
Failure Condition Normal operation

Examples of common Logics

Signals

Blanking RECR down and HECR down

and DECR down for more than given time interval

Bulb fusing After HR / DR goes up and if

corresponding ECR is not up with in the given time interval. Triggering signal is HR.

Flown back to danger -If TPR is

DOWN then RR should be UP,ASPR should be
DOWN, DR should be UP and DECR should be UP.

Signal blanking
Failure condition

Normal operation

Cause of common Logic Limitations

Logic Limitation Due to maintenance or due to momentary Bobbing of a Relay or due to non inclusion of LVR in a Logic, Fault may be declared wrongly

Route set failure

After button1 is up and button2 is up and signal is not up within the time interval sequence is checked. Triggering signals are Button1, Button2.

Route Cancellation failure.

After button1 is up and button2 is up and route is not cancelled within the time interval sequence is checked. Triggering signals are Button1, Button2.

Circuit Failure

Quick Identification of failures

HR Circuit failure. Button1, Button2 are up and after time interval if HR is DOWN

Relays which attained improper status

Cause of common Logic Limitations Logic Limitations Maintenance Momentary Bobbing of Relays Non-Availability of all the Relays Due to the above limitations some times Fault may be show up wrongly.

Importance of Analyzing Relay status changes

After seeing the above cases of Limitations in various Logics ,What do You feel is the better way of concluding about the failures? The Faults triggered and shown to you in various reports ,the corresponding relay information should be carefully studied before concluding the results.

Simulation

Train Passing through

Textual Display of changed Relay status

Some Frequent problems occurring in Data-Loggers are: 1. Chattering inputs 2. Validity of contact 3. Data entry Validation

Relay Report indicating Chattering Problem

Chattering On for 4 seconds

Chattering Relays Report

Validity Of Entered information

The Relay Name & Contact Type is to be carefully noted for all the inputs and entered in the database at the computer end, as negative logic is used for Back contacts.

Validity Of Entered information

The Fault Logics used should be tried and tested regularly and well tuned for better conclusions.

Validity Of Entered information

For Analog channels the Minimum, Maximum voltages and Multiplication Factor are to be carefully selected.

PREDICTIVE MAINTENANCE OF SYSTEM

Life Time & Bulb operations

Predicting Failures

Points working HARD

WLR does not change its status from UP to Down within the given time interval.

Frequently Bobbing Relays

Preventive Maintenance
The complete statistics of a Signal i.e. Down Time & Count, Up Time & Count, Current Status, and Date & Time of change in the status etc give the information about Relays operating too frequently and help in Preventive Maintenance.

Relay Operations

Frequency of Relay Operations

Signal UP Count

Signal Down Count

ANALOG VOLTAGE FLUCTUATIONS

Battery Discharge condition

Fluctuations in AC causing Fluctuations in DC due to the problem in charger

Fluctuations in a weak Battery

What Have you Learnt in this Module???

What is a Data-logger? How is it storing the changes in the Relay status ? How a better analysis of sequence of relay operations and analog voltages, be done ? How a better predictive and preventive maintenance is possible? What are the common problems in relay contacts and voltage channels?