Draft Technical Specification For Electric Hybrid ...

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Issued on: xx.xx.2020 Spec. No. RDSO/2020/EL/SPEC/0xxx(Rev.0) (Rev’1’)

Prepared by Checked by Issued by

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Government of India Ministry of Railways

Draft Technical Specification

For Electric Hybrid (Electric +Battery) Locomotive

Specification no: RDSO/2020/EL/SPEC/0xxx, (Rev ‘0’)

Issued on xx.xx.2020

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ELECTRICAL DIRECTORATE RESEARCH DESIGNS AND STANDARDS ORGANISATION

MANAKNAGAR, LUCKNOW - 226011

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Approved by Signature

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Status of Revision

SN Date of

Revision

Page

No. Revision Reason for Revision

1. All 0 First Issue - In compliance to RB letter no. 2019/ Elect.(TRS) /462

/1, dated 20.08.2020

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CONTENTS

SN Description Page No

1. Abbreviations and Definitions To be put

after finalization 2. Chapter-1: General Description

3. Chapter-2: Technical Requirement

4. Chapter-3: Operating and Environmental Conditions

5. Chapter-4: Scope of work/supply

6. Chapter-5: General Conditions, Inspection, Test & Trials and Other requirements

Annexure-I: Max. & Min. Moving dimension for BG Electric locomotive

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Abbreviations and Definitions

The following abbreviations & definitions are used in these specification and standards:-

AAR Association of American Railroad

AC Alternating current

Aux Auxiliaries

A1A-A1A Shall mean one unit of locomotive consisting of two bogies, with two driving axles and one non-driving middle axle per bogie with each bogie having two independent traction motors and the traction motor drive coupled to each wheel

BG shall mean 1676 mm Broad Gauge used in IR

BMS Battery Management System

BOM Bill of Material

CLW Chittaranjan Locomotive Works

Co-Co Shall mean one unit of the Locomotive consisting of two bogies, with each bogie having three wheels with three independent traction motors and the traction motor drive coupled to each wheel

DC Direct Current

EMC Electro-magnetic Compatibility

EN Euro Norm (European Standards)

FEM Finite Element Method

HT High Tension (Voltage) (according to Indian Electricity Rules)

IEC International Electro technical Commission

Inspecting Officer

The person, firm or department nominated to inspect the Electrics/bogie/complete loco etc. or the representative of the inspecting officer so nominated.

IR Indian Railways

IRS Indian Railways Standards

IS Indian Standard

ISO International Organization for Standardization

MCB Miniature Circuit Breaker

MMD Maximum Moving Dimension

MSU Motor Suspension Unit

OEM Original Equipment Manufacturer

OHE Over Head Equipment

PCB Printed Circuit Board

Purchaser The President of the Republic of India as represented by the Railways organisation entering into the contract

RAMS Reliability, Availability, Maintainability and Safety

RDSO Research Designs & Standards Organisation

SI System Internationale

Supplier The person, firm or company with whom the order for supply of the work has been placed

S&T Signal and Telecommunication

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TCN Train Communication Network

TE/BE Tractive effort/Braking effort

TM Traction Motor

UIC Union Internationale des Chemins de Fer (International Union of Railways)

VCB Vacuum circuit Breaker

VCU Vehicle Control Unit

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CHAPTER - 1: GENERAL DESCRIPTION 1.0 The Electric Hybrid (Electric +Battery) Locomotive shall conform to the technical

requirements of design, development , manufacture, testing , supply , delivery, commissioning and maintenance of 1676mm gauge, for use by the Indian Railways as per Specification and Standards set forth herein

1.1 Shunting operations are performed using diesel locomotives, although the tracks in the major stations are electrified including platforms. However the coaching depots and yards are not 100% electrified. Due to this bottleneck the shunting operation requires deployment of diesel locomotives as the complete shunting zone is non-electrified. In addition to these the washing pits of coaching depots can’t be electrified for safety reasons. These are the general forcing factors for using diesel locomotives for shunting. Diesel locomotive has some inherent disadvantages such as: noise and air pollution which is not desirable especially in major urban stations. Thus it is conceived that a shunting locomotive can be developed with battery backup to do the shunting operations in place of diesel shunting locomotives. During the small non-electrified sections of shunting zone these locomotive will be powered from battery. As soon as the OHE shall be available the normal 25kV supply will be utilized. This is a locomotive with the ability to operate from 25kV AC OHE supply as well as battery set. This specification defines the system and performance requirement for design, development, and manufacturing of battery operated dual mode shuntinglocomotive.

1.2 Tangible benefits of Electric Hybrid Locomotives are summarized as follows:

1.2.1 Emission free and noise free shunting is the prime concern in urban station area like Delhi, Mumbai, Howrah, Chennai etc.

1.2.2 Dependency on diesel locos will not be there. Further, the populations of diesel locos are decreasing as the same are being phased out for variousreasons.

1.3 The purpose of the specification is to provide the technical specification for integration of Traction battery with the propulsion equipment. The responsibility of Railways and Firm are mentioned in the subsequent clauses in the specification in Chapter-4.

1.4 The proven/suitably designed propulsion system (Integrated Converter) shall be used in the project and the battery shall be integrated on the DC link of the Power Converter. Supplier should take necessary approval of modifications carried out during design stage. Integrated converter is preferred owing to space constraint in loco as large size of battery has also to be accommodated. However, separate Traction & Auxiliary convertor may be used provided their fitment in available space is possible without any problem with regard to maintenance/accessibility of same.

1.5 The environmental and service conditions, performance requirements and technical requirements are specified in this Specification.

1.6 The design and manufacture of the equipments shall be based on the requirements set out in this Specification and in accordance with Good Industry Practice.

1.7 The Supplier shall demonstrate, to the satisfaction of the IR, that the sub-systems proposed to be used in the Locomotives are based on proven technology and design. For the avoidance of doubt, the IR may require the supplier to

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conduct such tests and trials as may be necessary to establish the reliability and efficiency of such technology and designs in accordance with the Good Industry Practice.

1.8 Due consideration shall be given at design stage to ambient conditions of dust, moisture, high temperature and vibrations prevalent in India as specified in Chapter-3 of this specification.

1.9 The validation, test and trials of the locomotive, its sub-component under the scope of supply shall be done up to the expectation level of IR. The chapter-5 may be referred for this purpose.

1.10 References to various standards

1.10.1 The standards applicable and relevant to the complete Locomotive and to the various sub systems and systems shall be:

i. IEC

ii. EN

iii. UIC

iv. AAR

v. IEEE

vi. IS Any other standards referred to in these specifications and standards.

In the event of any contradiction in the aforesaid standards, the following standards shall have priority in the order listed:

i. Standards mentioned in Specifications and Standards set forthherein;

ii. EN /IEC/UIC/AAR; and

iii. IS

For avoidance of any doubt, in case of any conflict between the requirements of these standards, the stipulations of this Specification shall have precedence.

1.10.2 The design of the equipment, system and sub-systems there of shall comply with

the following standards.

SN Standards Title

1

IEC 61133

Electric traction - rolling stock - test methods for electric and thermal /electric rolling stock on completion of construction and before entry into service

2 IEC 61287 Electronic equipment used on rail vehicles

3 IEC 60571 Specific rules concerning the electronic control part of converters.

4 IEC 60349 -2 Electronic converter fed alternating current motors

5

IEC 61377-1

Railway application - rolling stock - Part 1: combined testing of inverter fed alternative current motors and their control system

6 IEC 60505 Guide for the evaluation and identification of insulation systems of electrical equipment

7

IEC 60034-18

Rotating electrical machines: Functional evaluation of insulation systems

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8 EN50121-3-2/ IEC62236-3-2

Railway applications – electromagnetic compatibility - Part 3- 2: Rolling stock –Apparatus

9 EN50121-2/ IEC62236-2

Railway applications – electromagnetic compatibility - Part 2: emission of the whole railway system to the outside world

10 EN 50238 Railway applications - compatibility between rolling stock and train detection system

11 IEC 60310 Transformer and chokes

12 IEC 60296 Transformer oil

13 IEC 60077-4 High voltage AC circuit breaker

14 IEC 60494 pt.-I Rules for pantograph of electric rolling stock

15 IS3231, IEC60337, 60947

Relays, Suppliers and switches

16 IEC 60228, IS 10810

Cables

17 IEC60099-4, IS 3070 pt.III

Lightning arrestor

18 IEC 61373 Railway applications - rolling stock equipment -shock and vibration test

19 IEC 61131 Programming languages for PLC

20 IEC 60077 Railway applications - electric equipment for rolling stock

21 IEC 60571 Electronic equipment used on rail vehicles

22 IEC 61287-1 Power converter installed on board rolling stock- Part1:Characteristics and test methods

23 IEC 61287-2 Power converter installed on board rolling stock-Part 2:Additional technical information

24 IEC 61991 Railway application - rolling stock protective provisions against electrical hazards

25 IEC 60034 Auxiliary machines

26 IEC 60871 Power factor correction

27 IEC 60068 Control cubicle

28

IEC 60623 or any suitable latest standard as per chosen type of battery

Batteries

29 IEC 60529 Degree of protection provided by enclosures

30 EN 50343 Rules for installation of cabling

31 M-211 AAR approved couplers and coupler yokes

32 IRS R-34 Wheels

33 IRS R-43 Axle

34 EN15085 Railway applications, welding of railway vehicles and components.

35 RDSO's specification No.02-ABR-02

Air brakes

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36

IR Schedule of Dimension for Broad Gauge, revision 2004

Schedule of Dimension for broad gauge

37 IEC 61709 Reliability of electronic component

38 RDSO's technical circular no.ELRS/TC/0071 (Rev.'0')

Metalized carbon strip for pantograph

39 IEC 61375-1 Electric Railway Equipment-train communication network

40 EN 50126/ IEC 62278

RAMS

41 IEC-60563 Permissible limiting temperature in services for component of electrical equipment of traction vehicles.

42 IEC-61377-3 Combined testing of alternative current motors, fed by an indirect converter, and their control system

43 IEC-60077-1 Electric equipment for rolling stock-General service conditions and general rules

44 IEC-60077-2 Electric equipment for rolling stock- Electro technicalcomponents- general rules

45 EN 50153 Railway application- Rolling Stock- Protective action againstelectrical hazards

1.10.3 The latest version of the aforesaid standards, which have been published at least 60(sixty) before the last date of bid submission shall be considered applicable. The copy of all standard should be provided by the supplier.

1.10.4 Where the aforesaid standards are based on ambient and environmental conditions which are less onerous than those stated in this specification, the conditions stated in this specification shall be applied in the design and testing of the Electric Hybrid Locomotives and the systems and sub-systems; and the requirements of aforesaid standards shall be adjusted accordingly.

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

1.11 Quality of Materials, Manufacturing Processes and Workmanship

1.11.1 All Materials (including surface coatings, metals, insulators, adhesives, fluids, grease etc.) used in the manufacturing of the additional equipment required for Electric Hybrid Locomotives shall not give rise to health hazards for crew and staff. The materials shall also be suitable for standard repair operations such as those currently used by the IR (e.g. welding, cutting etc.) without the need for staff to be protected by other than standard means.

1.11.2 Materials shall be suitable for disposal without any special precautions.

1.11.3 Materials used for additional equipments required for Electric Hybrid Locomotives shall be appropriate for achieving the Design Life of the Locomotive.

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1.11.4 Reliability, Availability, Maintainability and Safety (RAMS)

1.11.4.1 The Supplier shall design the equipment required for Electric Hybrid Locomotives to ensure Guaranteed Reliability, Availability and high degree of Safety in order to provide a dependable service. The optimization of the system with respect to Reliability, Availability, Maintainability and Safety shall form an integral element of this Specification The plan for Reliability, Availability, Maintainability and Safety shall conform to EN 50126/ IEC 62278. Reliability of electronic components shall conform to IEC61709.

1.11.4.2 The Supplier shall develop RAMS targets both for the complete system and for the major sub-systems such as transformer, traction converter, auxiliary converter, electronics, traction motor, Transmission and Suspension System, Battery, high voltage equipments, blowers and other auxiliary machines, such that it will provide a high level of reliability.

1.11.4.3 There shall be an efficient means of operation of the locomotive after all failures in accordance with Good Industry Practice.

1.11.4.4 Components critical for safety shall fall into safe operating mode in case of malfunctioning. The system safety plan shall identify and list safety critical components and this list shall be updated periodically.

1.11.4.5 The Supplier shall establish and operate a detailed Reliability, Availability, Maintainability and Safety (RAMS) Assessment system in support of the design, manufacture and subsequent testing, commissioning, operation and maintenance of the Electric Hybrid Locomotives.

1.11.4.6 Safety assessment shall be carried out and shall include the following principles:

(i) Degraded modes and emergency operations shall be considered as well as normal operations;

(ii) Safety risk assessment shall utilize more than one methodology to assess risks;

(iii) Safety risk assessment shall include the consideration of dependent failures , in particular the traction power( in OHE & battery mode) , braking and control systems and

(iv) Safety risk assessment shall consider both severity as well as frequency of occurrences of each type of failure.

1.12 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 Electric Hybrid Locomotives and any other factor, which may be cause of such dispute. The responsibility to settle any issue lies with the supplier.

1.13 Documentation: Following documents shall be submitted by the supplier along with the offer for evaluation:

1.13.1 Schematic circuit:

- System design concept;

- Functional description;

- Communication protocol and software structure description along with compatibility with the locomotive control system;

- Cooling System concept;

- Mechanical interface diagram and compliance to existing mechanics;

- Clause by clause compliance of this specification;

- Credentials with details of supply made of similar items;

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- Data sheets for devices and other equipment proposed along with detailed description of supply proposed;

- Thermal calculation of power devices;

- Salient features and advantages of the offered system;

- Details of technical support and training offered, the training shall cover on assembly, testing, commissioning, operation, maintenance and repair to IR personnel and training shall also cover in software parameter settings, fault diagnostic and analysis;

- Recommended list of spares for 3-year maintenance after warranty along with full drawing/design and details of OEM;

- List of special tools, jigs and fixtures needed for assembly, testing, commissioning, maintenance and repair along with full technical specifications and probable suppliers;

- Logistics proposed for warranty support within India;

- Declaration for long-term support by the supplier;and

- IRIS/ISO 9001 certifications

1.13.2 The Supplier shall submit the design details, including but not limited to the following, to purchaser before commencing manufacturing. Production should begin only after approval from purchaser in written form:

- Technical documentation explaining the complete scheme, characteristics, diagnostics, protection and control etc.

- Detailed drawings of each system/sub-system with interface details;

- Design calculations for selection of devices, cooling systems and various subsystems, establishing the adequacy of the components selected;

- Complete BOM / technical specification of components with source of supply;

- Cooling system design description, data and cooling fluid data;

- Mechanical drawings, mounting arrangement, weight, details of mounting accessories;

- Procedure for parameter alteration, software downloading, diagnostic uploading, analysis etc.

- Schedule maintenance activities with periodicity;

- Maintenance, trouble shooting and repair manual in soft form & hard copy;

- Guaranteed values of efficiency of devices/subassemblies and assemblies;

- Calculation to withstand short circuit current under fault conditions;

- Details of short time rating of the integrated converter, Separate power /auxiliary converters

- Expected efficiency with respect to vehicle load/speed along with calculations;

- Calculation and simulation results of system behavior, including interference to the S&Tcircuits;

- All calculations evaluated on the basis of software simulations shall be supported by sample calculations; and details of tools and plants with design/drawings and supplies.

- The 3D models of all the cubicles, compatible to NXplatform.

Approval of design means approval of general design features. Notwithstanding the approval, the Supplier shall wholly and completely be responsible for the performance of the complete equipment in scope of supply.

1.14 Supplier’s responsibility: The supplier’s shall supply the materials as per the scope of work mentioned in this specification. Other minor items and its scope of supply shall be decided during design approval stage. The responsibility shall be extended to the following:

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a. The supplier shall design, evaluate, examine, and validate all the equipment in the scope of supply of the tender. The ultimate responsibility of the performance of the equipment vis-a-vis performance of the Electric Hybrid Locomotive shall lie with the supplier only.

b. The supplier shall supply detailed instructions for proper installation and commissioning of the equipments in the scope of this specification on the Electric Hybrid Locomotives. For this purpose, the supplier shall also depute their representative during installation and commissioning of the equipments, supplied against this specification.

c. The supplier shall arrange to carry out detailed test & performance proving, jointly with purchaser.

d. The supplier shall supply the special tools, jigs, instruments, spares required for troubleshooting and maintenance of the items of 10 loco sets of Electric Hybrid Locomotives supplied against this specification. The design shall be developed as per requirement given in this specification.

e. The supplier shall also quote for Annual Maintenance Contract (AMC) for equipments supplied against this specification.

f. The supplier shall supply suitable software for off-line analysis of diagnostic data downloaded from the converter and control electronics.

g. Supplier shall perform necessary simulation and analysis including FEM analysis and load analysis, running dynamics etc. for all the equipment to be supplied against this specification. Test results should be within acceptable limits. The test results with observations, if any, shall be submitted with the design document.

h. Integration & testing/validation of additional equipments with the locomotive shall be under Supplier’s scope of work. Supplier shall also associate themselves during the field trial of first locomotive.

i. Supplier should submit all the design details covering modified items, their mounting & integration details, wiring diagram etc. in hard and soft copy to purchaser.

j. Supplier shall submit all the Characteristics curves specified in the specification such as Power, Torque, current, power factor, stator & rotor frequency, voltage etc. with respect to speed (rpm).

k. Supplier shall submit the complete scheme for fitment of newly designed three phase traction motor in thebogie.

l. Supplier should take necessary approval of modification during the design approval stage.

m. Performance Curves: The preliminary throttle-wise "Tractive Effort Vs Speed" & 'Braking Effort Vs Speed' at standard as well as site conditions shall be submitted along with the offer. In addition, the manufacturer shall submit "Draw Bar Pull Vs Speed" characteristic curves at standard as well as siteconditions.

n. Efficiency: The Suppliers shall indicate efficiency for the different additional/modified components/equipments/systems supplied by them againstthespecification. Further, the overall efficiency of the locomotive under OHE as well as in battery mode shall not be less than 87% at full load.

1.15 Railway’s responsibility: The commissioning of the locomotive shall be done at Railway premises. The Railway’s responsibility shall be extended to thefollowing:

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a. The fixing arrangement and location of equipments shall be submitted by supplier during design approval stage and approval for the same shall be provided byrailway.

b. The railway will support for proper installation of the equipments required for dual mode shunting locomotive. For this purpose, railways will provide artisan staff in addition to the deputed representatives of the supplier during installation and commissioning of the dual mode shuntinglocomotive.

c. After getting the requisite information from the supplier regarding the equipment/sub-assemblies, the mounting and necessary cable laying and piping for different equipment shall be carried out by theIR.

d. Railway will provide proper space to carry out detailed test and validation jointly with thesupplier.

e. However, the supplier shall ensure close liaison for the commissioning of the equipment supplied against thisspecification.

f. The fixing arrangement, locations and layout of equipment shall be submitted during design approval stage and approval for the same shall be obtained.

g. All skilled as well as unskilled artisan staff shall be provided by theRailway.

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CHAPTER – 2: TECHNICAL REQUIREMENT

2.0 Car body: The car body shall be designed as per requirement, equipment layout and axle weight of the locomotive. The responsibility of designing, validation and manufacturing of the car body shall lies with the supplier. Firm shall submit the detailed design document and validation results of the Car body. Supplier need to perform the FEA analysis of the car body and should submit the report to purchaser. After design approval from purchaser, firm should manufacture the car body. The layout of various equipments of Electric Hybrid Locomotives shall be jointly worked out by Purchaser and the firm, during design approval stage.

2.1 General layout: The general layout of the Electric Hybrid Locomotives shall be decided jointly by the supplier and purchaser. Further the layout approval should be taken before manufacturing. Some of the features are tabulated below forreference:

a. There should be single cab design with ability to drive from the same cabin in both the direction. The layout of cab shall be decided during design approvalstage.

b. The roof area of the cab should be used for mounting the roof equipments like pantograph, VCB and various high voltage equipments. There should be single pantograph at the roof area of the single cab. The layout of roof equipments shall be submitted by the firm for approval and shall be decided during design approvalstage.

c. A dedicated annunciation panel shall be provided in the cab to inform crew the status of working of the locomotive in Battery mode or in 25kV ACmode.

d. Provision of only manual switch over from OHE to Battery & vice versa should be there during prototype development. Automatic switch over for the purpose may be decided during regular cut in as per outcome & experience gained during prototype testing.

e. There shall be Integrated Converter (Traction Converter and Auxiliary Converter with common DC link). The Aux rating of one auxiliary converter as a part of Integrated Converter shall be enough of cater complete auxiliary load. The other one auxiliary converter as part of Integrated Converter shall always remain in the 100% hot standby and shall come into service if first one unable to supply due tofailure.

f. The machine room layout of various equipments shall be designed by the supplier. Further the CG should be balanced. Firm shall ensure the CG of the locomotive along with the CG of each equipment. Further firm shall ensure the weight balancing with weight distribution of all equipments inside the locomotive.

2.2 Leading parameters and Performance Requirement:

The performance requirements of the Electric Hybrid Locomotives shall be governed according to the following leading parameters:

SN Technical parameter Value

1 Complete locomotive weight <129 T

2 Axle weight <21.5 T

3 Wheel diameter 1092mm(New condition)

1054mm( Half worn)

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1016mm( Fully worn)

4 Gear ratio Depend on design

5 Starting tractive effort under dry rail

condition

In Battery mode 17 T

In OHE mode 26 T

6 Continuous rated tractive effort

In Battery mode 15T upto 10kmph

In OHE mode 22T upto 15kmph

7 Operating speed

with load of 1400T

In Battery mode 15 kmph

In OHE mode 30 kmph

8 Operating speed for Electric Hybrid

Loco in OHE mode as well as in

battery mode

80 kmph

9 Design Test Speed of Electric Hybrid

Loco with fully worn wheel 90kmph

10 Sharpest curve to be negotiated 4˚

11 Gradient 1:500

12 Regenerative brake effort 25 % of gross weight of the

Locomotive over the speed

range of 10 km/h to 65 km/h

without sliding, and as close

as possible to 25% of gross

weight at higher speeds.

2.3 Battery for Traction purpose

2.3.1 Type of battery: Ni-Cd or Li-ion or other suitable battery (with high volumetric energy density) meeting the performance requirement should be used. Design approval should be taken from purchaser during the design approval stage. The battery should be able to deliver the required energy requirement so that load of 1400T shall be started with maximum gradient of 1:500 and 4˚curve and should continue to haul the load with speed of 15kmph for duration upto 90minutes.Traction battery energy requirement for 90 minutes at 15kmph comes out to be 917 kWh( approx.) taking the auxiliary load as 130kW, traction gear efficiency as 90%.This stipulated requirement is only for guidance purpose. Supplier shall do the necessary calculation to determine the battery capacity to meet the performance requirement stipulated in this specification.

2.3.2 The responsibility for safe operation of battery with reliability shall lie with the supplier. Suitable battery management system (BMS) should be adopted for reliable operation of thebattery.

2.3.3 It should be properly mounted in the locomotive with proper care of its size, weight and cooling arrangement to withstand the shock and vibration. The latest IEC standards of the selected battery should be followed i.e. standard for Ni-Cd OR Li-ion based battery.

2.3.4 Battery charger for traction battery: On-Board Battery charger should be able to operate both from Catenary and external 415V 3-phase supply. Battery charger shall also be able to operate from power generated during regenerative braking while working under battery mode. The battery charger shall be rated such that it can charge the battery from fully discharged state to fully charged

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state within 5hours.

2.4 Battery for Control Electronics: There should be separate Ni-Cd type 199Ah/C5A battery shall be used for control electronics of the locomotive.

2.5 Bogie: There shall be A1A - A1A bogie arrangement (shown below) with two traction motor per bogie and one non-driving axle without motor as it will lead to cost saving in terms of motor and gear and pinion with easier design and also provides the opportunity to use high rated traction motor. The Supplier shall design the bogie and suspension system and shall submit the detailed drawings and 3D models for approval. Firm shall perform the calculation for validation of the springs and dampers and submit the calculation with the design document to purchaser for prior approval. After design validation by firm, FEA results shall also be submitted by firm for evaluation by Railway. The validation shall be done by the firm and after approval from purchaser, firm shall start the manufacturing of thebogie.

Bogie shall be supplied along with all accessories like bogie frame, spring and dampers etc. Firm shall submit the design calculation for static and dynamic loading and loco weight transfer for necessary evaluation and validation.

2.6 Traction Motor and drives: The traction motor shall be suitably rated according to the Locomotive performance requirements. There will be two traction motors per bogie with two driving axles and one non-driving axle. The performance, testing, evaluation and validation shall lie in the scope of supplier. The cooling arrangement of traction motor for entire range of speed shall be designed and ensured by the suppliers. The general design and manufacture of the motors will be done to the standard IEC 60349-2 in accordance with the modern traction practices. The criteria of selection of the traction motor bearing (equivalent dynamic and static loading of the system with respect of those of bearings, limiting speed, reference speed etc.) and its lubrication system (thermal stability) shall be brought out and all the calculations should be given in design document. The supplier shall submit the detailed design document for approval. After design validation by the firm, reports shall be submitted to purchaser. After approval of deign document from purchaser, firm shall start the manufacturing at theirend.

Traction motors will be axle hung nose-suspended. The traction motors will be suspended on suspension tube mounted on the axle on the one side and nose-suspended through a link containing spheribloc( steel pin and bush bonded by rubber), on the bogie frame. The mounting arrangement of the traction motors on the bogies, transmission

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system shall be kept same upto the extent possible. The teeth design and the number of teeth of pinion and gear shall to be designed to meet the tractive effort required to meet the performance criteria of the specification.

2.7 Drive gear: The drive gear with axle shall be supplied by firm; wheel set shall be supplied by IR. The gear ratio shall be decided by the firm as per the technical parameters duly meeting the speed and hauling requirement as mentioned in the Performance requirement clause no.2.2.

2.8 Brake system: The existing brake system of Three Phase Locomotive shall be used.

2.9 Pneumatic system: The pneumatic systems shall be same as of WAG-9H locomotive. The supplier shall submit the mechanical and electrical connection for interfacing with piping and wiring for pneumatic circuit for approval.

2.10 Auxiliary Loads: firm shall propose the total auxiliary load in battery mode operation and OHE mode operation but the auxiliary load in both mode of operation may vary as required auxiliary load in battery mode are Traction Motor Blowers, Water pump converters, Scavenge Blowers, Compressors. Firm shall submit the ratings of the auxiliary machines along with detailed worked out ratings in the battery mode to purchaser. All the auxiliary machines shall be supplied by the firm.

2.11 Transformer: The traction transformer needs to be duly meeting the requirements with latest technical knowhow and practices being adopted worldwide for traction applications.

The transformer shall be oil immersed and forced oil cooled by means of an oil-circulating pump and a radiator. Further the footprint and cooling arrangement of the transformer shall be suitably designed as per the platform selected for the Electric Hybrid Locomotives.

The firm shall design and submit the rating of radiator for its efficacy to meet the cooling requirements.

Oil cooling blower units may be provided for necessary cooling to the heat exchanger. Firm shall propose better and efficient cooling system for Electric Hybrid Locomotives.

Firm should consider the performance requirement in the specification while designing the transformer. Firm shall submit the detailed design of the transformer for approval by purchaser. After approval from purchaser, firm shall start the manufacturing at their end.

2.12 Traction related details

2.12.1 The nominal overhead voltage is 25kV AC 50Hz, single phase. The supply voltage is fed to the traction transformer through a Vacuum Circuit Breaker (VCB). The transformer output is to be connected to the power converter. The overhead traction supply is subjected to variations as under:

Nominal Voltage -25kV AC Maximum Voltage -27.5kV AC Minimum Voltage -19kV AC Occasional Maximum Voltage -31kV AC Occasional Minimum Voltage -16.5kV AC Supply Frequency -50Hz±8%

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Stagger of the contact wire

± 200 mm on straight track ± 300 mm on curves

Normal OHE (from rail level)

High Rise OHE (from rail level)

Normal contact wire height in mid Span

5.5m 7.42 m

Max. contact wire height 5.8m 7.52m

Min. contact wire height 4.58m 7.37m

The occasional maximum and occasional minimum voltage may persist for 30 minutes.

Pantograph bouncing upto 45ms (limit of zero pressure contact) normally experienced in service shall not adversely affect the performance of Integrated Converter and its output.The design calculations & guaranteed performance will be based on voltage of 22.5kV.

2.12.2 Integrated converter: Suitably designed integrated converter shall be used and the traction battery should be integrated in the DC link of the power converter. Firm shall propose an integrated converter consisting of traction converter and auxiliary converter with common DC link and housed in the same space envelope available on the locomotive.

Both integrated converter shall be identical in all aspects. In such a case, auxiliary converter shall be capable of supplying the complete load of the auxiliaries at rated frequency including battery charger for locomotive battery. In case of isolation of one of the auxiliary converter the other converter shall take the complete auxiliary load including battery charging and the changeover arrangement shall be automatic. Firm shall propose the design during design stage prior to manufacturing of prototype unit. In order to reduce energy consumption as well as to increase equipment life, multiple level ventilation control shall be adopted, which shall vary the output of all the blowers according to the cooling needs. Auxiliary converter output and control system shall be designed considering the total harmonic distortion at output voltage shall be less than 10% and supply regulated to ±5% of the nominal voltage under all operating condition.

The following aspects should be considered while designing the integrated converter:

a. Fault of any converter module (traction converter/auxiliary converter) inside the integrated converter shouldn’t affect the performance of remaining converters of the integrated converter.

b. The integrated converter and footprint shall be designed in such a way that there would be no mounting issue in the locomotive. The design shall be submitted to purchaser during detailed design stage.

c. Firm shall design the cable index related to integrated converter and same should be provided to purchaser at the time of approval of design document.

d. There shall be Bogie controlled operation for Electric Hybrid Locomotives.

e. Suitable redundancy in the vital PCBs connected with safety and power

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supplies, so that the locomotive failure and degradation in performance is minimized in the event of the failure.

f. As the single auxiliary converter of one Integrated Converter shall be sufficient for total auxiliary load and in case of failure the total load shall be shifted to another auxiliary converter of other Integrated Converter. Hence it leads to redundancy of the battery chargers.

Firm shall submit the detailed design along with the interfacing of the Integrated Converter for approval and all the validated results shall be submitted to purchaser. After approval from purchaser, firm shall start the manufacturing at their end.

2.12.3 Control Electronics: The central electronics should be TCN based VCU and

have following features:

a. Control and communication shall be as per IEC 61375. The programmable devices shall be programmed using language compliant to IEC 61131.

b. The control algorithm and downloadable code with diagnostic uploading/downloading tool shall be provided to IR.

c. VCU set shall be fully redundant and there shall be concept of Master and Slave for which master is to be considered for VCU-1 and slave as VCU-2. In case of failure, the master shall shift to slave only with one acknowledgement with the help of BPFA (Push Button for fault acknowledgement) switch installed on Driver console.

d. Firm shall also provide proper tools and application software for viewing, editing, downloading, uploading, etc of the program/code into the upgradedlocomotive.

e. The control system shall integrate the task of fault diagnostics and display the same in addition to its control task. It shall be capable of monitoring the status of all the vital equipment continuously on real time basis. It shall also take appropriate protective action and shut down of the equipment whenever necessary.

f. Features of self-check and calibration shall be incorporated in the design.

g. The VCU shall have a diagnostics computer, with non-volatile memory, to store all the relevant diagnostic data. On occurrence of each fault, besides the fault information regarding equipment parameters, background data with time stamp shall also be captured with post-trigger and pre-trigger background information. The fault display to pilot shall also accompany the standard trouble shooting instructions in simple language. The diagnostic computer shall specify diagnostic of fault up to card level. The diagnostic system shall be able to identify and log the faults of the locomotive on account of wrong operation by the loco pilot and such data shall be stored in the diagnostic computer for a period of not less than 100 days. Application software shall be provided to facilitate the fault diagnosis and the analysis of equipment failures. The steps required for investigation shall be displayed in simple language along with background information. Such software shall be compatible for working on commercially available operating system.

h. The diagnostic equipment comprises a diagnosis computer with monitor and keyboard in the drivers cab. This provides an effective support for the

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duties of the loco pilot and maintenance personnel.

i. It shall be possible to access all the processors of the propulsion equipment within a locomotive using a standard laptop connected/interfaced to one standard port available on the VCU. Such access is needed for uploading of firmware/application program, visualization of process parameters and also force or record the same and downloading the diagnostic data. Required interfaces shall be built in the VCU so that standard laptops, with commercially available operating systems can be directly plugged to the VCU without any special interface. A suitable software tool shall also be provided in the laptops. Using this tool, it shall be possible to reset the diagnostic memory for further recording. This tool shall also provide details of line analysisfacility.

j. The electronics shall be seen from the remaining part of the machine room so as to ensure that there is no ingress whatsoever into the electronics. For its cooling, internal ventilation arrangement along with efficient heat exchanger for removal of heat shall be provided. The electronics shall be designed with adequate margin so that there are no failures on the thermalaccount.

k. The majority of control and monitoring function shall be implemented by the software so as to reduce hardware andcables.

l. It shall be possible to execute parametric changes in the software in respect of user interface viz. modifying some of the permissible parameters for adjusting the characteristic within permissible range, adding/ altering the protection features, if so required in future, in order to improve the operation of the locomotive. The firm shall provide all necessary equipment and accessories required for thepurpose.

m. In case the control unit architecture is rack based then the electronic cards and coupler/connectors shall be polarized or suitably designed with necessary locking arrangement to ensure that insertion in wrong position is notpossible.

n. Capacitors shall be suitably rated, keeping in view the high ambient temperature specified, vibrations of electric rolling stock and electrical surges expected during operation. High failure rates of electrolytes capacitors mounted on PCBs of electronic cards are expected due to high operating temperature/voltage/current vis-à-vis designed operating temperature/voltage /current. Dry type capacitors shall only be used. Expected life of cards, and electronics in general shall be at least 18 years under workingcondition.

o. It shall be possible to operate the locomotive in multiple with other locomotive of the same type. It shall be possible to operate upto 3 locomotive in multiple operation as perIEC-61375.

Firm shall submit the detailed design of the VCU for approval and all the validated results shall be submitted to purchaser. After approval from purchaser firm shall start the manufacturing at their end.

2.12.4 The system and equipments shall be of proven latest technology specially adopted for application to meet the performance requirements under environmental conditions specified in Chapter 3. Adequate margin shall be built in the design, particularly to take care of condition of high ambient temperatures, dusty condition, high humidity prevailing in India.

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2.12.5 High efficiency of equipment shall be important consideration, next only to high reliability. The overall efficiency of locomotive under OHE mode as well as in battery mode shall not be less than 87% at full load.

2.12.6 The design calculations of worst case temperature rise of equipment shall be made.

2.12.7 Dimension: Should be within the limit of MMD. These details shall be collected from Indian Railway. Annexure-I may be referred for MMD related information of BG electric locomotive.

2.12.8 The additional equipments including battery set will be located in such a way so that the Electric Hybrid Locomotives remains balanced weight wise and the Centre of gravity (CG) remains as before addition of battery mode equipments.

2.12.9 Interference: The harmonic currents injected in the overhead supply system (as also the track return current) can introduce voltage harmonics on power supply and can interfere with signal and telecom circuits. The following interference current in the input current shall not be exceeded at any point in the operating envelope of the locomotive:

SN Interference Current Limit

1. Psophometric current 10.0 A

2. DC component 4.7 A

3. Second Harmonic component (100

Hz)

8.5 A

4. 1400 Hz up to 5000 Hz 400

mA

5. 5000 Hz up to 32000 Hz 270

mA

6. 39500 Hz up to 43500 Hz 270mA

(Note: The measurement of interference current shall be done in track return current circuit of the Electric Hybrid Locomotive)

2.12.10 The Supplier shall undertake FFT (Fast Fourier Transformation) analysis of the total current from 1000Hz to 5000Hz and 5 kHz to 50 kHz separately to find out the frequencies which produce the highest currents within each bandwidth. In the frequency bands 32000Hz<f<39500Hz and 43500Hz<f<50000Hz the frequencies at which the current values exceed 270mA shall be identified. If the interference limits for track circuits and axle counters as per EN 50238 are more onerous than those stated in clause no. 2.12.9 then the limits as per EN50238 shall be applied.

2.12.11 The Supplier shall submit the simulated values of these interference currents during design evaluation stage.

2.13 Panel: There may be Single or Two Separate Panels for HV and LV equipment. These panels will be equipped with required MCBs, contactors, relays, diodes, DC-DC converters. All the items shall be properly indicated with nameplate for operation. Design shall be done by supplier. Suitable location shall be decided, should be designed in such a way that it is easily accessible.

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CHAPTER – 3: OPERTAING AND ENVIRONMENTAL CONDITIONS 3.0 The Electric Hybrid Locomotive shall be able to operate and achieve the safety

and reliability targets and performance requirements defined in this specification whilst satisfying the operating and environmental requirements detailed in the chapter 3 of this specification.

3.1 Operating Routes The Electric Hybrid Locomotive shall be able to operate on all BG network in India having operating and environmental conditions described in the chapter 3 of this specification.

3.2 Climatic and Environmental Conditions

Atmospheric temperature

Maximum temperature of metallic surface under the Sun: 75 degree Celsius and in shade: 55 degree Celsius Minimum temperature: - 10 degree Celsius (Also snow fall in certain areas during winter season) Maximum temperature near electronic cards inside stabled Locomotive standing under direct sunlight during summer: 70˚C (degree Celsius) Maximum temperature near electronic cards in working condition of Locomotive during summer:65˚C (degree Celsius)

Solar radiation Minimum value of 1kW/m2

Humidity 100% saturation during rainy season

Reference site conditions

i) Ambient temperature:50 ˚C ii) Humidity: 100% saturation during rainy season iii) Altitude: 1776 m above mean sea level

Rain fall Very heavy in certain areas.

Atmospheric conditions

Extremely dusty and desert terrain in certain areas. The dust concentration in air may reach a high value of 1.6 mg/m3. In many iron ore and coal mine areas, the dust concentration is very high affecting the filter and air ventilation system.

Coastal area

Humid and salt laden atmosphere with maximum pH value of 8.5, Sulphate of 7 mg per liter, maximum concentration of chlorine 6 mg per liters and maximum conductivity of 130 micro Siemens /cm.

Vibration

The equipment shall be designed to withstand the vibrations and shock encountered in service satisfactorily as specified in IEC 61287 and 60571 publication for the electronic equipments used on Rail Vehicle and relevant IECs as applicable to other equipment.

Wind speed High wind speed in certain areas, with wind pressure reaching 150 kg/m2.

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

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3.3 Electromagnetic Pollution: High degree of electromagnetic pollution is anticipated in locomotive machine room/HT & LT compartment, where the equipment shall be mounted. Necessary precaution shall be taken in this regard. The system shall be interference free from the communication system between the Guard-Driver-Control and Public address system. The system should be tested as per IEC 61000 for Electro Magnetic Compatibility.

3.4 EMC 3.4.1 The additional equipments of Electric Hybrid Locomotives shall comply with the

EN50121/IEC62236 series of railway electromagnetic compatibility standards and EN50238.

3.4.2 The supplier shall prepare, implement and maintain EMC management plan in accordance with the standards referenced in clause 3.4.1 of this specification.

3.5 Train and Locomotive Resistance Data: The train resistance and locomotive resistance data as followed by IR is given below:

3.5.1 Train resistance (of BOXN wagon excluding locomotive) (i) Mean starting resistance

on level tangent track (including acceleration

reserve):

4.0 kg/tonne

(ii) Mean running resistance on level tangent track

0.6438797 + 0.01047218 V + 0.00007323 V2 (kg/tonne)

V= The speed in kmph

(iii) Grade resistance = 1/G x 1000 (in kg/tonne),

where G is gradient (e.g. G=200 in case of 1 in 200

gradient)

(iv) Curvature resistance = 0.4 x curvature in degree (in kg/tonne)

3.5.2 Loco resistance

(i) Starting resistance on level

tangent track:

6 kg/tonne

(ii) Running resistance on level tangent track:

0.647+ 13.17/W + 0.00933 V + 0.057V2 /WN [kg/tonne] N = Number of axles

W = Axle load of the loco in tonne

V = speed in kmph

However, the resistance formula related to the locomotive to be manufactured

under this specification shall be supplied by supplier.

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CHAPTER – 4: SCOPE OF WORK/SUPPLY

4.0 In general, the differentiation of scope of work of supplier & purchaser shall be

done on the following lines as givenbelow:

SN Item description Responsibility of

Design and

validation

Responsibility

of

Manufacturing

or Procurement

1.0

Car body

Shell assembly Firm Firm

Modified Cab Firm Firm

Underframe Firm Firm

2.0

Bogie

Bogie Firm Firm

Bogie suspension, axle Firm Firm

Wheel set CLW CLW

Transmission system including Tractionbar/link

Firm Firm

Gear drive arrangement, Bull gear, pinion, gearcase,MSU

Firm

Firm

3.0

Roof equipments

Primary voltage

transformer

Firm

Firm

Primary current

transformer

AC vacuum circuit

breaker

VCB Earthing switch

Pantograph

Lightning Arrestor and roof equipments

4.0

Traction Equipments

Main Transformer with requiredaccessories

Firm

Firm

Integrated Converter Firm Firm

Battery for traction

purpose

Firm Firm

Battery charger Firm Firm

Batterymanagement system for the batteryfortraction purpose

Firm

Firm

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Three phase Traction Motor and mounting arrangement and other accessories

Firm

Firm

5.0

Control Equipments

Central Electronics, other components, MU control interface

Firm

Firm

Any additional MCBs,

connectors and relays

Firm

Firm

6.0 Panels HV & LV Firm Firm

7.0

Brake system

Brake equipments

Firm

Firm

Main Compressor

Auxiliary Compressor

Parking

brakeequipmentco

mplete

Pneumatic system

including

piping and brake rigging

8.0

Auxiliary Equipments

Oil Cooling arrangements

for transformer

and converters

Firm

Firm

MR blower with filters &

scavenge blowers

with motors

TM blowers &scavenge

blowers with motors

Set of air filter & grids

dynamic filters and ducts

Aux/control cabinet

andcomponents

LV cabinet and

components

9.0

Cab equipments

Driver desk complete

assembly

Firm

Firm

cab equipments including Cab windows, doors HVAC, lighting and seats, floor

cover, wipers, Master

Cum Brake Control

Driver Display unit/ Annunciation panel/Any

new item/Panel/Sub-

system of cab design

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10.0

Other equipments

Cable (Cable transit system along with control, power, data, communication cables and suitable lugs) and the harnessed cable.

Firm

Firm

Insulators & set of bus

bars

Firm

Firm

Firm CLW

Coolant and Pump for filling of coolant in the converter and oilpump

transformer

Special tools and jigs

forMaintenanceand

commissioning

Set up electric

schematics with part

list

Loco Battery for Control

electronics

Fire fighting

arrangement

All tacklers, jigs and tools for lifting, fixing and mounting of equipments in the locomotive

Cable layout and

Pneumatic piping

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CHAPTER – 5: GENERAL CONDITIONS, INSPECTIONS, TEST & TRIALS AND OTHER

REQUIREMENTS

5.0 General Conditions 5.1 General design features of Electric Hybrid Locomotive 5.1.1 (i) The equipments shall incorporate features to yield low maintenance

requirements, easy maintainability, high reliability in operation and high efficiency as compared to diesel shuntinglocomotives.

(ii) The Supplier will provide the items required for proper functioning of the locomotive in accordance with current international practices.

(iii) The specification has been prepared for the general guidance of the Supplier to prepare the key design for the proposed locomotives. Any deviation from specification, intended to improve the performance, utility and efficiency of the locomotive as a whole or part thereof may be proposed for consideration. All such proposals will, however be accompanied with complete technical details and justification for proposed deviation.

5.1.2 Approval of design: The design of the equipments of Electric Hybrid Locomotives shall be developed based on the requirements given in this specification and sound engineering practices. The design shall be developed in SI units.

5.1.3 The entire design of equipments for Electric Hybrid Locomotives being supplied by the Supplier to achieve the functionalities mentioned in the specification shall be carried out by the supplier and submitted to IR along with required technical data and calculations for necessary approval. The supplier shall be responsible for achieving the desired performance parameters of the locomotive for the equipment supplied by him. The manufacturing shall commence after the approval of design by purchaser.

5.1.4 The supplier shall submit all necessary data, designs, calculations, drawings and specifications referred in their drawings or design documents in English language as required by purchaser for examination and shall provide explanation and clarification of the documents for which approval is sought. The supplier shall depute his technical experts to purchaser for design discussions and finalization. During the design approval stage, the supplier shall furnish complete set of specifications and standards as mentioned in the approved drawings & documents and shall also submit the list of equivalent Indian Standards, wherever applicable. Supplier shall submit complete design details, block diagrams, functional description of all sub-systems, schematic drawings, loading calculations, circuits, component rating, wiring diagrams, ventilation design, device rating & data sheets of converter, inverter and other power, control and the major equipment, loading of electronic equipment/components calculated under the ambient conditions as specified etc. The aspects covered above are not exhaustive and the supplier shall commit to supply/furnish complete technical details with respect to their system and equipment design and to the satisfaction of purchaser for design approval.

5.1.5 Supplier shall enclose details of their system design, weight particulars and it disposition covering all items basic software specification, electronics, communication protocols, display systems and any other aspect/equipment which is within the scope of supply of the supplier.

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5.1.6 The supplier shall submit the complete material/technical specification and sources of the components during design approval. The specification shall specifically be indicated on relevant drawings/documents.

5.1.7 The supplier shall furnish details of its Quality Assurance and Quality Control at the design approval stage. The quality checks to be made at various stages of manufacture, final assembly and commissioning with tolerance would be indicated. The system would also cover the quality assurance for brought out items.

5.1.8 Approval of design means the approval of general design features. For this purpose detailed drawings will be submitted to purchaser for approval before commencing manufacture. Notwithstanding approval from purchaser, the supplier shall be wholly and completely responsible for the satisfactory performance of the equipment.

5.1.9 The supplier shall be responsible for carrying out the improvements and modifications at his own expense on all the equipment supplied, provided such modifications/improvements are decided to be necessary for meeting the requirements of reliability, performance, safety etc. jointly between supplier andpurchaser.

5.1.10 For the purpose of technical decisions on improvements/modifications etc. on equipment, the final authority from purchaser’s side shall be Indian Railways. However, the decision on obsolescence management of component/module/assembly etc. shall be mutually agreed by purchaser and Supplier.

5.1.11 The design will be made based on the requirements given in this specification and sound, proven and reliable engineering practices. The entire key design will be submitted with technical data and calculations for approval.

5.1.12 The Supplier will submit a program indicating the expected dates on which drawings will be submitted for approval to purchaser to assist for planning resources for their approval.

5.1.13 The Supplier’s engineer will deliver the drawings to purchaser and will provide explanation and clarification of the drawings for which approval is sought.

5.1.14 The design will be developed in SI units only. 5.1.15 Deviations proposed by the Supplier in the interest of reliability and better

performance will be examined by purchaser in close consultation and association with the manufacturer so as to arrive at the final locomotive design.

5.1.16 All necessary data, design, calculations and drawings required by purchaser for examination of the manufacturer’s proposals will be furnished by the Supplier.

5.1.17 The Supplier will, in addition to furnishing information required by IR, also liaise with purchaser for any exposure of purchaser to current state of the art technology abroad so as to assess the relative merits/demerits of different designs offered and to arrive at mutually agreed final designs. Information on experience on the equipment offered on different user railway systems will also be required by purchaser for an appropriate assessment. The supplier will give appropriate assistance in this regard also.

5.2 Inspection, test and trials: 5.2.1 The locomotive will be tested generally in accordance with IEC 61133, Ed.2.0:

Rolling stock- Testing of rolling stock on completion of construction and before entry into service. The inspection of the locomotive will be carried out by a representative of purchaser.

5.2.2 The individual equipments, system and subsystems, as may be necessary shall

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be type and routine tested in accordance with relevant IEC and standards as per details given in clause 1.10.2 and the same should be approved by purchaser, according to the test program to be drawn up by the Supplier in consultation with purchaser. All equipment shall be routine tested according to the relevant IEC publications.

Wherever the relevant standard test procedures do not adequately cover the requirements of arduous environmental conditions prevailing in India, purchaser might lay down and ask for special tests apart from those specified that shall be required to be conducted. These may include accelerated ageing tests and endurance test.

Required type tests of electrical and mechanical equipments shall be carried out by the Supplier at his own responsibility and costs and in the presence of and to the satisfaction of the Inspecting officials nominated by purchaser. The type test shall be carried out at the manufacturing premises of the Supplier where all the facility required for type test shall made available by the Supplier.

5.2.3 The Supplier shall formulate and submit type and routine test protocol/plan at design approval stage for approval of purchaser before undertaking manufacture. It shall, however, be open for purchaser to waive some of tests in case of equipment and subassemblies, where; the manufacturer can establish to the satisfaction of purchaser that such tests have already been carried out earlier on the same equipment and where equipment has been proved in prolonged service.

5.2.4 The serial production of the Electric Hybrid Locomotives shall be started after the prototype clearance of the Electric Hybrid Locomotives.

5.3 Bogie/Under frame/Body testing: Bogie:

The bogie frame shall be subjected to two times the normal duty load without any permanent distortion and to three times the normal duty load without any sign of cracking or failure.

The bogie frame will be subjected to dynamic load testing as per loading condition and Continuous rated tractive effort/braking effort and as per various parameters of the locomotive.

The dynamic tests will be done for 10 million cycles without any signs of cracks or deformations. The measured stress values will remain within the endurance limit of the material used at all critical locations.

5.4 Equipment/System/Subsystems testing: 5.4.1 The equipment, systems and subsystems will be type/routine tested accordingly

to this specification.

Wherever the relevant standard test procedure for type and routine tests prescribed in accordance with this specification do not adequately cover the requirements; purchaser might lay down the details of special tests other than that will be required to be conducted at the Supplier’s work. In such case the Supplier will give a budgetary quotation for specific tests. The tests which will come under this category may include:

i. Effects of electrical stresses.

ii. Special type of endurance tests on contactors, relays, master controller and such other equipments which may impose mechanical operation and electrical loadings simultaneously for a large number of cycles of operation.

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iii. Stress measurement and fatigue life estimation of parts subjected to alternating stresses, rotating parts like blower impellers, rotors etc.

iv. Special load simulation tests.

v. Tests to establish satisfactory performance over the entire range of variable system conditions like voltage, frequency, temperature, humidity etc.

It may be open for purchaser to waive some of these tests in the case of equipments/subassemblies where the manufacturer can establish to the satisfaction of purchaser that such tests have already been carried out earlier and where the equipments have been proven in prolonged service.

5.4.2 All the type and routine tests mentioned in the IEC 60349-2 including optional tests shall be conducted on the traction motor. Following additional special tests shall also be included if not done earlier:

i. Test on Speed/Temperature sensors

ii. Polarization Index test(shall be more than 2)

iii. Tan delta test

iv. Insulation Resistance Measurementtest

v. Traction Motor Roller Bearing test

vi. Flood test

vii. Motorette test

5.4.3 Witness of test: Some of these tests may be required to be witnessed by the Inspecting officer(s) nominated by purchaser.

5.4.4 Raw material/component testing: purchaser may also in addition, require test results on raw materials and components of critical nature, so as to ensure that they meet the performance and reliability stipulations. This may extend to components/equipments/raw materials not manufactured in the Supplier’s works, but purchased by him.

5.4.5 Furnishing of test results: The Supplier shall be expected to furnish results of necessary tests and inspections carried out internally and in the presence of the Inspecting officials nominated by purchaser.

5.5 Oscillation tests: The Electric Hybrid Locomotives shall be subjected to oscillation trials in India to prove the riding and stability performance of locomotive at the maximum tests speed as per the criteria indicated below on a track of standard specified in the table given below, which is to be confirmed before commencement of the trials, with new and minimum standard wheel tread profile to be agreed with purchaser.

i. Maximum lateral force (at axle box level): < 0.85(1+P/3) t where P is the axle load in tonnes.

ii. Maximum vertical dynamic augment:30%

iii. Maximum derailment co-efficient:1

iv. Lateral and vertical acceleration in the driving cab and at a point as close to the bogie:<0.3g

v. Maximum ride index in the driving cab at floor level:3.75

Instrumentation and tests shall be carried out by purchaser and evaluation of the

results shall be done by purchaser in consultation with the Supplier.

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Track condition:

a. Gauge Broad Gauge system of Indian Railway(1676mm)

b. Track structure Indian Railway track maintained as per track geometry standards under Para 522 of Indian Railways Permanent Way Manual , June -2020

c. Schedule of dimensions:

Indian Railways Schedule of Dimensions for Board Gauge (1676mm), Rev.2004 with latest corrections and addendum slip.

d. Overall moving dimensions:

The locomotive with new wheels will be within the dimensions shown in Annexure-I.

e. Sharpest curve and turnout to be negotiated:

175m radius (horizontal), 2500m radius (vertical). 6400mm overriding switch (curved) BG (1673mm) for 60kg (UIC).Vogel’s layout for negotiability; throw over at head stock and coupler movement with details of clearances will be submitted by Supplier.

f. Clearance above the rail level:

No component will infringe a minimum clearance of 91mm above rail level with the locomotive fully loaded and wheels in fully worn condition.

g. Maximum Super elevation

185 mm

h. Maximum cant deficiency

100 mm

i. Permissible track tolerances

Gauge widening on curves is provided as follows:

• For curves radius more than 440m, the gauge variation will be from +15mm

to-6mm.

• For curves radius less than 440m, the gauge variation will be upto+20mm.

5.6 Other tests: The locomotive shall be subject to certain other tests conducted by IR with Supplier’s representative on IR track conditions

BG Main

lines

BG high speed routes

(i) Unevenness (3.6m

base)

<15mm <6mm in general and <10mm at

isolated spots

(ii) Twist (3.6mm base) 2.78mm/m <2.08mm/m

(iii) Gauge variation <±6mm <±6mm

(iv) Alignment/versine

on 7.2m chord

<5mm <5mm in general with isolated 7mm

on curves and 10mm on straight

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mainly to satisfy the Railways regarding operational performance, capability and safety. The following tests may be conducted in this connection on one or more locomotives to satisfy IR regarding operation performance, capability and safety.

a. Dynamometer car tests to ascertain starting and rolling resistance of the locomotive and to prove tractive effort, speed characteristics and dynamic braking effort speed characteristics of thelocomotive.

b. Adhesion tests to prove the adhesive capability of the locomotive.

c. Load haulage tests on different sections with different speeds to prove the performance of the locomotive as indicated in the specification including specific energy consumption.

d. Emergency braking distance trials to prove the braking capability of the locomotive.

e. Tests for checking the current collection/pantograph performance of the locomotive.

f. Tests to determine the levels of interference with the traction power supply and signal and telecommunication equipments and facilities to prove that these are within acceptable limits.

g. Any other tests that may be foundnecessary.

5.7 Service Trials: The Electric Hybrid Locomotives shall also be evaluated during operation under actual load conditions under 25kV AC OHE and Battery Mode. These shall be termed as “Service/Field Trials”. Apart from checking on repeatability of the operational performance under different conditions of track, OHE, signalling systems etc as well as under different conditions of wear and tear on the locomotive itself these tests will also be used to throw light on the maintainability, accessibility, reliability and such other aspects which have been mentioned in this specification. Electric Hybrid Locomotives shall be subjected to service/field trials on IR for at least one month. The tenderer shall depute a team of engineers for commissioning, testing and field trials of the locomotive and its equipment in service. The tenderer’s representative shall associate in field trials with purchaser.

Modifications found necessary as a result of the tests/trials shall be incorporated by the Supplier at his own cost in the locomotives in a manner approved by purchaser. Drawings incorporating the modifications found necessary, as a result of tests and trials, shall be submitted to purchaser for final approval.

The system should be capable of continuous operation during varying atmospheric and climatic condition.

5.8 Characteristics of wheel slip & adhesion: Wheel slip and adhesion will receive proper attention during the tests and trials under different track conditions.

5.9 Prototype testing: The Electric Hybrid Locomotives shall be commissioned after supply of equipments by the firm. Firm shall submit all the validation and test reports to purchaser. Only after approval from purchaser, firm shall start the manufacturing. Further the Prototype testing of all the equipments shall be witnessed by purchaser.

5.10 Prototype trials: During the prototype tests/trials, which may last about 6 months or 50,000km whichever is later if any problems are thrown up or feedback information is obtained, which warrants a re-check of the design/manufacture/quality of the equipments and components(supplied by Supplier), action will be taken as may be necessary by the Supplier to carry out

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the required investigations and to incorporate the improvements considered most appropriate to reach compliance with the specification without any extra costs to the purchaser. Such improvements will be carried out in all locomotives and will be evaluated for their validity for a further period of time as may be agreed mutually in each case.

Modifications mutually agreed to comply with the specification will be incorporated by the Supplier at his own cost in the locomotives in a manner approved by the purchaser.

Drawings incorporating the modifications found necessary as a result of test and trial will be submitted to purchaser. Final documentation will be provided incorporating experience gained in final manufacturing phase and the first period of trials within 6 months after completion of these trials. Terms and conditions in this regard will be incorporated in the contract documents.

5.11 Training of IR personnel: The training of IR personnel at the Supplier’s work and design offices and suppliers of equipments/materials to the extent necessary as well as in the maintenance and operation of the locomotives employing similar systems/designs outside India will be co-ordinated by the Supplier or terms and conditions to be mutually agreed upon with purchaser, which will be required in equipments used for power electronics and control electronics.

5.12 Documentation: The Supplier will furnish drawings and tracings, manual of instructions for operation and maintenance of the locomotive and equipments, trouble-shooting instructions and such other technical information as may be required for the maintenance and operation of the locomotives in India. A preliminary version will be supplied during the commissioning of the first Electric Hybrid Locomotives. Final documentation will be provided incorporating experience gained in final manufacturing phase and the first period of trials within 6months after completion of these trials. Terms and conditions in this regard will be incorporated in the contract documents.

5.13 Technical support: The Supplier will ensure the availability of technical support in the service trials and during the period of guarantee and AMC. The terms and conditions regarding these aspects will also be incorporated in the contract.

5.14 Special extras: The Supplier will supply special tools, jigs, fixtures and testing kits and maintenance spares, tools and testing instruments which are considered necessary for 3 years maintenance of the locomotives. Further firm should provide spares, tools, testing instruments, other special jigs and fixtures as well as special training kits for simulation of locomotive operation, trouble shooting by loco pilot and maintenance staff be required by IR, the Supplier will provide a quotation for the supply of these items.

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MAX. & MIN. MOVING DIMENSION FOR BG ELECTRICLOCOMOTIVES

Annexure - I

Draft Technical Specification For Electric Hybrid ...

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Transcript of Draft Technical Specification For Electric Hybrid ...