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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

SPECIFICATION FOR 336 KW DIESEL ALTERNATOR SET


FOR POWER CAR

~mx.m.~.3lT./th.t/~/~.m./0084 - 2008 (~.'1')

Rosa, PE , SPEC' AC , 0084-2008 (Rev '1')


S.NO. Details of Page Reasons for
Amendment Number amendment
1. Complete spec. revised Nil Revised as per
field requirement

3ljlil~d
APPROVED
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CHAPTER No 1
---- ------------------------- - ---_._----
1.0 Forward 3
1.1 Scope 1
1.2 I Scope of ~upply 3
1._3 1 Governing specification 3-4
1.4 I Service requirement __-_-__ 5 _--_-.---.1
1.6 Test and performance 9 __I

------.!l~l--- inf~i~0~:~~a~~nt ri hts /--.------------=-.- __ -_ I --·-H-- --


1.9
1.10
ISO 9000 accreditation
Cartel formation
---t 12
13
)..1.1 .. Markirl9 & R~0i_rl9 _.1}_._
1.12 Training _ 14
. 1:._13__ ._ _ List gf sp~res andJl~tof special !~o~ __ 14
I
1.14
1.15
1.16
Drawin s to be submitted for approval
AP to be followed
Shedule of requirement
·r
.

----- - I -15-----
14
15 ---

CHAPTER NO.2 Technical requirement of diesel engine I 16-24


CHAPTER NO.3 Technical require!l"e~~ of alt.e.rnator _ I 25-34
ANNEXURE-A Schedule of technical data sheet to be furnished by till' 35-4 t
manufacturer alan with the tender and e test for dtesel_~1..9in.Q._. _
Schedule of technical data sheet to be furnished by the 1 47-48
manufacturer along with the tender and type test for alternat2i:.._--i _
Schedule of technical data sheet to be furnished by the I 45-46
manufacturer along with the tender and type test for r,l(!lcltor I I
s stem/ventilation s stem
Schedule of technical data sheet to be furnished by the r--49-S0
manufacturer along with the tender and type test for ventilation!
1 _

l
arran ement for en ine room. ! I
ANNEXURE<) List of drawin sand s cification 51 ~
ANNEXURE-E Undertakin for cartel formation ~ _~ __ ~
ANNEXURE-F Fire retardant test I 53 I
ANNEXURE-G Format for qualitY assurance plan ----- . - '54-55 I d_

ANNEXURE-H Noise level map2l,ng sketch. [ 56 ==1

--r;~)7)f:.J.---
SSE/ System 'Design
With el"kct from
June'20 12

CHAPTER-I
GENERAL DESCRPTION
1.0 FORWaRD
The power supply system with axle generation ,las limitations for services where the
electrical requirement. is very higl • For such trains, the system of end on generation with
diesel engine driven sets mOLnted in power cars at the two ends of the train has been
evolved and selectively adopted on the Indian Railways. At present, Rajdhani Expresses,
Shatabdi, and Garth Rath services are provided with End-On-Generation (EOG) system.

Presently the rakes of Rajdhani / Shatabdi express trains are working on end -cn-
generation system of power supply and are provided with two power cars each fitted with
two DG sets of 336 KW each.

1.1.1 This specification covers supply, assembly, installation, commissioning, performance, testing
requirement of Diesel Alternator set of electrical power output 336 KW, 750 Volt AC,
3-phase, ventilation system, instrumentation, protective devices and accessories, including
fuel pipe line, water pipe line, engine air intake pipeline, exhaust piping etc in High Capacity
Power Car.

1.1.2 This specification supersedes the Section-II of RDSO specification no. ELPS/ SPEC. / EOG /
02 issued in Nov.1994. However the DA set will meet General functional requirement for
diesel engine and alternator system for power car as per the specification for EOG / ELPS /
SPEC./ EOG / 02 issued in Nov.1994.

Manufacturer / supplier shall supply the DA set along with items as per Sill of material
(SOM) given in clause no 2.13 & 3.11. Control panel shall be supplied as per RCF
specification EDTS : 103 (REV. 'D') or latest revision. However, control panel is not part of
scope of supply of this specification.
Manufacturers shall ensure that engine supplied to Indian Railways must be complying to
latest applicable CPCB norm for emission on the date of supply.

1.3.1 FolloWing standards, regulations as far as they can appropriately be applied to the
coaches for Indian Railways shall be applicable.

lEC: 60571-1998 or latest -iRules for electronic equipment used on the rail vehicles.
lEC : 61373 __ Railwayapplication- Ro'ling stock equipment- shock & vibration test.

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IEC : 101 ; Ru le~.f...O! ~uxi!i9ry machines on motor vehicles. --


IEC: 61000 scries EIectromagnetic compatibility (EMC) Pt. 4, testing and measurement
! te chrli.9ue-se~<?n 4. Electrical test transient/burst immunity test.
BS : 5514 Part-I-1996 & IRe ciprocating intern31 Combustion Engine performance Part-I standard
ISO 3045-1 1995 or latest I re ference condition de-ration. of power fuel and lubricating oil consumption
, al ld test methods.
- --.- - - - --- - - -'--1'-- --
IRS: 5514 P,lr1.-3-1990 8< Reciprocating internal combustion engine part- 3 specification for test
I \50 30·\) 3 t 9U9 01 Idll";t III l ',1 'jl JrCrllt'1lt ').
-- - -_. -- ---------- ---
I B5 : 5.5 14 Part-4-1 997 & I Reciprocating Internal combustion engines part-4 speed governing.
ISO 3045-4 1997 or latest
BS: 5514 Part-5-1979 &
ISO : 3045-V 1978 or latest
t ciprocatillg internal combustion engines part-5 for torsiontll vibration.
-- ---- -- --- --_._- ---- . --
BS : 5514 Part-6-1992 & =ip,ocati..g internal combustion engines pac:- jspecification for over speed
ISO
-_. : 3045-6--- 1980 or latest
-------- otection. -
BS: 5514 Part-7-1996 & ciprocating internal combustion engines part-7 Code for engine power.
ISO : 3045-7 1995 or latest
IS: 10000-1980 Pt-9 or latest ethods of tests for internal combustion enqine (Endurance test).
IS : 4722-2001 or latest ecification for rotatinq electrical machines.
IS : 7132-73 or latest ide for te~,ting synchronous machine.
IS : 7306-74 or latest --
--------_._-- -- , ethq9s for determining synchronous machine from tests.
IS : 4889-68 or latest --'--' ethods of determining of efficiency of rotating electrical machines.
IS :- 1460-2001
- -- or latest -- _.
-"
Jtomotive diesel fuels.
IS : 13730 pt-l3 or latest lrtlcular types of winding wires part-13 polyester or polyester-amide over
- ~ted with polyamide-amide enameled round copper wire clause 200.
ELRS/ Spec. / ELC / 0019 beam halogen free cable with -copper conductors.
(Rev.2) or latest. ._- --.
---
ROSa spec. ELPS / Spec. / ec. and code of practice for wiring in 750V EOG system coaching stock.
EOG / 01 or latest
ROSO specification no. ELPS/
- ecification for broad-gauge high capacity power car for 750 V EOG
spec. / EOG /02 Nov., 1994 stem.
IS: 13847-1993 pt-I or latest I ecification for low voltage SWitchgear and control gear -- Pt-l, general
.-~--_._~_. qUlre~n_~.:...__
- - -- -- !
IS : 13778-1993 pt-1 - 6 or I ethod of test for winding wires thermal properties.
I
latest I

IS: 1239 Pt-2-1982 ol'l('\test M lid steel tubes, tubular and other wrought steel fitting of Pt-2 mild steel
II rllI/l.lI drlil otllf'r wrolJ9ht c;l(~d pipe: fittinS!'"
IS : 649 or lc1tc~t ~;ldl()r <llld rotor stamping.
IS 7624 or ROSO Lead acid battery f'1r starter battery.
specification , ._------ ---_._-
Note: Latest version of the above specifications/standards shall be applicable and shall be available
with the manufacturer before commencing the prototype type test.

I Prep;m:d by
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June'20 12
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---1.
I{DSU/I'IO/SI'Jo:UI\UlH)X·I-2()()X (1\I \'. ",") J
.

The generating sets fitted in power car shall be suitable to operate continuously under the
following varying climatic conditions existing throughout India normally encountered on the Indian
Rolling Stock:

- Minimum ambient temperature :-5°C


- Maximum ambient temperature : + 55° C
- Humidity : : 95%
- Altitude : Max.1200 metres above sea level.
- Atmosphere : Extremely dusty foggy, desert weather. The dust contents in
the air may re,3ch as high as 1.6 mg j meter3
: Very heavy in certain areas between 1750 to 6250 mm.

The equipment shall be designed to work in coastal area, humid salt laden and corrosive
atmosphere. The maximum values of the condition shall be as under:

- Maximum pH value 8.5


- Sulphate 7 mg j litre
- r"1ax.Concentration of chlorine 6 mg jlitre
- Max. Conductivity 130 micro Siemens jCM

The coaches are expected to run upto a maximum speed of 160 kmjh and is planned to be
increase up to 200 kmph in future in varying climatic conditions existing throughout India. DA set
as well as all accessories to be mounted on the coach shall be designed to withstand service
vibrations and buffing shocks.

i) Maximum vertical acceleration 3g


ii) Maximum lateral acceleration 3g
iii) Maximum longitudinal acceleration 3g
(corresponding to shunting shocks)
("g" being the "value of acceleration due the gravity)

1.5 GENERAL REQUIREMENT:

1.5.1 The Diesel Alternator set shall consist of approved make diesel engine coupled
approved make alternator both mounted on suitable common base frame.

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SSI-:! System
--- -- _.-------.------------,----~-,-,------,
With cfkct from RDSO/PI:::/SPEC/AC/0084-2008 (REV." I")
.Iullc·20 12

Electrical output power of diesel engine- Minimum 336 KW


alternator set at site condition of 55 deg C
ambient and 200 m altitude
----------

-=~~--~~~~=~
"
System Voltage & Frequency I 75UV AC 3 phase & 50 Hz ± 3%

Arrangement and mounting of DA set shall confirm to RCF drawing no. 1 11012 0 89 300
001 and 1 11012 0 89 300 002. Overall dimension of DG set shall be within the envelope as
being used presently. OGA drawing, mounting dimension and overall weight of DA set
system shall be approved by ICF/RCF before prototype test is undertaken.

1.5.3 Suitable anti-vibration mountings of proven design with cast steel top bearing plate as
recommended by the supplier shall be provided between the mounting base frame and the
coach under frame at mounting location to absorb the continuous vibrations and shocks
encountered during service. n-
2 su~plier shall furnish the de::~n calculation fur the base
frar.le together with selection of AVMs before fabrication to achieve follOWing conditions.
Vibration level measurement in all three axis x, y & z at front and rear foot of diesel engine
and alternator shall be taken as per ISO: 8528 pt. -9 or IS 4729

i. All three views of DA set with radiator placed in the coach and with footprint on the
coach floor.
ii. Silencer assembly with fitment of the roof on coach.

1.5.5 The proposal of the DA set supplier shall be acceptable after having validated the offer by
RCF validation using computer simulation etc.

1.5.7 The firm shall make his own arrangements for welding sets, welding rods and welders for
fahric<ltiol1 work to h(' done suit for commissioning at site.

1.5.8 Two sets of maintenance and operation manuills shall be supplied free of cost separately
with eac'l diesel engine and Alternator set.

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1: June'20
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1.5.9 Once a prototype approval for a make, type and rating of the diesel engine and alternator
has been granted, based on the type tests results,_ the design of the same shall not be
changed without the c;oeciflc and written approval of ROSO. In the event of any of the
parameter that have bearing on the performance, deviating from the type values, beyond
the permissible tolerance, ROSO reserves the right to. repeat the type tests.

1.5.10 A certificate to the effect that after sales service will be renelereel for cli("jel cngirw .1m!
alternator at all the cities where EOG trains originate along with the name, address and
telephone nos. of the service personnel shall be furnished. This information shall also be
included in the maintenance manuals.

1.5.11 The firm shall furnish complete information as per Annexure -'A' for the diesel engine and
Annexure-'B' for the alternator along with detailed design documents.

1.5.12 The firms shall furnish detailed drawings of radiator indicating the overall and mounting
dimensions and other details to fa':ilitate installation of the radiator separately. Technical
particulars of tt-,e radiator like minimum air flow required th~nL,oh tht=l ~"ldi2'C.,-- ·'t::r::::0 r
.... '~: ,.ct, . 1r. ~ ~)n ~t'"\;~!
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1.5.13 The engine electrical schematic wiring system with the details of components used
(protections, solenoids contractors, switches, gauges etc.) shall be submitted by the firm.

1.5.14 The interlocking system schematics along with wiring diagram with functional description of
the complete system shall be submitted by the firm.

1.5.15 Calculation for adequacy of diodes selected with their characteristics shall be submitted for
the approval by the firm.

1.5.16 The harness specific to the control switchgear required for the OG set shall be supplied by
the manufacturer. Cable shall be e-beam irradiated copper cable as per RDSO specification
no. ELRS / SPEC. / ELC I 0019 (REV-2) - Feb., 2011 with latest amendment / revision and
shall be of approved make of RDSO.

1.5.17 Cable shall be crimped at both ends with suitable lugs. Heat shrinkable PVC transparent
sleeve of ROSO approved make shall be provided over all the lugs and joints so that sleeves
do not dislodge.

1.5.18 Computer generated cable markers of reputed make shall be provided for identification of
cables.

-~

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With effect from
.lune·20 12
]
__ . _. -L ~

1.5.20 The firm shall associate during testing and commissioning of the DA set and its interface
with the switchboard cabinet in the power car.

1.5.21 The equipments working above 1l0V supply shall be provided with danger plate as per IS :
2551.

1.5.23 Electronic components, if used, in diesel engine or alternator or elsewhere shall confirm to
IEC: 60571.

1.5.24 The diesel- alternator set is also capable to work on 110 % over-load for one hour once in
12 hour period of operation under service conditions prescribed above.

1.5.26 Soft copies of design details, Circuit diagrams, detailed drawings of diesel engine and
alternator, type test results, field trial reports, drawings in auto cad should also be given
along with hard copy.

RCF-/ICFmay decide to gc fur rO\lIJercar with reduced nOise I~vnl as compared to p,·esent.
Present level of noise mapping is enclosed in Annexure - H. In such a case firm shall submit
details of noise reduction measures for prior approval of RDSO I ICF I RCF.

DA set layout shall be in such a way that minimum noise is transmitted outside the power
car in the platform area. Firm shall reorient I redesign radiator motor, ventilation system,
provide acoustic panel and use residential silencer to achieve noise reduction. Acoustic
matcrial uscd shall be fire retarJant. Noise level shall be measured as method prescribed in
ISO : 8528 pt.- 10 fig - 4.
Firm shall take prior approval of ICF/RCF for each noise reduction feature with respect to
mounting dimension, OGA dimension and weight. Residential silencer if provided shall have
at least 25 dBA noise suppression. Firm shall submit test certificate from NABL accredited
lab in this regard .
.- \ ----

, .(11)'(11 21----
"'''1 S: stem Design
With t:l'li:ct rrulll

r June'20 12

a) DA set prototype ',hdll be done by the Engineers of RDSO & ReF at the works of the
manufacturcr. After ',IJ((cssful typc testing and commissioning of DA sct on power car, it
'Ivill put undcr extenSive field trials for six months,

b) All type tests mentioned in table A & B in clause 2.12.2 and 3.10.2 shall be carried out on
Diesel engine and alternator at the works of the manufacturer.

c) Any defect noticed / design improvement found necessary as a result of these tests / trials
shall be carried out by the manufacturer in the least possible time.

d) All the system to be supplied against the tender shall incorporate without any extra cost, all
the modifications carried out in the first type tested unit after the field trials of the system.
e) All expense on labor, material and fud during the type test, acceptance test &
commissioning test shall be borne by firm.

The proto type test shall be undertaken either totally or in part on DA set as per clause 2.12
& 3.10 under the following conditions without any additional cost:

a. A manufacturer undertakes to manufacture for the first time as per this specification.

c. A fundamental change in design is introduced and modification of equipment likely to


affect its function.

All acceptance tests mentioned in table A & B in clause 2.12.2 and 3.10.2 shall be carried
out on Diesel enli-~e and alternator by an in5pectng al/th')rity nominated by the purchaser
at the works of the manufacturer.
I With l'lrcl'l from
I JUIlC' :111:
'-- -L-

Routine tests mentioned in table A & B in clause 2.12.2 and 3.10.2 shall be carried out on
Diesel engine and alternator by the manufacturer at his premises to ensure
compliance with the specification and the drawings. Authority nominated for acceptance
test shall verify routine test record of each Engine & Alternator

1.6.5 SPECIAL TEST ON COMBINED DIESEL ALTERNATOR SET DURING


PROTOTYPE APPROVAL:

1.6.5.1 Firm should have d test bed for complete DA set along with radiator and ventilation
arrangement simulating power car condition. Followinfj test shall be conducted on
combined set of diesel - alternator under following condition:

viii) Measurement of Specific fuel consumption (gm/kwh).

ix) Measurement of main Lube oil Pressure (kg / cm2).

xi) Measurement of inlet & outlet temperature (deg C) of lubricating oil.

xii) Measuremert of inl~t & outlet water temperature (deg C) of coolant engine.
I P"go II OF56--J~\'''h,'Iic''' In'", ---,- LDSO/PElSI'ECIAc/oosn-008 ('{EV,"''')
]un\?'20 12
------- - -- --------- --

Endurance test shall be conducted on DA set on test bed for 96 tlours (6 cycles of 16
hours each). DA set shall be loaded in each cycle as per clause 2.1 of IS : 10000 pt-9.

1.6.6.1 These tests are to be conducted after commissioning of DA sets in Power car at
production units i.e. rCF / RCF. These tests shall comprise of following:'

j) Engine room ventilation in terms of air exhaust through ventilation fans.

k) Checking of seall,lg' of Raoiators, Fresh air filt~r, ventilation fan bellows, ar,d

tt
Finn shall make complete booklet of these ~est conducted on first power car jointly
signed with cnncerned Elrctrical Production unit of rCF/RCF and shall send the

'7)I,JJ;(!i- Checked By ," ./'l


SSU ):- stem Desi_g_n_---'- D_ir_T_L_& C (~yS £o;;;;g:j
----r--------------'-
I Page 12 or 56 \\'ith ,:Ik"t from RDSO/PE/SPEC/ACI0084-2008 (REV,"]")
.Il1l1l'· ~I) 12

commissioning I eport to RDSO, For Subsequent DA set it should be submitted to CEE


of PUs.

1.6.7 The alternator and diesel engine shall be tested at ambient condition. However, the test
results shall be extrapolated to on site condition to check the compliance to declared
parameters.

1.7.2 The supplier shall be responsible for carrying out all the modifications at his cost on any
part of the equiprnel1t during the period or warranty required for satisfactory operation of
the equiprnent as PCI technical specification. For any technical decision the final authority
from the purchaser's side is RDSO.

Indian Railways shall not be responsible for infringement of patent rights arising due to
similarity in design manufacturing process, use of similar components in the design &
development of thiS Item and any other factor not mentioned h'erein which may cause
such a dispute The entire responsibility to settle any such disputes/matters lies with the
manufacturer/ supplier

Details / design/documents given by them are not infringing any IPR and they are
responsible in absolute and full measure instead of railways for any such violations.
Data, specifications and oth,=r IP as generated out of interaction with railways shall not
be unilaterally used with'out the consent of ROSa and right of Railways / ROSa on such
IP is acceptable to them

The firm seeking RDSO's approval for manufacture and supply of diesel alternator set
conforming to this Specification shall have ISO : 9COl accreditation to ensure its
U1I1folilldiH (' to Cjll,llily ',y'.II'Il1'; laid down in the stardard for design and manufacturing
processes at differellt '.:>LdSJes.

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The firms shall not engage in cartel formation with other firms and will also submit a
declaration in this regard as per Annexure - E attached.

1.11.1 The Diesel - Alternator shall be provided with suitable name plates, on which tt1e following
shall be marked / engraved:

The label shall be affixed on part necessary for normal operation of the ergine and rot
, ''I :L." il<.:! ,ep,a, ~~'neit du '::i the life ,; engine.

No. of machine manufactured in the particular Month e.g.


Serial No.08 02 0001 denotes machine manufactured in
February 2008 with Serial number of 0001.

1.11.3 The equipment and its sub assembly shall be packed with wooden box of sufficient
strength and the empty space shall be filled with suitable filling material.

1.11.4 Manufacture shall provide a screen-printed schematic diagram of power and control
circuit at suitable place, -......

Prepared by - ~f)1)~tf---- -r-Che-~W8-Y-- J Ii~~--'/ I


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- -

The supplier shall arrange for training to Indian Railway personnel in maintenance and
trouble shooting of the system supplied. Ten man-days training in operation, maintenance
& trouble shootil19 l)';pccts will be provided, The supplier will provide detailed technical
write-up to all the trainees, The syllabLs for training will have to be approved by the user/
purchaser. The venue of training will be mutually agreed. Training will be arranged free of
cost.

The Firms shall submit recommended list of spares for diesel alternator set and list of
special tools if required any,

1.14 Apart from details as per Annexure A, B , C1 & C2 , following documents shall
also be submitted to RDsa for approval before type test:

~~=/
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Dlr
~ AC (System Desi~~
\\' IIII " Ill', I II I Jill

,hUll" 20 12

a) Diagram of electrical connections together with assembly drawing showing full


particulars of Exciter / stator and numbers of turn, sections, weight and length per coil.
b) Circuit diagram of AVR,
c) Shaft design stress calculation.
e) Bearing life and luhriGJtion interval calculation.
f) Insulation scheme.
g) Diode selection calculation.
h) ,Any other desiyc related details.

1.15.1. Since the quality of the equipment bears a direct relationship to the manufacturing
process and the environment under which it is manufcctured, the manufacturer shall
ensure Quality Assurance Program of adeCluate standard.

1.15.2 The material purchased from outside agencies shall conform to the relevant Standard
Specification as specified in RDSO / IS Specification. The certificate conforming to
RDSO / IS Specification should also be made available for each lot of machines. It is also
preferred that in-h,)LJse test fe'':ilities for purchased items should be developed by the
firm so that testing of thesc' materials can be done within the factory premises so that
check can be exercised by the Inspecting Authority in case necessary, otherwise, the
testing of these materials should be done by NABL accredited Testing Agency.

1.15.3 Firm shall submit JII the technical documents i.e drawings, design calculation, layouts,
circuit diagrams ctc in sott copy as wel!.

Schedule of technical requirement for this assembly of DG set shall be


RDSO/PE/STR/ /;,(/0037- 2012

Y ( ,

[rcrac_cd_b _ Dir ~ystem Design)


"I· -"'ith cffect from
JUl1c'10 11
________ ~ _L._ ___'

TECHNICAL REQUIREMENT OF DIESEL ENGINE

2.0 DIESEL ENGINE:

The Diesel engine shall be of robust and reliable design, turbo charged and water-cooled.
Engine shall be able to deliver power for getting minimum electrical power output from
alternator of 336 KW at site condition of 55 0 ( and 200 m altitude at 1500 RPM, Firm shall
declare the BHP rating of engine at standard reference condition as per BS 5514 part-1 i.e
at total barometric pressure=100 kPa, Air temperature=25 0 ( Relative humidity 30 % and
charge air coolant temperature 25 0 C. Accordingly, deration curve if any shall also be
submitted. Manufacturers shall ensure that engine supplied to Indian Railways must be
complying to latest applicable (PCB norm for emission on the date of supply. Engine shall
be capable to work on 110 % overload for one hour in 12 hour period of operation.

2,1.1 The engine shall be water cooled and shall be supplied with Radiator. The radiator shall be
suitable for separate mounting at a remote location to facilitate cooling by a fan to be
driven by suitable capacity, 3- phase, 415 volts, and squirrel cage induction motor, The
engine shall also be supplied with sui~able circulating water pump, lubricating oil heat
exchanger, lut)rication oil pump, interconnecting pipes, silencers, and exhaust pipes.

2.1.2 The drawing for the location of the radiator with respect to the face of the engine and its
mounting and tile ventilation arrangements shall be submitted by firm for prior approval of
RDSO / ReF,

2.1.3 The cooling equipment (Radiator, water pump, pipe lines etc.) shall be of adequate capacity
such that the water temperature is maintained within the specified range with the engine
operating at the full rated load at site conditions with radiator clogged to 30 %.

2,1.4 The air duct design with guided flow to avoid back turbulence shall be designed by the firm
and shall be got approved by RDSO / R(F in order to reduce the noise level (Supply of
duct shall be in scope of tenderer as per firm's drawings),

:.1.:' rllt: opt:rcllllHj rclll~JC of waler temperature, under full !lad shall not exceed 95 0 C
maXimum,
j Wllh dICe! frOIll 1{L)SU/PU~')LU:\('/l)()X-l-lll()X (!{L \ I)
Junc-2012
'-------_. ---------- --- ----

2.1.6 Water level indication shall be provided on the radiator top tank at a visible location. If
water level falls below permissible limit engine should trip with low water level alarm in
crew compartment.

2.1.7 The Firms shall furn_ish detailed drawings of the radiator indicating the overall ill1d
mounting dimensions arid' other details to tacilitate installation of ttle Radiator
separately. Technical particulars about the radiator, like minimum Air flow required
through the radiator at 55 0 C ambient, its total heat rejection capacity, the pressure drop
across the radiator etc. shall also be furnished.

2.2.1 The engine shall be equipped with air filter of adequate capacity suitable for operation in
service conditions given in clause no. 1.4.

2.2.2 Drawing for fresh air inlet to air cleaner and turbo charger shall be submitted by firm for
prior approval of RDSO / RCF.

2:2.3 The air filter location shall be selecu?d in such a way that crew cabin staff shall be able to
check the filter condition for clogging and its attendance. To facilitate this, suitable
restriction indicator will be provided. Additional engine tripping mechanism shall also be
incorporated in the engine control circuit which will trip the engine in case filter gets choked
beyond permissible limit.

2.3.1 The scope of supply includes the supply and erection of seamless stainless steel heavy duty
pipes grade 55 316 and flexible hoses (SAE 100 Rl or better) of appropriate size and length
....
~ with necessary pipe and end fittings, isolating cocks, union sockets etc. as needed. The
exact quantity shall be as required at site. Rubber hose shall not be used in fuel circuit. No
banjo type frtting to be used as it is leakage prone.

2.4.1 The engine shall normally be required to operate on diesel fuel wtlOse properties standarcl
shall be as per IS 1460-2000 or latest. The diesel engine shall be tested with Bhar-at
Stage II fuel oil in type test. Even thougr diesel engine being Bharat stage III compliant, it
shall be capable of operating with Bharat Stage-II CPCB conforming fuel oil In case of
emergency.

C07l}7lt1-- I Checked By (;il.•


_s-_S_E_I _s_~s_tc_'11_1 _d_CS_-i",_PI_l
_ D ir_T_L_~_ACA_C,_~_~~s_t_c_m_D~_Sig:~.J
I With effect from
, .I11lh:·2012

2.4.2 Drawing for Fuel oil suction ard ,eDJri) from e,e engi'le p'Jmp ~o engine shall be submitted
by firm for prior approval of RDSa / RCF.

2.4.3 Required amount of lube oil and diesel oil for all the test dUring type testing and
commissioning tests shall be arranged by firm.

2.4.4 Bye pass circuit filter to be designed in such a way that frequency of lube oil change is not
less than 500 Ilrs. Firms may use centrifugal lube oil filter in bypass circuit instead of Paper
filter.

2.4.5 Engine shall require only indigenous RDSa approved lube oil which is presently used by
Indian Railways.

2.5.1 Fuel consumption meter shall be provided for monitoring the fuel oil consumption. Its
working shall be monitored during 6 months field trial.

::.6.1 The Silencer ~hall be suitable for location on the coact) roof exposed to atmosphere.
Adequate length of the pipes, elbows etc for carrying the exhaust hot gas in the silencer to
the atmosphere shall be supplied and erected by the firm. Provision shall also be made to
prevent water entry into the silencer. The portion of the exhaust pipe inside the coach and
from its manifold shall be suitably and adequately cladded.

2.6.2 Drawing for general arrangement of silencer and exhaust system mounting
arrangement shall be submitted by firm for prior approval of rCF / RCF.

2.6.3 The turbocharger exhaust manifold and the exhaust pipe lines shall be thermally insulated
and cladded with galvanized steel sheets or aluminum sheets and firmly secured so as to
ensure that there is no exces~ive heat in the engine room.

-:',7.1 The enoine shc111 be supplied with Electronic governor conforming to International standard
1,I<.eU~) / 11C / ISO. TtIe govel nor •.•hould he suitable for lransport application. Electronic
governor should be directly mounted on the engine varying of the ~peed (rom Idling speed
to maximum load speed and also in the Crew compartment.

: l}rcp;1r\:d [1\ - 1 Ihe-cked By---7r~'" -,


! t::_)_CS,ign
;n_~_ij_S_~_'~_tc_~_l ~m DC'~
I June'lOl2
L. _
2.7.4 There should be Electronic control panel & governor for Engine to improve regulation of
RPM and frequency, monitoring of engine parameters. The device shall be easily accessible
and preferably in crew area. The electronic control panel shall display the following
information:-

a) Lubrication oil pressure.

b) Water temperature.

c) RPM of engine.

d) Battery voltage.

e) Faults are displayed directly.

It should have memory to store & access the last 50 faults data (minimum). Firm shall give
details of ttle system along with Overall General Arrangement (OGA) drawings & circuit
diagram.

2.8.1 Diesel engine shall be E'juipped with a starter motor working from 24 V DC battery supply
and associated accessories like starter solenoid, fuel start Solenoid etc. for cranking the
engine. The motor shall be of adequate rating to crank the engine to firing speed under the
service conditions specified in Clause 1.4, without exceeding the temperature rise limits for
the class of insulation. The entire engine wiring shall be non-grounded. Starter motor shall
be of Delco Remmy, Lucas or reputed make with prior approval of RDSO / RCF.

2.8.2 It shall not be possible to energise the starter motor, when the engine is running at
•••.• speed above the minimum firing speed. Suitable cranking protection shall be provided.

2.9.1 A 12 cell (3 mono blocks each comprising of 4 cells) 24 volts tubular lead acid battery of
290 AH capacity to IS: 7624 (latest) or RDSO's specification shall be provided by the
supplier separate for each DA sets to feed \Xlwer to the engine starter. The firm shall certify
the adequacy of the battery. The battery shall be suitable for high discharge starting
current and shall be taken from OEM directly.

--=-~i
2.10.1 The engine shall be provided with fuel solenoid and safety devices like high water
temperature cut-out, low lube oil pressure .:ut-out, air filter choke cut-ou!~Mater level
Prcp'arCd "b-y ------ --r; I}I?T;-- Checked By '-/-fi
'¢i'
SSE/ System t;.;. D;, TL 0 qSy<tem De"g,,)
-r \\'Ilb crfect from
I JUl1e'2()12

cut-out, radiator air loss cut-out and over speed cute ut etc. to facilitate automatic tripping
of engine. Ttle gauges and meters as required she.dalso be supplied with minimum suitable'
length of leads, Complete protection scheme shall be submitted to RDSO / RCF for approval

2.10.2 The performance monitoring panel (remote gauges panel) shall be mounted in side the
crew cabin to facilitate monitoring/starting of Diesel engine from the cabin itself. Tile
audio and visual alarm for the fault shall also be provided in the crew cabin itself so that
fault can be understood and attended promptly by cabin crew staff. The inter connecting
cables, if any shall be supplied by the firm. The control panels shall also have the
lockable starting switch and push button for operating the engine and a ' STOP PUSH
BUDON "

2.10,3 During the emergency and other failures, stopping of the engine shall be by De - energizing
the fuel "Sht:Jt-Off valve" only or tripped through engine control Unit.

2.10.4 In emergency and other failure stopping of the engine shall be through Electronic
governor actuator or through engine ECU.

2.10.5 The panel shall also have the starting switch for operating the engine and an
EMERGENCYENGINE STOP push button for stopping the engine.

2.11.1 The ventilation system shall be such that in actual service operating conditions, with the
diesel engine and alternator operating at their full rated capacity, the temperature of the
engine room shall not be more than 5 0 C, over the maximum ambient temperature. Engine
room ventilation shall consist of blower assembly complete with fan, motor and housing /
brackets suitable mounting.

2.11.2 Ventilation fan motor shall be IP - 65, C1ass-Hinsulation of MIS ABB, Mis Laxmi Hydraulic,
Mis Crompton, Mis Siemens, Mis Kirlosker Electric make only. The motor shall conform to
IS :325.

2.11.3 Ventilation aspects relating to Radiator cooling and Engine Room are given in Annex.-e 1 &
C 2.

2.12.1 Prototype, acceptance, and routine tests as mentioned in the table given below shall be
concluctPd on the diesel engine:-

I Prepared b~
I
With cl'kcl lioll)

June'2012

Sr.no Tests Type Aeeepta- .Routine I CI. Of Relevant


test nee test Test h__ Stand ards
------ ---
1 Verification of dimensions of all Yes Yes - ' c; rer tilis spe cification
major ass~rntJlip.s and ')ub- I
assemblies and wei<jhl of [)ie,>(~1
Engine and Radiator

--l 2 Rating test at simulated site


condition. During tile '(~t the
Clause no. 15 :S.2'(Engine "\
group-3) of BS : 5514 pt-
I

following recordings shall be \ 1 1996 or latest


made
I I international standard.

- ----- --- I--- I ; I able ) IIst 1\ ll'~t


I a) Fuel consumption rate. Yes Yes Yes
I measurements S.N. A 1 to I
L - - ____
i b) LIJbe oil pressure-.-- - -
Yes Yes
-- Yes----j A 19 Tabte-7 list C and I
1etblC-8, list [)
I --- -----. I
I
I
c) Lube oil consumption. Yes No -
I. CPCB certifica tion "
I I d) Cooling water inlet and outlet Yes No No
i
i/
as per tile late st guideltn2s I
norms will have to be
tpm cratIJrr>.
I
I
pravi by tIle
I
: I
I III d III II d C t 1I1l.~r It) :
I I

1 substantiate tile I
I -- -i compliance of emiSSion I
I e) Exhaust gas temperature. Yes Yes No
I nornlS

I f) Smoketest.
t -
Yes Yes Yes
l
J
I
!,
I
I q) TorqlJf~ Yes Yes Yes I I
I ,
- I
h) Speed. Yes Yes Yes
i
3 Governing test Yes Nu No BS : 5514 Part-4 1997 and I
ISO : 3046-4 or Latest I
International Standarcl I
I

I
Specific fuel consumption (SFC) Yes Yes Yes Clause no. 15.5.2 Table 6
I i
14
list B of BS : 551'4 part- I or
I latest internt~tlollil\ i
~iest J-5t~'l9.?iQ: - ------ --- - - i
(at Yes No No I Annexure-Cl of this
6 Radiator capacity test
simulated or equated site ! specification for reference ;
- ---_. -_.-
---- -- - --- --
: \\"1 h-c n~~I--rrom---IR
DSOIPEISPEC/ AC/OOR4·200R (REV, T')
I JUllc'2012
~------------j~--------,-- ------_._----------------'

~ conditions 55 0 C) only.
I

:
I
I I SpeCia I test:
- -----
Clause
group-3)
no.
of
15.5.2
as 5514
(Engine
PH
!
1996 or latest
- ,- International Standard
I i i) Fn~ille heat bolance Yes No No

- --- ~------- - ----- Table-S list A test


I il) Sound level Yes No No
I measurements S.No, A 1
I -- - -- -"- -- -- --- . - - -
to A 19
I iii) Exhaust-gas emission Yes No No
cha raeteristics
Table-7 list C and Table - 8
, : - ---- --
I list D
I
I
r 8~- - i Environmental test on Electronic Yes No No Clause 10.2.3, 10.2.4,
! governor and electronic control 10.2.5, 10.2.6, 10.2.7,
I ! panel. 10.2.8, 10.2.9, 10.2.10,
I 10.2.11 of lEe 60571-
2006.
L-~

IS.
No.

I _
Ie

I ucl (Iller dlld lulx' oil filler


.- -- _._._--------,----,---~-
---"~N°'---~I 1 No.
----,

I I xhdu<;t pipill<) complete with rncli1l1ic f1cxibiel)ir;e,


Cld,ltllllU of tile ,'xll,lll<,1 pipe<;, ilnd .,ik~,)(cr with c1flrnps (qu;ll1t,ty
riCJid pipes elbows,
t1'>
f1(ln9~S,
W<\lllrl'c! <It
II lot

l l:C)' I
! -Pl:cparcd b\ --r ~-- Checked By ----(iC;r~--
l r
f_
g
)_dsSil_ l'_IlIl_-'-
s_:_::n_-:;_,_.~_1_t~_Il_: D_i_r
_T_L _&_~_c_l::c( DD_CC_SSi_ n_l-------1
_y_st_c_mm_
g
I-page 2) 0_r_5_{' 1 June
With elket
'2012
1;"0'"

Fuel circuit piping including seamless stainless steel pipes, flexible hoses;--pipe i 1IOt~---1
I

fitting (brass). Non-retum valves (as required at site). '

Engine monitoring panel provided with the radiator water temperature gauge, i
lube oil pressure gauge, Techno-hour meter, engine off push button, lube oil
temp. gauge, tripping of the engine due to failure of HWT, LOP,OS Cllon(j with the
parallel remote annunciator for the SCllnC,tripping of cnCJinc clue tu dlr flill-I
I choking, tripping due to kJvV water level ,tripping due to air loss fro 111 Icltlldtnl !
r motor etc.

! Set of gauges for ,:emote~mounting on the power and controlCircuit pone! for 11 set
monitoring radiator water temperature, lube oil pressure, lube oil temperature,
I fuel consumption meter ctc.

Safety devices (cut outs) for automatic tripping of engine in the event of high I' 1 set
water temperature, low Lube oil pressure and over speed mounted on the engine,
II low water level, air-filter chocking, tripping due to air loss from radiator motor etc.
------------- -------- ----- --- - ---
I Starting equipment 24 V dc consisting of adequate starter motor (not exceeding 1 set
I 10 KW), Starter solenoid & fuel start solenoid. I
j - --- ~_-- -- -------
I Electronic goverr:GI with engine control ?no dic;p y p?
----- - _ 1
Base frame for diesel altemator set complete, as per approved drawing with anti- I 1 set
vibration mounting (clause 2.2). Firm shall keep the mounting arrangement of the

F-
base rail common with the existing design i.e. keeping the mounting hole same to
avoid minimum changes.
___ I _
n I Coolant piping with fdings connected between radiator and engine. per
requirement

-ii--rRadiator assembly complete with rad-i.3tOr,water le-;el indicator, -blower fan, drive,
I motor frame work, fan housing, AVMs ete as per approved drawing. I I
iii T12 cell ( 3 mono blocks each comprising of 4 cells) tubular lead acid battery of 1 setl
290 AH capacity to IS:7624{latest) or ROSO's specification complete witll inter-cell'
connectors to feed power to the engine starter motor for cranking the engine I

Engine room ventilation consisting of blower assembly complete with fan, motor I
and housing I brackets suitable for mounting. Motor shall be of Mis ABB I
i Siemens I Kirlosker electric I Laxmi Hydraulicl CGL make. I

----------------------------- --
Dry type, fire retardant, removable and reusable panel type of approved make by As
/'
RDSO/PE/SPECIACI()()X.t-2()()X (REV""') l
--------~

Anti vibration IlloLJntinQ pads of Mis Res~;toflex or Mis Metalastik or any otiler
witl, pr-ior 2lppruviJl
1 set I
Ino~
I :V1lh
LC'2012
cf"fCcl from ! I:DSO/PI'/SPI:C/,!\C/()()X 1-.'(J(lX (1,1 \ I )

- ---- --- - --- ---- --------

3.1.1 Alternator shall be rated at minimum 336 KW , 1500RPM, 750 V, 3 - PI1Cl',{', 50 H; ,0.8 pf
at site condition of 55 0 C and 200m altitude. Firm shall also declare the rating of altern,ltol
at standard reference condition as per IS : 4722 Accordingly, deration curve if any shall also
be submitted. Alternator shall have 10 % overload capacity for one hour in a span of 12
hours.

3.1.2 Alternator shall be of the self-excited, self regulated and self-ventilated brusll less
design confirming to duly continuous class S 1 as per IS : 4722-2001 and shall have 3-
phase star connected winding with 4 terminals brought out for external connections.
The terminal shall be located in a terminal box, provided on alternator body.

3.1.3 The alternator shall be capable of catering to at least 30 % of unbalanced load in anyone or
two of the phases witli the current in any of the phases not exceeding the rated current
with the regulation maintained at 5 % or less and 2.5 % or better in manual and AVR mode
of operation respectively.

3.1.4 Stator and rotor stampings shall be CRNGO steel sheet M-45 grade with C 6 coating.
Stamping shall be tested as per IS : 648 and IS : 649. Firm shall procure stamping from r-1js
SAIL, Mis Nippons steel or any other make with prior approval of RDSO.

3.2.1 Voltage regulation of the alternator shall be of the dual control type i.e. both electric and
electronic. TIle electric control ';hall be through compound transformer or magnetic
amplifier open loop excitation and electronic regulation through solid- state automatic
closed loop excitation voltage control both sensing from all the three phases. The combined
regulation shall be within 2.5 % or better. There shall be "Stand-by" facility to ensure
regulation within 5% even in the event of failure of the automatic electronic voltage
regulator and this "Stand-by" facility shall automatically cut in, with the help of an over-
voltage I under voltage sensing device which would also indicate through LED indication
regarding failure of AVRs.

3.2.2 AVR (automatic voltage regulator) shall be modular type suitable for remote mounting in
power and control panel in crew room. Interconnecting cables and coupling arrangement
between alternator and AVR shall also be in the scope of firm. Dimensions layout
Prcpared by ~ 1';\; -1-- Checked l3y

SSE! S\stcm ))csign Dir TL &


\\.illl l,rICel li'oll1

.Il1llc·2012
I ,
_____________ ~I ~ ._

d.c,\ill,=, '-.I, hV~~ '>I;JIIUe got approvE:d by RDSO i ReF. f-:irm sholl submit wave-form of field
supply at no load and full load and also provide percentage (%) THO in field at various load
conditions.

3.2.3 The cables required for manual stand-by contrl)l device, leading from the alternator to the
Over' Voltage I under voltage sensing device provided externally shall be in the scope of
firm. Cables shall be e-beam of ROSO approved make.

3.2.4 The input leads to the AVRs shall have fuse protection with appropriately rated fuse of
Siemens I L & T make. The AVRs shall be of the plug-in type. AVR and over voltage sensing
device shall meet the environmental condition as per IEC : 60571-1998 in respect of clry
Heat, Damp Heat, Voltage Surge, insulation resistance test & vibration etc.

3.2.5 The rotating diodes used for supplying DC power to the main field winding shall be of
current rating equal to at least 2 times the loa, ';ng on therl under full load of the
alternator. They shall be of minimum 1000 V PIV rating. Under the full load operating
conditions the case temperature of the diodes shall be at least 20 0 C below the limit
recommended by the manufacturer. Provision of appropriately rated fuses / MOV on the
input side of the rectifier bridge is desirable.

3 2.7 Firm stlall submit detail~; of harmonics content at various load condition to ROSO for
approval. This is very essential to limiting neutral current at design stage. There shall be no
need of any neutral current limiting reactor.

3.2 8 In layouts, where the rotating diodes are located at the hot air exit end, the current rating
of diodes stlall be at least 3 times Lhe loading.

3.L.9 Calculation for adequacy VI i.he.. jiodes selected with tnere- Lharacteristics shall be
submitted for approval to ROSO / RCF.

3.3.1 The term 111 a I box sha, located at the non-drive end. Suitable cut-away with a cover plate
having cable entry holes (suitable for 150 sq.mm e-beam cables) for output power. cables
shall be provided as per RDSO specification no. ELRS / SPEC. / ELC / 0019 (REV.'2'), Feb.,
2011 or Idte~L.

3.3 2 The internal and external cable terminations shall be on fiber glass DMC / SMC terminal
board located across each other without crisscrossing and suitable for crimped terminations
connected palm to palm. The spacing between terminals shall be minimum 75 mm between
phases and phase to neutral. The head of the terminal studs (preferably hexa onal) shall
; Prq'arl<f t~\ . -- - - - -...-:..
J) ~fYJ)f Chcd~2C By 4~ :=-=-l
SSLI S\sl\.:lll DI.:Slgll p.m Design) I
I
With cffect from
Junc"20 12

be embedded on the rear of the terminal board and be further secured on top by a nut. For
securing cable lugs, nuts, lock nuts, flat and spring washers shall be provided.

3.3.3 The air clearance between un-insulated live parts and body of aller nalor shall flol be
less than 75 mm.

3.3.4 FIRE RETARDANT TEST: Fire retardant test for terminal board shall be done as per
Annexure -F

In order to prevent dust ingress, the cooling air will be drawn from the inside of the engine
room or through the side walls through dry type air filters and ducts. The firm shall submit
the drawings for general arrangement of ducting for approval by RDSO I RCF.

3.5.1 The alternator shall have stator insulation of class 'H', rotor insulation of class 'H' and
exciter insulatio:l of class' H' . Slot liners and slot wedges used in stator, exciter rotor and
exciter field shall be of class 'H' and minimum 4 kV (mm) breakdown voltage. Coil
insulation, head insulation, aeration wedge et:c. used in main rotor shall be of class 'H' and
minimum 4 kV (mm) breakdown voltage. All sleeves shall be of class 'H' insulation. All
winding wires used in main stator, exciter and main rotor shall be insulated with class 'H'
insulation by vacuum pressure impregnation process.

3.5.2 The manufacturer shall submit the insulation scheme of the alternator with details of
thermal and electrical insulation properties of the material used with relevant standard
specification.

3.5.3.1 The main field winding which shall he on the rotor shall be strip conductor having
enameled glass covered insulation conforming to IS : 13730 Pt- 13- 1993 or better with
c13ss200 of insulation "H".

3.5.3.2 VACUUM PRESSURE IMPREGNATION PROCESS (VPI): All the windings used in the
alternator shall be impregnated through Vacuum Pressure impregnation process (VPI).
The winding shall be subjected to pressure imprE..'Qnationas per recommended procedure
of varnish manufacturer. Varnish used shall be FT 2005 of Mis Dr. Beck.

-:rn ffiJ~t!J--
SSE! System' beslgn
I With dkct from --
1~Ul_lc_·2.~O_12_~ ~~. _

3.5.3.3 TIle test on enameled winding wires shall be conducted as per IS : 13778 Pt. 1 to 6. The
manufacturers shall maintain separcte documentation for these tests, indicating the
winding wire supply particulars. Winding wire shall be from RDSa / CLW approved
sources.

3.6 ..1 Alternator sllall be designed so that the total harmonic distortion is below 5 % of the rated
capacity .

3.6.2 Firm shall arrange to test the quality of power supply in actual service condition with
rake for voltage, frequency and harmonic contents.

The type, size and make of bearings used in the alternator shall have the prior approval of
RDSO

Special care shall be taken in regard to design and manufacture of rotor shafts. The
detailed manufacturing drawing of the shaft shall be got approved by ROSO. The supplier
shall ensure that the raw material for the shaft is EN 24 hardened and tempered. At change
of sections, smooth ground finish should be obtained after giving maximum possible radius
with form tool. Finished shafts shall be subjected to ultrasonic to detect internal flaw. The
ultrasonic testing shall be conducted on each rotor shaft and certificate of the same shall be
attactled with each lot at the time of inspection.

-
The Rotor of alternator shall be dynamically balanced to balancing quality grade of G 2.5 to
IS / ISO 1940 -1 : 2003. The dynamic balancing of rotor shall be checked individually on a
Ixlidll( IIHJ IlldC 11111C.

Checked By ~~

~-:tJs~~!c;,d);;gn ~m De,;gn) I
______ --J- I
I-page 2<) or )() \ ilh e l'lCel Irolll
Junc'20ll
l__..__

3.10.1 Test Instruments: The indicating instruments used in electrical measurement shall conform
to relevant Part of IS : 1248 of 1984 or latest. Instruments with the following accuracy shall
r.p- uss::d:

b. For surge protection test, the amplitude and duration of the surge voltage shall be
measured by oscilloscope and stop watch,

c. Stator resistance shall be measured by a micro ohmmeter or Ammeter Voltmeter


method.

3.10.2 Type, acceptance and routine tests as mentioned in the table given below shall be carried
out on the alternator in accordance with IS : 4722-1868, in conjunction with IS : 7132-
1973, IS : 7306-74 and IEC-11S to check for adequacy of the design to meet ttle
stipulations in respect of designs, workmanship and materials.

sno Tests Type Acceptance Routine Clause of relevant IS / lEe


test test test

1. Verification of Yes Yes Yes As per approved drawing


dimensions of
alternator
assembly --- - -- - - ---
2. Measurement of Yes Yes Yes Clause 8 of IS : 7132-73 I
-I
\
resis+:ance
3. Phase sequence Yes Yes Yes Clause 11 of IS : 7132-73
test -
4. Regulation test Yes Yes Yes Clause 7 of IS : 7306-74 i
5. Measurement of Yes Yes No Clause 5.2 & 5.3 of IS::
leakage reactance 7306-74 II
---
& po~~r reactance. J
I
6. Measurement of Yes No No Clause 21 of IS : 7132-73 I
I
OCC (open cirCL,k- I

characteristics) i
7. Measurement of Yes No No Clause 21 of IS : 7132-73 l
I
short circuit ------ ------ ~._-- -'---

~~}c jhCCkCd By
SSE/ systcm~n
-----
~ - ~--- ---- -~-- - --
I Pa~(' ~() of ~() I With effect from
i .Il1I11:"2012

Characteristics
Efficiency test Yes
---\----
! Yes
-
~'----r_=r=~---~---_-. .-~ - .-\
No Clause 6.2 of IS : 4889-68 I

Temperdture r1~e I Yes No No Clause 25 of IS: 7132-73 &. I

I test for windings. CUI of IS : 4722-2001 or I


.
latest.

1C)_:-Tempe~ature--- rise-; Y~ No 10.2.4, 10."2-:5of IEC-605il-=-1


I te~t on rotating I 2006 I
I Diodes ! ,
I
11.1Overload test i Yes Yes No Clause 16-0--f-I-S-:--7-1-3-2--7-3-&-1
CI. 12 of IS : 4722-68 the I
diesel alternator is also I
capaole to work on 110 % -
over- load for one hour under
service conditions prescribed
above.
I.
12.j Over speed test. No . Clause-13 of IS ':713i~73-& I
Clause 24 of IS : 4722-2001 I
I
or latest
i I
13.1 Insulation I Yes Yes Clause 22 of IS : 4722-2001
resistance test
!
or latest
II I. __
H.! High voltage test I Yes Yes- Clause 9 of IS: 7132-73-&1
\ I CI. 21 of IS : 4722-68
_ -l I
. __ ~

15.1 Determination of I Yes


I \vave form
i deviation factor
16.1\Determination--of Yes
wave form
. __j _Qis1_0.r!ioo
fac~Qr _
17.1 Determination of Yes
11,1r 1110n Ie f lKtOi
18.1 I e.c.l 101 rllclrlual IJY Yes As per Clause 3.2 of this
I
I pass with specification
! automatic change
t over arrangement. I

-0; 6)"rJ)~ ~
SSE/ S~stell1 Design
Wllh cf'fCcl from

I Junc'20ll

19. Test on AVR for Yes Clause 10.2.3, 10.2.4, 10.2.5,


environment 10.2.6, 10.2.7, 10.2.8,
10.2.9, 10.2.10, 10.2.11 of
IEC: 60571-2006.

20. Test on over- Yes No No Clause 10.2.:1, 10.I.oi, 10.2.5,


voltage sensing 10.2.6, 10.2.7, 10.2.8,
device for I 10.2.9, 10.2.10, 10.2.11 of
environment
I IEC : 60571-2006.
i
-----
21. Endurance test on , Yes No No
over voltage
1
I sensing device 500
operation at 30 sec.
I ON & 30 Sec. OFF.
22. Tesl (or verification Yes As-per Clause 3.6 of this i
Yes No
of lhe lolal speclflGltlOll
I harmonic
distortion.
23. Checking dynamic Yes No Yes
balancin of rotor.

It shall be measured by suitable resistance measuring device when the alternator is at


ambient temperature. Ambient temperature at the time of carrying out the test shall also be
recorded. The stator and field resistance at 20 0 C shall be averaged for first 5 machines.
The resistance of any stator or any field winding shall not vary by more than ±7 % from
the declared value.

The alternator in conjuncti0'1 with the Automatic voltage regulator (AVR) shall run at rated
current & voltage at 1500 rev/min speed till the temperature stabilizes. Temperature of the
stator winding, field windings, bearings, terminals and frame shall be measured. The
temperature rise above the ambient of 55 0 C shall not exceed the following values uJlejer
full load condition as well one hour over load conditions: -

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(System Design)
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I -
I l.lunc·2012

I Class of insulation I Temp. rise limit


~
: HillS
1- C 0

The temperature rise of terminals, frames etc. shall be as low as possible. The maximum
bearing temperature at the highest ambient temperature of 55 °C shall not exceed 100 ° C.
The temperature measurements on all location shall be made by point contact pyrometers
unless otherwise specified or agreed to.

3.10.5.2 The temperature rise of main diodes shall be less than designed temperature limits of
each component under worst operating conditions.

3.10.7.1 The insulation resistance shall be carried out on all the circuits, before and after high
voltage test between all live terminals shorted together and body with a megger. The
meggering voltage and values of tt1e i1sulation for the various circuits shall be as under:

Sno . Rated circuit voltage--l Meggering- vo/tage- r Insulation resistance value - - - I


I 1. . 750V AC ! 100Q V'_~ _. _.__ L~ot ~S~~~Cl!UQ9 m~a Ohms__
~)-:__ ~-±l~Y.f:.L_._ 1500 V DC___ Not les:) than 100 mega Ohms 1
[3. 230V AC 500 V DC Not less than 100 me a Ohms ~
r j~~+'~19~OV AC 500 V DC - Not less t~an 100 mega Ohms J
I 5. ,110V AC 500 V DC Not less than 100 m a Ohms
[js~'-'1 24V AC-' ----1-500 ,-'De Not less than 100 m a Ohms

Immediately after the temperature rise test, an AC potential of 1500 V rms at 50 Hz shall be
applied between all external terminals of the alternator shorted together and the frame for
a period for 1 minute. The test shall commence at a voltage of less than one third the test
voltages and shall be increased gradually to the full test voltage. The leakage current shall
not exceed 30mA for the above tests.

3.10.8.1 The test is to be conducted as soon as possible after the temperature rise, test, while the
alternator is still hot. The alternator shall be subjected to 20 % over speed (1800 rprn=
60 Hz. for 4 pole construction) for a period of 2 minutes.
I PrCl~i1rcd"b~- - -,.- __"'" 'I Checked By
( (;)1)7))fJt-.
S S E/ System Design
i'ag<.::l j of Sf, I Willi clfl:cl
June '2012
I'lt)111 J RUSU/l'i'I'l!'1 ('jA('j()()~·1 _\(I()~ (1\/ \ I )

L- -1 . . _

The output terminals of the alternator shall be short circuited with an ammeter In cirCUit
before starting this test and excitation shall be adjusted in such a way that 50 %, 75 %
and 100% of full load current flows through the armature windings. The test shall be
carried out at various speeds covering complete speed range. The spee<ic;selected for ttlic;
test shall be same as selected for open circuit test. Curves sllall be plotted at differellt
speeds for field current versus short circuit current. This test shall be carried out on a cold
macr.ine.

In case of failure of AVR, relay of the over voltag.: sensing device should be actuated
and manual by pass of the system to be checked.

3.10.11.1 The efficiency te~t shall be conducted on 50%. 75 % 100% 110% load. The efficiency
at 1500 rev/min s~1allilot be le::.sthan 92 % aL full load.

3.11 THE BILL OF MATERALS OF ALTERNATOR SHALL BE AS PER THE DETAILS


GIVEN BELOW:

S. Quantity I DG
No. set
-- ---- ._-~-~~~~. __ ._---_._-----_._----_._- -
self excited, self regulated self ventilated brush less 336 'r0N 1 set I'

alternator at site condition of 55 deg C and 200 m altitude. .-1

Crimping sockets forcopper cable of sizes 150sqmm, 120-'I-l-s-e-t


sq. mm., 16 sq. mm. to specn. EDTS 200 and Crimping
sockets for copper cable 0'" sizes 6 sq mm and 1.5 sq mm to
specification no EDIS 201.

3 e-beam cables of various sizes as required of ROSa 1 set


approved make and as per ROSO specification

Set of special tools required for maintenance (list to be 1 set


submitted during tendering stage l_. _
Computer generated cable marker of reputed make I As per I

SS~)~~5~ r~B;·~~·'D,,~-L{Jl:D:,'gnl
___ _ __ I requirement
6 AVR (automatic voltage regulator) modular type [1 set
I Interconnecting cables and coupling arrangement between
I alternator and AVR

7
. Plug- in type fuse protection
I
-----_._---------
-
with appropriately
----
rated fuse of I As
~ - ------
per
i M/s Siemens, M/s L&T I M/s Ferraz make for AVR!:, I requirement
I I
IS :The rotating diodes for supplying DC power to the main fie'IAS per
I I winding of current rating equal to at least 2 times the requirement
I I
loading on them with mInimum 1000V PIV rating

rg---l M/s SKF / FAG -/--N-S-K-m-a--k-e-o-f-bea--ri-ng-s-ap-p-r-ov-ed-b-y-RO·-S-O


As I' per
I used in the alternator requirement

; Fiber glass OMC / SMC terminal board with box cover I As per
approved by ROSa I requirement
l
I 11 i FleXible coupling for engine and alternator. 1 set I
I

r 12 i- R-elays/contactors of M/s ASS/Siemens/ Schenlder/L& T - AS---~

J_rnake_ _ __. __ . reqUirement'r I

T : c 1 S"'t'C e
T' _C ld, ta S,leet "Ite 1Cl -
AIlf1exlJre-Cl Technical details for radiator system
Annt2xure-C2 Technical details of ventilation arrangement
for engir1e room
Annexure-O List of drawings and specifications
Annex lJ rc- E Cartel formation certificate
Anll~x lJI t:- r- Fire retardant test
Annexure-G Format for Quality Assurance Plan

-C-heCkCdBY---·---D-i-r~-r:~eSign) I
I
I With cl'fCcl li·Olll

'--- --'-1 _J line· 2012

SCHEDULE OF TECHNICAL DATA SHEET OF DIESEL ENGINE (PARTICULARS TO BE SUPDLIED BY


THE MANUFACTURER AT THE TIME OF REGISTRATION /PROTOTYPE TEST.)

1.0 Following particulars pertaining to diesel engine and auxiliary equipment shall be submitted by
the tenderer to RDSO/RCF:

A-La The particulars for diesel engine .

. a) Make & Model & No.


1\I~C .'(, or .'(, With effect from
I JUllc'2012
______L _

12 Specific fuel consumption at half, full and 10% overload conditions with tolerance band
under NTP and site conditions. Indicate the lower calorific value of the fuel used in arriving
at the specific fuel consumption figure.

i) Over speed
ii) Low lube oil pressure
iii) High cooling water temperature
iv) High lube oil temp.
v) Any other

i) Turbocharger
ii) After-Cooer
III) Cylinder block
IV) PI~torl ancJconnecting rod
v) Cylinder liner
vi) Cylinder head

23. Periodicity of overhauling the following critical items:


I) Turboclwrger

I Prcp:1rcd b~
Wllh cnccl liollJ I I{DSO/PI'.iSPH'/i\('/()()X,I- '()llX (1<1·\' ''1'')
Junc'2012 ~
L- -L . _ _

ii) Piston and piston rings


iii) Air and exhaust valve
iv) Main bearings
v) Connecting rod bearings
vi) Fuel injection pump.
vii) Fuel injectors

30. Heat dissipation characteristic or. radiator under operating conditions power consumption of
radiator fans motors.

1. Number of turbocharger used for engine.


2. Make and model.
3. Air flow at rated output
4. Speed of turbocharger at rated output.
5. Types of bearings.
6. Details of lubrication.
7. Whether pre and po~t lubrication provided.
8. Booster pressure at full load.

2. Details of mounting indicating whether cooler can be removed wit.hout removing


tu rbocha rger,

I
I
Preparcd by
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SSEI S,slcll1 Design
: With effect fro'11
! .Il1lh~·2()12

- ------_. -_.- - I -----.


~

1. Type 0:
exhaust system
2. Number of exhaust gas entry segments.
3. Whether the exhaust manifold is shrouded/insulated.

1. Material specification of piston and rings.


2. Method of cooling
3. Shape of bowl in piston crown
·t Number Clnd configuration of piston rings.

1. Material specification of valve


2. Single/composite type.
3. Whether valve rotators used.
4. Recommended tappet clearance
5. Angle of valve and seat

1. Material
2. Coolant flow distribution
3. Weather reclaimable by welding

1. Material
2. Whether cast for fabricated
3. Is the mounting rigid or on resilient pads
4. Experience regarding block distortion

1 Material specification
2. Type of bearings calculate bearing loads
3. Pariiculars of vibration damper
Page 3i)~T.<(;------ ,With
June
effec_t_fr"_o_~_n
'2012
,lRD__
SO_/PE/~PEc/,A.C/{)()X4-2()()X (RL\·.··I··)

1. Material
2. Dry of wet liners
3. Water sealing arrangement between liner and cylinder block

1. Material of connecting rod


2. Material composition of bearing shells.

1. Make and type


2. Minimum idle speed. Rated full load speed and droop characteristics.
3. Torque available on the output shaft
4. Control/safety feature provided.

1. Detail of cooling circuit


2. Type of water pump and its characteristic viz delivery vs flow resistance.
3. Is the cooling system pressurized? If so, up to what pressure)
4. Max permitted cooling water temperature at inlet &. outlet of circuit
5. Normal cooling water temperature at full load under NTP and site conditions.
6. Radiator construction and dimensional details.

1. Details of oil circuit with flow diagram


2. Lube oil pressure at full & idle speed
3. Max temperature at hottest point
4. Lube oil pump characteristic and power absorption at various points.
5. Details of all filters used in the lube oil circuit.
6. Efficiency of filtration and periodicity of attention.

1. SChematic fuel oil circuit.


2. Details of fuel oil lift pump and its drive _, ._.--(-- ..t~-~___.-/ _",
Prepared by ~ ~ I
Checked By ~ I

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'--- S__S_E/_Systcm Dcsign 1_.___________ Oir 'N~..&--AC\S~stcmDesign)
I)J~c~~~-(I--'-~I-"-'i-tll-C-ffi-cc-t~~-OI-n---~R=D~SO~~=8~S~P~IT~/~A~C~m~O~84~.~20~O~8~(R~E~V
I 11111L •... :'! II :!

3. C.:tdils of filte,s used in fuel ,:,'1 circuit.


4. Periodicity of attention.

1. Details of engine intake air system.


2. Type of primary and secondary :,tage filters and their efficiency.
3. Pressure drop permitted at the operating point for periodicity of attention.

A-lS.lO Design c('llculalion for the base frame together with selection of AVMs to limit the
vibrations as stipulated in clause-4 .2.

A-l8.12 Total heat rejection capacity of radiator minimum air flow reqUired end pressure drop
dll()'.', llll' \dtlld\OI.

-~-----~-_.-
r
A-lfU 4 Heat load calculation for complete scheme with selection of radiator fan, ventilation fan,
radldtor IllOlol fall capacity and ventilation fan motor capacity.

PrcparcJ b~ \ Checked By

........ ~?~;ut~cs;gn_ _ D_ir_T _


1 . rhecked By

~~t~CSigl1 C (System Design)

---------~
· Pa'::L' of:? l1l"."(1 -- .. - '-j With effect from RDSOfPE/SPEC/AC/0084-200R (REV."l'")
.f11l1l:-":)() 12
L L -.1.. ~

(PA:11LCULARS TO BE SUPPl lED BY WE MANUFACTUR,ER AT THE TIME OF


REGISTRATION / PROTOTYPE TEST.)

a) Output ........... KVA

b) Current ........... Amps.

c) voltage / phase ........... Voltage

d) Frequency ....... Hz.

e) Power factor at full load.

f) De-rating factor at on site condition

0) Speed of Alternator in ............ RPM

a) Stator Wlrldlflg

b) Rotor winding

8-1.5 Excitation system

<1) Type of C'XClt,ltlon.

b) Excitation system voltage

c) Excitation current.

__r_Cl_ll_)\_·--
_PI_~._pa __ - :__
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W II" cl'll:c( Ii 0111
Junc'2012

B-1,6 Efficiency

a) Full load ••.••••••.•. %

b) Three/fourth(3/4) •.••.•••.••• %

c) Half load( 1 /2) ........... '1<.

d) 110% of full load •..••••• %

_. . -

[
Prcpan;d by .\
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1{/ Systcm Design
-- ---------
_~,,~,,~,_t'_'I :~,:::~_:;I;.~_t
_rr_o_Il1 ~_R_D_S_O_/P_E_j_S_r _,X__I_A_C_I_O_O_H_4,_-I_'O_O_8_(_R_E_V_' ._._I_"), ~

(b) Length of the shell

(c) Outer dia of the shell

(d) Inner dia of the shell

(e) Drg. )f the Shell with all toleran(l~s and manuf3cturing process

._------ -
I l'rq);Ir.:l! b\
I
Will, dIn 1 frllill
June'2012

(d) Outer dia of stamping

(e) Total length of stamping

(f) Thickness of stamping

(g) No. of stampings used

(h) Wt. Of rotor core

U) Supplier's name

(k) Power loss per kg

(p) Finished shaft draWing clearly indicating bearing seat, dimension on ,,11,lftr1l1{1 dimension of
bearing with tolerances.

(q) Both ends end-shield manufacturing drawing

(r) rotor skew (l ngIe


,/
B-9.0 Windings of alternators:

(a) Size of copper wire (Stator with specification and maker)

(b) Size of copper wire (Field with specification & maker)

(c) No. of turns per coil (stator)

(d) No. of turns per coil (field)

(e) Type of Varnish used for impregnation

~
(f) Method of Impregnation used

------y---.

~~ tpJ / t,
\
1-
S_S_L/_S_'~_'S_I~_n_ll_
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Checked By

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D_I_rl_·_& DC~
I
I \\'1l11 CITcct-:=rrolll RDSOfPE/SPECIACIOOR4-2U08 (REV.""I"')
I JlIl1~<?O 12
__________ --,0.----- ._.__ _ ~

i
I
Prq)arcd b~ '\
31)Yl)f,~
S S L! S\ stem Design
Willi cl'krt 1'()111

June'2012

SCHE ULE 0 TFCH T Hf"" ~ RADIA -" 'Y~- "


'3 CTURf
-< TEST.)

(-1.1 The radiator and its cooling system layout should be designed in such a way that it should
transmit minimum noise on the Railway plate form.

(-1.2 The power required for radiator cooling should be as low as possible and in no case should
be more tha n 30 kW.

(-1.3 The fan shall have an air handling capacity (in cu. meter /hour) of at least 20% more than
the minimum requirements of the radiator to maintain the engine cooling water
temperature at the specified level under continuous full rated load of the engine at site
conditions. The fan shall deliver the air volume at a minimum static head of 50 mm W.G

(-1.4 Suitable louvers/sound attenuator are to be provided in front of the radiator to facilitate air
flow and prevent ~ound leakage.

(-1.5 Suitable louvers /sound attenuator are to be provided in front of Ule radiator to faCilitate air
flow and prevent Sound leakage .

.,/ (-1.6.1 Blower motor shall be subjected to type and acceptance tests in accordance to relevant IS
specification.

i) Under this test diesel engine is connected to tile radiator designed for use in the high
capacity power car and operated at 100% and 110% load. This test is conducted with t~le
radiator in the free and 30% choked condition. For the later the surface area of Ule radiator
is blockE::din a distributed manner for 30% of the area. During thiS test Ule inlet and outlet
temperature and the flow of water and air are measured.
~-

Dir TL
71f~
IrAC (System Design)
--, I
I
,llIlk' ~dJ -' I
______ I ~

II) Ttle water temperature, the heat transferred through water and air are computed and
cOfT~;:'lred\'Ji~r ~'le declared heat balance characteristjcs,

iii) If the radiator inlet air is preheated to 55 0 C (for simulation) then the test is conducted in
the prevailing ambient te,mperature and th,= water temperature at the equated site
conditions is uetermined, The radiator inlet water temperature recorded shall be well below
0
tile maximum per miSSlble temperature by the value equal to the difference between 55 C
and tile te~t ambient temperature,

iv) For the purpose of the test, thermostat regulating the V\ater flow through the radiator shall
be kept open

- .-- ----\-
--,-'i)l ~'1) If ~ /'
--'---Ch-ec-ked By --CE-~ -:---=--J
SSh S~SIClll'(ksl!.'11 Dj 2J. ,AC (Sy~tem Design)

~·_-------~-------~-_. __ .--. I
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Junc'20ll
frllill
~I/I'I ",1'11/;\1/11"" I ~"':',,~\~_l
_
l-- _

SCHEDULE OF TECHNICAL DATA SHEET FOR VENTILATION SYSTEM


(PARTICULARS TO BE SUPPLIED BY THE MANUFACTURER AT THE TIME OF
REGISTRATION / PROTOTYPE TEST.)

(-2.1 For the purpose of engine room cooling/ventilation, two numbers of centrifugal type
fans With dual radial oulleb are to be mounted on 0:'1(11 D/\ '.I't, <ll tilt' l,llll 1,111 It'vI'1 III
roof. The cooing air shall be drawn through the two louvered openings of size 600 x
1600 rnm with filter panels and through the engine room bottom circular inlet of the
blowers, exhausted through the 10uverecJopenings of size 475 x 300 mm, provided on
the curved portion of the roof. The rating of the motor snail not exceed 5.0 KW.

(-2.2 Blower shall be of ABB/ Siemens/Kirlosker make with terminal connections suitable for
Star-Delta starter.

(-2.3 he selection of blower shall be such that its capacity is at least 10% mone than the
requirements to meet the Engine room temperature conditions specified. In deciding
the static pressure to which the blower rating is to be designed the same conditions
given in clause 2.0 shall be taken into account.

(-2.2.4 The impellers of the blower should be fully welded. Stiffening arrangement has to be
provided for the impellers to eliminate the distortion due to service conditions.

(-2.2.5 The blower design and motor shall t)e in accordance with clause 1.3 of Annexure-( 1
and tests shall be performed on blower as per para 1.6 of Annexure-( 1.

C-2.2. Panel Filters:

The panel filters used shall be of the panel mounted type. The filter media shall consist
of three layers of graded density fire retardant glass fiber pads and a layer of woven
fiber-glass cloth at the outlet side, all sandwicr,ed together and stitched securely. The
filter media shall be given a spray of dust trapping oil (servo friz-68 or equivalent) on
the inlet face. The filter media pleats shall be properly sealed and secured with the
frame to prevent air leakage and media migration. These filters shall give a service life
of maximum six months before choking. All metallic parts shall be properly painted. The
design of the filter shall be got approved in advance from RDSO. The filters shall be of
PDSO approved make.

(-2.2.2 The pressure drop across the filter shall not be more than 5 mm of WG when new and
18 mm of WG when in fully clogged condition.
P,cp"cd by
~fP)J(~
\ I Checked By
------....-----
SSE/ Systcm Design Dir TL & LlSystern Design)
-------------------'
\\'lll1 ,'I'I~Cl 1'1\)111 T RDSO/PE/SPECI ..\CI()()X~-2()()X (REV "\")
I .IlJl1l<~(I12
I

(-2,;:'.3 Tile filter shall !)e capable of filtering out dust particles of size greater than 20
microns.C-2.3,4 The material USE..'C1 for housing the filter element shall be either electro-
galvanized or sllall be of non-colTosive material.

C-2.2.5 The type of filter to suit the dimensions for two nos. of panels provided in coach shall
be clearly furnish by the firm.

At least one filter panel shall be subjected to type tests in accordance with the relevant
IS specification and the remaining will be checked for dimensions and physical
damages. ')

The capacity of blower for engine room cooling, calculations to establish their adequacy,
rating of the motor, filter details, overall dimensions, V\eights etc, shall be furnished
along willI Ule tender.

i Prepared In'
,--~ 1)YJ ) (.!}~
S S FI S~stcll1 DeSign Dir TL & AC (System Design)
I
[PO gC_S 1 "_I"_)._{)
_
-'---W_i [1_1
Junc'2012
_d_'fl.:_' C_l .1"_1'1_)_1_11
L_
1 R [) S_' 0/1_' 1 IS 1'1 ('I A (' /(III, -1-.' 1111' "" \ - - 1--I

A) GENERAL ARRANGEMENT OF DIESEL ENGINE

B) RADIATOR MOUNTING DRAWING

C) VENTILATION MOTOR MOUNTING

D) RAIL BASE FRAME DRAWING

/0
. 'rJ61
cA1
. <:/OWJC~
r I Checked By
/~
.sSE/ ~\'s(cm Dcrign Dir TL'-AC (System Design)
I \\,111 ,rIed iro-n-j ---iRDSO/p-tiSPEclt\C/()()X4-2{){)X (fU:V. T')

2(J '_2
J. .I~II1C' L ~

We are aware of the fact that the Registering Authori0' i.e. RDSO
may de-list the name of our firm from the Master List of Approved Vendors if complaint is received
about such cartel for mation from any of the Railways/Production DA sets.
to,',,' ", __
\Villi dICe! Illllll_II{I)~()/111
JUl1c·20 12
---.1________ ._
'~I'U '/:\( tltIS·I·.'tHIS
(1,1\

1.0 t\ piece of terminal board of alternator measuring about 150 x 25 mm or nearest to thiS size
<,hall be subjected to the luminous batswing flame, preferably ~upplied tN a Bunsen l)urner.
Th~ ,)~C1m'?n (,hall be held with t.he flat side up at an angle of LISo to the 11oriLontai. The
flame shall be of 25 mm. in width across the tips.

2.0 The flame st/all be applied to the specimen at the lower end for 30 seconds and removed
for 30 seconds and then applied again to the same end for second period of 30 seconds
and then removed again.

3.0 Should be specimen get ignited, it shall not continue to burn for more than 50 seconds after
the flame has been removed.

~5)7})C~·
" -

SSE/ Systcm Dcsign


I \\'jlh cn~cl rrO~l----

I JUl1c<W12

The firm shall submit the organizational chart, along with the qualification and experience
of key persons in management involved in quality assurance program.

The manufacturer shall maintain all necessary documents and data that will help him have
consistency in producing quality product.

Raw material/eqUipments shall be procured only from well-proven sources, conforming to


relevant standards, Critical components shall be procured from reputed OEM or their
accredited agents.

Screening of critical electronic component/devices shall be carried out as a part of process


quality control method adopted should be clearly explained.

(i) Receiving Material: The manufacturer shall ens ,re that incoming material is not used for,
processing until it has been inspected and verified as confirming to specified
requil'ements, Verification shall be in accordance with quality plan or laid down
documented procedures.

(II) In ploce~~ IIl~peclion and testing: Inspect, test and identify product as required by the
quality plan or documented procedures evolved on the basis of ROSa specification and
other relevant specification/standard.

(Iii) Tile supplier shall carryout all final tests and inspection in accordance with the quality
plan or documented procedures evolved on the basis of ROSO specification and specified
standard to complete the evidence of conformance of the finished product.

- -- ------ - \
CO) fTY) )(!)----
ssU SYSICI~ Design
I g
pa c.'_S_O_f_5_(). j With eUcct (iom
Junc':Wll ~
, RlJS()/I'l.!~I)U1:\( /()(I~-I .'lltlS (1\1 \

------ ------ -._-----_.-

The instrument and equipment used for testing, and inspection shall be of the required
accuracy.

The firm shall indicate the organizational structure of their R&D Wll1g (Jlol1g WllIl
qualification of the personnel. Firm should have at east one Engineering Graduate design
engineer with experience of more than 3 years in the field of Mechanical and Electrical
engineering

8. Laboratory Test House: The manufacturer stlall have a well equipped Laboratory(rest
House to carry out various tests on the raw material, stage inspection and inspection of the
finished product.

9. Traceability of comp<'nents used: Manufacturers shall elaborate the procedure beinq


followed for ensuring traceability of critical components used, and in house test performed
on each critical components, sub assembly & complete equipments individually.

10. Handling /Storage/Delivery: The manufacture shall have proper facilities for hancJling
and storage of raw material and finish product. The supplier shall control packinq
presentation and marking process so as to ensure conformity to the railway requirement.

/~)
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SSE/ System Design Di T (System Design)
Page56 of'5;;--- "'lilhcl'ICCl
1"1'0111'--'---

JUl1c'2012

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