M/E No.

C-12, M/E Name: Engine Governor Test Stand for

Woodward Governor
Quantity: 1

1. Activity
The test bench is required for testing, calib ration and correct g rouping of Woodward Governors Type
Ele ctro hydraulic – PGR used on Alco 251 C, D,E (HP- 1200 to 2600) and EM D 567C, 567CR, 645 E 3C,
645 E 3 BC (HP-875 to 1650) eng ines fitted in the locomotiv es.

The test bench hav e a close loop system and shall be capable of check ing and testing of oil pressure,
oil leakage at reg ular base, gasket between base and main frame, all pipe plugs, all oil seals cylinder
heads, oil filter mounting plates, power frame of base, gear cases etc.

The test bench shall be capable of performing Speed test, Load Test, Timing test and MAP test in
automatic / manually by the computer. Details of the methodology should be clearly explained in the
offer.

The machines and equipment shall be capable of quick installation of W oodward Governors for
testing. Governor installation sequence and time should be mentioned in the offer by the Tenderer.

The Equipment shall be capable of performing continuously in Bangladesh Railway workshop

env ironment with ambient temperature up to 45 deg ree and relative humidity up to 98% without any
dev iation in performance or loss of accuracy.

2. Description
The specif ication covers design, manufacture, supply and commissioning of the test bench as per
parameter given below:

Major Parameters
• M aximum rotational speed of : 0 -1800 RPM test stand
• Speed Variation : Fully closed loop speed mic ro– processor
based speed controlle d system with integ ral control giving steady state drop. Bi-directional
rotational and speed control.
• Dig ital display of RPM : 4 Digits up to 9999 RPM
• M aximum Noise level : 75 db

Other Parameters
• Calibrating oil tank : Capacity-30 liters, fitted with low level
system indicator, micro filt ers, 2 KW heaters.
• Calibrating oil supply : Geared pump, fitted with separate motor,
capable of supplying normal fuel up to 0-5 bar with a pressure control with a manual course
and fine pressure control with a least count of 0.1 bar.
• Temperature controller cum indicator : Dig ital 0-99o C with a L.C of 0. 1o C, being
display ed on the LCD screen controlled through PC.
• Oil filtration system : Two stage filter, for clean oil supply.
• Protections : Under v oltag e, over voltage, ov er load, earth
leak age, phase sequence, single phasing indiv idual circuit MCBs, emergency cut off, etc.
• Power supply : AC 415V + 10%, 3 phase, 50Hz
3. Scope of supply
The scope of supply shall include all Equipment and accessories of computerized Woodward governor
test stand along with 3 termin als and wireless LAN which are optional accessories. The test bench
shall be fully functional when installed and connected to a power source.

4. Specific Character istics

The Equipment shall be robust in design with user-friendly controls for ease of operation.

The Equipment shall be provided with an emergency stop switch on the main control stand within
easy reach of the operator. The Equipment shall have adequate operator and Equipment protection
features which should be listed in the Tender. These should, interalia, include the following:

- Over voltag e protection

- Earth fault protection
- Sin gle phasing protection
- Safety cover inter locks

The machine shall incorporate all safety dev ices so as to provide complete protection to the operator
and machine. S ome of the important safety features which should be available on the machine are
mentioned below:

a. Suitable interlocks should be prov ided to protect the machine in the event of hydraulic oil
failure, lubrication fail ure, pneumatic system failure, fluctuation in v oltag e and frequency.

b. The safety feature shall include safety device against over loading of any driv e, other travel of
any slide and interlock against conflicting motions.

c. Mushroom type of emergency stop shall be provided on the machine which shall be easily
accessible and capable of disabling the machine drives in case of any emergency.

d. The Tenderer should give details of all the safety features in the machine in their offer.

Transducers and Gauges

The test bench shall have reliable transducers and necessary dev ices to capture data pertaining to oil
temperature and pressure, rpm, and vacuum etc. The data shall be captured through a proven and
internationally reputed data acquisition system and analyzed through efficient software in both
graphic and non-graphic form. The metering system should be based on the V irtual Instrumentation
System / Displayed on the LCD screen. The software shall be prov en and of internationally reputed
type, suitable for working in LAN environment.

The data measuring accuracy of tests transducers shall be minimum 0.01 cc for volume, 0.1 bar for
pressures, 1 cm for vacuum, 1 rpm for rotational speed and 1o C for temperature and 0.1 mm for
linear transducers etc.

The following transducers sourced only from proven, internationally reputed makes shall be provided
in the test bench. The type, make and accuracies of transducers used shall be indicated in the offer.

Rang e
i. Calibrating oil pressure 0 to 10 bar
ii. RPM/ Strokes per minute 0 to 1000 rpm
iii. Calibrating oil temperature 0 to 80 o C
iv. Fuel rack position 0 to 15 mm

Controls and Integrated Computer ized Main Contr ol Unit:

The following controls shall be provided throug h the integrated computerized control unit:
• Drive motor rpm control in the directions with infinitely variable step less speed variation over
the range.
• Start and stop of test cycle.
• Indication of temperature and pressure of calibrating oil.
• Energ isation of test bench.
• Rack setting and locking
• Injection pump discharg e.

Calibrating oil pressure reg ulation and power swit ch to integrate computerized control unit shall be
prov ided on the control desk and controlled manually.

Har dware Config uration and System Software.

The test bench will be controlled from a central control desk wit h integrated computerized control
unit consisting of data acquisition and signal conditioning hardware system of proven, internationally
reputed make, integ rated with industrial grade high end PC of latest config uration. The control unit
shall be erg onomically desig ned with V isual Display Unit (VDU) and keyboard with mouse placed
conveniently. Emergency stop switch and pressure reg ulating valv e will also be placed within easy
approach of the operator. UPS shall be built in the control desk with conv enient connections and
easily approachable power switch.

5. Spare Parts:

The Tenderer shall provide a detailed list of spare parts for two years operation as per specification.
The spare parts shall be supplied accordingly tog ether with the Plant.

Pay item shall be

9.12.1 Supply of Eng ine Gov ernor Test S tand for Woodward Governor each
9.12.2 Desig n services of Engine Governor Test S tand for Woodward Governor each
9.12.3 Installation services, testing and commissioning of Engine Governor Test each
Stand for Woodward Governor