August- 2014 SPECIFICATION FOR IGBT BASED 3X130KVA AUXILIARY CONVERTER TO BE USED FOR THREE PHASE LOCOMOTIVES Specification No: CLW/ES/03/IGBT/0485, Alt-B Total No. of sheet-29TABLE OF CONTENTS CL. No. Description 1 Foreword 14 ‘Scope & Object. 12 Contractor's Responsibility 13 Railways Responsibility 14 Reference to various Specification. 15 Documentation 16 Infringement of patient Rights. 2 Technical Specification 3 Climatic & Environmental Condition 4 ‘Scope of Supply 5. Tests 6. Annexure ra Pe ECEOTON FA | oncrey. | cecxen ay vearsco | sopoeo | Acepes > pi] CENTRE FOR DESIGN 8 OEVELOPMIENT oe AO “GATTARRINLOCOMOTNE WORKS a WESTEEIGHL ROA ee _ no SIMESHS TMs Nast 1ALTERATION RECORD SHEET Amendment Date of | Page No | Alteration Changes i inclause no. | | | [422] oeh | 128 6; A ly - | 134 17-10-2011 07 | A - Clause 1.3.4 has been deleted | 14 | 17-10-2011 Hl 7 | A it Clause 1 4 various standards are added. | 15 /17-40-2011 | 08 A Clause 1 5 have been modified and more information required | | being included. 23 Haza0z01 | 17 | A= Some Parameter value changes tke | | | frequency OHE voltage variation | | | \ etc | 233 | 17-40-2011 14 | 4A ~The contractors are controled by ausiary | i | i converter control electronics. | 25 | 102011 | 12 | A - Frequency steps for multiple operations is | | | | | modified and about out put connectoris | | added | 26 17-40-2011 | B A | = Control & communication of | | auxiliary converter with MICAS S2 control | | electronics willbe done through software. | 5 |ar02011 | 20 Teas | TEC sub-clause updated. al 123 /1208.2014 | 04 B | - Clause 1.2.3 has been modified | ar li20e2014 | 21 7B = Clause 47 has been deleted ya aor 0 roo a 5 seat oaseo | Seenad | keean J eae S| cae cece | WEST BENGAL ROMA | “ng eaese res | ro Frio to}CHAPTER — : GENERAL 1.0 FOREWORD Auxiliary converters (Aux Conv) are used to supply three-phase auxiliary load (auxiliary motors) ‘and battery charger, The Auxiliary Converter units are mounted in the machine room and are forced cooled. The Aux Conv electronics wil be mounted in the converter cubicles and shall have the necessary interface with the vehicle control electronics. The auxliary converters shall be supplied in two preassembled units. The contractor is expected to study the existing machine room layout. ducting, cable routing etc. in detail in a site visit if required. Such a site vist shall be arranged on prior intimation to LW. Submission ofthe offer shall deem that all the aspects are known at the time of making offer. IR intends to go for open control system for vehicle control and would lke to integrate, in futur. The auxiliary converter with the vehicle control electronics on a bus system conforming to Published open standard. The design of auxiliary converter should keep this aspect in view, though it is not covered in the present scope of supply 14 SCOPE & OBJECT This specification covers the technical aspect of the Railway's requirement for the three Numbers 130kVA IGBT based auxiliary converters for three phase locomotives of the type WAG-9 & WAP-5. It explains the interface requirement of the equipment with the locomotive and traction system, clarifies the load pattern on the auxiliary converters and lays down the desired performance and testing methodology. Relevant IECs will be the governing specification except for what is mentioned inthis specication 1.2 CONTRACTOR'S RESPONSIBILITY ‘The contractor's responsibilty shall be extended to the following 121 The supplier shall supply detailed instructions for proper installation of the equipment on the locomotive. For this purpose the supplier should also depute his representative during installation of the auxiliary converter in the locomotive at each location(Shed/CLW) 1.2.2 The supplier shall be responsible for commissioning, testing & field trials of the prototype ‘equipment in service and depute team of engineers for this purpose. The supplier shall arange to carry out detailed test & field trial jointly with CLWW & RDSO. 1.2.3 The supplier shall also quote for special tools, testing jigs and instruments, which may be required for troubleshooting and maintenance of the auxiliary converter separately. FEORCATON | —~ OR PREP ey | cMEcKED av % icarsasen | SSEDKD | AEEIDED ey SK IGORVA | ‘oat | aunuieey ‘CENTRE FOR DESIGN 8 DEVELOPMENT | converter ‘CHTTARANIAN LOCOMOTIVE WORKS, TOBEUSED1.24 The supplier shall quote for spares, which may be required for satisfactory maintenance of the equipments for a period of 5 years. 1.25 The supplier shall also submit on demand repair charges for the cards. The repaired card will have warranty of one year A separate contract wil be executed by the Railways with the contractor for the repairs 1.28 The supplier shall supply suitable software “if applicable” for of-ine analysis of diagnostic data downloaded from the Auxiliary converter 1.27 The design shall be developed as per requirement given in the specification. The detailed design shall be submitted to CLW and RDSO for scrutiny and approval before commencing of the manufacturing. Here “approval” means the “approval of design features” only. The suppliers shall be responsible for performance of complete Auxiliary Converter 1.2.8 Warranty ‘The supplier shall warrant that everything to be furnished under the contract shall be free from defects and faults in design, material, workmanship and manufacture, and shall be of the highest grade and consistent with the established and generally accepted standards for siores of the type ordered and in full conformity with the contract and samples, if any, and shall, if operable, operate properly according tothe contract The warranty for the stores,to be supplied under this contract shall be 42 months from delivery or 36 months from date of satisfactory commissioning and acceptance test of the stores, whichever is earlier. The contractor shall immediately on receipt of notice of defect depute his engineer to start action for rectification of defects under warranty. In the eventuality of major design modifications during the warranty period, the warranty for ‘such components shall be extended for such period as is mutually agreed. 1.29 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 4.210 Training The supplier shall arrange for training to IR personnel in maintenance & trouble shooting of the system supplied. Five days training for six persons per location is to be offered in the field of maintenance & trouble shooting. Number of locations will be mutually agreed between manufacturer and CLW based on the ordered quantity, 1.211 The supplier shall supply the write up and the elaborate manual for maintenance and trouble shooting free of cost to I for easy maintenance 4.2.12. The supplier shall submit detailed system design manual for the system foe INFORMATION ONLI FOR ener ey. | crecKeD a vosranseo | S808 | AEEDED SuigoKve es ES 1 : | 4 hegat AUXILIARY | (TRE FOR DESIGN & DEVELOPHEN” | comertes | MTAROAN LOGON THE RRS | eee | | ear EL ADA | for oo Mo euesesTGBrs } mse | MORAY ———~S ia Pr a [econo Wen at [a | Loi-6- 1.3. RAILWAYS’ RESPONSIBILITY Railways willbe responsible for following 1.3.1. System interface design in terms of hardware & software and changes associated with them in the locomotive contro system will be done by Railways 1.32. The cabling in loco for modifed load distribution and protection 1.3.3 The isolation and switching arrangement for auxiiary motor. 134 Deleted 1.3.5 Any equipment re-ayout on locomotive necessary for installation of Aux Conv shall be done by the raitways. 1.36 All labour consumable materials, electrical energy for erection, testing & commissioning of Auxiliary Converter will be provided by the IR free of cost. 1.3.7 The wages and allowances as well as the cost ofthe passage to and from the place of traning for the railway personnel 1.4 REFERENCE TO VARIOUS SPECIFICATIONS This Particular Specification is based on the following Normative References Only those revisions shall be taken, which are valid on the date of signing the contract. In addition tothe folowing, relevant ToT documents shall also be referred wherever required Standards {ee : aes lec 6007-1 Railway applications - Roling Stock General Rules tC 1287-1 [Rainy ‘applications — Power converters installed on rolling stock IEC 60571 Specific rules conceming the electronic control part of converters. | tec 61373 Railway applications tock equipment — shock and vibration test | EC 60310 Traction transformers and inductors on board rolling stock | EN50121-3-2 | Railway applications — Electromagnetic compatibility (CENELEC) | Part 3-2. Rolling stock - Apparatus EN 50121-2 | Railway applications ~ Electromagnetic compatibility (CENELEC) Part 2 : Emission ofthe whole railway system to the outside world \EC -61375-1 Electric Railway Equipment-Train Bus Part—1 : Train communication network EN 50153 | Railway applications — Rolling stock — Protective actions against electrical hazards 3 | ssn EN 60529 | Protection classes of cases (IP-Code) oe SEORORTON | — = +R PHASE “APPROVED BY a ies [bree Cy for | PREP SY. | cHecKeD ey ¢ | Seer = } ca isco oso | aeeaD Nut aun P Ls ‘GENRE FOR DESIGN 8 DEVEL OPHEST ‘CHITTARANAAN LOCOMOTIVE WORKS "WEST BENGAL, NDIA NO: CLES GBTIOEaS T T a [ao | 1 l ce | creuses | roa |DOCUMENTATION The tenderer must submit the folloking information with the offer in printed form and neatly compiled in a booklet form. Offer wth incomplete information may not be considered Detailed specification ofthe offered converter, major equipments like transformer, chokes, and DC link capacitors as well as MCCBs & fuses et Details of semiconductor devices used, their specification and data sheet. Design calculations including the calculation of safety margin in voltage, current, thermal (for junetion temperature) along with the limit value of power devices. Detailed calculation of cooling system design and its efficiency are to be furnished. Minimum airiow rate, which will give the desired cooling, should be mentioned Mechanical drawings of complete cubicles as well as Major subassemblies | rack with details of dimensions, mounting arrangement and weight, which are required to be taken out for maintenance Details of protection provided and their effectiveness / proposed set values and range and working principle. Details of implementation. system description, power circuit diagram along with bil of material of major equipments, Circuit description, working principle and salient features. The details of microprocessor | microcontroller used, functional block description of PCBs used, control system hierarchy, protocol used and interfacing Detail operation of panel and function of each switch, indications and fault diagnostic feature QAM (Quality Assurance Manual) Declared output voltage and current waveform, THD and regulation Test protocol with procedure of te Data sheet of major components duly filed. 'S0 9000 certification ‘Schematic Circuit om MATION Functional Description rox THOR! ‘Mechanical interface diagram and compliance to existing mechanics Clause by clause compliance. Calculation and simulation results of system behaviour, including Fy FICATION PREP BY oR creoceo By § voateasen | S Delaiis of Tools and Plants with design/drawings and suppliers. ac as o FEOROTER : TET Trrctay | ogo or eS | ae = concoct ocr arnacaieamneags oe ea | 2fitee — Pieenoven er T. odoworves | Br cet o8D ar fa |e |16 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 cause such dispute The responsibilty to settle any issue lies with the manufacturer PREP BY S040 ‘caTiOn (CHECKED By AEEDED CS - ‘see TRE FOR DESIGN & OE. APPROVEDEY | ov cee! Dap-10- CHAPTER - 2: TECHNICAL SPECIFICATION 24 The auxiliary at AC input may use thyristors or IGBTS. The inverter should, however, be with IGBTs. The control should be microprocessor | micro-contoller based with diagnostic facilities. The specification has been drawn for three auxiiary converters identical in all respects each with 130 KVA capacity and battery charging unit (details in 2.2) constitute one loco set of equipment, however, for sake of clarity unless otherwise specified following applies to each of the converters which may be referred as BUR1, BUR2 and BUR3 respectively housed in two cubicles, cubicle-1 shall have BUR1 and cubicle-2 shall have BUR2 & BUR3 2.2 Converter Ratings (BUR1, BUR2 & BUR3) INPUT (2) Voltage 1000 V single phase at a catenary voltage of Nominal Voltage -225KVAC Maximum Voltage = 27.5KVAC Minimum Voltage = 19kV AC Occasional Maximum -31kV lnstantaneous Minimum “16.5kV Supply Frequency = SOHz+ (8%) The occasional maximum and instantaneous minimum voltage may persis for 30 min. (b) Frequency 50 Hz + 8% (©) Power factor (0.8 or more (at full load) between OHE voltage 419KV to 27.5kV and min, 0.55 above 27 5kV. (d) (THD) Total Harmonic To be kept to minimum, manufacturer will distortion (Current) indicate the optimized value at full load {e) Winding Details 334 KVA 5.82% Impedance / 268.58 mc FOR prep ey | ciecxeD av vopreaseo | seqoHD | AezDso j 3 as Cee FoR DESI &DEVELOPLENT ol -e* Grurratauncocowarve ers WEST BENGAL NDIA esi | | i ie 1 es tasUe ouTPUT (i) AC, 3 phase (a) AC voltage (U-L) 415V45% (b) Nominai Output Frequency S0H2#3% (6) KVA output 130 KVA (A) Short time current rating ‘same as overload rating of existing GTO based 3 X 100KVA auxiliary converter ie approximately 450 A for 4 lo 6 sec (@) Total harmonic distortion (THD) in Less than 10% the output voltage to the 3-ph mator (fh dvidt Less than S00ViMicrosecond (a) The auxiliary converter shall be suitable for generating 3-phase AC out put at ‘muitiple voltages and “frequencies as detailed in para 25 below (i), DC output (a) 110V, 80A with current ripple less than 5% and voltage regulation +5%, with battery current maximum of 1108 (b) The Battery Charger characteristic should bé suitable for charging the existing 199 AH Ni-Cd battery & supplying the 110 V load in 3-phase locomotives C._ Efficiency at rated output Minimum 92% at rated load (130 KVA) of 0.8 pf Note: Rated capacity of 130 kVA is expected for input voltage range of 19kV to 30kV. However, degraded performance in terms of lower output voltage or frequency is acceptable below 19kV and manufacturer will specify the extent of degraded performance. It will not be possible to regulate the duty oycle ofthe loads. The existing smoothing choke which is rated at 155A (Max. 190A) shall be explored for adoption in the improved design of Auxiliary Converter (3X130 KVA). In the event of inadequacy of the existing choke, the tenderer shall offer alternative choke design, Keeping in mind that this choke will be provided in the machine room and os INFORMATION ONLY =] | | wept aasen | SREOED | AEEDRD SNK er ira oR rer er | cHecxeo av CENTRE FOR DESIGN & DEVELOPMENT TARANIAN LOCOMOTIVE WORKS NGA, NDIA WESOY IGETO4NS = -_ ; weeIe, may lead to increase of machine room temperature The details of the existing smoothing choke 's given below Pos. 513 Type |: eGobi20 Quantity || Three-phase choke | Location | Inside transformer tank | Data | Refer to specification No. 3ETIE 428048 | Inductance value of each BUR | choke at different currents | - | OA Ti | | 0A | = | USS. A 2 190.4 20 mit Verminal Notation: 23 xH23 xu34 Ly (a! BURI BUR? BUR3 xn24 XB33 bend = xp3i XB32 xpl3 xuld Each choke consists of a magnetic frame. The chokes are arranged in a stack. Since asymmetric voltages are applied across these, the chokes are decoupled. The DC link elements are designed for a nominal power of 100 kVA. Load pattern The normal & emergency loadings are shown in Annexure. 23.4 Three phase auxiliary load 232 DC load an’ gee OO ‘Auxiliary loads on individual BUR, in normal and fault conditions shall be distributed as detailed in Annexure. Auxiliary converter should be in a position to soft start the loads using variable voltage variable frequency control Trie locomotive control circuit, loco head light, flasher light etc. are fed through 110V DC circuit containing locomotive battery. ORO = FOR eeeray. | cuecreo By ‘oe \oaT BASED seEbeD q Se 10 KA heasih Aya ‘CENTRE FOR DESI A DEVELOPMENT converter ‘GATTARANIAN LOCOMOTIVE WORKS owe use WEST BENGAL DA FoR LIES GETS sovnse | RAPRGVEDEY cocouorves | Ov CEE!D80 Etted in the Buxiliary convertor shalt be te Protected against high rate of rise ot ‘Gurren line transient surge Switching surges alc The converters shall be protected Open circult In aindlary winding - Ground fault in AC input circuit Ground fault in 3-phase load Auxiliary convertor phase fault Line fe line short circuit due to'dead short at motor terminalsde Based on the ventilation requirement the auxiliary converter shall be required to be operated at 50 Hz even in case of isolation of one of the auxliary converter. Therefore the output connector shall be suitably modified to carry fullload as per annexure 26 Integration with Vehicle Control Electronics: The Auxiliary converter has to work with the existing Vehicle Control Unit, which is based on MICAS $2 control & communication (C&C) system of Mis. Bombardier Transportation, The tenderer shall give a suitable interface to the existing VCU. All the contro! and communication functionalities of the existing Auxiliary Converter shall be met by the proposed IGBT based auxiliary converter. Modified software suitable for the converter shall be within the scope of ‘supply. The Auxiliary converter shall be ready for use with upcoming TCN compliant VCU which is as per CLW specification No.-C-D&D/TCN/VCU/HWIMICAS-S2/VER3. Specification shall be made available tothe tenderer at CLW on demand 27 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 auxiliary converter. The faults shall be down loadable on a laptop computer through a standard pot interface. Large capacity of storage of faults along with the background data should be provided, so that data pertaining to at least 90 days are kept stored. Details of the fault diagnostics and indication of faults / health status shall be finalized during the design approval stage. 28 Safety Following shall be provided in each Auxiliary converter cubicle for human safety. 2.8.1 _ Indication of presence of high voltage ( Voltage Indicator ) 282 Safety inter lock on front panel with lock and key to be integrated with existing key mmutipler system 29 Mechanical dimensions The spaces for retrofitment of Auxiliary converter in place of existing equipment are mentioned under The changes if any are to be agreed to between Railways and the auxiliary converter manufacturer It is to be ensured that the above equipment could be fitted in existing types of locos of IR namely WAPS, WAG9 & WAP7. Envelope size of the space available in the locomotive for mounting the equipment (all dimensions are in mm) for retrofitment on WAPS / WAGSIWAP7 locos, will be as under: on ort ATI : vos SIFORME ‘SPECICATION * = 7 ae isco | Seon | Meow” Gy scar basen | SE Bia OS CENTRE Fn DSI DEVELOMENT eae Zs GTARARUAN LaCOMDTNE WORKS Tour seo NES ENGL oa | ai ng cues Ge shrnse_ [WPROVEDRY T sects forowo® mY far [a fo [ |a15= Overall Size Mounting Dimensions (Cubicle 1 1460 «10201860 (LxDxH) 1120%900 (LxW) (i) Cubicle 2 1520 1020*1860 (L*DxH) 1480 *900 (LW) Note: ‘A. Agap of 50 to 100mm only is available between roof and equipment in the locomotive and hence cooling system design should be done accordingly. B Each cubicle houses fully identical 130 KVA converter as described in 2.1 C._ Offer should include power loss calculation considering existing cooling system 210 Weight: The weight ofthe existing auxiliary converter cubicles are approximately Cubicle -1 (BUR-1) 608 Kg Cubicle -2 (BUR-2& BUR-3) - 1130 Kg 241 Enclosure : 211.1 This would be as per TOT design documents for auxiliary converter of 3 phase loco. Any alternative design meeting functional requirement can be offered with full details for IR's ‘scrutiny and approval 211.2 The enclosure for electronics shall be free from dust and moisture Design of cooling heat exchanger shall be done to ensure temperature difference less than 10 degree centigrade across the heat exchanger. 242 Cooling From machine room blowers. a part ofthe cooling air is guided to the auxiliary converter. The heat losses in the BUR’s are carried away through the heat exchanger. The ventilation air guiding ducts from the machine room to auxilary converter cubicle 1 & 2 provide following air values Cubicle 1 Airflowrate Front. ; 1100 mh Rear. §50m%h Airspeed Front. > 2.5 mis sor INFORMATION Owner Rear 50mis PEE Texcran | cca oy re i | Sevan | aetna Qs CENTRE FOR ESIGN 8 DEVELOPMENT (OTTARANIAN COCOMDTIVE WORKS | BENGAL NOW 08 FOR seas auore WROVED| Dy Ee! 08D : | | lBee Pressure Front: 30Pa Rear: 6Pa Cubicle 2 Airflow rate Front: 1700 mith Rear 1100 miih Airspeed Front’ = S mis Rear Smis Pressure Front: 30Pa Rear 20Pa The existing arrangements for the cooling of the auxiliary converter shall be preferred However, the tenderer shall furnish detailed alternative arrangement if existing arrangement is found inadequate 243 Locomotive cable interface: It is proposed that the cables for connection to the locomotive should be in the bottom of the panel. Following are the sizes of various cables proposed to be Used, However, this may change as per the requirements and needs and shall be discussed & finalised after placement of order.EB irradiated cables shall be used for intemal wiring (a) Transformer auxiliary winding to input of Auxiliary converter panel ~ 70 mm cable. (b) Output of auxiliary converter — 50 mm? cable. (a) Battery charger to battery base ~ Two 10 sq mm cable Control cables are connected from upper side of the cubicle through a circular connector However, finalisation of cable outlets shall be done during design approval after award of contract Location of input & out put terminal should be same as the one in existing Aux converter to provide for interchangeabilty of different makes of Aux converter 2.14 General design feature 2144. Safety factor (@) Inthe circuit configuration, 25% safety margin in the rating of both voltage and current under worst conditions is to be ensured. This should be established in the offer with calculation. * ot non cee | ay seuse_ PweROWEDET or cero TYR jar fae L-17- (b) A minimum thermal margin of 10°C for junction temperature under worst operating condition for the power devices is required, Over load margins and duration are to be furnished 2142 Current density of the bus bars °4A / sq. mm 2143. Acoustic Noise : Acoustic Noise generated by circuits and components should be as low as possible, less than 80 dB (A) at a distance of 1 M from the equipment 2144 The cards shall be provided with LED indication to show the health of cards, to assist maintenance and operating personnel in trouble shooting 2.145 The power portion of the equioment should be suitably protected to prevent accidental contact The shields and screens shall be properly earthed 2146 Reliability : Component to be selected and tested as per intemational reliability assurance specification including bum-in test and necessary de-rating for traction duties. The components are to be sourced from reputed sources. MTBF of the equipment will be furnished by supplier 2.147 Maintainability : The use of general purpose ICs should be encouraged and use of ASICs restricted for better maintainabilty Modular system with plug in and easily replaceable control cards with polarization for non-interchangeabiliy shall be provided. Accessibilty to components, [subassemblies requiring frequent maintenance should be ensured. Access is available only from the corridor sides. 2.14.8 Marking : The major equipments / subassemblies should bear marking and serial number. The equipment should contain serial number and make of supplier (2) All equipments / cubicles shall contain name plates of anodised aluminium with ‘engraved / punched letters. (b) The inverter rating plate shall be marked with the following information Type / Make (i) Contract number (ii) Month and yéar of manufacture / batch no. / Serial no, (iv) Rating ~KVA ~ Input voltage range ~ Output voltage. frequency and wave shape far INFORMATION ONL —T - ey Fae | exerar | cyte ov Py scereiseo | S8qOA | Stee } x 130HvA Yuast - ae cea om ces 8 DEVELOFMEN | ‘weet Garanutat LOCOMBINE WOPKS | esr bengee NDE sense | T T | | Looj dt | TOBE USE2149 Cable -18- he use of wires / cables shall be reduced to minimum. Bus bars will be of high grade Copper and 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 wires with circuit and 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. 2.14.10 Cable grommets / glands of suitable size as required for input and output cables shall be provided at cable entry/exit RECREATION [= FOR. pre ey | cuecnto By IGBT BASED. ‘SSEID8O | AEEDEO q i yes ‘CHTTARAWAN LOCOMOTIVE WORKS CONVERTER es ‘WEST BENGAL DIA (OBE USED No CLM IEBTONS FoR = spuse | waRGven ey cocoworives | OY CEE/O8D KN arCHAPTER - 3 : CLIMATIC & ENVIRONMENTAL CONDITION 3a 33 34 35 36 37. 38 Temperature Maximum temperature inside stabled Locomotive under sun 70,deg. C Maximum temperature inside working loco 55 deg C Minimum temperature Odeg ¢ The equipment shall be able to start up at the maximum specified temperature inside the locomotive without any pre-cooling requirement. Humidity Upto 100% during rainy season. Altitude - Upto 1000 m above mean sea level. Rainfal - Very heavy in certain areas, The propulsion equipment shall be designed suitably, ‘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. In many iron ore and coalmine areas, the dust concentration is very high affecting the filter and air ventilation system. 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 folows: a) Maximum pH value 85, b) Sulphate 7 mg per lire Max. concentration of chlorine: 6 mg perlite 4) Maximum conductivity 130 micro. siemens ICM Vibration The equipment shall be designed to withstand the vibrations and shock encountered in service satisfactorily as specified in IEC 61287 and 60571 publication for the converter and electronic equioments respectively and relevant IEC's as applicable to other equipment 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 Auxiliary Converter or EXFORMATION ONLY OR DESIGN 8 DEVELOPMENT NIAN LOCOMOTIVE WORKS 0 S00 ESTONES coMERTE TOBE User-20- 3.9 Input Power Interface (a) The auxiliary converter wit be supplied through the auxliaries winding of the locomotive transformer. (b) A RC snubber is placed across the auxiliary winding with R = 220, 320W and C = 0.66yF, 2000V. In addition, toroid cores are inserted in the input cables to minimise the didt and interaction between multiple converters across same winding. The tenderer has to study the present scheme and to ensure that offered converter is protected in all operating conditions, (c)__ The catenary voltage can vary from 19.0kV to 30kV. However, voltage may dip down to 17.5kV which may lasts for upto half an hour. (a) Input power frequency = S0H2:8% (e) Panto bouncing duration upto 45 ms (limit of zero pressure contact} should not affect auxiliary converter with or without loads, 3.10 Signal and telecommunication installation : The tracks over which the locos will run may be equipped with 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, “SRDRCATION ] = FOR Pree ey. | checaED ay wwatease | senso | sess apse CENTRE FOR DESIGN DEVELOPUENT cowenreR SS CGATTARARUAN LOCOMOTIVE WORKS Tee used WEST BENGAL NDIA FOR oS GBT4es sense | APPROVED EY —* T cocouores | Brewer [A |e |4a 42 43 44 45 46 47 48 49 coMERTER CHAPTER —4 : SCOPE OF SUPPLY The scope of supply covers design and development of complete set of 3 nos 130 KVA IGBT bbased auxiliary converter for 25kV AC 3 phase locomotive, including battery charger to meet the 110V DC load requirement. Contactors as provided on the existing locomotives for itching and transferring of loads shall be retained. Supplier shall supply suitable software for offine analysis of diagnostic data downloaded from the auxiliary converter The Auxiliary Converter should have provision for cab air conditioning, which may be adopted in future. The tenderer should also submit the complete proposal consisting of related hardware and software Commissioning of complete set of 3 nos 130 kVA IGBT based auxiliary converter on the locomotive Five days training for six persons per location isto be offered for IR personne! for training in the field of maintenance and troubleshooting, For the ordered quantity of 10 sets, training shall be provided for the personnel of maximum two locations Detailed operation and maintenance manual Deleted List of spares for § years maintenance Repair charges for the PCBs Tenderer shall separately quote for the item mentioned under clause no. 4.8 - 4.9 or HFORMATION Om.~ PREP BY CHECKED By-22- CHAPTER ~ 5: TEST 5.1. The converter shall be tested in accordance with IEC61287, IEC411.6 & the control electronics shal be tested as per IEC60571 52 The list of tests to be carried out is as follows S.No. Sub Clause | | 1 “081287 clause 4.5. 53. 4 Visual sspection | | 2 16061287 clause 453.2 | Verification of dimension &| ¥ | | | Tolerance | | | 3. 1661287 clause 45.33 | Weighing | “| | | 4 eCe1287 clause 4534 | | Marking Inspection | [74 | 5. (EC61267 clause 4535 | Cooling system performancetests | 6. 42061287 clause 45:36 | Test of mechanical and electrical | 7 | | protection and measuring | equipment 7. 1€C61287 clause 4.5.37 "Light oad test | | 8 | 1EC61287 clause 4.5.3.8 | Test of he degree of protection ZI | | 9. | 1EC61287 cause 453.9 | Commutation test v | 10. 1EC61287 clause 453.10 | Acoustic noise measurement |” | | ¥_ ora de 45311 | Terps vt 12. | 1E061287 clause 4.5.3.12 | Power loss determination “ | 13. | 1E061287 clause 4.53.13. | Supply over voltage and transient | | energy | 14 1EC61287 clause 4.5.3.14 | Sudden variations of load | ) 45 1€C61287 clause 4.53.15 |-insulation resistance tests | | 4g | 1EC61287 clause 45.318 | Dielectric test | 7, | 16061287 clause 45.347 | Paral Discharge tet | 4g. | 1E081287 clause 45.318 | Safety requirements 49. | 1€C61287 clause 4.5:3.19 | Vibration and shock 29 (EC61287 clause 4.5.3.20 Electromagentic compatibility | FERRO] —= c Fa | rmcrav. | crecreo oy vcatesses | Sos | eevee sora ve CaN FOR DESIEN 8 EVEL OPMENT Owen CHTTARANLAN LOCOMOTIVE WORKS ‘owe used WES GAL ND ron gaye Gos cotties [Rees | nls L | [|21, 1EC61287 clause 4.5.3.21 | Step change of line voltage test | 22 1EC61287 clause 45.3.22 Short time supply interruption test | 23 | 1EC61287 clause 46.323 | Current sharing test | < 24 IEC411 Sclause 43.8 Short ime interruption 2 | 25 |IEC411Sclause 43.11 DC link discharge | v 26 1EC411.5 clause 4.2.7 Rated current load a 27 Output voltage & frequency. (HECA11S clause 4.3.3, | - | range | | | 26 |IECSIS cause 1022 | perormance test by faut) | Y | | | simulation | \ 29 IEC61S71 clause 10.262 voltage surge on Control | Electronics 30 | HECB1S71 clause 1.264 | Electrostatic discharge test on| | control electronics | | : 31_| 060571 Yous 1027 | Transetbusteusepbay est | | 32 1EC60571.1 clause 10.28 | Radio interference test on control) Y | | _ | electronies | | 33 IEC60571.1 clause 10.25 | Damp heat on control electronics | | tov 34 IECB0571.1 clause 10.24 | Dry heat on controlelectronics | 5.3 The suppliers shall submit complete test programme for type and routine test to authorised representative of CLW for its approval, Authorised representative of CLW may also decide to carry out certain special tests on the equipment, which are not covered by relevant IEC specification. Manufacturer will carry out the test as per mutually agreed test programme at his ‘own cost. 54 The prototype auxiliary converter units will be inspected & tested by the engineers of CLW and RDSO at the factory premises or at mutually decided venue where all the facilities should be made available for carrying out the prototype test. The equipments wil be kept in field trials for 2 period of six months. The CLW and RDSO engineers will associate and witness the tests in the locomotive also til they are successfully completed Any defects noticed / design improvement found necessary as a result ofthe test trial shall be carried out by the tenderer in the least possible time. Serial production shall only start after successful tial run on loco and clearance to this effect given by RDSO. Por INFORMATION Onn CATION Be for” | ewepox | crecnen ey ee veorarses | S8g0ED | Seeea Gy SeOKVA haat AUXLARY CENTRE FOR ESE & DEVEL OFNENT ‘Toe USED Cirimmumicconmine nome | St oevoA no | |-24- 5.5 The individual equipments, system and sub-system as may be necessary shall be type tested and routine tested in accordance, with relevant IECs. 5.6 Necessary arrangement should be made by the successful tenderer to carryout certain tests to establish conformance to specified requirements e.g. dvit, THD etc 57 Type test will 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 some or all the type tests shall be repeated once in two years by CLWV and purchaser on sample basis so as to confirm the quality of the product. This wil be part of revalidation of vendor approval. In addition, the manufacturer shall repeat all the type tests after 5 years. Type test will also be repeated in following cases: - Modification of equipment, which is likely to effect its function First time supplier to IR - Failure or variations established during type or routine test — Resumption of production after an interruption of more than two years, ~ _Atthe time of indigenisation, if the supplier has supplied with foreign collaboration in product originally. - “The type test will be carried out for the equipment / sub-assembly indigenised. The type test on the full unit in the case of indigenisation will be considered only if there is major design change” 57 Routine tests are to be carried out to verify that properties of the product corresponding to those measured during type tests. Routine test are to be by the manufacturer on each equipments, 5.8 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. 59 Authorised representative of CLWW / ROSO 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 CLs specication on™ mont 5.10 Instrurentations c aaron (2) All the instruments used for testing should 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 will be measured by power analyser during the prototype test. True value of output voltage rms is also to be measured for record ‘SEGRCATION |= a 5 For | eRceov | creoxeo ay oy scareaseo | S080 | Keene Aunty CENIRE FOR DESI 8 DEVELOPMENT coven =e CCHTTARANUAN LOCOMOTIVE WORKS ie NEST BNCAL ND For io CASO Bes - om. [Rete ae | [| cities [mewae fp ur [a |e LE5 (c) Input power factor and the efficiency will be measured by using power analyser al rated load of 130 KVA at 0.8 pt 5.11 The following clarifications are issued on the tests included in 5.2 (2) Visual inspection - The object of visual inspection is to check that the equipment is free from defects and the equipment are as per approved drawing. Bill of materials will be submitted The make, rating of equipments, subassemblies will be checked with the details as per approved design proposal submitted in design proposal. If a change is needed in make or rating of important equipments, subassemblies, it should be intimated and should have approval of CLW. Auxiliary converter with modified equipments, subassemblies will be given separate revision number. All the important «dimensions will be measured and should be in permissible tolerance. (b) Power loss determination test - This test will be done at voltage corresponding to 22.5kV in OHE, The efficiency will be measured at full and 80% of load at 0.8 pf. The performance at different input voltage will be monitored. The measurements will be taken at 17.5kV, 19KV, 22.5kV, 25KV, 27kV and 30 kV. (c)__ Earth fault - Simulate the earth fault by connecting a suitable resistor between cubicle frame and output phases. The inverter should not trp and earth fault indication will be in “OFF” state til the leakage current is less than 10mA. If the leakage current will, exceed 50mA, the earth fault will occur (©) Cooling test - The purpose of this test is to verify that the cooling of various components / assembles. The air flow rate wil be measured to confirm compliance with that claimed by the manufacture. (Insulation resistance and Dielectric test - The insulation resistance with 1000V meager shall not be less than 100M ohms at 70% RH tor all the circuits. The dielectric test shall be carried out after shorting semiconductor device, pulse transformer earthed, earthed special cards if necessary before applying dielectric voltage. The ‘corresponding voltages are given below The following are the voltage and leakage current setting © Input circuit.~ the test is to be done at 3.3kVrms for 60sec. The leakage Current to be less than 10mA + 110V control side - 1.5kV AC for 60 sec. The leakage current will be less than ima. + 24V electronics side ~ 500V AC for 60 sec. The leakage current to be less than mA, + Battery charger — (418V side) 2kV for 60 sec. The leakage current to be less than 1mA for INFORMATION ons [RncTor le ‘= FoR rar | vont Base Ee aes - come roreeset roe nier CONVERTER \ <—S CHATTARONUAN LOCOWOTINE WORDS comers acca = se sane se pep ; tines 4 eras Cen fer | l | : Lea I —a-26- - ‘Temperature rise test : The Auxiliary converter shall be loaded to full load for 6 hours (9) with input OHE voltage of 19kV and with 50% blockade of the inet fiers, i used. 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 purchaser and manufacture. The maximum recorded temperature under worst condition shall be corrected for 55°C and compared with maximum permissible temperature. (for power devices at junction). The thermal margin available shall be compared with the safely margin declared by the manufacturer. The temperature of the power devices shall have a margin of minimum 10°C. The inverter shall also be subjected for short time rating after continuous loading to ensure the temperature rise in within the permissible mit. The maximum temperature rise ofthe electronic devices on the PCBs should not exceed approximately 20°C above its ambient. In case it is exceeding the limit, use of mitgrade component can be considered keeping CLW and its authorised representative informed. (h) Damp heat test : Function test of electronic rack will be carried out after the damp heat test. (i) DC Tink discharge : The DC link voltage should come down below SOV within § minutes 0 Short time rating : Short time current rating shall be same as existing GTO based 3X 100 KVA auxiliary eonverter. as oo o* +s SFEFERTON ton | emcee | cuecned ay veararsen | sge080 | AeEoaD ‘ SeI30KvA ae CENTRE FoR DESIGN DEVELOPMENT or seh area een WEST BENGAL, NOR me No" CLvest Ges Fa a a a a27 6. Annexure ( Existing load connections (Revised load distribution with modification release 434) BURI Both oll cooling units BUR2 Both traction motor blowers & all four oll pumps. BUR3 Both compressors, both scavenge blowers & battery charger Distribution with Three Converters Following are the load distribution However, IR reserves right to redistribute the load as per its requirement. This shall be finalized with the successful tenderer. This distribution is for 3*130 KVA concept | BURA | Oil cooler blower-1 25 KW | | Oil cooler blower-2 | Totat | BUR-2 _ } | | Traction motor blower 1 Se ELC | Traction motor blower -2 | 25KW |47 KW il pump transformer - 2 larkw | Oil pump converter — 4 onkw | Oil pump converter ~ 2 Latkw | } I Total [81.4 KW | BUR ] Scavenge blower — 1 [3kw | Scavenge blower - 2 3 KW | Compressor ~ 1 18 KW | | Compressor ~ 2 15KW | Battery charger 12KVA | | | Total 43 KW | Pee INFORMATION orn» a - - , =] tor | ewepey | one fermi | SoH | Aeon ie OMvERTER =< ‘Gurtatusuan cocoMoi Ne WeaKs TOBEUSED WEST BENGAL NO FoR cable a2 ov eLWesMs cards roast | SPROWEDEY 1 LTWhen BUR-1 ISOLATED | Traction motor blower -1 | Traction motor biower -2 | Oil cooter blower ~ 1 Oil cooler blower - 2 Scavenge blo ‘Scavenge blower 2 | Oil pump transformer — Oil pump converter - 1 il pump converter - 2 Compressor ~ 1 | Compressor - 2 | | Battery charger | Total When BUR-2 ISOLATED Tractor blower Gil cooler blower — 1 Oil cooler blower - 2 Scavenge blower - 1 Scavenge blower — 2 | Traction motor blower 1 { Total Oil pump transformer ~ 4 Oil pump transformer ~ 2 Oil pump converter 1 il pump converter 2 | Compressor ~ 1 [Compressor ~ 2 7 | Battery charger Total ECREATON |= For | pREPY | cuore 8y vearrse | s9e080 | Seeman Sowa ee X ww cue FoR DESIGN 8 Dev OPMENT cowerteR a HT TARANIAN LOCOMOTIVE WORS ‘ove use WEST SENGAL NDA ror sw ceS09 GBro4ss apace | aeROVED ST coeitines | br ceva chee |e |e fe | :When BUR-3 ISOLATED | BUR-1 | Traction motor blower -1 25KW | Traction motor blower -2 | 25kW |_| leader bower- | KW | | Oi cooler bower - 2 | 25 KW [3 Kw | [3kw 106 KW | BUR | Oil pump transformer — 1 47 KW | | Oil pump transformer - 2 a7 KW | Oil pump converter ~ 1 11 KW | Oil pump converter — 2 (kW | Compressor ~ 1 Hs kW Compressor = 2 18 KW | Batiery charger | 12kva Total _ 73.4 KW Per RFORMATION Onr woraesco | SSe080 | Sehtan ey age bee — CATA er ae Toe ste EST NGA MOA a “tL = __NGINESOES Ns PHASE APPROVED | T, “| | | ccowotnes | bv emo 5 I Lt | 29- Cl