2 X 500 KVA IGBT BASED HOTEL LOAD CONVERTER FOR...

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SPECIFICATION FOR 2X500 KVA IGBT BASED HOTEL LOAD CONVERTER FOR

3-PHASE LOCO

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CENTRE FOR DESIGN & DEVELOPMENT CHITTARANJAN LOCOMOTIVE WORKS

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

APPROVED BY. DY. CEE/CON/TU-II

ALT.

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SPECIFICATION FOR

2 X 500 KVA IGBT BASED HOTEL LOAD CONVERTER

FOR THREE PHASE LOCOMOTIVES

(WAP-7)

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

Total No. of sheets – 29

(Issued on October, 2013)

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SPECIFICATION FOR 2x500 KVA IGBT BASED HOTEL LOAD CONVERTER FOR 3-PHASE LOCO

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

APPROVED BY Dy.CEE/ CON/TU-II.

ALT A B

ALTERATION RECORD SHEET

Date of Amend.

Amendment in Clause

Page No.

Alt Changes Authority

12.05.11 1.1 5 A 4 wire system of coaches is added at 3rd para

***

12.05.11 3.1.1 6 A “The successful bidder shall also supply UIC couplers …… by CLW” has been added.

***

12.05.11 3.1.3 6 A “Field trial jointly with RDSO & CLW” has been added.

***

12.05.11 4.0 7 & 8 A Potential free contacts (S.No.3) has been added.

***

20.07.11 8.1 09 A Frequency variation has been modified from ±6% to ±8%

**

20.07.11

8.2 09 A In the rated output, voltage between phase to earth feeder and output power factor has been added.

* & **

12.05.11 8.3 10 A “Shall be close to unity at full load … parameters” has been added.

***

16.06.11 8.5 10 A New clause for THD has been added. * 20.07.11

8.6 10 A Deleted. * & **

20.07.11 8.7 10 A New clause for voltage unbalance has been added.

* & **

16.06.11 8.8 10 A New clause for expected current unbalance in load current has been added.

*

20.07.11 8.11 10 A New clause for direct on loading starting of converter has been added.

* & **

16.06.11 8.13 10 & 11

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

*

16.06.11 8.14 11 A Indications have been added.

*

12.05.11 8.18 13 A Mechanical dimensions changed, “the successful tenderer is advised …. loco cable tray” has been added and in enclosure clause “the firm has …..the design stage” has been added.

***

12.05.11 8.24 15 A Control Methodology clause has been added.

***

16.06.11 9.1 16 A Maximum temp. in the loco standing dead under sun has been modified with 75°C.

*

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ALT A B

Date of Amend.

Amendment in Clause

Page No.

Alt Changes Authority

16.06.11 9.2 16 A New clause for solar radiation has been added.

*

16.06.11 9.8 16 & 17

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

*

12.05.11 10.4 18 A Clause 10.4 has been added.

***

12.05.11 10.5 18 A Clause 10.5 has been added.

***

12.05.11 10.9 18 A At least 250 GB hard disc has been added in 4th line.

***

16.06.11 11.1 18 A IEC 411.5 has been deleted as IEC 61287 supersedes on it.

*

12.05.11 11.2 18 A Burn in Test clause has been added.

***

12.05.11 11.3 19 A S.No. 29 (Burn in test as per IEC60517 cl. 10.2.13, L marked test has been updated.

***

13.09.13 8.18 13 B The term “otherwise the offer shall be treated as incomplete and noncompliant” has been deleted.

***

13.09.13 11.3 S.No. 7 19 B IEC clause changed as IEC 61287 Clause 4.5.3.7 in lieu of 4.5.3.8.

***

16.06.11 Annex-1 23-28 A Load has been modified * 12.05.11 Annex-2 29 A New Annexure has been added to

include transformer details. ***

* = Modified by vide RDSO’s Letter No. EL/11.5.5/6 dated 16.06.2011 ** = Modified by vide RDSO’s Letter No. EL/11.5.5/6 dated 19.07.2011 *** = Modified by Dy.CEE(Con)/TU-II

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TABLE OF CONTENTS

CL No Description

Nil Alteration Record Sheet

1. Foreword

2. Scope & object.

3. Contractor’s Responsibility

4. Railways Responsibility

5. Reference to various Specification.

6. Documentation

7. Infringement of patient Rights.

8. Technical Specification

9. Climatic & Environmental Condition

10. Scope of Supply

11. Tests

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1.0 FOREWARD

1.1 Chittaranjan locomotive works is manufacturing 3-phase electric locomotives. These

locomotives take power from OHE through pantograph to traction transformer. This traction transformer is provided with a hotel load winding to cater for the power supply to coaches (also referred to as Hotel Load). The capacity of this winding is 1245 KVA, which gives 960 volt single phase at 50 Hz ±6% at 25kV primary voltage with rated maximum current 1260 A ,which varies with OHE voltage variation. The details of transformer are provided in Annexure-2.

With the technological up-gradation and continuous advancements in the field of

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

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

Hotel Load of the train. In Electric locomotives, power is taken from the OHE through pantograph to traction transformer of the locomotive which is provided with a hotel load winding of 1245 kVA, at nominal voltage of 960 V single-phase, which shall vary with the OHE voltage variations. This 960 Volts single-phase supply shall be fed to Hotel Load Converter, which shall give 750 Volts 3-phase 50 Hz supply as output, for feeding the hotel load of the train. Converter output shall further be stepped down to 415 V, 3-phase AC by existing transformers provided in every coach. This electrical power shall be used to operate the lights, fans, air conditioning, water raising apparatus of the coaches and the pantry car equipment.

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2.0 SCOPE & OBJECT This specification covers the technical aspect of the Railway’s requirement for the

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

3.0 3.0.1 3.0.2 3.1

BIDDER'S QUALIFICATION Bidder shall have designed, manufactured and supplied 180 kVA IGBT based converter or of higher rating to Indian Railways or to other foreign Railways. Bidder shall be Indian subsidiary/company of the OEM who qualifies vide clause 3.0.1. CONTRACTOR’S RESPONSIBILITY

The contractor’s responsibility shall be extended to the following:

3.1.1

The bidder shall supply the 2 X 500 kVA IGBT based Hotel Load Converter of approved design conforming to the various operational and functional requirement. The bidder shall supply detailed instructions for proper installation of the equipment on the locomotive. For this purpose the bidder shall also depute his representative during installation of the first two equipments in the locomotive at each location (i.e. CLW / Shed). The bidder shall supply the items like Inter Vehicular Couplers (4 nos. for each loco set) of specifications to be supplied by CLW. The successful bidder shall also supply UIC couplers for control signals between locomotive and power car. The UIC couplers shall be provided in both Locomotive and the power cars. Details shall be furnished by CLW.

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

3.1.3 The bidder shall be responsible for commissioning, testing & field trials of the prototype equipment in service and depute team of engineers for this purpose. The bidder shall arrange to carry out detailed tests & field trial jointly with RDSO & CLW.

3.1.4 The rates shall include supply of special tools, testing jigs, portable diagnostic/troubleshooting tools preloaded with suitable latest operating system and application software and instruments, which may be required for troubleshooting and maintenance of the Hotel Load Converter. The firm has to supply the breakup of the rates of the same along with the offer.

3.1.5 The rates shall include supply of a suitable software “if applicable” for off-line analysis of diagnostic data downloaded from the hotel load converter along with the offer.

The design shall be developed as per requirement given in the specification. The detailed electrical and mechanical design including Finite Element Analysis shall be submitted to CLW for scrutiny and approval before commencing of the manufacturing. Here “approval” means the “approval of design features” only. The bidders shall be

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responsible for the performance of complete Hotel Load Converter for hotel load. 3.1.6 Warranty The bidders shall be responsible for any damage of the equipments supplied due to

defective design, materials and workmanship upto a period of 36 months after commissioning on the locomotive or 42 months from the date of supply, which ever is earlier. The bidder shall repair/ replace all such equipment supplied during the warranty period at his own cost. The bidder shall warrant that everything to be furnished hereunder shall be free from all defects and faults in material, workmanship and manufacture and shall be of the highest grade and consistent with established and accepted standards of material of the type ordered and in full conformity with specifications and drawings. The bidder’s liability in this respect of any complaints, defects and / or claim shall be limited to the furnishing and installation of replacement parts free of any charge. The warranty clause in commercial agreement, if any, shall prevail.

The bidder 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.

3.1.7 Training The bidder shall include the rates of arrangement for training of IR personnel in

maintenance & troubleshooting of the system supplied. Five days training for six persons per location in the field of maintenance & trouble shooting with the offer. Number of locations, preferably at OEM's work place under the guidance of OEM's engineers, shall be mutually agreed between manufacturer and CLW based on the ordered quantity.

3.1.8 The bidder shall supply the write up and the elaborate manual in both hard and soft copy for maintenance and troubleshooting free of cost to IR for easy maintenance.

3.1.9 The bidder shall submit detailed system design manual both in hard and soft copy. 3.1.10 Spares management

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

4.0 RAILWAYS’ RESPONSIBILITY Railways shall be responsible for the following: 1. System interface design in terms of hardware & software and the associated

changes in the locomotive control system. 2. The cabling in loco from Hotel Load Converter to the IV coupler. 3. The cable for connecting potential free contacts to vehicle control electronics

(VCE).

4. Any equipment re-layout and mounting platform on locomotive necessary for installation of Hotel Load Converter for hotel load shall be done by the railways in association with the bidder.

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

6. Facilities for erection, commissioning & in loco testing of Hotel Load Converter shall be provided by IR free of cost.

5.0 REFERENCE TO VARIOUS SPECIFICATIONS

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

(b) IEC61287-1: Railway applications – Power converters installed on rolling stock (c) IEC-60310: Rules for traction transformer & reactor

6.0 DOCUMENTATION

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

(a) Detailed specification of the offered converter, major equipments, etc. (b) Details of semiconductor devices used with their specification and data sheet. (c) Design calculations including the calculation of safety margin in voltage, current,

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

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

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

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

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

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

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

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

diagnostic feature h) QAM (Quality assurance manual).

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(i) Declared output voltage and current waveform, THD and regulation. (j) Test protocol with procedure of testing. (k) Data sheet of major components duly filled. (l) ISO 9000 certification 7.0 INFRINGEMENT OF PATENT RIGHTS

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

8.0 TECHNICAL SPECIFICATION CONVERTER REQUIREMENTS

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

17.5 kV to 30 kV, 50 Hz ±6%. 8.2 Rated output Voltage phase to phase - 750 V,50 Hz ±6%. 3 phase sine wave

AC, 3 Wire Voltage between phase to earth feeder – less than 1.0 kV (Peak) Frequency - 50 Hz ±2%. Capacity - 2X500 KVA (Two units of 500 KVA per locomotive) at power factor not less than 0.8

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

Load to be attached with the converter is given in Annexure-1 8.3 Input Power factor Shall be close to unity at full load with normal input

parameters.

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8.4 8.5 8.6 8.7 8.8

Current harmonics at full load Total harmonic distortion (THD) Deleted. Voltage unbalance Expected current unbalance in load current

Less then 5% up to 20th harmonic. Less than 10% in output voltage Less than 3% Up to 15% of rated output current

8.9 Cooling Direct or forced air cooled / Water cooled preferably

direct or forced air cooled 8.10 8.11

Efficiency at full load Direct on loading starting of converter

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

8.12 Construction Modular 8.13

Protection

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

(a) Open circuit in hotel load winding and no input voltage available. (b) Ground fault in AC input circuit. (c) Ground fault in 3-phase out put. Limits for earth fault detection shall be not more than

30 mA. (d) Converter phase fault. (e) Line to line short circuit due to dead short at load terminal. (f) Thermal over loading. (g) Fuse failure in converter if fuses are used. (h) High / low voltage in DC link. (i) Failures of power supply to control electronics. (k) DC link short circuit. (l) Input over voltage / under voltage. (m) (n) (o) (p)

Input over current. Single phasing in load Output over voltage and under voltage; and Output over current

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

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

The converter at AC input and output must use IGBTs. The control shall be

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

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

Main contactor stuck ON/OFF;

Input over current

Input earth fault;

Input available;

Output available;

Converter healthy;

Converter faulty; and

Output earth fault

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

8.16 Fault Indication, Diagnostics and Trouble Shooting A suitable fault diagnostics and trouble-shooting arrangement as per functional

requirement of 3-phase locomotive shall be provided locally on the Hotel Load Converter. The faults shall be down loadable on a laptop computer through a standard port /interface. Large capacity of storage of faults along with the background data shall be provided, so that data pertaining to minimum latest 200 faults are kept stored. Details of the fault diagnostics and indication of faults / health status shall be finalized during the design approval stage.

8.17 Safety

Following shall be provided in each Hotel load converter cubicle for human safety. Indication of presence of high voltage ( Voltage Indicator ) Safety inter lock on front panel with lock and key to be integrated with existing key multiplier

system used in auxiliary converter ( 3phase loco)

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8.18 Mechanical dimensions

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

Space-1 Space-2 Width - 1400 mm Width - 1400 mm Depth - 1075 mm Depth - 1075 mm Height - 1750 mm Height - 1750 mm Spaces for Additional Equipments A: Space – 1 Space - 2 Width - 300 mm Width - 300 mm Depth - 1075 mm Depth - 1075 mm Height - 1750 mm Height - 1750 mm Spaces for Additional Equipments B: Space – 1 Space - 2 Width - 384 mm Width - 384 mm Depth - 700 mm Depth - 700 mm Height - 435 mm Height - 435 mm For proper installation of the Hotel Load Converter some installed equipment may be required to be shifted. The successful tenderer is advised to inspect the loco for availability of space as mentioned above prior to submission of their design documents. Bidder is expected to study the existing layout thoroughly and suggest possible layouts of equipments for proper installation of the Hotel Load Converter along with the offer. IR shall approve the most appropriate layout.

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

Enclosure The enclosure for electronics shall be free from dust and moisture. Design of cooling heat

exchanger shall be done to ensure temperature difference of less than 10 degree centigrade across the heat exchanger. The panel sheets used for fabrication shall be of SST grade 321 as per ASTM-A240 of min. 3 mm thickness. The firm has to submit the 3D models, compatible to NX platform, of all the cubicles, during the design stage.

Cooling Suitable and efficient arrangement shall be made for cooling of the Hotel Load

Converter. In case cut-out provisions are required to be made in the shell of the locomotive then the details of the same shall be furnished to IR for study.

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8.19

Safety factor

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

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

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

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

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

accidental contact. The shields and screens shall be properly earthed. 8.20 Reliability: Component to be selected and tested as per international reliability

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

8.21 Maintainability :

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

8.22 Marking: The major equipments / subassemblies shall bear marking and serial

number. The equipment shall contain serial number and make of bidder.

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

aluminum with engraved / punched letters.

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

(i) Type / Make

(ii) Contract/purchase order number

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

(iv) Rating

-- KVA -- Input voltage range -- Output voltage, frequency and wave shape

8.23 Cable The use of wires / cables shall be reduced to minimum. Bus bars shall be of high

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

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

be provided at cable entry / exit. 8.24 Control Methodology:

The Hotel Load Converter shall be installed in the loco machine room at the

prescribed location as per clause no. 8.18 of this specification. The Loco Pilot shall close the input contactor through BLHO Key installed in each cab of the loco. The indication of closing of the contactor shall be made available to the power car operator in the power car. Power car shall house a panel which shall have complete control of operation of Hotel Load Converter which in turn shall have prescribed interlocks with the Alternator available in the power car. The scheme shall be as per the latest RDSO Modification Sheet (MS) which shall be made available on demand or which may be downloaded from RDSO’s official web site. The supplier has to supply all the equipments/cables/panels and any other material needed for interfacing the hotel load converter with the power car. For each set of Hotel Load Converter two power cars shall be modified.

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8.25 The Railways are going for installation of Train Protection and Warning System in all the locomotives. The proposed foot print of the TPWS shall be 560mmx560mm which has been planned to be installed between HB-1 panel and Hotel Load Converter. This shall require some equipment shifting. This aspect shall be discussed during the design stage.

9: CLIMATIC & ENVIRONMENTAL CONDITION

9.1 The Hotel Load Converter shall be fitted in locomotive machine room where the temperature shall be - (a) Maximum temperature : Locomotive standing dead under sun 750C Working loco 55ºC

(b) Minimum temperature : 0ºC

(c) Average temperature : 47ºC

9.2 Solar radiation: 1 kW/m2

9.3 Humidity : Upto 100% during rainy season.

9.4 Altitude : Upto 1200 m above mean Sea level.

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

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

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

(a) Maximum pH value : 8.5

(b) Sulphate : 7 mg per litre

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

(d) Maximum conductivity : 130 micro siemens/cm

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

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9.9 Electromagnetic pollution: High degree of electromagnetic pollution is anticipated in locomotive machine room, where the equipment shall be mounted. Necessary precaution shall be taken in this regard.

9.10 Input Power Interface

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

(c) The catenary voltage shall vary from 17.5kV to 30kV. However, voltage may dip down to 17.5kV, which may lasts for up-to half an hour.

(d) Input power frequency = 50Hz±6%

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

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

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

10. Scope of supply

10.1 The scope of supply covers design and development of complete loco-set ie. 2 nos. of 500 KVA (IGBT) based hotel load converter for 25kV AC 3 phase locomotive. Their location and control shall be decided mutually between CLW and the successful tenderer and CLW shall incorporate logic for contactor operation in the locomotive.

10.2 Bidder shall supply suitable software and hardware for offline analysis of diagnostic data downloaded from the Hotel Load Converter.

10.3 The bidder shall supply the items like Inter Vehicular Couplers (IVC), HOG coupler of detailed specifications to be supplied by CLW. Approval of items like IVC, HOG coupler shall be obtained from the CLW.

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

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

10.6 Commissioning of complete set of 2 nos. of 500 kVA IGBT based Hotel Load Converter on the locomotive.

10.7 Five days training for six persons per location is to be offered for IR personnel for training in the field of maintenance and troubleshooting. For the ordered quantity of 10 sets, training shall be provided for the personnel at maximum two locations.

10.8 Detailed operation and maintenance manual in soft and hard copy.

10.9 The bidder shall give a portable data logging and processing unit, preloaded with suitable operating system and software for each loco set for downloading and analysing the failure data of the equipment. This unit shall be with latest Pentium Core 2 Duo or latest processor, Minimum 2 GB RAM, at least 250 GB hard disc, Window XP or the latest to process the diagnostic data, display size upto 12.2” diagonal. Bidder shall also provide testing jigs for troubleshooting at card level.

10.10 Necessary jigs & fixtures for commissioning of the converter on the locomotive including fixture for air duct shall be in the scope of supply of contractor for first two locosets.

11. TESTS

11.1 The converter shall be tested in accordance with IEC61287& the control electronics shall be tested as per IEC60571.

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

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0 C0

+25 C0

+70 C0

-25 C0

On

Off

1.4 2.1 5.2 5.5 9.1 9.4 12.5 13.2 15Time (Hrs)

0.1=10 Min1.55 5.27 5.42 9,17 9.32 12.57 13.12 14.41

Temperature CycleTemperaturein Degrees

BURN-IN TEST

11.3 The list of tests to be carried out is as follows :

S.No. Test Clause Type Routine

1. Visual inspection IEC 61287 clause 4.5.3.1 √ √

2. Tolerance & dimension IEC 61287 clause 4.5.3.2 √ √

3. Weight IEC 61287 clause 4.5.3.3 √

4. Cooling IEC 61287 clause 4.5.3.5 √

5. Protection and measuring IEC 61287 clause 4.5.3.6 √ √

6. Trigger eqiupment IEC 61287 clause 4.5.3.7 √ √

7. Light load IEC 61287 clause 4.5.3.7 √ √

8. Noise measurement IEC 61287 clause 4.5.3.10

√

9. Temperature rise IEC 61287 clause 4.5.3.11

√

10. Power loss determination IEC 61287 clause 4.5.3.12

√

11. Supply over voltage & transient

IEC 61287 clause 4.5.3.13

√

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12. Short circuit IEC 61287 clause 4.5.3.9 √

13. Sudden variation of load IEC 61287 clause 4.5.3.14

√

14. Insulation IEC 61287 clause 4.5.3.15

√ √

15. Dielectric IEC 61287 clause 4.5.3.16

√ √

16 Vibration & shock IEC 61287 clause 4.5.3.19 the panel used during the shock and vibration test shall not be allowed to be used for series supplies against the contract as vibration and shock test is a destructive test. The panel shall be kept with the manufacturer. No item of this panel would be allowed to be used for supplying spares to any railway.

√

17 Interference on control electronics

IEC 61287 clause 2.4.6.23

√

18 Short time interruption IEC 61287-1 √

19 DC link discharge IEC 61287-1 √

20 Rated current load IEC 61287-1 √

21 Output voltage & frequency range

IEC 61287 clause 4.3.3 √

22 Performance test by fault simulation

IEC 60571 clause 10.2.2 √ √

23 Voltage surge on control electronics

IEC60571.1 clause 10.2.6.2

√

24 Electrostatic discharge test on control electronics

IEC60571.1 clause 10.2.6.4

√

25 Transient burst susceptibility test

IEC60571.1 clause 10.2.7

√

26 Radio interference test on control electronics

IEC60571.1 clause 10.2.8

√

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27 Damp heat on control electronics

IEC60571.1 clause 10.2.5

√

28 Dry heat on control electronics

IEC60571.1 clause 10.2.4

√

29 Burn in test IEC60517 clause 10.2.13 √

11.4 The bidders shall submit complete test programme for type and routine test to authorised representative of CLW for 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 shall carry out the test as per mutually agreed test programme at his own cost.

11.5 The prototype Hotel Load Converter units shall be inspected & tested by the engineers of CLW at the factory premises or at mutually decided venue where all the facilities shall be made available for carrying out the prototype test. The equipments shall be kept in field trials for a period of six months. The CLW engineers shall associate and witness the tests in the locomotive also till they are successfully completed. Any defects noticed / design improvement found necessary as a result of the test / trial shall be carried out by the tenderer in the least possible time.

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

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

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

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

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

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

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

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

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11.9 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 done by the manufacturer on each equipments.

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

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

11.12 Instrumentations

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

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

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

12. Delivery

The firm has to deliver the prototype set within six month from issue of purchase order. Along with the offer the firm shall mention the time schedule of other activity such as

(a) Submission of design document

(b) Date of offer for prototype inspection,

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

(d) Subsequent delivery schedule for rest of the sets

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

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Annex-1/1 Power Requirement with Different

Coach Combinations with HOG System

TYPE COACH COMBINATION EXISTING

CONNECTED LOAD (IN KW)*

POWER REQUIREMENT AT

0.8 DIVERSITY FACTOR (IN KW)

24 COACH RAJDHANI

AC-20, POWER CAR-2, PANTRY-2 932 745.6

19 COACH RAJDHANI

AC-15, POWER CAR-2, PANTRY-2 742 593.6

12 COACH SHATABDI

AC-19, POWER CAR-2, PANTRY-1 440 352

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

CONNECTED LOAD CALCULATION FOR LHB TYPE COACHES 1-AC

S.NO. COMPONENT POWER QTY

TOTAL CONNECTED LOAD

IN (WATTS) IN (WATTS) 1 ANTI-SKIDDEVICE 48 1 48 2 FAN

2.1 EXHAUST FAN 132 2 264 3 PANTRY EQUIPMENT

3.1 HOT CASE 1200 1 1200 3.2 BOTTLE COOLER/ 800 1 800 3.3 REFRIGERATION 4 SWITCH BD CABINET 500 1 500 5 COACH LIGHTING

5.1 LIGHTINGS 40 WATTS 40 9 360 5.2 LIGHINGS 20 WATTS

5.3 SINGLE COMT.+ VASTIBULE +DOORWAY 20 17 340

5.4 READING LIGHT 10 24 240

5.5 TOILET OCCUPIED LIGHT 16 4 64

5.6 LAV. LIGHT 16 4 64

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6 AC SYSTEM 6.1 AC UNIT 13600 2 27200 6.2 CONTROL PANEL 140 1 140 7 SANITARY SYSTEM

7.1 WC CONTROL SYSTEM (24 V) 40 4 160

7.2 WATER PUMP 220 1 220 7.3 MAGNETIC VALVES 8 6 48

7.4 ELECTRIC SHAVER SOCKET 20 4 80

8 PA SYSTEM

8.1 LOUDSPEAKER EQUIPMENTS 60 1 60

9 ELECTRIC CAR EQUIPMENTS

9.1 BATTERY CHARGER 6160 1 6160 37948 TOTAL LOAD 37.95 KW


S.NO. COMPONENT POWER

(WATTS) QTY TOTAL CONNECTED

LOAD (WATTS)

1 ANTI-SKID DEVICE 48 1 48 2 FAN


3.1 HOT CASE 1200 1 1200

3.2 BOTTLE COOLER/REFRIGERATION 800 1 800

4 SWITCH BD CABINET 500 1 500 5 COACH LIGHTING



5.4 READING LIGHT 10 52 520 5.5 TOILET OCCUPIED LIGHT 16 4 64 5.6 LAV. LIGHT 16 4 64

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6 AC SYSTEM 6.1 AC UNIT 13600 2 27200 6.2 CONTROL PANEL 140 1 140 7 SANITARY SYSTEM

7.1 WC CONTROL SYSTEM(24 V) 40 4 160 7.2 WATER PUMP 220 1 220 7.3 MAGNETIC VALVES 8 6 48 7.4 ELECTRIC SHAVER SOCKET 20 4 80 8 PA SYSTEM

8.1 LOUDSPEAKER EQUIPMENTS 60 1 60 9 ELECTRIC CAR EQUIPMENTS

9.1 BATTERY CHARGER 6160 1 6160 TOTAL 38188 TOTAL 38.2 KW


S.NO. COMPONENT POWER IN WATTS QTY

TOTAL CONNECTED LOAD

IN (WATTS) 1 ANTI-SKID DEVICE 48 1 48 2 FAN


3.1 HOT CASE 1200 1 1200 3.2 BOTTLE COOLER/ 800 1 800 4 SWITCH BD CABINET 500 1 500 5 COACH LIGHTING



5.4 TOILET OCCUPIED LIGHT 16 4 64

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5.5 LAV. LIGHT 16 4 64 6 AC SYSTEM

6.1 AC UNIT 13600 2 27200 6.2 CONTROL PANEL 140 1 140 7 SANITARY SYSTEM

7.1 WC CONTROL SYSTEM(24 V) 40 4 160 7.2 WATER PUMP 220 1 220 7.3 MAGNETIC VALVES 8 6 48 7.4 ELECTRIC SHAVER SOCKET 20 4 80 8 PA SYSTEM

8.1 LOUDSPEAKER EQUIPMENTS 60 1 60 9 ELECTRIC CAR EQUIPMENTS

9.1 BATTERY CHARGER 6160 1 6160 TOTAL IN WATTS 37568

TOTAL KW 37.57

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

S.NO.

COMPONENT

POWER IN

(WATTS) QTY

3-PH AC/415

V 1-PH

AC/240V 1-PH

AC/110V DC/110V

WATTS WATTS WATTS WATTS 1 ANTI-SKIDDEVICE 48 1 0 0 0 48 2 FAN

2.1 EXHAUST FAN 132 2 264 0 0 3 PANTRY EQUIPMENT

3.1 HOT CASE,FOR 140MEAL 1500 1 0 1500 0 0

3.2 BOTTLE COOLER 90 LTRS 200 1 0 200 0 0

3.3 REFRIGERATOR, 310LTRS 300 1 300

3.4 DEEP FREEZER, 230 LTRS 400 1 400

3.5 OVEN TOSTER GRILL 1200 2 2400 3.6 WATER BOILER-1,2 &3 3000 3 9000 3.7 ELECTRIC BURNER-1 2000 2 4000

3.8 ELECTRIC BURNER-2 & 3 2000 2 4000

3.9 ELECTRIC BURNER-4 5100 1 5100

3.10 ELECTRICAL CHIMNEY-1,2 & 3 300 3 900

3.11 INSECT KILLER 20 2 40 3.12 WATER FILTER 200 1 200

SUB TOTAL OF PANTRY EQUIPMENTS 28040

4 SWITCH BOARD CABINET 500 1 0 0 0 500

5 COACH LIGHTING 0 5.1 LIGHTINGS 40 WATTS 40 9 0 0 360 360 5.2 LIGHINGS 20 WATTS 0

5.3 SINGLE COMT.+ VASTIBULE + 20 15 0 0 300

5.4 DOORWAY 0 5.5 LAV. LIGHT 16 2 0 0 32 0

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5.6 TOILET OCCUPIED LIGHT 16 2 0 0 0 32

6 AC SYSTEM 6.1 AC UNIT 13600 2 27200 0 0 0 6.2 CONTROL PANEL 140 1 0 0 0 140 7 SANITARY SYSTEM

7.1 WC CONTROL SYSTEM(24 V) 40 2 0 0 0 80

7.2 WATER PUMP 220 1 220 0 0 0 7.3 MAGNETIC VALVES 8 6 0 0 0 48

7.4 ELECTRIC SHAVER SOCKET 20 2 0 0 0 40

8 PA SYSTEM

8.1 LOUDSPEAKER EQUIPMENTS 60 1 0 0 0 60

9 ELECTRIC CAR EQUIPMENTS 0

9.1 BATTERY CHARGER 6160 1 6160 0 0 0 SUB TOTAL 33844 28040 392 1608

TOTAL Watts 62276 TOTAL (KW) 62.276

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Annexure-2 Important Data of Transformer

SN Parameter Value 1 Type LOT-6500 / LOT 7500 2 Original Design Secheron SA 3 Windings Traction 4 Auxiliary 1 Filter 1 Hotel load 2

4 Frequency (f nom) 50 Hz 5 Primary Voltage Maximum 30.0 kV Nominal 25.0 kV Minimum 17.5 kV

6 Voltage Ratings (at 25.0 kV Catenary)

Traction 1269V Auxiliary 1000V Filter 1154V Hotel Load* 960 V

7 Current Ratings HT 261.25 A Traction 4 x 1142 A Auxiliary 334 A Filter 347 A Hotel Load* 2x648A A

8 Thermal Ratings Primary 6531 kVA Traction 4 x 1449 kVA Filter 400 kVA Hotel Load* 2x622.5 kVA

9 Winding Data Traction 37.0 mΩ, 2.1 mH + 15% Auxiliary 60.0 mΩ, 0.43 mH Filter 19.0 mΩ, 0.29 mH Hotel Load* 11.0 mΩ, 0.37 mH

* Hotel Load winding is available only in LOT 7500

2 X 500 KVA IGBT BASED HOTEL LOAD CONVERTER FOR...

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