SPECIFICATION FOR 2 X 500 KVA IGBT BASED HOTEL LOAD CONVERTER FOR …clw.indianrailways.gov.in/works/uploads/File/16-08-17-Review Specification of Hotel... · page 3 of 45 specification

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SPECIFICATION FOR 2X500 KVA IGBT BASED HOTEL LOAD CONVERTER FOR

3-PHASE LOCO

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CENTRE FOR DESIGN & DEVELOPMENT CHITTARANJAN LOCOMOTIVE WORKS

WEST BENGAL, INDIA NO: CLW/ES/3/ IGBT/ 0490

ISSUED BY. DY. CEE/D&D

ALT.

A B C D

SPECIFICATION FOR

2 X 500 KVA IGBT BASED HOTEL LOAD CONVERTER

FOR THREE PHASE LOCOMOTIVES

(WAP-7)

Specification No: CLW/ES/3/IGBT/0490 (Alt.D)

Total No. of sheets – 45

(Issued on ******, 2016)

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SPECIFICATION FOR 2x500 KVA IGBT BASED HOTEL LOAD CONVERTER

FOR 3-PHASE LOCO

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WEST BENGAL, INDIA NO: CLW/ES/3/ IGBT/0490

ISSUED BY Dy.CEE/ D&D

ALT A B C D

ALTERATION RECORD SHEET

Date of Amend.

Amendment in Clause

Page No.

Alt Changes Authority

12.05.11 1.1 8 A 4 wire system of coaches is added at 3rd para ***

12.05.11 3.1.1 9 A “The successful bidder shall also supply UIC couplers …… by CLW” has been added.

***

12.05.11 3.1.3 9 A “Field trial jointly with RDSO & CLW” has been added.

***

12.05.11 4.0 11 A Potential free contacts (S.No.3) has been added. ***

20.07.11 8.1 16 A Frequency variation has been modified from ±6% to ±8%

**

20.07.11

8.2 16 A In the rated output, voltage between phase to earth feeder and output power factor has been added.

* & **

12.05.11 8.3 16 A “Shall be close to unity at full load … parameters” has been added.

***

16.06.11 8.5 16 A New clause for THD has been added. *

20.07.11 8.6 17 A Deleted * & **

20.07.11 8.7 17 A New clause for voltage unbalance has been added.

* & **

16.06.11 8.8 17 A New clause for expected current unbalance in load current has been added.

*

20.07.11 8.11 17 A New clause for direct on loading starting of converter has been added.

* & **

16.06.11 8.13 17 A (n) Indications. In protection clause, protection against single phasing in load, output over voltage/under voltage and output over current has been added.

*

16.06.11 8.14 18 A Indications have been added. *

12.05.11 8.18 20 A Mechanical dimensions changed, “the successful tenderer is advised …. loco cable tray” has been added and in enclosure clause “the firm has …..the design stage” has been added.

***

12.05.11 8.24 22 A Control Methodology clause has been added. ***

16.06.11 9.1 23 A Maximum temp. in the loco standing dead under sun has been modified with 75°C.

*

16.06.11 9.2 23 A New clause for solar radiation has been added. *

16.06.11 9.8 23 A For vibration test, IEC 1287-1 has been modified to IEC 61287-1.

*

12.05.11 10.4 25 A Clause 10.4 has been added. ***

12.05.11 10.5 25 A Clause 10.5 has been added. ***

12.05.11 10.9 25 A At least 250 GB hard disc has been added in 4th line.

***

16.06.11 11.1 26 A IEC 411.5 has been deleted as IEC 61287 supersedes on it.

*

12.05.11 11.2 26 A Burn in Test clause has been added. ***

12.05.11 11.3 26 A S.No. 29 (Burn in test as per IEC60517 cl. 10.2.13, L marked test has been updated.

***

19.01.14 8.18 20 B The term “otherwise the offer shall be treated as incomplete and noncompliant” has been deleted.

***

19.01.14 11.3 S.No. 7 27 B IEC clause changed as IEC 61287 Clause 4.5.3.7 in lieu of 4.5.3.8.

***

19.01.14 Annex-1 35 B Transformer details has been modified ***

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ALT A B C D

Date of Amend.

Amendment in Clause

Page No.


19.01.14 Annex-2 36-40 B New Annexure has been added to include load details.

***

19.01.14 3.1.7 & 10.9 10 & 25

B In the content of training, no of man days have been added.

****

19.01.14 6.0 (l) 14 B ISO 9000 has been replaced with ISO 9001-2008.

****

19.01.14 8.2 16 B Voltage between phase to earth feeder has been modified.

****

19.01.14 8.16 19 B Details of messages to be recorded in the memory of hotel load converter have been added.

****

19.01.14 11.3 26-28 B Two sub-clauses – 11.3.1 & 11.3.2 have been added.

****

19.01.14 11.4 & 11.5 28 B RDSO has been added with CLW for conducting type test jointly.

****

19.01.14 13 33 B Clause 13 for commissioning has been added ***

19.01.14 10.10 to 10.15

25 B Clause 10.10 to10.15 has been added and scope of supply has been modified.

***

19.01.14 3.0.1 & 3.0.2 9 B Both the clauses have been deleted. ***

15.07.15 3.0 9 C Name changed ***

15.07.15 3.1.1 9 C Two equipments deleted and male jumper cable added

***

15.07.15 3.1.6 10 C Wording changed ***

15.07.15 3.1.10 11 C Clause have been added *****

15.07.15 3.1.11 11 C Clause have been added *****

15.07.15 8.2 16 C Voltage between phase to earth feeder has been modified.

***

15.07.15 10.1 24 C Added “and top fixing of all cubicles”

***

15.07.15 10.4 25 C No. of UIC Couplers modified ***

15.07.15 10.5, 10.6 & 10.7

25 C Deleted ****

15.07.15 10.11,10.13, 10.14 & 10.15

25 C One set of spares to be supplied for every 10 loco sets against 5

***

15.07.15 13.2 & 13.3

26 C Deleted ******

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Date of Amend.

Amendment in Clause

Page No.


07.09.16 3.1.6 10 D Modified #

07.09.16 4 11 D Modified #

07.09.16 5 12 D Modified #

07.09.16 5.1 to 5.2.5 12-13 D Added #

07.09.16 6 13 D Modified #

07.09.16 6.1 to 6.3 14-15 D Added #

07.09.16 8.0, 8.2 15, 16 D Modified #

07.09.16 8.18 20 D Modified and added. #

07.09.16 10.5 to 10.7 24-25 D Added #

07.09.16 11.12 to 11.16.10

29-33 D Modified and added #

07.09.16 13.2 & 13.3 34 D Added #

* = Modified as per RDSO’s Letter No. EL/11.5.5/6 dated 16.06.2011 ** = Modified as per RDSO’s Letter No. EL/11.5.5/6 dated 19.07.2011 *** = Modified by Dy.CEE/D&D **** = Modified as per RDSO’s Letter No. EL/11.5.5/6 dated 05.12.2013 ***** = Modified as per Rly. Bd’s Letter No. 2003/Elect(Dev)/225/6 Pt. dtd. 23.07.2014. ****** = Modified as per Rly. Bd’s Letter No. 2005/Elect(TRS)/440/18/4 3ph dtd. 21.05.2015. # = Modified as per RDSO’s letter No. EL/11.5.5/6 dated 10.08.2016.

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TABLE OF CONTENTS

CL No Description Page No

Nil Alteration Record Sheet 2

Nil Abbreviations 6

Nil Definitions and Interpretations 7

1.0 Foreword 8

2.0 Scope & object. 9

3.0 Tenderer/Supplier’s Responsibility 9 - 11

4.0 Railways Responsibility

11

5.0 Reference to various Specifications. 12 - 13

6.0 Documentation and Design Approval 13 - 14

7.0 Infringement of patient Rights. 15

8.0 Technical Specification 15 - 23

9.0 Climatic & Environmental Condition 23 - 24

10.0 Scope of Supply 24 - 25

11.0 Tests 26 - 33

12.0 Delivery 33

13.0 Commissioning 33-34

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Abbreviations The following abbreviations are used in this Specification:

Abbreviation Full Name

AC Alternating Current

BOM Bill Of Material

CFD Computational Fluid Dynamics

CLW Chittaranjan Locomotive Works

DA Diesel Alternator

DC Direct Current

ELS Electric Loco Shed

EOG End on Generation

HOG Head on Generation

IR Indian Railways

OHE Over Head Equipment

MTBF Meat Time Between Failures

OEM Original Equipment Manufacturer

RDSO Research Designs and Standards Organization

RAMS Reliability, Availability, Maintainability & Safety

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Definitions and Interpretations Terms or words not defined in this Specification shall be governed by the definitions contained in the standards applicable. In this Specification, the following words and expressions shall, unless repugnant to the context or meaning thereof, have the meaning hereinafter respectively assigned to them:

Term Definition

BLHO Shall mean switch at driver’s desk to operate input contactors of hotel load converter;

LSHO Shall mean indication lamp at driver’s desk to show the healthiness of the hotel load converter;

Hotel Load Shall mean electrical loads of coaches of a train such as lights, fans and air conditioning, pantry etc. As detailed in Annexure-2;

Design Concept Shall have the meaning in Clause No 6 (a to r);

Design Package Shall have the meaning in Clause No (6.1 to 6.2);

Inspecting Officer Shall mean the person, firm or department nominated to inspect the hotel load converter (s) or the representative of the inspecting officer so nominated;

LHB Shall mean coaches manufactured in accordance with design of Linke Hofmann Busch;

Purchaser Shall mean the President of the Republic of India as represented by the IR organization entering into the contract;

Supplier Shall mean the firm or company with whom the order for supply of the hotel load converter (s) for WAP-7 locomotive (s) has been placed; and

Tenderer Shall mean firm or company participating in the tender for supply of hotel load converter for WAP-7 locomotive.

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1.0 Foreword 1.1 Chittaranjan locomotive works is manufacturing 3-phase electric

locomotives. These locomotives take power from OHE through pantograph to traction transformer. This traction transformer is provided with a hotel load winding to cater for the power supply to coaches (also referred to as Hotel Load). The capacity of this winding is 2x622.5 KVA, which gives 960 volt (which varies with OHE voltage variation), single phase at 50 Hz ±8% at 25kV primary voltage with rated maximum current 2 X 648 A. The details of transformer are provided in Annexure-1.

With the technological up-gradation and continuous advancements in the

field of power electronics, control system and power supply systems, Indian Railways has decided to adopt an energy efficient power supply system for power supply to the coaches referred to as Head On Generation (HOG) for Rajdhani/Shatabdi trains, presently having “End On Generation” (EOG) system. LHB type of coaches are best suited for adoption of “Head On Generation” (HOG) scheme as the rake integrity with these coaches is expected to be maintained due to the specific design of their inter vehicle mechanical coupling. In EOG system the electrical load (i.e. load of lights, fans and air conditioning, pantry etc. referred to as “Hotel Load”) in the coaches of Rajdhani and Shatabdi Express trains are fed from the power cars placed at either ends of the rake. Each power car is installed with 2 DG sets generating 3-phase (4 wire) power supply at 750 Volts, 50 Hz and the same is transmitted to entire rake through two cable feeders, running through the whole length of the train. This electric power supply is tapped at each coach through a 50 KVA transformer in Conventional Coaches and 60 KVA transformers in LHB coaches and is converted to 415 volt for feeding the equipment working at this voltage and further transformed down to 110-volt AC single phase for feeding the equipment working at that voltage. Since the power cars are placed at either end of the rake, the system is termed as End On Generation, which shall be referred in this specification as EOG.

1.2 In HOG scheme, power is fed from the Electric locomotive to the train to

cater for the Hotel Load of the train. In Electric locomotives, power is taken from the OHE through pantograph to traction transformer of the locomotive which is provided with a hotel load winding of 2 x 622.5 kVA, at nominal voltage of 960 V single-phase, which shall vary with the OHE voltage variations. This 960 Volts single-phase supply shall be fed to Hotel Load Converter, which shall give 750 Volts 3-phase 50 Hz supply as output, for feeding the hotel load of the train. Converter output shall further be stepped down to 415 V, 3-phase AC by existing transformers provided in every coach. This electrical power shall be used to operate the lights, fans, air conditioning, water raising apparatus of the coaches and the pantry car equipment.

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2.0 Scope & Object

This specification covers the technical aspect of the Railway’s requirement for the IGBT based hotel load converters for the three phase locomotives of the type WAP7, to cater for the hotel load. It explains the interface requirement of the equipment with the locomotive and traction system, and lays down the desired performance and testing methodology. Relevant IECs shall be the governing specification except for what is mentioned in this specification.

3.0 3.1

Tenderer’s/Supplier’s Responsibility: The Tenderer’s/Supplier’s responsibility shall be extended to the following in addition to requirement spelt out elsewhere in this specification:

3.1.1

The Supplier shall supply the 2 X 500 kVA IGBT based Hotel Load Converter of approved design conforming to the various operational and functional requirements. The Supplier shall supply detailed instructions for proper installation of the equipment on the locomotive. For this purpose the Supplier shall also depute his representative during installation of the first two loco sets of hotel load converter in the locomotive at each location (i.e. CLW / ELS). The bidder shall supply the items like Inter Vehicular Couplers (4 nos. for each loco set) of specifications to be supplied by CLW. The Supplier shall also supply UIC couplers for control signals between locomotive and coach/power car. Details shall be furnished by CLW. The supplier shall also be responsible for ensuring connection at both converter end as well as coupler end. Required material like extra cable loom for Power/Control Cable for hotel load converter shall also be provided by the supplier.

3.1.2 The Supplier shall plan and suggest all the modifications/re-organizing of the equipment required for providing the hotel load converter on the locomotive in association with CLW for the first two sets which shall be subsequently done by CLW in regular production. Supplier shall submit the drawings for all the changes required/carried out for cut-in in the normal production with the offer.

3.1.3 The Supplier shall be responsible for commissioning, Interfacing, testing & field trials of the equipment and complete system and depute a team of engineers for this purpose at CLW & Electric Loco shed. Any special tool required for commissioning and testing equipment shall be provided by supplier as per clause 10.13. The Supplier shall arrange to carry out necessary field trial jointly with RDSO, CLW and zonal railway.

3.1.4 TheTenderer should give the price for supply of special tools, testing jigs, portable diagnostic/troubleshooting tools preloaded with suitable latest operating system and application software and instruments etc., which may be required for troubleshooting and maintenance of the Hotel Load Converter. The Tenderer should give the breakup of the rates of the same along with the offer.

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3.1.5 The Supplier shall include the rates of supply of a suitable software (compatible with windows xp and higher version of windows) “if applicable” for off-line analysis of diagnostic data downloaded from the hotel load converter along with the offer. The Supplier shall also furnish the complete details of protocol and interface used for communication between Hotel Load Converter and the software.

The design shall be developed as per requirement given in the specification. The detailed electrical and mechanical design including Finite Element Analysis shall be submitted to CLW/RDSO for scrutiny and approval before commencing of the manufacturing. Here “approval” means the “approval of design features” only. The Supplier shall be responsible for the performance of complete Hotel Load Converter.

3.1.6 Warranty

The Supplier shall be responsible for any damage of the equipments supplied due to defective design, materials and workmanship upto a period of 60 months after commissioning on the locomotive or 72 months from the date of supply, whichever is earlier. The Supplier shall repair/ replace all such equipment supplied during the warranty period at his own cost. The Supplier shall warrant that everything to be furnished hereunder shall be free from all defects and faults in material, workmanship and manufacturing shall be of the highest grade and consistent with established and accepted standards of material of the type ordered and in full conformity with specifications and drawings. The Supplier’s liability in this respect of any complaints, defects and / or claim shall be limited to the furnishing and installation of replacement parts free of any charge. The warranty clause in commercial agreement, if any, shall prevail. In the eventuality of major design modification during the currency of the warranty period, the warranty for such components shall be extended for such period as is mutually agreed. ******

The Supplier shall be responsible for carrying out all the modifications at his

own cost on any part of the equipment supplied during the period of warranty required for satisfactory operation of the equipment as per technical specification after approval from CLW.

3.1.7 Training

The Supplier shall arrange for the training of CLW, RDSO and the maintenance & operating personnel of IR of minimum 60 man days in the field of assembly, testing, commissioning, maintenance, repair & troubleshooting and fault diagnostic analysis of the system supplied under the guidance of OEM's engineers. The cost of training shall be included in the offer. The details of training shall be worked out during contract finalization stage/design approval stage.

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3.1.8 The Supplier shall supply the write up and the elaborate manual in both hard and soft copy for maintenance and troubleshooting free of cost to IR for easy maintenance as per clause 10.10. A minimum three set of hard copies of design & maintenance manual will be submitted to CLW before delivery of first set.

3.1.9 3.1.10 3.1.11

Spares management

The supplier shall supply spares for Hotel Load Converter as per clause 10.15.

Additionally bidder shall quote separately for the availability of spares needed for 5 years maintenance, its management and the time period in which spares shall be required. The same shall be made available by the bidder.

Supplier shall provide necessary arrangement in Hotel Load Converter to keep record of energy consumed over a period of time through hotel load converter. The user should be able to generate report on energy consumption on the basis of day wise, weekly, monthly for a period of minimum three months.

Suitable indication for the healthiness of the hotel load converter shall be provided in the driver desk/panel.

4.0 RAILWAYS’ RESPONSIBILITY

Railways shall be responsible for the following:

i. System interface design in terms of hardware & software and the associated changes in the locomotive control system.

ii. The cabling in loco from Hotel Load Converter to the IV coupler.

iii. Cable laying for connecting potential free contacts to vehicle control electronics (VCE).

iv. Any equipment re-layout on locomotive necessary for installation of Hotel Load Converter for hotel load shall be done by the railways in association with the supplier.

v. Electrical energy for erection, testing & commissioning of Hotel Load Converter shall be provided by the IR free of cost.

vi. Facilities for erection, commissioning & loco testing of Hotel Load Converter shall be provided by IR free of cost. However, the responsibility of commissioning and testing of hotel load converter shall be of the supplier as per clause 3.1.3.

vii. The wages and allowances as well as the cost of the travel to and from the place of training for IR personnel.

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5.0 REFERENCE TO VARIOUS SPECIFICATIONS

(a) IEC-60571 (1998-02): General requirements and tests for electronic equipment used on Rail vehicles. (Latest Edition)

(b) IEC61287-1: Railway applications – Power converters installed on rolling stock

(c) IEC-60310: Rules for traction transformer & reactor

(d) IEC-60077-1: Railway applications – Electric Equipment for Rolling Stock – Part I: General Service Conditions and General Rules

(e) IEC-61373: Railway applications – Rolling stock equipment – Shock and vibration tests.

(f) EN-50121-3-2 (CENELEC): Railway applications – Electromagnetic compatibility Part 3-2: Rolling stock - Apparatus

(g) EN-50121-2 (CENELEC): Railway applications – Electromagnetic compatibility Part 2: Emission of the whole railway system to the outside world.

(h) EN 50153: Railway applications – Rolling stock – Protective actions against electrical hazards.

(i) IEC-60529: Degrees of protection provided by enclosures (IP Code)

(j) EN-50126/IEC62278: Railway applications – Specification and demonstration of reliability, availability, maintainability and safety (RAMS).

(k) EN 50238: Railway applications – Compatibility between rolling stock and train detection systems. General

EN 50264: Railway applications – Railway rolling stock power and control cables having special fire performance. General requirements

5.1 Alternative Standards: The requirements listed in this specification are the minimum. The Supplier may adopt alternative internationally recognized codes, standards and specifications if it can demonstrate to the Purchaser that such alternative is superior or more pertinent to the Hotel Load Converter than the standards specified in this Specification. The Supplier shall seek the prior approval of the RDSO for any alternate standards proposed to be used.

5.2 Reliability, Availability, Maintainability and Safety (RAMS):

5.2.1 General

a) The supplier shall design the Hotel Load Converter to ensure high degree of reliability, availability and high degree of safety in order to provide a dependable service. The optimization of the system with respect to reliability, availability, maintainability and safety shall form an integral element of this Specification.

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b) The plan for reliability, availability, maintainability and safety shall conform to EN 50126/IEC 62278. Reliability of electronic components shall conform to IEC 61709.

5.2.2 Components to be selected and tested as per international reliability

assurance specification including burn-in test and necessary de-rating for traction duties. The components are to be sourced from reputed sources. MTBF of the hotel load converter shall be furnished by tenderer/supplier.

5.2.3 Only general purpose ICs shall be used for better maintainability. Modular

system with plug in and easily replaceable control cards with polarization for non-interchangeability shall be provided. Accessibility to components / subassemblies requiring frequent maintenance shall be ensured. MCBs used for blower and internal churning fans shall be made accessible from the outside of the cabinet. In the locomotive, the access is available only from the corridor sides.

5.2.4 The Supplier shall develop RAMS targets both for the hotel load converter and for the major sub-systems such as rectifier module, DC link, inverter module, contactors, control electronics etc., such that it shall provide a high level of dependability. The RAMS targets shall be defined in Design Package.

5.2.5 The Supplier shall establish and operate a details reliability, availability,

maintainability and safety (RAMS) assessment system in support of the design, manufacture and subsequent testing, commissioning, operation and maintenance of the hotel load converter.

6.0 DOCUMENTATION AND DESIGN APPROVAL

The Tenderer must submit the following information with the offer in printed form and neatly compiled in a booklet form. Offer with incomplete information may not be considered.

(a) Detailed specification of the offered converter, major equipments, etc. (b) Details of semiconductor devices used with their specification and data

sheet.

(c) Design calculations including the calculation of safety margin in voltage,

current, thermal (for junction temperature) along with the limit value of power devices. Detailed design calculation of cooling system and its efficiency are to be furnished. Minimum coolant flow rate, which shall give the desired cooling, shall be mentioned.

(d) Mechanical drawings of complete cubicles as well as Major subassemblies /

rack with details of dimensions, mounting arrangement and weight of equipment, which are required to be taken out for maintenance. Details of mounting accessories shall also be provided.

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(e) Details of protection provided and their effectiveness / proposed set values,

range and working principle. Details of implementation, i.e., through software and hardware shall be clearly given.

(f) System description, power circuit diagram along with bill of material of major

equipments, circuit description, working principle and salient features. The details of microprocessor / microcontroller used, functional block description of PCB’s, details of IC’s used, control system hierarchy, protocol used and interfacing.

(g) Detailed operation of panel and function of each switch, indications and fault

diagnostic feature h) QAM (Quality assurance manual).

(i) Declared output voltage and current waveform, THD of input supply current

and voltage and voltage regulation at output. (j) Test protocol with procedure of testing.

(k) Data sheet of major components duly filled.

(l)

ISO -9001:2008 certification.

(m) Data sheet for devices and other equipment proposed along with detailed description of supply proposed;

(n) Logistics proposed for warranty support within India;

(o) Declaration for long-term support by the Tenderer;

(p) Details of short time rating of the converter;

(q) Expected efficiency with respect to loads;

(r) Undertaking on Infringement of Patent Rights as per Clause 7.0 6.1 The Supplier shall submit, including but not limited to the following, as part

of Design Package to RDSO for approval, before commencing manufacturing. Only on getting the approval from RDSO in writing shall the production begin.

a) Technical documentation explaining the complete scheme, block

diagram, characteristics, diagnostics, protection and control etc. Including electric schematic circuits;

b) Mechanical drawings of complete cubicles as well as major subassemblies / rack with details of dimensions, mounting arrangement, weight, details of mounting accessories;

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c) MTBF along with detailed assumptions, calculation etc. Of the hotel load converter;

d) Interfacing and control scheme of hotel load converter with power car; e) Detailed drawings of each system / sub-system with interface details; f) Complete BOM/technical specification of components with source of

supply; g) Procedure for software downloading, diagnostic uploading, analysis

etc.; h) Type & routine test protocol with procedure of testing; i) EMS management plan of the hotel load converter. 6.2 The Supplier shall submit, including but not limited to the following, as part

of Design Package to RDSO for approval, before prototype clearance. Prototype clearance shall be given only after submission of following document and their approval of RDSO.

a) Schedule maintenance activities with periodicity; b) Maintenance, trouble shooting and repair manual in English language

only in soft from and hard copy; c) Details of tools and plants with design/drawings and name of

probable suppliers; d) Detail instructions for proper installation of the converter in the WAP-

7 locomotives. e) Details of technical support and training offered; f) Recommended list of spares for 5-year maintenance after warranty

along with part no., datasheet and details of OEM; g) List of special tools, jigs and fixtures needed for assembly, testing,

commissioning, maintenance and repair along with full technical specifications and probable suppliers;

6.3 Approval of designs means approval of general design features.

Notwithstanding the approval, the Supplier shall wholly and completely be responsible for the performance of the hotel load converter.

7.0 INFRINGEMENT OF PATENT RIGHTS

Indian Railway shall not be responsible for infringement of patent rights arising due to similarity in design, manufacturing process, components used in design, development and manufacturing of inverter and any other factor which may be a cause of such dispute. The responsibility to settle any issue lies with the manufacturer.

8.0 TECHNICAL SPECIFICATION a) Types of Neutral sections i) 41 m in length having insulated over

lap on both end and neutral wire in between which is not earthed; and

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ii) Short neutral sections of approx. 4.61 m and 9.6 m length having an insulated portion (of PTFE) on both sides and middle portion of neutral section which is solidly earthed.

iii) There shall be power interruptions at neutral sections varying from 12 seconds to 30 seconds.

b) Pantograph bounce Up to 45 m (limit of zero pressure

contact). Hotel load converter shall be able to supply the rated power without any supply interruption during the pantograph bouncing. Also the pantograph bounce shall not affect the hotel load converter with or without loads.

8.1 Input 960 V at 25 kV OHE voltage nominal. OHE Voltage

varies from 17.5 kV to 30 kV, Frequency - 50 Hz ±8%.

8.2 Rated output Voltage phase to phase - 750 V+ 5% -2%, 3 phase

sine wave AC, 3 Wire Voltage between phase to earth feeder – less than 0.80 kV (Peak) Frequency - 50 Hz ±2%. Capacity - 2X500 KVA (Two units of 500 KVA per locomotive) at power factor not less than 0.8

Note

Rated capacity of each converter shall be 500 kVA for OHE voltage range of 17.5kV to 30kV. It shall not be possible to regulate the duty cycle of the loads.

The details of loads to be connected with the hotel load converter are given in Annexure-2.

8.3 Input Power factor Shall be close to unity at full load with

normal input parameters. 8.4 8.5

THD of input current at full load Total harmonic distortion (THD) of output voltage

Less than 5% (up to 20th harmonic). Less than 10%

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8.6 8.7

Efficiency at full load Output Voltage unbalance

Not less than 93% at rated input voltage of 750 V. Less than 3%

8.8 Expected current unbalance in load current

Up to 15% of rated output current

8.9 Cooling Direct or forced air cooled / Water cooled;

preferably direct or forced air cooled 8.10 8.11

Efficiency at full load Direct on load starting of converter

Not less than 93% at rated input voltage of 960 V. Minimum 750 A (steady state current) of induction motor load for 3 seconds.

8.12 Construction Modular 8.13 Protection

The devices used in the inverter shall be protected against high rate of rise of voltage & current, line transient surge, switching surges etc.

The converters shall be protected against:

(a) Open circuit in hotel load winding and no input voltage available.

(b) Earth fault in AC input circuit.

(c) Earth fault in 3-phase out put. Limits for earth fault detection shall not be more than 30 mA.

(d) Converter phase fault.

(e) Line to line short circuit due to dead short at load terminal.

(f) Thermal over loading.

(g) Fuse failure in converter if fuses are used.

(h) High / low voltage in DC link.

(i) Failures of power supply to control electronics.

(k) DC link short circuit.

(l) Input over voltage / under voltage.

(m) Input over current.

(n)

(o)

(p)

Single phasing in load

Output over voltage and under voltage; and

Output over current

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The details of such protection shall be submitted by the successful Tenderer for review during design stage.

The equipment shall be protected against internal transient, spikes and surges as per limit laid down as per IEC 60571 (1998-02).

The converter at AC input and output must use IGBTs. The control shall be microprocessor / micro-controller based with diagnostic facilities. The specification has been drawn for two Hotel Load Converters for hotel load identical in all respects each with 500 kVA capacity housed preferably in a single cubicle of dimensions given in the drawing. However, if necessary, splitting shall be done to accommodate in available space in the locomotive.

8.14 Indications:

The following indications shall be provided on the hotel load converter:

Main contactor stuck ON/OFF;

Input over current

Input earth fault;

Input available;

Output available;

Converter healthy;

Converter faulty; and

Output earth fault

8.15 Integration with Vehicle Control Electronics The IR intends to integrate the Hotel Load Converter with the existing Vehicle Control Electronics (VCU) in future. For this purpose hardwired connection through spare 110V DC digital input/output potential free contacts would be required. The operational control and status shall be communicated through digital input/output lines. These shall include but not be limited to commands and feedback signals for ON/OFF, failure/ healthy status, etc. These signals shall be suitably integrated with vehicle control electronics for which necessary software changes shall be made by IR. Cabling between Hotel Load Converter and VCE shall be provided by IR. In case of digital signals not available Hotel Load Converter shall work as standalone system with 50Hz 3-phase AC output. Details shall be finalised during the design approval stage. IR intends to go for open control system for vehicle control and would like to integrate, in future the hotel load converter with the vehicle control electronics on a bus system conforming to published open standard (IEC-61375)/CAN BUS etc. The design of hotel load converter shall keep this aspect in view, though it is not covered in the present scope of supply.

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8.16 Fault Indication, Diagnostics and Trouble Shooting

A suitable fault diagnostics and trouble-shooting arrangement as per functional requirement of 3-phase locomotive shall be provided locally on the Hotel Load Converter. The faults shall be downloadable on a laptop computer through a USB interface. Large capacity of storage of faults along with the background data shall be provided, so that data pertaining to minimum latest 200 faults are kept stored.

The following messages shall be recorded in the memory of hotel load converter for the purpose of fault diagnostic:

SN Fault Remarks

1. Input Fuse Failure In case the input fuse is blown due to high current drawn

2. Input Voltage High Input voltage exceeding upper limit

3. Input Voltage Low Input voltage drops below limit

4. DC Link / Input Current High

Excess current following in the DC Bus or input High current conditions persisting

5. DC Link Voltage High DC Link voltage exceeds upper limit

6. DC Link Low Voltage DC Link voltage drops below lower limit

7. Output Current High In case of output high current conditions persisting

8. Output Voltage High Output voltage exceeding upper limit

9. Output Voltage Low Output voltage drops below lower limit

10. Input Earth Fault In event of earth fault at input of the converter

11. Output Earth Fault In event of earth fault at output of the converter

12. Single Phase Fault Unbalance / single phasing at the output

13. Fault in cooling system Failure of blower/pump/radiator for cooling

14. Rectifier Fault In event of fault in Rectifier section

15. Inverter Fault In event of fault in Inverter section

16. Chopper Fault Chopper section faulty (if design includes chopper)

17. Over Temperature Any temperature sensing device operated in the Rectifier and Inverter sections

18. Power Supply Fault In event of failure of any of the electronic/ control power supply

19. Chopper Current High Chopper section current exceeds upper limit (if design includes chopper)

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20. No synchronization/ Communication Error

Communication fault in software

21 XXXXXXXX Any other faults to be specified in Design Document

8.17 Safety

Following shall be provided in each Hotel load converter cubicle for human safety.

(i) Indication of presence of high voltage ( Voltage Indicator )

(ii) Safety inter lock on front panel with lock and key to be integrated with existing key multiplier system used in auxiliary converter ( 3phase loco)

8.18 Mechanical dimensions

Each 500kVA converter shall be housed in single cubicle. Space available for mounting the converter in the locomotive WAP-7 is, as under: Space available in the Locomotive (all dimensions are in mm).

Space for Hotel Load Converter Cubicle:

Space-1 Space-2 Width - 1400 mm Width - 1400 mm Depth - 1075 mm Depth - 1075 mm Height - 1750 mm Height - 1750 mm

Spaces for Contactor Cubicle :

Space – 1 Space - 2 Width - 384 mm Width - 384 mm Depth - 700 mm Depth - 700 mm Height - 435 mm Height - 435 mm For proper installation of the Hotel Load Converter some installed equipment may be required to be shifted. The Supplier is advised to inspect the loco for availability of space as mentioned above prior to submission of their design documents. Supplier is expected to study the existing layout thoroughly and suggest possible layouts of equipments for proper installation of the Hotel Load Converter along with the offer. Approved layout of hotel load converter and contactor panel are attached in Annexure – 3 to Annexure - 7.

Note:

A gap of 50 to 100mm only is available between roof and equipment in the locomotive and hence cooling system design shall be done accordingly. Lifting arrangement of all cubicles should be from the topside.

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Enclosure

The enclosure for electronics shall be free from dust and moisture and shall comply with IP-54. Design of cooling heat exchanger shall be done to ensure temperature difference of less than 10 degree centigrade across the heat exchanger. The panel sheets used for fabrication shall be of SST grade 304 as per ASTM-A240 of min. 3 mm thickness. The firm should submit the 3D models, compatible to NX platform, of all the cubicles, during the design stage.

Cooling

Suitable and efficient arrangement shall be made for cooling of the Hotel Load Converter. In case cut-out provisions are required to be made in the shell of the locomotive then the details of the same shall be furnished to IR for study.

8.19 Safety factor

(a) In the circuit configuration, 25% safety margin in the rating of both voltage and current under worst conditions is to be ensured. This shall be established in the offer with calculation.

(b) A minimum thermal margin of 10ºC for junction temperature under worst operating condition for the power devices is required. Over load margins and duration are to be furnished.

(c) Current density of the bus bars : 4A / sq. mm (d) Acoustic Noise generated by circuits and components shall be as low as

possible, less than 80 dB (A) at a distance of 1m from the equipment. (e) The PCBs shall be provided with LED indication to show the health of cards, to

assist maintenance and operating personnel in trouble shooting. (f) The power portion of the equipment shall be suitably protected to prevent

accidental contact. The shields and screens shall be properly earthed. 8.20 Reliability

Component to be selected and tested as per international reliability assurance specification including burn-in test and necessary de-rating for traction duties. The components are to be sourced from reputed sources. MTBF of the equipment shall be furnished by bidder.

8.21 Maintainability

Only General purpose ICs shall be used for better maintainability. Modular system with plug in and easily replaceable control cards with polarization for non-interchangeability shall be provided. Accessibility to components / subassemblies requiring frequent maintenance shall be ensured. In the loco the access is available only from the corridor sides

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8.22 Marking

The major equipments / subassemblies shall bear marking and serial number. The equipment shall contain serial number and make of bidder.

(a) All equipments / cubicles shall contain name plates of anodized aluminum

with engraved / punched letters.

(b) The inverter rating plate shall be marked with the following information :

(i) Type / Make

(ii) Contract/purchase order number

(iii) Month and year of manufacture / batch no. / Serial no.

(iv) Rating

KVA

Input Voltage range

Output voltage, frequency and wave shape

8.23 Cable

The use of wires / cables shall be reduced to minimum. Bus bars shall be of high grade copper, insulated bus bar is preferable. The wires / cables shall be of high grade, copper with halogen free thin walled insulations. All the cable terminations shall be made through crimped sockets / lugs and with circuit diagram furnished. Each cable / wire shall be numbered at both ends for easy identification. The use of pre-insulated lugs suitable for double crimp for insulation and conductor is recommended. Current collection through threads must be avoided and terminals of adequate size shall be provided.

Cable grommets / glands of suitable size as required for input and output cables

shall be provided at cable entry / exit. All cables, cable lugs etc. should be as per CLW specification and should be procured from CLW approved sources only.

8.24 Control Methodology:

The Hotel Load Converter shall be installed in the loco machine room at the prescribed location as per clause no. 8.18 of this specification. The Loco Pilot shall close the input contactor through BLHO Key installed in each cab of the loco. The indication of closing of the contactor shall be made available to the power car operator in the power car. Power car shall house a panel which shall have complete control of operation of Hotel Load Converter which in turn shall have prescribed interlocks with the Alternator available in the power car. The scheme

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shall be as per the latest RDSO Modification Sheet (MS) which shall be made available on demand or which may be downloaded from RDSO’s official web site.

8.25 The Railways are going for installation of Train Protection and Warning System in

all the locomotives. The proposed foot print of the PWS shall be 560 mm x 560 mm which has been planned to be installed between HB-1 panel and Hotel Load Converter. This shall require some equipment shifting. This aspect shall be discussed during the design stage.

9 CLIMATIC & ENVIRONMENTAL CONDITION

9.1 The Hotel Load Converter shall be fitted in locomotive machine room where the temperature shall be -

(a) Maximum temperature inside stable : 750C Locomotive under sun (b) Maximum Temperature inside : 55ºC Working Locomotive (Temperature inside working locomotive may reach 60ºC)

(c) Minimum temperature : -5ºC

The equipment shall be able to start up to the maximum specified temperature inside the locomotive without any pre-cooling requirement.

9.2 Solar radiation: 1 kW/m2

9.3 Humidity : Upto 100% during rainy season.

9.4 Altitude : Upto 1776 m above mean sea level.

9.5 Rainfall : Very heavy in certain areas. The loco equipment shall be designed suitably.

9.6 Atmosphere during hot weather: Extremely dusty and desert terrain in certain areas. The dust concentration in air may reach a high value of 1.6 mg/cub meter.

9.7 Coastal area: The equipment shall be designed to work in coastal area in humidity and salt laden and corrosive atmosphere. The maximum values of the condition shall be as follows:

(a) Maximum pH value : 8.5

(b) Sulphate : 7 mg per litre

(c) Max. concentration of chlorine : 6 mg per litre

(d) Maximum conductivity : 130 micro Siemens/cm

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9.8 Vibration : The equipment shall be designed to withstand the vibrations and shock encountered in service satisfactorily as specified in IEC-61287-1 (second edition) and 60571.1 (1998-02) (second edition) publication for the converter and electronic equipments respectively and relevant IECs as applicable to other equipment.

9.9 Electromagnetic pollution: High degree of electromagnetic pollution is anticipated in locomotive machine room, where the equipment shall be mounted. Necessary precaution shall be taken in this regard. The hotel load converter shall comply with the EN 50121 series of Railway Electromagnetic Compatibility standards and EN 50238.

9.10 Input Power Interface

(a) The Hotel Load Converter shall be supplied through the Hotel load winding of the locomotive transformer.

(b) The catenary voltage shall normally 19 kV to 27.5 kV. However, occasionally maximum and minimum Voltage can be 31 kV & 16.5 kV respectively.

(c) Input line frequency = 50Hz±8%

(d) Pantograph bouncing duration up to 45 ms (limit of zero pressure contact) shall not affect Hotel Load Converter with or without loads.

(e) There shall be power interruptions at neutral sections varying from 12 sec. to 20 sec. However it must be taken into consideration that power interruptions shall be of longer durations than specified above.

9. 11 Signal and telecommunication installation: The tracks over which the locos shall run may be equipped with DC track circuit, 83-1/3 Hz track circuit as well as track circuits at higher frequencies. Similarly, other devices like axle counters, block instruments, point machines etc., may also be employed. On the communication network, control circuit, tele-printer circuit as well as VHF / UHF and micro-wave circuits are employed.

10. Scope of supply

10.1 The scope of supply covers design and development of complete loco-set i.e. 2 nos. of 500 KVA (IGBT) based hotel load converter for 25kV AC 3-phase locomotive along with the base platform & top fixing of all cubicles for mounting it. The location and control of hotel load converter shall be decided mutually between CLW and the Supplier and CLW shall incorporate logic for contactor operation in the locomotive.

10.2 Supplier shall supply one set of suitable software (compatible with windows Xp and higher version of windows) and hardware for offline analysis of diagnostic data downloaded from the Hotel Load Converter for each set of hotel load converter.

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10.3 The Supplier shall supply the items specific to hotel load converter like Inter Vehicular Couplers (IVC), (04 nos.) as per RDSO specification No. RDSO/PE/SPEC/AC/0177(Rev.1)-2013 or (latest alteration). Approval of items like IVC, HOG coupler shall be obtained from the RDSO.

10.4 UIC Coupler (04 nos.) for interfacing the coach/power car and hotel load converter as per clause no. 3.1.1 of this specification. UIC coupler shall be provided both in the locomotive and coach/power car. Suitable jumper cable shall also be provided.

10.5 Modification and supply of cable/equipment/panel and any other material in two power cars for each set of hotel load converter.

10.6 Modification of two power cars and maximum of 23 coaches of Rajdhani / Shatabdi

rakes for each set of hotel load converter. The same shall be carried out in accordance with latest RDSO modification sheet, to be supplied by Indian Railways.

10.7 Any other modification in power cars and coaches with respect to hotel load converter shall also be within scope of supply.

10.8 Commissioning of complete set of 2 nos. of 500 kVA IGBT based Hotel Load

Converter on the locomotive.

10.9 Training shall be provided for IR personnel as per clause 3.1.7.

10.10 One set of installation drawings, Maintenance, Operation and repairer manual in A4 size paper and in English language only (hard copy and soft copy both) for each set of Hotel Load Converter.

10.11 Supplier shall also provide one set of testing jigs for troubleshooting at card level for every ten loco sets or part thereof.

10.12 Necessary jigs & fixtures for installation of hotel load converter on the locomotive including fixture for air duct shall be in the scope of supply of supplier for first two loco sets.

10.13 One set of special tools, tackler and jigs for maintenance for every ten loco sets or part thereof.

10.14 For water cooled Hotel Load Converter, coolant used for Hotel Load Converter shall be provided by supplier. Supplier shall also provide one pump for filling the coolant for every ten loco sets of Hotel Load Converter supplied or part thereof.

10.15 One converter set of power supply module, IGBT module, gate drive unit and all electronics PCB cards as spare for maintenance of Hotel Load Converter for every ten loco sets or part thereof.

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11. TESTS

11.1 The converter shall be tested in accordance with IEC-61287 and the control electronics/PCBs shall be tested as per IEC-60571 including all optional tests in both of the IECs.

11.2 Burn in test – The cards used on the equipment shall be subjected to burn-in test for 80 hours as per the temperature cycle. The cards shall be kept energized during the test. Functional test of each card shall be carried out after the burn in test. (Plz. refer Clause 10.2.13 of IEC 60517). This shall be part of internal test by manufacturer, whose results shall be submitted during routine test.

11.3 List of tests

11.3.1 The list of the tests as per IEC-61287 to be carried out on hotel load converter is as follows:

S. No. Test Clause No. Type Routine

1. Visual inspection 4.5.3.1 √ √

2. Verification of dimensions and tolerance

4.5.3.2 √ √

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3. Weighing 4.5.3.3 √

4. Marking inspection 4.5.3.4 √ √

5. Cooling system performance test

4.5.3.5 √

6. Test of mechanical and electrical protection and measuring equipment

4.5.3.6 √ √

7. Light load test 4.5.3.7 √ √

8. Test of the degree of protection

4.5.3.8 √

9. Commutation test 4.5.3.9 √

10. Acoustic noise measurement 4.5.3.10 √

11. Temperature rise test 4.5.3.11 √

12. Power loss determination 4.5.3.12 √

13. Supply over voltage & transient energy

4.5.3.13 √

14. Sudden variation of load 4.5.3.14 √

15. Insulation resistance test 4.5.3.15 √ √

16. Dielectric test 4.5.3.16 √ √

17. Safety requirements 4.5.3.18 √

18. Vibration & shock 4.5.3.19

The panel used during the shock and vibration test shall not be allowed to be used for series supplies against the contract as vibration and shock test is a destructive test. The panel shall be kept with the manufacturer. No item of this panel would be allowed to be used for supplying spares to any railway.

√

19. Electromagnetic compatibility

4.5.3.20 √

20. Step change of line voltage test

4.5.3.21 √

21. Short time supply interruption test

4.5.3.22 √

22. Current-sharing test 4.5.3.23 √

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23. Output characteristics test 7.4.1 √

24. Starting and restarting test 7.4.2 √

25. Voltage and frequency ranges verification

7.4.4 √

26. Rated load test 7.4.5 √ √

27. Overload capability test 7.4.6 √

11.3.2 The list of the tests as per IEC-60571 to be carried out on control electronics/PCBs is as follows:

S. No. Test Clause No. Type Routine

1. Visual inspection 10.2.1 √ √

2. Performance test 10.2.2 √ √

3. Cooling test 10.2.3 √

4. Dry heat test 10.2.4 √

5. Damp heat test (cyclic) 10.2.5 √

6. Supply overvoltage, surges and electrostatic discharge tests

10.2.6 √

7. Transient burst susceptibility test 10.2.7 √

8. Radio interference test 10.2.8 √

9. Insulation test 10.2.9 √ √

10. Salt mist test 10.2.10 √

11. Vibration, shock and bump test 10.2.11 √

12. Equipment stress screening test (Burn-in test)

10.2.13 and as per burn-in cycle mentioned in Para-11.2 above

√ √

11.4 The supplier shall submit complete test programme for type and routine test to authorised representative of RDSO / CLW for approval. Authorised representative of RDSO/CLW may also decide to carry out certain special tests on the equipment, which are not covered by relevant IEC specification. Manufacturer shall carry out the test as per mutually agreed test programme at his own cost.

11.5 The prototype Hotel Load Converter units shall be inspected & tested jointly by the engineers of CLW and RDSO at the manufacturer’s premises or at mutually decided venue where all the facilities shall be made available for carrying out the prototype test. The equipments shall be kept in field trials for a period of six months. The

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CLW/RDSO engineers shall associate and witness the tests in the locomotive also till they are successfully completed. Any defects noticed / design improvement found necessary as a result of the test / trial shall be carried out by the Supplier in the least possible time. Serial production shall only start after successful trial run on locomotive and clearance to this effect given by RDSO.

11.6 The individual equipments, system and sub-system as may be necessary shall be type tested and routine tested in accordance, with relevant IECs.

11.7 Necessary arrangement shall be made by the Supplier to carry out certain tests to establish conformance to specified requirements.

11.8 Type test shall be performed on one unit of given design to verify that the product meets the requirements specified and agreed upon between users & manufacturer. Subject to agreement between user and manufacturer, CLW at it’s direction may carry some or all the type tests once in five years on sample basis so as to confirm the quality of the product. Type test shall also be repeated in following cases:

-- Modification of equipment, which is likely to affect its function.

-- Failure or variations established during type or routine test.

-- Resumption of production after an interruption of more than two years.

-- At the time of indigenisation, if the bidder has supplied with foreign collaboration self systems / onwards in product originally.

“The type test shall be carried out for the equipment / sub-assembly indigenised. The type test on the full unit in the case of indigenisation shall be considered only if there is major design change.”

11.9 Routine tests are to be carried out to verify that properties of the product corresponding to those measured during type tests. Routine tests are to be done by the manufacturer on each equipment.

11.10 Investigation tests are intended to obtain additional information regarding the performance of the product. They shall be specially requested either by the user or the manufacturer.

11.11 Authorised representative of CLW/RDSO may conduct surprise check on manufacturing process and quality control along with any of the test to ensure quality of product and its conformance to CLW’s specification.

11.12 Additional Tests: a) Duty Cycle Test: This test shall be routine test. After continuous full load, the

unit shall withstand 50 cycles of 90 seconds ‘ON’ and 90 seconds ‘OFF’ for the compressor load with continuous load of evaporator motor, AC control

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and compressor crank oil heater load ‘ON’. The temperature rise of semiconductor power devices shall be within specified limit value after applying correction for 65 degree Celsius surrounding air temperature.

b) Output voltage harmonics between Line to Earth: This test shall be type

test. Voltage harmonics between Line to Earth in output voltage of the hotel load converter shall be conducted during prototype testing. Measured voltage peak in harmonics should be well below 800 Volts.

c) Input power factor measurement: This test shall be routine test. This test

shall be carried out during ‘Voltage and frequency range verification test’. Input power factor shall not be less than 0.95 at full load with normal input parameters.

d) Output voltage unbalance test: This test shall be routine test. This test shall

be carried out to verify the unbalance in output voltages. Output voltage unbalance shall not be less that 3%.

e) Expected current unbalance: This test shall be routine test. This test shall

be carried out to verify the current unbalance in output load current. Expected current unbalance in output load shall be up to 15% of rated output current.

f) Direct on load starting: This test shall be routine test. Converter shall be

able to deliver minimum 750 A (steady state current0 of induction motor load for at least 3 seconds.

g) Test to check the interface and control signals: This test shall be routine

test. This test shall be carried out to satisfy the clause no.8.15 &8.24 of this specification.

h) Test on protection and measuring meters: The purpose of this test is to

verify that protections provided are functional and operative at set value. The voltage and current sensors used in the converter shall be verified by using external calibrated digital multimeter / differential voltage probe and clamp meter. All the measurements shall be within ± 2% tolerances.

11.13 Acceptance tests 11.13.1 This testing including routine test shall be carried out on hotel load converter in 55

of lot size to confirm the quality of the product by the RDSO engineer. 11.13.2 The details of such acceptance tests excluding routine test are as under:

Sl. No.

Clause No. of IEC-61287-1

Description Remarks

1 4.5.3.5 Cooling system performance tests

2 4.5.3.6 Test of the degree of protection Xa

3 4.5.3.11 Commutation test

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4 4.5.13 & 7.5.7 Temperature-rise test

5 4.5.3.14 Power loss determination

6 4.5.3.16 Sudden variation of load Xa

7 4.5.3.17 Safety Requirements

8 4.5.3.18 Test for withstanding vibration and shock

9 4.5.3.20 Step change of line voltage test

10 4.5.3.21 Short-time supply interruption test

11 7.5.5 Voltage and frequency ranges verification

12 7.5.6 Overload capability test

Xa = The execution of the test is subject to agreement between the Supplier and the purchaser.

11.14 Other points to be followed 11.14.1 The suppliers shall submit complete test programme for type and routine test to

RDSO as part of Design Package. The Supplier shall carry out the test as per mutually agreed test programme at his own cost.

11.14.2 Investigation tests are intended to obtain additional information regarding the

performance of the product. They shall be specially requested either by the purchaser or the Supplier.

11.14.3 Authorized representative of IR may conduct surprise check on manufacturing

process and quality control along with any of the test to ensure quality of product and its conformance to specification.

11.15 Instrumentations

(a) All the instruments used for testing shall be duly calibrated. The calibration certificates are to be shown to inspecting authority on demand.

(b) Value of the fundamental component and THD of inverter output voltage, input current etc. shall be measured by power analyser during the prototype test. True value of output voltage rms is also to be measured for record.

(c) Input power factor and the efficiency shall be measured by using power analyser at rated load of 500 kVA.

11.16 Clarifications with respect to certain tests are given below: 11.16.1 Visual Inspection: The objective of visual inspection is to check that the

equipment is free from defects and the equipment is as per approved drawing. Bill of materials (BOM) submitted as part of Design package shall be verified. The make, rating of equipments, sub-assemblies shall be checked with the details as per approved Design Package. If a change is needed in make or rating of

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important equipment, sub-assemblies, it shall be intimated and shall have approval of RDSO. All the important dimensions and arrangement, bus bar termination and other parameters considered necessary shall also be measured and verified from approved drawings and plan.

11.16.2 Short time supply interruption test: This test is intended to simulate the

interruption due to pantograph bouncing conditions given in clause 8 (b) of this specification. Suitable arrangement shall be made available to simulate the input power supply interruption for the duration up to 45 milli-seconds. This test shall be considered satisfactory if converter does not trip at full load during the interruption in input power supply of minimum 45 milli-seconds.

11.16.3 Test of mechanical and electrical protection and measuring equipments:

The purpose of this test is to verify that the protections listed in clause 8.13 of this specification are functional and operative at set values. Also the set values in software shall be verified by external measuring instruments and comparative results shall be recorded.

11.16.4 Insulation Resistance test: The insulation resistance with all the circuit shall not

be below 10 mega Ohm when measured with 1000 Volt megger. 11.16.5 Dielectric Test: The dielectric test shall be carried out after shorting power

semiconductor devices, primaries of trigger equipment pulse transformers earthed and disconnecting special card if necessary before applying dielectric voltage corresponding to the voltage given below:

i) 415 Volt AC circuit, 3.0 KV (rms), sine wave, 50 Hz for 1 minute; ii) 110 Volts DC circuits, 1500 V (rms), sine wave, 50 Hz for 1 minute; iii) Below 110 Volts DC circuits, 1000 V (rms), sine wave, 50 Hz for 1 minute; iv) 24 Volts circuit, 500 V (rms), sine wave, 50 Hz for 1 minute; The test is considered satisfactory if there is no flashover or tripping of dielectric

test equipment set at specified leakage current for specific circuit. The maximum leakage current for power circuits (more than 415V) shall be less than 50 mA and for control circuit shall be less than 10 mA. Insulation resistance test shall be conducted followed by dielectric test.

11.16.6 Power loss determination test: This test shall be done at voltage corresponding

to 25 kV in OHE. The efficiency shall be measured at full and 80% rated load. 11.16.7 Earth Fault: Simulate the earth fault by connecting a suitable resistor between

cubicle frame and output phases. The hotel load converter shall not trip and earth fault indication shall be in “OFF” state till the leakage current is less than limit approved as part of Design Package submitted by the Supplier.

11.16.8 Burn in test: The electronic cards used on the equipment shall be subjected to

burn-in 90 hours as per the temperature cycles in Clause No. 11.2. The cards shall be kept energized during the test. Functional test of each card shall be carried out after the burn in test. (Please refer clause10.2.13 of IEC 60571). As a

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part of type test, this test shall be witnessed by RDSO engineers. However, for routine test, the same shall be part of internal test by manufacturer, whose results shall be submitted during routine test.

11.16.9 Cooling Test: The purpose of this test is to verify the cooling of various

components / assemblies. The parameters for measurement to check efficacy of cooling system shall be decided based on scheme proposed as part of design proposal.

11.16.10 Temperature Rise Test: The hotel load converter shall be loaded to rated full

load current and nominal output voltage corresponding to 500 kVA rating of converter with input voltage corresponding to 17.5 KV of OHE for at least 6 hours. The temperature rise shall be recorded by temperature detectors mounted at the specified reference points on the body of semiconductors, capacitors, and other components as agreed between the Purchaser and the Supplier. The maximum recorded temperature under worst condition shall be corrected for 60 degree Celsius and compared with maximum permissible temperature (for power devices at junction). The thermal margin available shall be compared with the safety margin declared by the manufacturer of the devices. The temperature of the power devices shall have a margin of minimum 10 degree Celsius. This test is declared successful if the extrapolated maximum temperature of any component does not exceed the specified limit.

11.16.11 Vibration and Shock Test: The hotel load converter when supported at its

designed fixings (including anti-vibration mounts when fitted), shall be able to withstand vibration and shock test as per IEC-61373. If the mass of the converter cubicle is higher than 500 kg, one may test sub-assembly only.

12. Delivery

The firm shall deliver the prototype set as per condition mentioned in purchase order. Along with the offer, the firm shall mention the time schedule of other activity such as

(a) Submission of design document

(b) Date of offer for prototype inspection,

(c) Actual delivery schedule of prototype set after clearance of prototype test

(d) Subsequent delivery schedule for rest of the sets

The time schedules thus submitted along with the offer has to be strictly followed.

13. Commissioning:

The commissioning shall include the following:

1) Successful installation and commissioning of hotel load converter in loco at CLW/Shed.

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2) Successful modification and commissioning of two nos. of power car.

3) Successful modification and commissioning of maximum 23 nos. Of LHB coaches as per latest RDSO modification sheet.

4) Successful demonstration of satisfactory working of complete system in field.

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Annexure-1 Important Data of Transformer

SN Parameter Value

1 Type LOT 7500

2 Original Design Secheron SA

3 Windings

Traction 4

Auxiliary 1

Filter 1

Hotel load 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 960 V

7 Current Ratings

HT 311 A

Traction 4 x 1142 A

Auxiliary 333 A

Filter 347 A

Hotel Load 2x648 A

8 Thermal Ratings

Primary 7775 kVA

Traction 4 x 1449 kVA

Auxiliary 333 kVA

Filter 400 kVA

Hotel Load 2x622.5 kVA

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 11.0 mΩ, 0.65 mH

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Annexure-2 Power Requirement with Different

Coach Combinations with HOG System

TYPE COACH COMBINATION EXISTING

CONNECTED LOAD (IN KW)*

POWER REQUIREMENT AT

0.8 DIVERSITY FACTOR (IN KW)

24 COACH RAJDHANI

AC-20, POWER CAR-2, PANTRY-2

932 745.6

19 COACH RAJDHANI


742 593.6

12 COACH SHATABDI


440 352

* Considered power factor for inductive load is 0.7. The types of load in detail for each and every type of coaches are given below:

CONNECTED LOAD CALCULATION FOR LHB TYPE COACHES 1-AC

S.NO. COMPONENT POWER QTY

TOTAL CONNECTED LOAD

IN (WATTS) IN (WATTS)

1 ANTI-SKIDDEVICE 48 1 48

2 FAN

2.1 EXHAUST FAN 132 2 264

3 PANTRY EQUIPMENT

3.1 HOT CASE 1200 1 1200

3.2 BOTTLE COOLER/ 800 1 800

3.3 REFRIGERATION

4 SWITCH BD CABINET 500 1 500

5 COACH LIGHTING

5.1 LIGHTINGS 40 WATTS 40 9 360

5.2 LIGHINGS 20 WATTS

5.3 SINGLE COMT.+

VASTIBULE +DOORWAY 20 17 340

5.4 READING LIGHT 10 24 240

5.5 TOILET OCCUPIED LIGHT 16 4 64

5.6 LAV. LIGHT 16 4 64

6 AC SYSTEM

6.1 AC UNIT 13600 2 27200

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6.2 CONTROL PANEL 140 1 140

7 SANITARY SYSTEM

7.1 WC CONTROL SYSTEM (24

V) 40 4 160

7.2 WATER PUMP 220 1 220

7.3 MAGNETIC VALVES 8 6 48

7.4 ELECTRIC SHAVER

SOCKET 20 4 80

8 PA SYSTEM

8.1 LOUDSPEAKER EQUIPMENTS

60 1 60

9 ELECTRIC CAR EQUIPMENTS

9.1 BATTERY CHARGER 6160 1 6160

37948

TOTAL LOAD 37.95 KW


S.NO.

COMPONENT POWER (WATTS)

QTY


(WATTS)

1 ANTI-SKID DEVICE 48 1 48

2 FAN


3 PANTRY EQUIPMENT

3.1 HOT CASE 1200 1 1200

3.2 BOTTLE

COOLER/REFRIGERATION 800 1 800


5 COACH LIGHTING



5.3 SINGLE COMT.+ VASTIBULE

+DOORWAY 20 15 300

5.4 READING LIGHT 10 52 520


5.6 LAV. LIGHT 16 4 64

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6 AC SYSTEM

6.1 AC UNIT 13600 2 27200


7 SANITARY SYSTEM

7.1 WC CONTROL SYSTEM(24 V) 40 4 160

7.2 WATER PUMP 220 1 220


7.4 ELECTRIC SHAVER SOCKET 20 4 80

8 PA SYSTEM

8.1 LOUDSPEAKER EQUIPMENTS 60 1 60



TOTAL 38188

TOTAL (KW) 38.2 KW


S.NO. COMPONENT POWER IN

WATTS QTY


IN (WATTS)

1 ANTI-SKID DEVICE 48 1 48

2 FAN


3 PANTRY EQUIPMENT

3.1 HOT CASE 1200 1 1200

3.2 BOTTLE COOLER/ 800 1 800


5 COACH LIGHTING



5.3 SINGLE COMT.+ VASTIBULE

+DOORWAY 20 10 200


5.5 LAV. LIGHT 16 4 64

6 AC SYSTEM

6.1 AC UNIT 13600 2 27200


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7 SANITARY SYSTEM

7.1 WC CONTROL SYSTEM(24 V) 40 4 160

7.2 WATER PUMP 220 1 220


7.4 ELECTRIC SHAVER SOCKET 20 4 80

8 PA SYSTEM

8.1 LOUDSPEAKER EQUIPMENTS 60 1 60



TOTAL IN WATTS 37568

TOTAL (KW) 37.57

CONNECTED LOAD CALCULATION FOR LHB TYPE PANTRY CAR (HOT BUFFET)

S.NO.

COMPONENT

POWER IN

(WATTS) QTY

3-PH AC/415

V

1-PH AC/240V

1-PH AC/110V

DC/110V

WATTS WATTS WATTS WATTS

1 ANTI-SKIDDEVICE 48 1 0 0 0 48

2 FAN

2.1 EXHAUST FAN 132 2 264 0 0

3 PANTRY EQUIPMENT

3.1 HOT CASE,FOR

140MEAL 1500 1 0 1500 0 0

3.2 BOTTLE COOLER 90

LTRS 200 1 0 200 0 0

3.3 REFRIGERATOR,

310LTRS 300 1 300

3.4 DEEP FREEZER, 230

LTRS 400 1 400

3.5 OVEN TOSTER GRILL 1200 2 2400

3.6 WATER BOILER-1,2 &3 3000 3 9000

3.7 ELECTRIC BURNER-1 2000 2 4000

3.8 ELECTRIC BURNER-2

& 3 2000 2 4000

3.9 ELECTRIC BURNER-4 5100 1 5100

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3.10 ELECTRICAL

CHIMNEY-1,2 & 3 300 3 900

3.11 INSECT KILLER 20 2 40

3.12 WATER FILTER 200 1 200

SUB TOTAL OF PANTRY

EQUIPMENTS

28040

4 SWITCH BOARD

CABINET 500 1 0 0 0 500

5 COACH LIGHTING 0

5.1 LIGHTINGS 40 WATTS 40 9 0 0 360 360

5.2 LIGHINGS 20 WATTS 0

5.3 SINGLE COMT.+

VASTIBULE + 20 15 0 0 300

5.4 DOORWAY 0

5.5 LAV. LIGHT 16 2 0 0 32 0

5.6 TOILET OCCUPIED

LIGHT 16 2 0 0 0 32

6 AC SYSTEM

6.1 AC UNIT 13600 2 27200 0 0 0

6.2 CONTROL PANEL 140 1 0 0 0 140

7 SANITARY SYSTEM

7.1 WC CONTROL SYSTEM(24 V)

40 2 0 0 0 80

7.2 WATER PUMP 220 1 220 0 0 0

7.3 MAGNETIC VALVES 8 6 0 0 0 48

7.4 ELECTRIC SHAVER

SOCKET 20 2 0 0 0 40

8 PA SYSTEM

8.1 LOUDSPEAKER EQUIPMENTS

60 1 0 0 0 60


0

9.1 BATTERY CHARGER 6160 1 6160 0 0 0

SUB TOTAL 33844 28040 392 1608

TOTAL Watts 62276

TOTAL (KW) 62.276

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ANNEXURE - 3

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ANNEXURE – 4

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ANNEXURE – 5

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ANNEXURE – 6

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ANNEXURE – 7

Documents

SPECIFICATION FOR 2 X 500 KVA IGBT BASED HOTEL LOAD CONVERTER FOR …clw.indianrailways.gov.in/works/uploads/File/16-08-17-Review Specification of Hotel... · page 3 of 45 specification