HANDBOOK ON STUDY OF DATA LOGGER REPORT...• LED’s to indicate the status of 512 digital input....

HANDBOOK ON STUDY OF

DATA LOGGER REPORT

CAMTECH/S/PROJ/2015-16/HB-DL/1.0 August 2015

MAHARAJPUR, GWALIOR – 474 005

Hkkjr ljdkj &GOVERNMENT OF INDIA

jsy ea=ky;& MINISTRY OF RAILWAYS

¼dk;kZy;hu iz;ksx gsrq½& (For official use only)

CONTENTS

Sr. Description Page No.

1 Introduction 1

1.1 Failure related to operation 1

1.2 Failure related to Engg. Department 1

1.3 Failure related to Electrical Department 1

1.4 Failure related to Signalling Department 2

1.5 Abnormal incidences 2

2 Data logger 2-3

2.1 Advantage of Data logger 3-4

2.2 Technical Specification 5

2.3 Other Specification 6

3 Operating condition 6

4 Inputs of data logger 6

5 Main features of data logger 6-7

6 Key provision in software 7-8

6.1 NMDL Software and data logger network 8-9

6.2 Classification of NMDL and Fault Entry 10-12

6.3 NMDL 13

6.3.1 Features 13

6.32 Network monitoring features 14

6.3.3 Signalling monitoring features 15-16

6.4 Online Signalling Monitoring Architecture 17

6.4.1 On line Fault 18

6.4.2 Track Simulation and train charting 18-21

6.5 Reports, Relay operation Graph, Fault report 21-30

6.5.1 Extra features of report 31

6.5.2 Off line simulation with features 32-33

6.53 Features of Data analysis 33

7 Backup facility 34

8 Power Supply Monitoring System 34

8.1 Features 34

8.2 Required primary setting 34

8.3 On line failure trouble shooting process 35

9 Central office application and multi monitor simulation 36

10 Installation practices 37

10.1 Addition features 37

11 Maintenance 38

11.1 Daily check data logger by on duty ESM 38

11.1.1 Check LED position both side modem 38

11.1.2 Testing and maintenance of power supply 38

11.2 Data logger monitoring by JE/SSE/Signal/Telecom 39

12 Trouble shooting 40

13 Do’s and don’ts 41

Page 1 of 41

CAMTECH/S/PROJ/HB-DL/15-16

DATA LOGGER

1. INTRODUCTION

On Indian Railways, for the safe movement of trains, signals have been provided

on all stations. Traffic department controls the operations of these signals. The

failure in operating a signal is made available to traffic department. This

information is then conveyed to Signal Department.

Mainly for signal failure, following are reasons :

1.1 Failure relating to operation

i. Wrong operation

ii. Choosing wrong sequence of operations

iii. Wrong reporting failure

iv. Delay in operating the signal gears

1.2 Failure relating to Engineering Department

i. Failure due to creeping

ii. Failure due to distracted insulation of track circuit by rail fittings,

Ballast resistance and water logging etc.

iii. Failure due to stock /switch rail fittings, packing, out of square related

failures.

1.3 Failure relating to Electrical Department

i. Low/ high voltage

ii. Short circuit due to traction return current strip

iii. No electrical supply

Page 2 of 41


1.4 Failure relating to Signalling Department

i. Blown off circuit fuse

ii. Fused signal bulb

iii. Due to change in parameters of track circuit/ Axle counter .

iv. Failure of power supply equipment due to which power is not

available to the signal circuit.

v. Intermittent failure in relay contacts or high resistance .

vi. Poor maintenance

1.5 Abnormal incidences

i. Bursting of point

ii. Derailment of train

iii. Train accident

iv. Passing of signal in RED i.e. danger aspect

If failure gets automatically set right:

A. Measuring all parameters

B. Operating the gears

C. Observing the gears

D. Doing detail investigation

2. DATA LOGGER

The process of using a computer to collect data through sensor , analyze the data and

save the data is called data logging and the instrument used in this called data loggers.

Data logger is microprocessor-based system, which logs the information about the

relays, which are connected to the data logger . Data logger monitors and records all

activities and event in the signalling system of a railway station.

Data logger acts like a “black box”, which can scan, store and process the data for

generating various user-friendly reports. It is also knows as “event logger.”

With the help of data logger and the feedback given by the staff, actual position of

system can be verified. Adjusted parameters can be viewed.

It is a microprocessor based equipment and logs the events occurring in the signalling

function of a yard through the energized contact of the relays.

Page 3 of 41


The logged information is conveyed in the form of “information packets” to the

computer. The packets are sent in till the next data logger gives the acknowledgement

of receipt of packet. The data can be sent either in single direction, BI-direction or in all

direction. A data logger has a capacity to store 1.7 lakhs events. When a large amount

of data is received, the old data will be erased on first–in–first-out basis.

Data logger can work as a single data logger for a particular RRI/PI.

The individual data loggers of various stations can be interconnected through

networking technology. Due to networking feature, the data of remote terminal units

or remote panel stations can be viewed. For away places where round the clock staff is

available like S&T control/ rest room.

2.1 Advantage of data logger

I. Real cause of failure can be identified. Staff can not hide the cause.

II. Failure of intermittent nature can be identified in first attempt only. So staff time

can be saved as they observing such failure for its repetition for a long period.

For major detention of failure many times staffs are advised to observe faults

during round the clock..

III. Enquiry is easy in case of unusual/ dispute case.

IV. Failure restoration time can be reduced with the help available i.e. analog and

digital inputs.

Also suitable program can be prepare to check failure in the relay logic

of RRI/PI circuit on the basis of line sequence operation of relays for each

route setting /cancellation. The programmed information is displayed at any

point in the sequence failure, giving complete information of the circuit relay,

its circuit diagram sheet number and concerned fuse particulars. Other failure

like panel failure due to button relay stuck up/auto relay stuck up and power

sensing relay failure help can be prepared.

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V. Signalling system will be more reliable as many failures can be saved on checking

the analog inputs and taking the corrective measure on time.

VI. Timer setting is proper or not can be monitored. This monitoring can be done for

4 types of settings-

a) Timer setting for more than 120 sec.

b) Timer setting for less than 90 sec.

c) Timer setting for less than 120 sec.

d) Timer setting for more than 90 sec.

VII. Bobbing of signal/ track/ point/ crank handle - which cannot be seen by necked

eyes, is identified.

VIII. Preventive/ needless maintenance can be done. Following problems can be

identified

• Point operation-sluggish, if point is taking more than 8-10 sec./ Loose packing

by detecting the break of wkr1 relays.

• Point setting in more than one attempt than problem can be either due to

slackness in the track or signalling fittings or insufficient

voltage for the point motor to operate.

• Analog voltages-parameter sensing to detect the variation of values beyond

lower and upper limits of standard settings.

• Unusual reports which are very useful to analyze-late start of train, late

lowering of signal, more time taken by the driver in section, wrong operation,

more speed of train, bursting of points, signal passed at “on” etc.

Page 5 of 41


2.2 Technical specifications of data logger

The data logger has

• 32 bit motorola 68000 microprocessor.

• Seven segment display for displaying the current time in hh:mm:ss format.

2x24 liquid crystal display (LCD) screen for displaying the status of Dgital

/analog signals, time & temperature etc.

• 3x4 numeric keyboard to carryout various functions by viewing necessary

parameters on LCD screen.

• LED’s to indicate the status of 512 digital input.

• A temperature sensor to measure the temperature inside the data logger

for every 115 minutes. If temperature execs 400

c, it generates an alarm. • Two sets of three 4- male fdc connectors are provided for power supply at the

backside of the data logger.

• Using eight 37 –pin male d-connectors,256 digital inputs are connected

internally through internal stack cards.

Each 37-pin d-connectors can cater up to 32 digital input.

• There are totally 9 communication ports available for connecting different

equipment to the data logger.

• To a computer for running nmrh software for single cataloger through a

9- pin male d-connector.

• The communication port 2 & 3 are used to connect networking the data logger

switch each other through a 25-pin female d-connector.

• The communication port 6,7, 8 & 9 are used for 20ma current loop

communication through 9-pinmale d-connectors.

• A printer can be connected to data logger through a 25-pin female

d - connector to have a hard copy of all the events occurred.

• Two sets of controls are provided for connecting tele controls to the data

loggers with the help of 25-pin female d –connectors.

• The data loggers are interlined with the help of modems through two 9-pin

male d- connectors.

• Data logger can measure the temperature outside using a connector.

• Real time clock with internal battery backup & internal oscillator, data retention

up to 10 years.

• Internal buzzer for alarming during failures.

• External two relay contacts for remote buzzer.

• 1 mega bytes of flash ram’s.

Page 6 of 41


2.3 Other specifications

Power supply-( 12 /24 volts dc supply )

For continuous operation of data logger a charger with battery is provided.

Battery should 12v /40 ah and maintenance free. 3. Operating conditions:

Temperature : 0-500c Power : 230v ac +10% 47-67 Hz

Consumption : 2 watts max

4. INPUTS TO DATA LOGGER

A data logger records two types of inputs

4.1 Digital

4.2 Analog

5. Main features of data logger

• Scanning of digital inputs

• Scanning of digital inputs after every 20 milli. seconds.

I. Each input is optically isolated.

II. Each scanner card can support 256 inputs.

• Every input requires a current of 10 ma.

• FIFO logic implemented for data being stored in the memory.

III. Validity of each record should have its own identity

IV. On switching on power, the processor conducts diagnosis of the

entire processor viz.-I/O chips and other peripherals.

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V. After successful diagnosis, time is displayed on the seven segment in the

following format- hh:mm:ss ( hours, minutes and seconds)

Vi. After scanning, the data is processed and various reports can generated

by data logger or data can be updated to the computer.

VII. Now with the help of key board various functions as listed below can be

carried out, by viewing the necessary parameters/ details in the LCD

panel .

• setting of time

• page display

• status of digital signal

• status of analog

• fault q

• printer / buzzer

• temperature display

• change of password

6. Key provisions in software

Objectives:

To Receive & Process the raw data logged by the Data Logger & display the information

in user understandable format for Centralized Monitoring and Controlling of Data

Logger Network

To provide user friendly tools, for appropriate decission making by analyzing the

logged data .

Page 8 of 41


Railway Data Acquisition System Softwares

6.1 NMDL software

To get on line information sent by individual data loggers placed at different stations of the network and to effectively manage the communication between the networked data loggers.

Purpose:

1. To receive data from Data Logger network.

2. To process the Data Logger wise data in sequence for

Real Time Mimic of Station Layout

Real Time Signalling System failure alarms

To avail Remote monitor & control of assets like

Data Loggers

Relay Huts

Modems

To Log Data Logger wise data in Data Base.

3. To analyze the Unusual occurances, for appropriate decission making.

1. NMDL

2. Simulation

3. Reports

4. Multi Monitor Simulation

5. Fault Entry

6. Signalling Monitoring

7. Network Monitoring

8. COA

9. TIMS

10. Train Charting

11. PMS

Page 9 of 41


Data Logger Network

Page 10 of 41


6.2 Classification of NMDL Modules

NMDL Modules have been classified as :

1. Configuring Modules

Fault Entry

Fault Entry for Signaling Monitoring

Track Editor

2. Processing Modules

NMDL

3. Analysing Modules

Reports

Off Line Simulation

4. Utility Modules

Auto Back Up (Oracle)

Extract DB

VoltTimeP

NMDL Test Protocol

Page 11 of 41


Configuring Modules - Fault Entry

Page 12 of 41


Configuring Modules - Fault Entry for Signal Monitoring

Page 13 of 41


6.3 Processing Modules - NMDL

6.3.1 Features:

1. Product Health Indication like

a. SSI Health

b. Digital Stack Card Status

c. Nand Flash Health

d. Safety Point Health

2. Network Monitoring System for easy Maintenance of Data logger

Network

3. Signaling Monitoring Application

4. On-line Asset-Failure Alarms

5. On-line Yard Simulation

6. Supports Oracle, Inter base data bases.

7. This data can be useful in other applications like

a. Train Charting

b. Train Information Management System

8. Auto Time Synchronization

Page 14 of 41


6.3.2 Network Monitoring Features

A. Status display of Sub Systems and Failure Details.

1. Modem Link Status

2. Healthiness of data flow in each direction

3. Data Logger / Relay Hut status

4. FEP Status

5. CMU and Server status

6. LAN Status

B. Restoration of Network Failures from Central Location.

1. Modem Reset

2. Data Logger / RTU Time Setting

3. Getting old data from data logger to central location

4. Blocking of redundant data after restoration of data path after failure

Page 15 of 41


6.3.3 Signaling Monitoring Features

I. Status display of Sub Systems and Failure Details.

1. Relay Room Door Status

2. SM Key Status

3. Power Supply Status

4. Data Logger, Relay Hut, LC Gate, IB status

5. Modem Link Status

6. Block Section Status

7. Healthiness of data flow in each direction

8. Equipment Failure Details

9. Unacknowledged confirmed Fault Count

10. Magnifier option

11. FEP Status

12. CMU and Server status

Page 16 of 41


Signalling Monitoring Faults:

Page 17 of 41


6.4 Online Signaling Monitoring

Architecture:

Database

CMU Online signaling

clinet - 1

Online signaling

clinet - N

SWITCH

Page 18 of 41


6.4.1 On-line faults

To expect the forthcoming problems due to the faults in signal operating

mechanism as well as to replace the damaged equipment. To identifying faults in

the station based on pre-fixed logic given by railways like :

I. Blanking of signals

II. Fusing of signals lamps

III. TPR bobbing

VI. Inter-slotting problems

V. Under wheel flashing of points

VI. Point, track circuit, route failure ,emergency cancellation of route

VII. Timer not properly set for 120 seconds.

VIII. Push button stuck

IX. Point failure- sluggish operation, loose packing .

6.4.2 Track simulation

To get the scenario of complete yard layout with the help of a simulated yard

environment reflecting on line and offline status of various signals such as signal

glowing, TPR occupation, track movement etc. This facility helps to know at

remote end .

I. Analyzing the real cause of failure/

derailment in yard and status of

associate gears/bursting of points.

II. Need not to ask the field staff.

III. Train speed can be calculated.

IV. Real time of point and signals operation.

V. Wrong operation/ intermittent failure.

VI. Signal passing at danger.

Page 19 of 41


NMDL

Online Yard Simulation

Page 20 of 41


Processing Modules – NMDL

Train Charting

Page 21 of 41



Extra Features:

Auto SMS of Asset Failure.

Auto Mailing Facility of Asset-Failure Reports

Display of real time line occupancy and signal status of yards in a section

for Controller.

NMDL can act like an FEP and sends received data to a remote system through

E1 modems.

Instant SMS.

6.5 Reports

To get the offline reports of the status of various relays operating in the panel

stations with real time . To analyze the reports of routes, relays, log of entries,

faults and analog graphs, life of various equipments etc.

Analysing Modules - Reports

Features:

1. Reports

a. Log of events Report

i. Digital

ii. Analog

Page 22 of 41


b. Relay Report

c. Relay Status Report

d. Digital Stack Cards Status

e. Analog Card Status

f. Chattering

g. Sequence Miss

h. Communication Report

i. Packet Information

j. Data logger States

k. Relay Room Report

l. Faults

i. Detailed Report

ii. Summary Report

iii. Summary Report with Time details

iv. Occurance - Restoration details

v. Category wise Report

vi. Safety Point Operation Report

2. Graphs

a. Relay Operations

b. Power Supply variations

c. Communication

d. Duplication

Page 23 of 41


Analysing Modules – Reports

Page 24 of 41



Page 25 of 41



Relay operation graph :

Page 26 of 41



Relay operation graph :

Page 27 of 41



Fault – Report

Page 28 of 41



Fault – Report

Page 29 of 41



Fault – Report Summary

Page 30 of 41



Fault – Report Summary With time

Page 31 of 41



6.5.1 Extra Features:

1. Drill down mechanism

a. Detailed Fault Report for selected Fault, from Summary Report .

b. Log off events report for Relays / Channels involved in selected Fault

occurance .

c. Simulation of Station Mimic for selected Fault occurance timings, from

Detailed Report .

2. Seperate indications for high lighting Chattering, Digital Stack card fail in Log

Off events report .

Page 32 of 41


Analysing Modules - Off Line Simulation

Page 33 of 41


Analysing Modules - Off Line Simulation

6.5.2 Features:

Route indication for Panel / Route Relay Interlocking mechanisms.

Optional display of Route indication for Shunt signal.

Off Line Faults displaying.

Off Line Faults processing.

Flashing of Signal, Point relays when they are not in required state.

Simulation for multiple Data Loggers / Relay Huts in single Map.

Overview of total map

Displaying of Train Speed

Relay Search option

Recording of Simulation

Analysing Modules - Off Line Simulation:

6.5.3 Features for Data Analysis:

• Continue and Stop options when simulating a station for selected time interval.

• Previous and Next options to control the process manully.

• First option to restart the simulation.

• Latest Relay Status Window to show the textual representation of a set of

latest relay operations.

• Zoom In and Zoom Out options .

• Simulation with Actual Time option to process each record with time gap that

originally exist between two relay operations.

• Simulation with Fixed Time option to process each record with fixed time

interval.

• Speed Bar to manage the simulation speed (For Fixed Time option).

Page 34 of 41


7. Backup facility

This software which is in built in NMDL( network) management of data loggers) takes the backup of data that is logged by data loggers automatically soon after the size of database exceeds its limit( as specified by user) and stores it in permanent storage devices like CD or ZIP drives.

Utility Modules - Auto Back Up (Oracle)

1. Daily backup

a. To move data from Main user to Back up user

2. Periodical backup

a. To save Back up user data as files

8. Power Supply Monitoring System

8.1 Features:

1. Monitors, Stores the status of power supply to a central place.

2. Gives bird's eye-view of all stations power & power equipment status at easy

monitoring-reduces MTTR

3. Long term data analysis of power supply & equipment status leads to actions for

increase of MTBF of power equipment.

8.2 Required Primary Settings:

1. NMDL_PMS Application should run at CMU

2. PMS Application receives data through LAN from NMDL System.So, the LAN

Connectivity should established between the systems.

Page 35 of 41


8.3 On Failure-Trouble Shooting Process:

1. Check whether PMS Defined NMDL Running in CMU or not.

2. Check whether windows Firewall is in off state or not. (in both the systems).

3. Verify the LAN connectivity between 2 Systems & Database connectivity with

the server.

Power Supply Monitoring

Page 36 of 41


9. COA-Central Office Application

In Previous train departure and arrival timings at interchange stations and

terminal stations are taken by COA from manual charting data of section

controllers.

On observing serious discrepancies in train departure and arrival timings

recording by two adjacent division section controllers, Railway Board (CRB&ML)

decided to take the train arrival and departure events from data loggers of

interchange and terminal stations and post them to the COA server of CRIS .


Multi Monitor Simulation

Page 37 of 41


10.Installation practices

1. Potential free contacts to be provided for all relays to be monitored.

2. Potential free contacts shall be terminated as per specification enclosed.

a. Analog voltages to be measured should be brought on to a strip

connector near the RTU with provisions for 10-mA fuse.

3. Power supply to be provided nears the point where RTU will be placed.

4. Communication wire [ quad ] terminated on to a strip connector near the RTU

5. Intermediate termination should be rigid. This cable should be isolated

electrically from other cable.

6. No parallel path should be existing for this cable.

7. Good earth terminal should be provided near the equipment.

8. Communication cable-jelly filled 0.9-mm section copper conductor [0+12+2]-

paper quad, remain telecomm. unloaded cable pairs.

9. Tested communication cable.

10. Repeaters will be provided depending upon the necessity for communication

when the intermediate distance between location boxes or between location

box and control room exceeds 4.0 km (cable distance) hence provision to

install repeaters at these locations should be provided. UN-interruptible 230 V/

110-V supply should be provided at repeaters.

10.1 Additional Feature

Interface is to be provided for user-defined fault logic so that user ( Railway) can

enter fault logic without necessitating help of supplier (Datalogger). This

provision is to be made in software at central monitoring unit. By doing this, the

user should be able to write length logic on his own choice.

Ex. ( a ↑), (b↑), (c↑), (d↓),(e↓), (f↑)-------say up to 25 relays. The exist software

should be able to execute these user defined logic in the same way as doing for

company defined fault logic.

Page 38 of 41


11. Maintenance

11.1 Daily check of data logger by ESM on DUTY

11.1.1 Check the LED position of both side modems.

CD,REL,COM-LED should continue glow - Normal condition TD & RD LED should

blink (flickering) - Normal condition

a. If LED’s status is different then reset the modem by pressing the reset

button.

b. If status of LED’s not changed then put off the modem supply, wait for

few minutes and put on the supply of modem.

c. If LED’s are still not blinking then repeat the position of LED’s to

sectional SI, TCI, SI-control and TCI test room.

d. Check the Data logger supply. RED and GREEN LED should glow.

e. Whenever such resetting required ESM must attend immediately.

11.1.2 Testing and Maintenance of power supply,

Battery and Batterycharger

a. Check the AC supply to the charger and record.

b. Put off the charger.

c. After 5 minute check the battery voltage and record, it should not be less

then 13 V DC.

d. Put on the charger.

e. Record all measurement of individual battery voltage with sp. gravity,

total battery voltage, charger voltage, charger + battery voltage properly.

Inform any abnormal position to sectional JE/SE (signal).

Page 39 of 41


11.2 Data logger monitoring by sectional JE/SE (signal)/

(Telecom.)

A. All sectional JE/SE (signal)/(Telecom) monitor the position of Data

logger should interact with JE/SE( signal) control.

B. Sectional JE/SE (signal)/(Telecom) should check/ test and record the

measurement once in a month.

C. Sectional JE/SE (telecomm.) must check the cable for noise if any with

the permission of SE(signal) control only.

D. Sectional JE/SE (signal)/(Telecom)must check for any loose

termination, wiring etc.

E. Never switch off the Data logger supply, if required take permission of

JE/SE(signal)/(telecomm).

F. Sectional JE/SE/Sr.SE (signal)/(Telecom) will monitor the Data logger.

Page 40 of 41


12. Trouble shooting All Modules Sr. no.

Error type Context/checking to be done

Remedy for the error

Database Exceptions:

1 1 NMDL Not taking data from FEP/Data Logger

Check the communication port in the system

2 Check the port and baud rate details in communication setting in NMDL

Set appropriate port and baud rate

3 Check communication cable between computer and FEP/Data Logger

4 Check FEP/Data Logger, for hang condition

Reset the data logger/FEP

5 Check whether Disk is full Remove unnecessary files and make the hard disk free

2 1 NMDL going to hang condition

Check the data. Gdb size and replace it with dataskel ,if its size is large.

2 Check the color setting of the system and set it to at least 16 bit high color

3 Check the RH setup whether the information is matching the configuration of data logger

4 Close the software and remove corresponding station. Sta file from C:\Nmrh\Data folder.

5 While closing the software Check the NMDL software and load the compatible version

6 While opening the simulation map

Check the simulation maps for any wrong entries. Reload the simulation maps.

7 Close the NMDL software and rerun it.

8 Check the date format in control panel-> regional setting. Date format must be DD/MM/YYYY restart the computer.

3 Incorrect parameter

While loading maps Check the color setting for minimum 16 bit high color problem may be with display

4 NMDL is already Running

Restart the computer and run NMDL

Page 41 of 41


13. DO’S AND DON’T

Sr.no.

DO’S

DON’TS

1 Install the CMU in a Dust free and cool environment.

Do not open Floppy’s/ CDs in the CMU without confirming that they are Virus free.

2 Please assure that the system is running, with the NMDL software , round the clock.

Do not use the CMU for other software like Signal failures entry / Signal incidence software/ Auto CAD etc as the system setting required for NMDL Modules may be disturbed.

3 Assure from time to time that the system has enough free space in the ‘c’ Drive

Do not install Games/Screen savers / wall papers etc they may occupy maximum RAM , disturbing the proper working of NMDL Modules.

4 Regularly at least once in 3 months , takes a copy of the previous 3 months database in a CD.

Do not Shutdown the system without proper close of NMDL and other Modules.

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HANDBOOK ON STUDY OF DATA LOGGER REPORT...• LED’s to indicate the status of 512 digital input....

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