EXPRESSION OF INTEREST (EOI) FOR MANUFACTURING AND...

EXPRESSION OF INTEREST (EOI) FOR MANUFACTURING AND SUPPLY OF SUBASSEMBLIES, PARTS, COMPONENTS ETC FOR APPLICATION IN DIESEL LOCOMOTIVES (Development of Specification): Motive Power Directorate of Research, Designs & Standards Organisation (RDSO), Lucknow, under the

Ministry of Railways (MOR), is interested in developing sources for subassemblies, parts, components etc

for application in diesel locomotives. Details of such items, for which this part of EOI intends to cover the

stage of development of specification, are as follows:

S.

No.

Description Details of

Specification

Contact Details

1 Micro turbine based Auxiliary

Power Unit for Alco locomotives

MP.0.2400.82 Rev.0

dt. 13.07.16 (Draft)

P. Srinivasu Director/Motive Power-EC Room No: 104 Building: Manak Bhawan Telephone no. 0522-2465732, email: [email protected]

2 Functional requirement

specification for Condition Based

Monitoring System for Diesel

Electric locos Alco and HHP

locomotives.

MP.0.0402.07

(Rev.0) date

18.10.2016

3 Functional Requirement of

Specification (FRS) for Up-

gradation of existing EMD locos

by retro-fitment of Emission kit

on EMD 710 engines.

Provided as

attachment 1 (one

sheets, Total

Page=07)

Spec.no.MP-

0.08.00.111(Rev-00)

Aug-2016

Abhijit Singh,

Director/Motive Power-Eng

Room No: 106 Building: Manak Bhawan Telephone No. 0522-2465728

Email:

[email protected]

4 AC Motor Insulation Scheme. --- Pankaj Saxena, Dy. Director/Motive Power- EM Room No: 111 (L3 Hall)

Building: Manak Bhawan

Telephone no. / Mobile no. : 9794863118 email: [email protected]

5 Fabricated Buffers for Passenger

Locomotives

Preparation of

Functional

requirement

specification

Anurag Mishra, Jt. Director

/Motive Power- LD

Room No: 105 Building: Manak Bhawan

mailto:[email protected]

Telephone no.

0522-2465729, email: [email protected]

Details of the above-mentioned Functional Requirement Specification (FRS) are attached herewith.

Firms who have enough experience/capabilities in the field, have ISO certificate and are interested in

developing and supply of above items are requested to submit details in the prescribed format attached

herewith to the concerned officer mentioned against each item.

In case of any doubt, please contact the concerned officer mentioned against each item in office at

Lucknow, on any working day.

Annexures: A & AA

Executive Director Motive Power Directorate.

Annexure A

FORMAT FOR LETTER OF RESPONSE

Respondents Ref No.:

Date:

Designation of officer to whom the respondent replies Room No: , Building: Research Designs & Standards Organization Ministry of Railways Manak Nagar Lucknow, INDIA 226011

Dear Sir,

Subject: RESPONSE TO – EOI FOR PARTICIPATION __________________________ 1. We, the undersigned, offer the following information in response to the Expression of Interest sought

by you vide your Notification No._______, dated _____.

2. We are duly authorized to represent and act on behalf of ________________ (hereinafter the “respondent”)

3. We have examined and have no reservations to the EOI Document including Addenda No(s)

______________________. 4. We are attaching with this letter, the copies of original documents defining: -

4.1. the Respondent’s legal status; 4.2. its principal place of business; 4.3. its place of incorporation (if respondents are corporations); or its place of registration (if

respondents are cooperative institutions, partnerships or individually owned firms); 4.4. Self-certified financial statements of Last three years, clearly indicating the financial turn over

and net worth. 4.5. Copies of any market research, business studies, feasibility reports and the like sponsored by the

respondent, relevant to the project under consideration

5. We shall assist MOR and/or its authorized representatives to obtain further clarification from us, if needed.

6. RDSO and/or its authorized representatives may contact the following nodal persons for further

information on any aspects of the Response:

S. No. Contact Name Address Telephone E Mail

1

2

7. This application is made in the full understanding that:

7.1 Information furnished in response to EOI may be used confidentially by RDSO for the purpose of development of the product.

7.2 RDSO reserves the right to reject or accept any or all applications, cancel the EOI and subsequent process without any obligation to inform the respondent about the grounds of same.

7.3 We confirm that we are interested in participating in development of the product.

8. We certify that our turnover and net worth in the last three years is as under:

Financial Year Turn over Net worth

9. In response to the EOI we hereby submit the following additional details annexed to this application.

9.1 Details of various items being manufactured/consultancy undertaken. 9.2 Details of customer(s) and supplies made in the field of item under EOI. 9.3 Experience and expertise for the items proposed in EOI. 9.4 Details of man-power with their qualification and experience. 9.5 Detailed proposal for items proposed in EOI including alternative proposal, if any. 9.6Details of Intellectual Property Rights (IPR) held, patent filed/held and MOU/agreement signed. 9.7 Details of ISO certification. 9.8 Undertaking as per Annexure-AA

10. The undersigned declare that the statements made and the information provided in the duly

completed application are complete, true, and correct in every detail. We also understand that in the event of any information furnished by us being found later on to be incorrect or any material information having been suppressed, RDSO may delete our name from the list of qualified Respondents. We further understand that RDSO will give first preference to the applicants considered relevant for the purpose.

11. Our response is valid till (date in figures and words):_______________________________________

Yours sincerely,

(Sign)

Name

In the Capacity of

Duly authorized to sign

the response for and on

behalf of

Date

Annexure-AA

(To be taken on non-judicial stamp paper of appropriate value as applicable in the respective state and duly notarised and witnessed)

UNDERTAKING I, son of ……………… aged about …..... Years resident of ………….. do hereby solemnly affirm as under: 1. That the deponent is the Authorised signatory of (Name of the Sole Proprietorship Concern/Partnership Firm/ Registered

Company/ Joint Venture). 2. That the deponent declares on behalf of (Name of the Sole Proprietorship Concern/ Partnership Firm/ Registered

Company/Joint Venture) that:

a) In regard to matters relating to the security and integrity of the country, no charge sheet has been filed by an agency of the Government and/or conviction awarded by a Court of Law for an offence committed by the -----------------------------------(name of the entity) or by any sister concern of the ----------------------------------(name of the entity) which would constitute disqualification of-----------------------(name of the entity or any of it’s sister concerns).

b) In regard to matters other than the security and integrity of the country, ---------------(name of the entity) has not been

convicted by a Court of Law or indicted / passed any adverse order by a regulatory authority against it or it’s any sister concern which relates to a grave offence, or would constitute disqualification. Grave offence is defined to be of such a nature that it outrages the moral sense of the community.

DEPONENT

VERIFICATION

I declare that the contents of para 1 to 2 above are true as per my knowledge and nothing has been hidden.

DEPONENT

Document No: MP.0.2400.82 Revision No: 0 Date Issued: 13/07/2016

Specification Title: Micro turbine based Auxiliary Power Unit for ALCo Locomotive

INDIAN RAILWAYS, RESEARCH DESIGNS & STANDARDS ORGANIZATION

Page 1 of 11

LIST OF AMENDMENTS

S. No. Amendment Date Revision Details

1. 1 13/07/2016 0 First issue for development of Micro turbine based Auxiliary Power Unit for ALCo Locomotive




Page 2 of 11

CONTENTS 0 Introduction ........................................................................................................................................... 3 1 Objectives ............................................................................................................................................. 3 2 Scope of supply .................................................................................................................................... 3 3 Terms and abbreviations ...................................................................................................................... 3 4 General requirements ........................................................................................................................... 4

4.1 Manufacturers qualification ........................................................................................................... 4 4.2 Equipment Requirements ............................................................................................................. 4

5 Environmental/Climatic requirements ................................................................................................... 4 6 Functional requirements ....................................................................................................................... 4

6.1 Logic of fuel save mode in APU ................................................................................................... 5 6.2 Interface of APU with MBCS ........................................................................................................ 6 6.3 Feature of isolating APU ............................................................................................................... 6 6.4 Feature of Data Logging: .............................................................................................................. 6 6.5 Emergency Shut down ................................................................................................................. 6 6.6 Fail-safe Feature .......................................................................................................................... 6 6.7 Driving Motor Driven Air Compressor (MDAC) ............................................................................. 6

7 Sub assembly of APU ........................................................................................................................... 6 7.1 Micro Turbine: ............................................................................................................................... 7 7.2 Alternator: ..................................................................................................................................... 7 7.3 Compressor .................................................................................................................................. 7 7.4 Control Unit ................................................................................................................................... 7

8 Numbering ............................................................................................................................................ 8 9 Applicable drawings .............................................................................................................................. 8 10 Referred standards ........................................................................................................................... 8 11 Life cycle management ..................................................................................................................... 8

11.1 Expected life ................................................................................................................................. 8 11.2 Support during lifetime .................................................................................................................. 8 11.3 End of equipment life management .............................................................................................. 8

12 Documents required from manufacturer ........................................................................................... 9 13 Warranty ........................................................................................................................................... 9 14 Training ............................................................................................................................................. 9 15 Tests& Verification ............................................................................................................................ 9 16 Sampling plan ................................................................................................................................... 9 17 Types of tests ................................................................................................................................... 9

17.1 Type test and field trials: ............................................................................................................. 10 17.2 Field trial ..................................................................................................................................... 10 17.3 Makers test certificate for outsourced item ................................................................................. 10

18 Painting, labeling and marking ....................................................................................................... 11 19 Packaging and delivery/shipment ................................................................................................... 11 20 IPR disclaimer pin pointing responsibility on supplier for violation if any ....................................... 11

20.1 Undertaking by equipment manufacturer ................................................................................... 11 20.2 Declaration of confidentiality of submitted documents by manufacturers .................................. 11

LIST OF REFERENCED DOCUMENTS

S. No. Document name / number

1. IEC 60571

2. IEC 60812

3. IEC 60529

4. IEC 62262

5. ISO 1217

6. IS 10431

7. IS 2500

8. EDPS 179

9. IEC-60349-1 (Latest)




Page 3 of 11

0 Introduction A diesel engine in idle condition consumes roughly 20 liters of diesel oil per hour. While idling, the main engine of diesel locomotive performs two functions

a. Running the compressor to maintain Main Reservoir pressure between 8 to10 kg/cm2

b. Charging the locomotive batteries.

However, at stand still with brakes applied, the requirement of air from compressor is less and it is required to compensate leakage. These two functions requires less power, however as the main diesel engine runs to cater this requirement, the energy consumed is very large.

To cater the requirement of low power including the cab AC load (1.75 ton, 6.7 HP), this specification is for developmental purpose for the Auxiliary Power Unit as an add on unit comprising of Diesel run Micro turbine generator, Electrical Driven Air Compressor and associated control units for charging the Main Reservoir and battery charging while facilitating main engine shut down automatically based on monitoring of the engine and electrical parameters while loco is idling at standstill condition. The APU will drive the Motor Compressor using the electrical output of Micro turbine Generator Set when loco is shut down to compensate the formation leakage. The proposed APU is to be fitted with ALCo locomotives in its Nose Compartment. The APU (Auxiliary Power Unit) is an important fuel saving device for loco while loco is idle and standstill.

1 Objectives

This specification covers the design requirements of a system (auxiliary power unit –APU with Micro turbine) for shutting down the idle engine to reduce emissions, noise, wasteful burning of fuel, wear and tear & maintain all the critical parameters of the locomotive that will keep the locomotive in a state of readiness for operation at very short notice. The specification also details the test standards to ensure reliability of APU.

Following benefits are derived with APU:

Reduced Consumption of fuel and other lubricants.

Reduced wear and tear of Engine components due to unnecessary idling.

Reduced NOX emissions and noise pollution with a potential to earn carbon credits.

2 Scope of supply

The deliverables to this specification for APU shall include the complete APU system comprising of :

i. Microcontroller based Control unit with associated relays, contactors, sensors, cables and other associated parts.

ii. Micro turbine and alternator mounted on a single shaft. iii. Motor driven Air Compressor iv. Automatic Voltage Converter (AVC) to convert alternator AC output into 72V DC for electrical

loads like driver cab AC unit, battery charging etc. v. Control cables complying to EDPS 179.

3 Terms and abbreviations

S. No Term / Abbreviation

Description

1. MBCS Microprocessor Based Control System

2. PU Production Units

3. RDSO Research Designs & Standards Organization

4. ZR Zonal Railways

5. IEC International Electro Technical Communication

6. MDAC Motor Driven Air Compressor

7. CPCB Central Pollution Control Board, Govt. of India

8. IRS Indian Railway Standard Conditions of Contract




Page 4 of 11

4 General requirements

4.1 Manufacturers qualification

The manufacturer of the equipment shall be a reputed organization dealing with manufacture / integration of electronic, electrical and embedded systems. The manufacturer is having experience in development of control system on Microprocessor system in Rolling stock or solution of industrial automation on embedded system for emergency power application using Micro turbine set. The manufacturer shall be capable of providing spares and support services during the operational life of the equipment from setups located within the international boundaries of the India.

4.2 Equipment Requirements

The equipment supplied against this specification shall meet the following general requirements:

4.2.1. The equipment shall be designed for installation on diesel electric locomotives. The equipment manufacturer shall get the equipment design approved by RDSO before fitment on locomotives.

4.2.2. The equipment supplied shall be of good quality, rugged and reliable and capable to withstand environmental and service conditions. The individual components shall meet the lifecycle requirements for that category of equipment as elaborated at clause no.11.

4.2.3. The APU system shall be accommodated in the envelope of 1685 mm x 930 mm x 1285 mm (Excluding chimney) (LxBxH). Envelope is intended to mean the space available within the existing Nose compartment. The OGA drawing shall be furnished by the firm for RDSO approval.

4.2.4. The weight of the APU system in complete shall not exceed 1000 kg.

4.2.5. Where ever outsourced equipment is used, care shall be taken to ensure that the equipment is sourced from reputed manufacturers. Firm shall produce the relevant test compliances of outsourced equipment’s on demand from RDSO or inspecting agency.

4.2.6. The supplier of equipment supplied under this specification shall ensure proper interfacing and connectivity between equipment / software.

4.2.7. Failure Mode Effects and Criticality Analysis of the equipment shall be done during the design process in conformance to IEC 60812. The records of this analysis shall be provided upon requirement.

5 Environmental/Climatic requirements The equipment shall be tested as per the environmental requirements of IEC 60571(Latest) for electronic and control equipment.

6 Functional requirements

The APU must meet the following requirements for ALCo diesel electric loco, A Micro turbine coupled to an alternator will maintain the MR pressure and keep the batteries charged while the main locomotive engine remains shut down. APU system will have the own microcontroller system which will monitor critical parameters of APU Micro turbine, alternator and other associated equipment’s and will monitor the APU health status.

* The Alternator output for compressor should be compatible with Voltage rating and electrical characteristics of Motor for Compressor.

Micro processor based APU Control Unit

Micro Turbine Coupled with Alternator

Motor Driven Compressor (1200

lpm)

Suitable AC Voltage* (15 kW)

72 V DC (7.5 kW)

Loco Battery Charging and Cab AC




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6.1 Logic of fuel save mode in APU

The APU System will have following logic to trigger main engine shut down with start APU and vice versa.

YES

NO

Monitor following conditions satisfied for 30 sec. Loco Battery charging current is <10 amps

Eng. Temp. >55 deg.Cent. MRPR >7.5 kg/cm2 BCP >1.5 kg/cm2

Reverser Handle in Neutral position

Check following Parameters Throttle in Idle

Loco Speed Zero BC Pressure>1.5Kg/cm2

Loco is not set for Self Load Test or any other Test modes APU Health status is ok.

Satisfied?

Check the condition Satisfied for 9 minutes

Satisfied?

Display decremental counter for 30 sec. And Display message Loco

Entering into fuel save mode All conditions

Satisfied except reverser

handle not in neutral.

Display message for

every 10 minutes "Fuel Save mode

prohibited" Keep reverser handle

In Neutral position

All conditions Satisfied but BC<1.5 kg/cm2

Display message for

every 10 minutes Loco Brakes are

Not applied "Fuel save Mode prohibited" Apply Loco brake.

30 seconds

Driver wants To exit fuel Save mode

Keep reverser

Handle in working Direction

Fuel Save mode

Inhibited

Start APU

APU started and APU is running, Shut Down Main Engine

Driver wants To exit fuel Save mode

Keep reverser

Handle in working Direction

APU safety

Devices operated

Shutdown

APU APU Engine

Start Main Engine

Shutdown APU




Page 6 of 11

6.2 Interface of APU with MBCS

MBCS is provided in ALCo Locomotives. The MBCS has required sensors for implementation of APU logic. Hence, integration of APU with MBCS will minimize the additional sensors and hardwares.

Note : However, standalone APU with their own sensors may also be permitted provided the standalone APU will not degrade the functioning of Loco Control system and will not override the functionality of MBCS.

6.2.1 Online Health and function monitoring for APU System

Online health and function monitoring system for APU is required. In case of firm has existing such system already available that may be configured for use for APU system and access for online viewing of data and report should be given to Railway for APU.

6.3 Feature of isolating APU

APU Circuit Breaker to enable/disable the APU should be provided on the CB Panel. Whenever the APU is disabled, a suitable Crew Message and audio-visual alarm should be given to the driver and log a fault. The APU must have self-diagnostic feature.

6.4 Feature of Data Logging:

The APU will have in built data logging facility to log the Fuel saving data and fault data in the prescribed format. Firm will have to submit the required reporting format of fuel data for approval by RDSO to incorporate during design approval.

Data logging should contain the fault log with time stamp. 90 sec. fault data pack of APU should be stored in memory of APU containing all related parameters with time stamp.

The data in the APU should be logged at an interval of one minute and should store the status of all the inputs to the APU system. A suitable graphical user interface (PC Based software with print facility) shall be provided for the analysis of the logged data. It should be possible to download the recorded data from the memory of APU Computer by using any commercially available USB pen drive. On-board data storage device of adequate capacity to record data for storing all data for at least 45 days and the data for engine idle time and fuel saving report for at least 90 days. The APU health status, enable/disable status, APU related crew messages should be displayed.

6.5 Emergency Shut down

APU can be shut down on emergency by isolating APU from CB panel. Shut down button should be provided on APU also to interrupt the APU and shut down APU in case of emergency.

6.6 Fail-safe Feature

The APU shall be provided with fail-safe feature so as to cause shut-down of the APU Micro trubine in the event of malfunctioning of the APU. As an add-on feature APU will in no case control the functionality of MBCS. It will work as slave only and get isolated with APU shut down as fail safe measure. Driver will be prompted by displaying crew message of APU faulty.

6.7 Driving Motor Driven Air Compressor (MDAC)

The alternator of APU shall therefore be able to drive the MDAC. The micro controller of the APU should drive the motor driven compressor to maintain the MR pressure between 8 to 10 Kg/cm

2.

Loading / unloading - The compressor should be loaded at 8.00 ±0.1 kg/cm² (approximately 120 PSI) and get unloaded at 10.0 ± 0.1 kg/cm² (approximately 140 PSI)

7 Sub assembly of APU

The APU shall comprise following major sub assembly:-




Page 7 of 11

7.1 Micro Turbine:

A suitable Microturbine operating on Diesel oil to supply primary power generation for APU. The prior credential of Microturbine in mobile/vehicle applications should be submitted. The Microturbine should be capable of starting with power sourced either from the locomotive battery or separate low maintenance battery of adequate capacity. Suitable DC-DC Converter may be used to reduce the Loco battery voltage, if required. The Micro turbine should be oil & coolant free preferably. The Micro turbine should be maintenance friendly and should not require frequent schedule attention. Any attention shall have to necessarily coincide with the locomotive maintenance schedule. The emission from the Micro Turbines has to comply the applicable pollution norms. APU manufacturer shall submit the test compliance of national/International standard, technical details, must change spare items details, maintenance schedule, consumable details and frequency of change of consumable. The prototype clearance of Micro Turbine shall be based on submission of test compliance from approved agency as per International Standard applicable to micro turbine to the satisfaction of RDSO. Required data sheet of the Microturbine and maintenance spare and periodicity shall be submitted to RDSO for obtaining the prototype clearance of the model and make of Micro turbine.

7.2 Alternator:

The alternator of suitable capacity (22.5 kW Approx) built with Micro turbine shall be able to cater to load to drive compressor motor for minimum 1200 FAD output from compressor at rated voltage of Motor Compressor and 72 V DC output for driver cab Air-conditioning Unit (1.75 tons capacity), battery charging and other minimal Control circuit loads required in engine shut down condition. The output of the alternator shall be constantly monitored by the Microprocessor of APU. In case the desired output voltage is not obtained at full rpm, a fault message shall be logged and crew message should be displayed. Test compliance and standard shall be as per IEC-60349-1 (Latest) or equivalent test standard.

7.3 Compressor

The compressor shall be motor driven and to be driven with electrical output of alternator. Compressor shall be able to deliver the required air flow (1200 lpm FAD). The compressor shall be designed for operation at a discharge pressure of 10.2 Kg./Cm². The compressor shall preferably be air cooled and oil lubricated. In case of oil cooled rotary compressor the maintainability should be at par with air cooled compressor. Prior approval of RDSO shall have to be obtained for use of any make/design of the compressor. The compressor shall not consume more than 15 kW at maximum rpm in loading condition and delivers at least 1200 lpm FAD on 100% duty cycle. The compressor out let should be connected to MR tank through non-return valve. Loading / unloading - The compressor should be loaded at 8.00 ±0.1 kg/cm² (approximately 120 PSI) and get unloaded at 10.0 ± 0.1 kg/cm² (approximately 140 PSI) The compressor shall be sourced from reputed manufacturer. APU manufacturer will submit the test compliance of national/International standard, technical details, must change spare items details, maintenance schedule, lubricant details and frequency of lubricant change while seeking approval for use of the compressor. The acceptance test will be as per ISO 1217. The capacity test of FAD (Free air delivery) will be carried out as per IS 10431. The Motor of the compressor should comply the IEC 60349 standard or equivalent.

7.4 Control Unit

The system should be an independent 32 bit Micro controller to control the APU Micro turbine, Alternator and Compressor through associated control equipments such as Relays, Contactors and Sensors housed in the APU Control unit. The system offered must have its own data storage capability and for this purpose a suitable memory shall be provided.

7.4.1 Real-time clock

The system shall have a real-time clock with accuracy of better than +/- 5 seconds over 30 days. The RTC shall be capable of time synchronization through laptop/ Display. The battery of RTC Clock should

work for minimum 3 years and should be replaceable easily. Time synchronization through

Laptop/Display based on Password protection should be provided.




Page 8 of 11

7.4.2 Software:

Necessary software for adjusting the user settable parameters and analyzing the data of the APU shall be provided.

8 Numbering Each Control unit, APU sub assembly shall contain a number plate indicating

a. Serial number b. Date of manufacturing c. Name of manufacturer d. Model number.

The major sub-assemblies in each unit should also be numbered and recorded with the supplier for future reference.

9 Applicable drawings

10 Referred standards

The following standards are referred by this specification. Operational understanding of all the referred standards should be ensured.

• IEC 60571 • IEC 60812 • IEC 60529 • IEC 62262 • IEC 60349 • IS 2500 • EDPS 179

11 Life cycle management The equipment supplier shall ensure that the lifecycle requirements of the equipment be met as detailed in the paragraphs below.

11.1 Expected life

The expected life of the equipment shall be 12 years or more.

11.2 Support during lifetime

The equipment manufacturer shall ensure that the following support is available on demand during the equipment lifetime:

Service / spares support for the equipment

Options for comprehensive maintenance contracts

Modifications in equipment design to meet new requirements or to improve reliability

The options for demanding these support services shall be reserved by the Indian Railways and the equipment manufacturer shall provide the same on demand.

The equipment manufacturer shall submit an undertaking to support the equipment during its declared lifetime. This undertaking shall be provided during type testing and design approval and also while entering into purchase contracts.

Note: Cost of the services shall be determined through a mutually acceptable process between the manufacturer and the users on the Indian Railways.

11.3 End of equipment life management

The equipment manufacturer shall provide options to upgrade / refurbish equipment at the end of life of the equipment when requested by the Indian Railways.




Page 9 of 11

The equipment manufacturer shall submit an undertaking to provide options for end of life management when required by Indian Railways. This undertaking shall be provided during type testing and design approval and also while entering into purchase contracts.

12 Documents required from manufacturer

The manufacturer shall supply the following documents with the equipment. All documents shall be provided in both hard copies and soft copies (PDF)

a. Product catalogue and standard data sheet of APU system

b. Outline and general arrangement drawings

c. Schematic circuit, functional description and protection scheme

d. The software logic of APU function in flow diagram.

e. Schedule of supply, listing all equipment with part numbers

f. Operating instruction and trouble shooting hand book

g. Maintenance manual with full description of maintenance and repair procedures

h. Maintenance schedules required along with list of components which are required to be replaced in those schedules

i. List of maintenance spares required for normal maintenance and emergency repairs

j. A copy of detailed bill of materials including relays, contactors, sensors, test compliance, make, model nos., qty used and location with supporting drawings.

k. List of in house and outsourced items of APU System.

l. Recommended list of spares with cost for 3 years maintenance after warranty

m. Test protocol with procedure of testing

n. Details of technical support and training offered

o. Detailed calibration procedure

p. Foot print and weight schedule of APU system.

13 Warranty

The manufacturer shall provide warranty as per IRS terms and conditions.

14 Training The supplier shall train adequate number of IR personnel in operation and maintenance of the offered APU. Adequate documentation shall be provided. Personnel of Indian Railways shall be nominated to attend. The equipment manufacturers shall arrange training for operations and maintenance of the equipment, as an integral part of the equipment supply.

15 Tests& Verification

The equipment shall be tested for functional capability, ability to withstand environmental conditions and for reliable performance under field conditions.

16 Sampling plan Sampling shall be done as per IS2500 wherever not specified but required. Sampling shall be done as per the requirements wherever specified in this document. If the specific contract includes specific clause for sampling, the same shall be applicable.

17 Types of tests The equipment shall be subjected to the following types of test during different stages of design approval. Prove out, field trials and testing of the offered APU - Testing including prove out & validation shall be in accordance with the referred standard




Page 10 of 11

SN Category of Test Remarks

1. Type tests and Validation test (Prototype)

These tests shall be done on a sampled lot of prototypes as per following standards.

a. IEC 60571 or equivalent – For APU Control system b. IEC 60349-1 or equivalent -For Alternator & Motor c. ISO 1217 and IS 10431 or equivalent – For Compressor

Such tests are required only on initial approval, change of design and change of manufacturing processes. Prototype test and validation test protocol will be submitted by the firm for approval by RDSO before conducting prototype test. These tests shall be done as pre-requisite for design approval. Test report from NABL accredited Lab, Govt Test Lab, CE certification or UL certification as applicable may also be accepted.

2. Field trials These trials shall be conducted for establishing equipment reliability under field conditions. A minimum sample size shall be installed to work under field conditions and performance monitored for a specified time. These shall be conducted after type tests.

3. Routine tests Tests are required to verify the functional working of the system. These may require simulated inputs for testing the operations under full range of inputs. These tests shall be done by the manufacturer during manufacturing and records maintained for inspection.

4. Acceptance tests These tests shall be done on all or sample of lot for bulk supply. Sampling shall be done as per IS2500. These tests shall normally consist of routine tests and additionally those specified in the specific contract. Acceptance test protocol will be submitted by the firm for approval by RDSO.

17.1 Type test and field trials:

The prototypes of the equipment shall be subjected to type tests and field trials prior to approval. Prove-out and validation - One APU shall be subjected to durability and performance test at firm’s premises as per the referred standards in presence of IR personnel or at designated center decided by Railways. After successful type test, validation test will be conducted at Loco before clearing prototype to establish the performance capability with locomotive systems..

17.2 Field trial

At least one loco set of equipment (or as decided by IR) shall be subjected to field trials for 12 months before clearance is given for bulk supply. During this period, the performance of the equipment shall be closely monitored and evaluated by RDSO. These trials are intended to prove

• Reliability under rigorous environmental and operating conditions

• Advantages for locomotive operation and maintenance

• Maintainability of the equipment.

If modifications found necessary as a result of the tests, the supplier at his own cost shall carry out trials after the relevant modifications as approved by RDSO.

17.3 Makers test certificate for outsourced item

All items that are outsourced by the equipment manufacturer shall be indicated so. The type and extent of quality control that has been exercised shall be provided with proper documentation. The manufacturers (of the outsourced sub-assembly) test certificates shall be provided.




Page 11 of 11

18 Painting, labeling and marking The equipment shall be appropriately painted for operational use, aesthetics and protection. The parts, connector ports, mounting points etc. shall be clearly marked in a manner that these are easily readable and remain legible over the lifetime of the equipment.

The offered APU and all major components and parts shall have proper identification and traceability to facilitate failure analysis and life cycle data.

ID plate Name of Component, Make, Sl. No, Date of Manufacture, Ratings shall be provided on all assemblies/subassemblies.

19 Packaging and delivery/shipment

The equipment consists of sensitive and fragile electronic systems. These should be packed with precautions required to prevent damage in transit.

All requirements of IRS conditions for packaging and delivery shall be applicable.

20 IPR disclaimer pin pointing responsibility on supplier for violation if any

20.1 Undertaking by equipment manufacturer

All the specifications issued by RDSO shall include a requirement of undertaking to be signed by Vendors on “INFRINGEMENT OF PATENT RIGHTS”. The undertaking can be as under

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

Details / design/documents given by them are not infringing any IPR and they are responsible in absolute and full measure instead of railways for any such violations. Data, specifications and other IP as generated out of interaction with railways shall not be unilaterally used without the consent of RDSO and right of Railways / RDSO on such IP is acceptable to them.

20.2 Declaration of confidentiality of submitted documents by manufacturers

While submitting a new proposal/design, manufacturer must classify their documents confidentiality declaration, such as

This document and its contents are the property of M/s XYZ (Name of the vendor) or its subsidiaries. This document contains confidential proprietary information. The reproduction, distribution, utilization or the communication of this document or any part thereof, without express authorization is strictly prohibited. Offenders will be held liable for the payment of damages. Indian Railways/RDSO is granted right to use, copy and distribute this document for the use of inspection, operation, maintenance and repair etc.

Specification No: MP.0.0402.07 Revision No: 0-DRAFT Date Issued:18 /10/2016

Specification Title: Functional requirement specification for Condition Based Monitoring System for Diesel Electric locos Alco and HHP locomotives.


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REVISION HISTORY

S. No.

Revision Brief details of changes

Date Number

1. 1 18/10/2016 0-DRAFT First Issue




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CONTENTS

0 Introduction ........................................................................................................................................... 4

1 Back Ground ......................................................................................................................................... 4

2 Objectives and Scope of the specification ............................................................................................ 5

3 Scope and other requirements ............................................................................................................. 5

4 Terminology / Abbreviations / Definitions ............................................................................................. 5

5 Details of standards/Specification followed .......................................................................................... 5

6 General requirements ........................................................................................................................... 6

6.1 Manufacturers qualification ....................................................................................................................... 6

6.2 Equipment Requirements ......................................................................................................................... 6

7 Functional requirements ....................................................................................................................... 6

7.1 Condition Monitoring of Locomotive Engine : ........................................................................................... 6

7.2 Online condition monitoring system for bearings in Diesel Locos ............................................................ 7

7.3 Radiator Performance Monitoring ............................................................................................................. 7

7.4 Fuel Level Monitoring & SFC Calculations ............................................................................................... 7

7.5 Condition Monitoring with use of additional sensor and existing sensors in REMMLOT fitted ALCo Loco: .................................................................................................................................................................. 7

7.6 Condition Monitoring with use of additional sensor and existing sensors in REMMLOT fitted HHP Loco: ................................................................................................................................................................ 11

7.7 Trend Analysis of Existing Parameters ................................................................................................... 14

7.8 Other Requirements ................................................................................................................................ 15

7.9 Memory ................................................................................................................................................... 15

7.10 Reporting Format .................................................................................................................................... 16

7.11 Self test ................................................................................................................................................... 16

7.12 Fail safe feature ...................................................................................................................................... 16

8 Environmental/Climatic requirements ................................................................................................. 16

9 Safety requirements ............................................................................................................................ 16

10 Power supply ...................................................................................................................................... 16




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11 Documentation .................................................................................................................................... 16

12 Training ............................................................................................................................................... 17

13 System integration .............................................................................................................................. 17

14 Types of tests ..................................................................................................................................... 17

15 Safety related modification ................................................................................................................. 18

16 Warranty and service support ............................................................................................................. 18

17 Life cycle management ....................................................................................................................... 18

17.1 Expected life ........................................................................................................................................... 18

17.2 Support during lifetime ............................................................................................................................ 18

17.3 End of equipment life management ........................................................................................................ 18

18 Painting, labeling and marking ........................................................................................................... 19

19 Packaging and delivery/shipment ....................................................................................................... 19

20 Undertaking by equipment manufacturer ........................................................................................... 19

21 Declaration of confidentiality of submitted documents by manufacturers .......................................... 19




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0 Introduction

This document is the functional requirement specification for development of Condition based monitoring System utilizing the existing REMMLOT System fitted on Diesel Electric Locomotive. The REMMLOT System is provided on the diesel electric locomotive as per RDSO Specification no. MP.0.0402.04 (Rev.5 or latest), which has the facility to capture data and monitoring the Loco parameter remotely through web based application. The REMMLOT tool is useful for loco monitoring, however it requires further refinement to make it suitable for condition based loco monitoring for predictive maintenance. This specification should be read in conjunction with RDSO specification no. MP.0.0402.04 (Rev.5 or latest) for REMMLOT System.

To enhance the scope of REMMLOT system, additional sensors, hardware are to be fitted on loco and data obtained from sensors need to be analyzed through a set of software algorithm to derive the condition of the components of loco required for immediate attention. At present preventive maintenance is followed based on the conventional system of km earned and fixed time period.

1 Back Ground Indian Railways (IR) follows the system of preventive maintenance for its Rolling Stock so as to achieve the maximum possible availability and reliability in service.

The system of preventive maintenance envisages a schedule for maintenance attention at regular specified intervals including replacement of components. It aims to replace the components before they actually fail in service due to aging, wear and tear, while also endeavoring to obtain maximum life possible for the components. The system also aims at synchronization of attention to all related components so that the manpower and engine days lost on account of the examination is minimized.

Basis of Maintenance : The system of preventive maintenance has evolved on one of the following criterion:

i. Time;

ii. KM;

iii. Engine hours

Time basis is used for scheduling the preventive maintenance of diesel locos due to its simplicity. Time involved between schedules being adjusted according to the utilization of the locos. In case of POH of Alco locos, both time and Km basis is presently specified i.e. 10 lac Km or 8 years, whichever is earlier.

IR established microprocessor based control system for locomotive excitation and propulsion with recent addition of remote capturing and monitoring of all sub system operational and health parameters at centralized server level. IR considers to introduce the concept of Condition Based Maintenance to bring down both cost and as well as down time for maintenance. To achieve this, it is necessary to lay down a list of parameters which are required to be monitored remotely and also during the last shed attention paid to arrive at the decision about next schedule to be given to the loco.

Remote monitoring is an essential requirement in achieving this objective. Condition Based Maintenance technique tries to plug the loophole of preventive maintenance by incorporating condition monitoring of component parameters. These parameters are mostly temperature, vibration, Insulation Resistance, current, run down time, energy consumed, rpm, drop in level, concentration, condition of lube oil & fuel oil. etc.

Condition Monitoring is the process of monitoring a parameter of condition (temperature, pressure, vibration, current, etc) in machinery in order to identify a significant change which is indicative of a developing fault. It is a major component of Predictive maintenance. Predictive maintenance is a condition driven preventive maintenance program. An effective preventive maintenance program includes both condition driven and time driven tasks. Statistics and probability theory are the basis for condition monitoring.

Introduction of MBCS in ALCO locos and AC-AC system of the HHP facilitated Fault Diagnostic System , which is the first major jump in condition monitoring. Introduction of REMMLOT




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further enhanced the online condition monitoring.

2 Objectives and Scope of the specification

This specification has been prepared to guide development of Condition Based Monitoring System for a variety of Diesel electric locomotives (with Microprocessor based control system and on line remote monitoring system.

It covers the functional requirements of the system and specifies features to be incorporated, the reliability and performance requirements and lays down the acceptance criteria.

3 Scope and other requirements

Condition Monitoring with the help of sensors installed as part of the MBCS/AC-AC Traction Control Systems.

o Identify the parameters being monitored.

o Output of the sensors and relate to the condition of the equipment through software algorithm.

o The output reports through REMMLOT.

Condition Monitoring by installing additional sensors/condition monitoring sub system.

o Identify the new additional sensors.

o Identify new additional condition monitoring sub systems.

o Output of the sensors and relate to the condition of the equipment through software algorithm.

o The output reports through REMMLOT.

Integration and interface with REMMLOT.

Note: This specification outlines the basic architecture of the condition based monitoring which is under development. Hence, if the vendor considers some additional requirement for condition monitoring system that may be considered based on merit of justification furnished by the vendor.

4 Terminology / Abbreviations / Definitions

REMMLOT Remote Monitoring and Management of Locomotives and Trains

RAM Random Access Memory

MBCS Micro processor based Control System

LTMS Loco Train Management System

LRMS Loco Remote Monitoring System

IR Indian Railway

RDSO Research Designs and Standards Organisation

DLW Diesel Locomotive Works

DMW Diesel Loco Modernisation Works

5 Details of standards/Specification followed

i. IEC 61375




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ii. IEC 60571

iii. EN 50155

iv. RDSO Specification No. MP.0.0402.04 (Rev.5 or latest)

6 General requirements

6.1 Manufacturers qualification

Manufacturer of the equipment shall be an RDSO approved supplier of the MBCS/AC-AC Traction Control System or REMMLOT system for diesel-electric locomotives.

In case of third party supply, the manufacturer shall have a formal MoU with the RDSO approved MBCS/AC-AC Traction Control System or REMMLOT manufacturer for complete integration required for condition based monitoring system.

6.2 Equipment Requirements

The equipment specified in this document is expected to meet the following general requirements.

i. The equipment shall be designed for installation on diesel electric locomotives equipped with MBCS in ALCo Loco and with AC-AC Traction Control System in HHP Loco. The equipment manufacturer shall get the equipment design approved by RDSO before fitment on locomotives.

ii. The embedded system of the equipment shall be interfaced with the REMMLOT system (LRMS), preferably be an integral part of the system and shall plug into the system bus.

iii. The equipment, cabling and connectors shall be designed to handle the harsh environmental conditions of the locomotive.

iv. The equipment shall be capable of working in all types of electrified as well as non-electrified territories.

7 Functional requirements

Condition based Monitoring system shall comprise of the sensors, embedded module integrated with REMMLOT system. The system shall utilize the data obtained through REMMLOT and their own sensors and based on the software algorithm shall alert the Railways through SMS, email and web application for the impending failures of the major sub system to get it attended well before failure. It is desired that the Condition based Monitoring system should be made on the REMMLOT platform of Indian Railways. REMMLOT is provided for Diesel Electric Loco by REMMLOT manufacturer so as to minimize the duplicity of hardware. Hence, the interface with REMMLOT system is required by Condition based Monitoring System supplier. The interface shall be with CBMS supplier. Functional requirement is furnished.

7.1 Condition Monitoring of Locomotive Engine :

Cylinder specific information such as: Combustion / Compression, Excessive fuel consumption, based on the consistency of the power contribution of the cylinders, Cylinder specific injection problems (i.e. injectors),Cylinder specific low compression (i.e. piston rings),Internal friction as a general condition of the engine, massive changes as an indication for up-coming major damages, Real-time monitoring with regard of rapid friction changes, Monitoring of auxiliary components such as Turbocharger. The likely parameters monitored by the onboard engine diagnostic system is given below –

Monitored parameters

Description




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Compression

Indicates the consistency of the compression in each cylinder.

Injection Shows the distribution of pressure during the combustion phase of the cylinders.

Bearings It is the image of the dynamic behavior of the crankshaft rotation.

Combustion Gives an indication of correct/incorrect fuel consumption.

Cam & Pumps Detects loading outside of the bottom end of the engine, such as camshaft, oil pumps, water pumps, externally driven devices.

Friction Indicate if there is abnormal friction along the crankshaft.

Damage/ Irregularity

Identifies the presence of irregularities or pulses generated by mechanical issues.

7.2 Online condition monitoring system for bearings in Diesel Locos

Vibration is an early indication of deterioration of the bearing. The vibration data generated by the sensor is converted into health index of the bearings by analysis of the vibration signature through sophisticated algorithms. Depending on the use and extent of problem, temperature sensors can also be used for monitoring the condition of the bearing. Bearing condition monitoring system shall cover comprehensively 12 axle journal bearings, 12 traction motor suspension system bearings and 6 traction motor pinion end bearings.

7.3 Radiator Performance Monitoring

1. The CBMS shall continuously monitor the inlet and outlet temperatures of radiator and shall indicate the degraded performance of the radiator before it leads to the damage any part of the engine. Because the lack cooling will directly impact the engine performance and leads to damage of engine parts.

2. The CBMS shall identify this by monitoring the difference temperature of the inlet and outlet temp. of the radiator.

7.4 Fuel Level Monitoring & SFC Calculations

1. The CBMS system shall also monitor the FUEL level of the tank and there shall be a possibility of calculating Fuel consumption of the locomotive time to time by monitoring Fuel Level. From this fuel consumption system shall compute SFC and the increase in SFC shall be alerted.

2. As the fuel consumption and fuel level are monitored by the system, the system shall give reports on fuel consumption and fuel re-filling and also the system shall give an alert when theft identified. The system shall estimate the remaining time to refuel based on SFC and available Fuel level.

7.5 Condition Monitoring with use of additional sensor and existing sensors in REMMLOT fitted ALCo Loco:

7.5.1 Condition Monitoring with use of existing sensors in REMMLOT fitted ALCo Loco:

Sensors Parameter measured

Functions Likely failures

targeted Primary Secondary




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Rectifier

Voltage sensor

Rectifier Output Voltage

Excitation control & Protection of Equip.

Fault diagnosis

& Redundancy Functions

Traction Alternator along with other parameters, and also used for Load reference for many parameters / alerts.

Current sensor

Rectifier Output Current

Current Sensor

Power Ground Leakage Current

Protection of Equip. - Power circuit leakage currents

Traction Motors

Current sensors

Armature Currents of TMs individually

Wheel Slip & Propulsion control

Fault diagnosis


Traction motors along with other parameters

Used to detect TM circuit open, TM high current, Locked axle, slip detection, etc

Speed sensors

Traction Motor Speeds individually

Exciter

Current sensor

Exciter Armature Current

Excitation control & Protection of Equip.

Fault diagnosis

Exciter performance along other parameters

Current sensor

Exciter Field Current

Auxiliary Generator

current sensor

Auxiliary Generator Armature current

Battery Charging & Protection of Equip.

Fault diagnosis


AG & BATT performance along with other parameters

current sensor

Auxiliary Generator Field current

voltage sensor

Auxiliary Generator Armature Voltage

Battery

Current sensor

Battery Charging/ Discharging Current

Battery Charging & Protection.

Fault diagnosis


Battery & AG along with other parameters

Voltage sensor

Battery Voltage

current sensor

Battery Earth Fault Protection of Equip. -




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Pneumatic system

Pressure sensor

MR Pressure

Compressor Loading and Unloading Control

- Air Compressor / Air Brake System along with other parameters

pressure sensor

Brake Pipe Pressure

Air Brake Monitoring

Event Recording

Pressure sensor

Brake Cylinder Pressure

Air Brake Monitoring

Event Recording

Engine

Speed sensor

Engine Speed Excitation, Battery Charging & Propulsion control

Fault diagnosis

Key parameter for all as Engine speed reference

Water cooling system

Temperature Sensor

Engine Water Temperature

Protection of Equip. Fault diagnosis


Engine cooling system along with along with other parameters

Pressure Sensor

Engine Water Pressure

Lube oil system

Temperature Sensor

Lube Oil Temperature



Can be used for condition monitoring of Engine Lubrication system along with along with other parameters Pressure

Sensor Lube Oil Pressure

Air system

Temperature Sensor

Ambient Air Temperature

Excitation control - For calculating load reference which is important for other parameters

Pressure Sensor

Booster air pressure

Governor Functions - Turbo Super Charger along with along with other parameters

Fuel oil system




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Pressure Sensor

Fuel Oil pressure

Governor Functions - Fuel system along with other parameters

Electrical Braking system

Voltage sensor

Master Controller Braking Potentiometer

Dynamic Braking control

- -

Current Sensor

Grid Blower Current Protection of Equip. Fault diagnosis

-

Other

Altitude Sensor

Site Altitude

Excitation control - For calculating load reference which is important for other parameters

Voltage Sensor

Governor Load Control Rheostat Output

Excitation control - -

7.5.2 Condition Monitoring with use of additional sensors/standalone condition monitoring modules in REMMLOT fitted ALCo Loco

S No. Additional sensors / equipment proposed

Health parameter monitored

Likely failures targeted

1.

Condition monitoring system of locomotive engine by special sensors for monitoring speed of crankshaft and camshaft

Acceleration of speed of crankshaft / camshaft

Failures related to Fuel injection, combustion, pumps, main bearings, camshafts etc.

2.

Condition monitoring of bearings (Axle box & TM) by mounting vibration sensors

Vibration signature of the bearings

TM bearing

Axle box bearings

3.

Water level sensor in Exp. Tank

Level of water in expansion tank

Failures related to water system causing reduction in water level

4. Current Sensor for FPM Current drawn by fuel pump motor

To monitor fuel pump performance and any fuel supply difficulties in pipe line or filters health

5.

Radiator inlet / outlet temperature sensors

Measurement of temperature of inlet cooling water / outlet

Failures related to hot engine alarm of WCS




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cooling of radiator, i.e. the efficiency of cooling of Radiator

6. Current sensor Phase 1 current of TA Traction alternator output and Rectifier inputs monitoring to detect phase imbalance and phase open to protect Rectifier and TA

7. Current sensor Phase 2 current of TA


9. Turbo RPM Sensor Turbo RPM To monitor performance of turbo

10. Temp Exhaust Gas To monitor engine performance and exhaust gasses

11.

Lube oil cooler inlet/ outlet temp. sensors

Efficiency of cooling of Lube oil cooler

Failures related to lube oil cooling system

12.

Pressure Sensor for crankcase vacuum

Crankcase vacuum. Failure related to power assly and CCEM

13. Current sensor CCEM Crankcase vacuum To monitor CCEM performance

14.

Current sensor Eddy Current Clutch

Current drawn by Eddy Current Clutch.

To monitor Eddy Current Clutch performance

7.6 Condition Monitoring with use of additional sensor and existing sensors in REMMLOT fitted HHP Loco:

7.6.1 Condition Monitoring with use of existing sensors in REMMLOT fitted HHP Loco:


Functions Likely failures targeted

Primary Secondary

Alternator :

Voltage sensor

DC Link Voltage Excitation control & Protection of Equip.

Fault diagnosis


Traction Alternator along with other parameters, and also may be used for Load reference for many parameters / alerts.

Current sensor

DC Link Current

Current Sensor

Power Ground Leakage Current

Protection of Equip. Fault diagnosis Power circuit leakage currents

Current Sensor

Power Ground Phase Imbalance

Protection of Equip. Fault diagnosis The Phase Imbalance in Alternator.

Traction Motors

Current sensors

TM Phase Current Sensor

Phase current Imbalance

Fault diagnosis

Traction motors along with other parameters Speed

sensors Traction Motor Speeds individually

TM Torque control and Wheel slip control

Fault diagnosis




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Primary Secondary

Temp Sensor

Traction Motor Temperature individually

Protection of Equip & Torque control Fault diagnosis

Traction Inverter

Current Sensor

DCL 1-6 Current sensors (Traction inverter Input)

Protection of Equip. Fault diagnosis Traction inverter along with other parameters.

Temp Sensor

Temperature of Traction inverter & Capacitor individually


Auxiliary Generator

Current sensor

Auxiliary Generator Armature current

Battery Charging & Protection of Equip.

Fault diagnosis


AG & BATT performance along other parameters.

Current sensor

Auxiliary Generator Field current

Voltage sensor

Auxiliary Generator Armature Voltage

Battery

Current sensor

Battery Charging/ Discharging Current

Battery Charging & Protection.

Fault diagnosis


Battery & AG along with other parameters

Voltage sensor

Battery Voltage

Temperature sensor

Battery Box Ambient Temperature sensor

Companion Alternator

Voltage Sensor

Companion Alternator Phase voltage Sensor

To monitor CA out put

-----

CA along with other parameters

Brake Chopper, if available

Current Sensor

Brake chopper current Protection of Equipment

Fault diagnosis

Brake chopper along with other parameters

Temp Sensor

Brake Chopper temperature

Protection of Equip.

Pneumatic system

Pressure sensor

MR Pressure

Compressor control Loading / Unloading.

Air Compressor / Air Brake System along other parameters

Engine

Engine Speed sensor

Engine Purge Unit Excitation, Battery Charging, Torque & Propulsion control

Fault diagnosis & Redundancy

Key parameter for all as Engine speed reference.

Turbo Charger

Speed sensor

Turbo Purge Unit Excitation control Fault diagnosis.

Turbo along with other parameters

Water cooling system

Temperature Sensor

Engine Water Temperature 1&2


&Redundancy Functions

Engine cooling system along with other parameters




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Primary Secondary

Dynamic Braking system

Voltage sensor

Master Controller Braking Potentiometer

Dynamic Braking control

-

Current Sensor

Grid Blower Current 1 & 2

Protection of Equip. Fault diagnosis Grid Assembly along with other parameters

Current Sensor

Grid Path Current sensor 1&2


Other

Altitude Sensor

Site Altitude

Excitation control - Load reference which is important for other parameters

Voltage Sensor

Governor Load Control Rheostat Output


Temp Ambient Temp.

Excitation control - Load reference which is important for other parameters

Voltage sensor

Load Control Reference voltage sensor.


7.6.2 Condition Monitoring with use of Additional sensors/standalone condition monitoring modules in REMMLOT fitted HHP Loco:




1.

Condition monitoring system of locomotive engine by special sensors for monitoring speed of crankshaft and camshaft

Acceleration of speed of crankshaft / camshaft

Failures related to Fuel injection, combustion, pumps, main bearings, camshafts etc.

2.

Condition monitoring of bearings (Axle box & TM) by mounting vibration sensors

Vibration signature of the bearings

TM bearing

Axle box bearings

3.

Water level sensor in Exp. Tank Level of water in expansion tank

Failures related to water system causing reduction in water level

4. Current Sensor for FPM Current drawn by fuel pump motor

To monitor fuel pump performance and any fuel supply difficulties in pipe line or filters health

5.

Radiator inlet / outlet temperature sensors

Measurement of temperature of inlet cooling water / outlet cooling of radiator, i.e. the efficiency of cooling of

Failures related to hot engine alarm of WCS




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Radiator

6. Current sensor Phase 1 current of TA Traction alternator output and Rectifier inputs monitoring to detect phase imbalance and phase open to protect Rectifier and TA



9. Temp Exhaust Gas To monitor engine performance and exhaust gasses

10.

Lube oil cooler inlet/ outlet temp. sensors

Efficiency of cooling of Lube oil cooler

Failures related to lube oil cooling system

11.

Pressure Sensor for crankcase vacuum

Crankcase vacuum. Failure related to power assly and CCEM

12.

Fuel oil pressure sensor To measure Fuel oil pressure.

condition monitoring of Fuel system

13.

Lube oil pressure sensor To measure Lube oil pressure.

condition monitoring of Lube oil system

14.

Lube oil temperature sensor To measure Lube oil temperature.

condition monitoring of Lube oil cooling system

Note :

Sl. No.1 and 2 of Para 7.5.2 and 7.6.2 are standalone condition monitoring systems whereas the remaining are sensors.

Additional Embedded system may require as a standalone system for digitization of the sensor input and monitoring the real time data of sensor locally through algorithm for additional sensors and condition monitoring sub system. The Embedded system should be robust and rugged for rolling stock application and should have following broad specification:

The above details are for understanding the sensor requirements to target the failure & condition monitoring. It is seen that the algorithm and analysis of multiple sensor data input are required out of which some are already available in REMMLOT system and some are through additional sensors of CBMS. CBMS system is to be tightly integrated with REMMLOT system. Hence, the MoU with REMMLOT manufacturer is mandatory requirement .The complete algorithm development, reporting format, SMS alert, software for trend generation and analysis will be provided by the CBMS supplier. The CBMS supplier shall work out with REMMLOT manufacturer for enabling the feature on REMMLOT server and Web application. The overall responsibility will lie on CBMS supplier for integration with REMMLOT and MBCS.

7.7 Trend Analysis of Existing Parameters

1. Better use of the existing sensors already built in as part of MBCS of ALCO loco or AC-AC Traction Control System of HHP loco to tap the full potential of the existing hardware available to predict the health of the equipment.

2. Output of the sensors of MBCS fitted ALCO locomotives/HHP Locomotives, which is primarily used for fault diagnostics at present, can be utilized for condition/ health




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monitoring by showing trend of the deterioration / changes in their values prior to the failure.

3. The control chart graph will indicate how a parameter changes over time. Data should be plotted in time domain. A control chart always has a central line for the average, an upper line for the upper control limit and a lower line for the lower control limit. These lines may be determined from historical data. By comparing current date to these lines, one can draw conclusions whether the process variation is consistent (in control) or unpredictable (out of control, affected by special causes of variation).

4. Control Chart and parameter graph will indicate and predict abnormal values as they occur. It will also indicate whether a process is stable (in statistical control) and expected range of outcomes from a process.

5. Patterns of process variation from special causes (non-routine events) or common causes (built into the process) should be highlighted.

6. Appropriate control chart for each parameter should be plotted based on data downloaded from bench marked locomotives. MIS report should indicate “out-of-control signals” on the control chart.

7. Obvious consistent or persistent patterns that suggest something unusual should be automatically highlighted.

8. Identify failure prone equipment/systems whose health cannot be monitored with the existing sensor network and plan for fitment of additional sensors to monitor the health of these equipment / systems.

7.8 Other Requirements

1. All issues of system integration and interfacing with third party system like microprocessor based control system and REMMLOT with CBMS system shall be the responsibility of CBMS supplier. IR dedicated server for REMMLOT shall be used to capture CBMS data and to do further analysis and report generation.

2. The CBM system on diesel locomotives are required to work in a very hazardous environment having oil, dust, vibrations combined with high level of electrical surges, electromagnetic induction and radio frequency interference. It is therefore of utmost importance that the CBM system, being sought for development, gives trouble free service with a very high degree of reliability.

3. The system hardware offered shall be of proven design having trouble free service performance on diesel electric locomotives on established Railway systems. The supplier shall furnish a list of the offered equipment supplied by them to other Railways, giving relevant details and evidence of its satisfactory performance. The software employed should also be of a type/family, which has been proven on Railroad application.

4. The prototype system shall require only minimal changes in the physical layout and operating function of existing equipment in the driver’s cab including driver’s controls, switches, indication lamps and meters, and such changes shall be made by mutual agreement.

5. The requirement of driver display functions of CBMS system shall be integrated with existing driver display system and interface with existing driver display system will be provided by RDSO.

6. Change in performance, functionality and deviation for scope if any with the proposed system, shall be brought out clearly prior and approval of RDSO should be obtained.

7.9 Memory

The Raw data which is captured for analysis of condition monitoring shall be stored in internal memory. The frequency of storing shall be such that, it shall be possible to analyze the condition of the sub assembly by off line analysis without any obligations.

Storing of data at higher frequency is not recommendable until unless if it is not possible to analyze it by offline analysis methods. The system shall also store the ALARMS generated




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by the on-board CBMS system.

The internal memory shall be accessible through a separate USB port (with proper sealing arrangement, pen drive / lap top computer for down loading the data.

A graphical and tabular analysis of the recorded data should be supported by the LTMS if the raw data is uploaded to server software. It should be possible to analyze the desired time span through zooming and examine the values at specific points of interest by positioning cursor.

The supplier shall be responsible for the supply and commissioning of the desired sensors/ shunts/ transducers to record the above events for satisfactory and reliable operation.

7.10 Reporting Format

The formats reporting in Web application shall be submitted to RDSO by the supplier, on approval of formats same shall be incorporated in web application. If changes are required in the reporting format, prior approval shall be taken from RDSO before implementation.

7.11 Self test

The system shall be able to run a self-test at power ON or at driver's request to verify satisfactory functioning of all component system including Input/ Output. During operation, the system shall be capable of identifying internal faults as may occur from time to time and indicating these to the driver. Fault recovery capabilities and limited fault tolerance are desirable details of which shall be indicated in the offer for evaluation of the system.

7.12 Fail safe feature

The equipment shall have failsafe feature where, in case of a system failure the system goes to SAFE MODE so as not to cause any damage to any equipment connected it. The system should preferably have built-in feature to ensure that in case of failure of a component, locomotive operation, if feasible, is either not affected at all or downgraded only in such a manner that the locomotive is enabled to complete the trip safely. Addition of considerable hardware or other complications in hardware/software, however, for incorporating this feature is not desirable.

8 Environmental/Climatic requirements

All the Electronic equipments shall be compliant to IEC 60571 or EN 50155 to meet the Environmental requirement required for rolling stock.

The Data cable shall be properly shielded and grounded for EMI/EMC complying IEC 61375.

9 Safety requirements

The equipment shall meet the required international safety standard applicable for cables and Electronic equipments.

10 Power supply

A 64 V battery is available on the locomotive for meeting the power requirement of the system. When the engine is running, this battery floats across 72+2 V regulated supply from an auxiliary generator.

During cranking, the battery voltage may drop to around 22V for about 0.8 sec. The offer should indicate the details of Power supply modules proposed.

It is desirable that CBM system do not require any cooling airflow, in fact, equipment should be air tightened for proper sealing against humidity.

11 Documentation i. Block diagram and the flow charts of the hardware and system user manual




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ii. Schedule of supply, listing all equipment with part numbers

iii. Outline and general arrangement drawings

iv. Printed product catalog and standard data sheet of offered system.

v. Detailed specifications (technical catalog and data sheet) for the equipment offered.

vi. Maintenance schedules for the major equipment

vii. Maintenance manual with full description of maintenance and repair procedures.

viii. Loco operational manuals.

ix. List of maintenance spares required for normal maintenance and emergency repairs.

x. Commissioning test schedule for the locos.

xi. Driver's operating instructions and trouble shooting handbook.

xii. Schematics for the control equipment

xiii. Circuit descriptions

xiv. Sequence of operation where necessary

xv. Such design data as may be required by RDSO to establish the adequacy of the design.

xvi. Detailed trouble shooting directory.

12 Training

The supplier shall train adequate number of IR personnel in operation and maintenance of the offered System. Adequate documentation shall be provided. Personnel of Indian Railways shall be nominated to attend.

The equipment manufacturers shall arrange training for operations and maintenance of the equipment, as an integral part of the equipment supply.

13 System integration

The CBMS Supplier shall be responsible for the complete system integration of the CBM system with the MBCS/AC-AC Traction Control System of the locomotive and REMMLOT System.

14 Types of tests

The equipment shall be tested as per the following scheme.

S. No.

Category of Test

Remarks

1 Type tests (Prototype)

These tests shall be done on first prototype as per IEC 60571.. Such tests are required only on initial approval, change of design and change of manufacturing processes.

These tests shall be done as pre-requisite for design approval.

2 Field trials These trials shall be conducted for establishing equipment reliability under field conditions. A minimum sample size shall be installed to work under field conditions and performance monitored for a specified time.

3 Acceptance tests

These tests shall be done on all or sample of lot. Sampling shall be done as per IS2500. These may require simulated inputs for testing the operations under extreme conditions of inputs.




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4 Routine tests Tests are required to verify the functional working of the system. These may require simulated inputs for testing the operations under extreme conditions of inputs.

15 Safety related modification

During implementation of the CBM system any safety related modifications issued by IR are to be carried out by the tenderer.

16 Warranty and service support

The equipment manufacturer shall provide warranty guarantee for performance as per the IRS conditions.

17 Life cycle management

The equipment supplier shall ensure that the lifecycle requirements of the equipment be met as detailed in the paragraphs below.

17.1 Expected life

The expected life of the equipment shall be 12 years or more.

17.2 Support during lifetime

The equipment manufacturer shall ensure that the following support is available on demand during the equipment lifetime:

Service / spares support for the equipment

Options for comprehensive maintenance contracts

Modifications in equipment design to meet new requirements or to improve reliability

The options for demanding these support services shall be reserved by the Indian Railways and the equipment manufacturer shall provide the same on demand.

The equipment manufacturer shall submit an undertaking to support the equipment during its declared lifetime. This undertaking shall be provided during type testing and design approval and also while entering into purchase contracts.

Note: Cost of the services shall be determined through a mutually acceptable process between the manufacturer and the users on the Indian Railways.

17.3 End of equipment life management

The equipment manufacturer shall provide options to upgrade / refurbish equipment at the end of life of the equipment when requested by the Indian Railways.

The equipment manufacturer shall submit an undertaking to provide options for end of life management when required by Indian Railways. This undertaking shall be provided during type testing and design approval and also while entering into purchase contracts.




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18 Painting, labeling and marking

The equipment shall be appropriately painted for operational use, aesthetics and protection. The parts, connector ports, mounting points etc. shall be clearly marked in a manner that these are easily readable and remain legible over the lifetime of the equipment.

The offered CBMS and all major components and parts shall have proper identification and traceability to facilitate failure analysis and life cycle data.

ID plate Name of Component, Make, Sl. No, Date of Manufacture, Ratings shall be provided on all assemblies/subassemblies.

19 Packaging and delivery/shipment

The equipment consists of sensitive and fragile electronic systems. These should be packed with precautions required to prevent damage in transit.

All requirements of IRS conditions for packaging and delivery shall be applicable.

20 Undertaking by equipment manufacturer

Vendor shall provide a signed copy of the undertaking on “INFRINGEMENT OF PATENT RIGHTS”. The undertaking shall be as under

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

Details / design/documents given by them are not infringing any IPR and they are responsible in absolute and full measure instead of railways for any such violations. Data, specifications and other IP as generated out of interaction with railways shall not be unilaterally used without the consent of RDSO and right of Railways / RDSO on such IP is acceptable to them.

21 Declaration of confidentiality of submitted documents by manufacturers

While submitting a new proposal/design, manufacturer must classify their documents confidentiality declaration, such as

This document and its contents are the property of M/s XYZ(Name of the vendor) or its subsidiaries. This document contains confidential proprietary information. The reproduction, distribution, utilization or the communication of this document or any part thereof, without express authorization is strictly prohibited. Offenders will be held liable for the payment of damages. Indian Railways/RDSO is granted right to use, copy and distribute this document for the use of inspection, operation, maintenance and repair etc.

(For official use only) (dsoy ljdkjh iz;ksx gsrq)

Hkkjr ljdkj jsy ea=ky;

GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

-DRAFT-

FUNCTIONAL REQUIREMENT OF SPECIFICATION (FRS) FOR

UP-GRADATION OF EXISTING EMD LOCOS BY

RETRO-FITMENT OF EMISSION KIT ON EMD 710 ENGINES.

Specification no.MP - 0.08.00.111 (Rev-00) August - 2016

Issued by vuqla/kku vfHkdYi ,oa ekud laxBu] Ekkud uxj] y[kuÅ - 226 011

RESEARCH DESIGNS AND STANDARDS ORGANISATION MANAK NAGAR, LUCKNOW – 226011

RDSO (MP) ISO 9001 : 2008 Specification No: MP-0.08.00.111 Revision no.00 Date Issued: Aug - 2016

Title: Functional Requirement of Specification (FRS) for Up-gradation of existing EMD locos by retro-fitment of Emission kit on EMD 710 engines. (DRAFT)

Page 2

C O N T E N T S

Sl. No. Description Page No.

1. Preface 3

2. Functional Requirement of Specification (FRS) for Up-gradation of existing EMD locos by retro-fitment of Emission kit on EMD 710 engines.

4

ANNEXURES Annexure - I Duty cycle for the purpose of comparison SFC



Page 3

PREFACE

1. BRIEF DESCRIPTION:

This document contains the Functional Requirement of Specification (FRS) for Up-gradation of existing EMD locos by retro-fitment of Emission kit on EMD 710 engines.

2. FOREWORD:

This document is a Functional Requirement of Specification (FRS) for Up-gradation of existing EMD locos by retro-fitment of Emission kit on EMD 710 engines. The specifications given in this document are generic and are subjected to change in future with the development.

3. DISCLAIMER: Although, every care has been taken in specifying details adequately and

unambiguously. RDSO shall not liable for any kind of damages / losses incurred by any and all due to errors or omission in this document. When using the information described herein, the user is ultimately responsible for their own actions, as well as the actions of subordinates and assistants, and the consequences arising there from.

This document may mention numerous commercial and proprietary trade names,

registered trademarks and the like (not necessarily marked as such), patents, production and manufacturing procedures, registered designs, and designations. RDSO wishes to point out very clearly that the present legal situation in respect of these names or designations or trademarks must be carefully examined before making any commercial use of the same.

Names of industrially produced apparatus and equipment may be included to a

necessarily restricted extent only and any exclusion of products not mentioned in this document does not imply that any such exclusion has been based on quality criteria or any other qualifying consideration.

4. COPYRIGHT: RDSO has the copyright of all its publications. No part of these publications may be reproduced in any form without the prior permission of RDSO. Enquires relating to the copyright should be addressed to Executive Director (Administration), RDSO.

5. ADDRESS FOR COMMUNICATION:

Government of India -Ministry of Railways, Research Designs & Standards Organization Manak Nagar Lucknow Uttar Pradesh India Pin: 226 011Fax: +91 (522) 2458500 Phone: +91 (522) 2451200 (PBX) +91 (522) 2450115 (DID) Website: www.rdso.indianrailways.gov.in



Page 4

Functional Requirement of Specification (FRS) for Up-gradation of existing EMD locos by retro-fitment of Emission kit on EMD 710 engines.

1. Background:

1.1 EMD diesel locomotives produced at DLW are not meeting to EPA Tier ‘0’

emission norms. NOx and PM emission level of the locomotives are much higher than EPA Tier’0’ emission level, whereas HC & CO emission levels are below /at par than EPA Tier ‘0’ level. Ranges of NOx, PM, HC and CO emissions observed in EMD locomotives are as below.

Ranges of emissions observed (in g/bhp-hr) NOX PM HC CO

8.68 – 14.10 0.24 – 1.14 0.44 – 1.49 0.76 – 1.46 In order to upgrade emission level to EPA Tier ‘0’ emission norms or better, it is

required to reduce NOx & PM emissions by retro-fitment of emission kit. The following benefits are expected by introduction of emission kit in EMD locomotives:

i. Reduction in PM & NOx emissions in comparison to existing locos. ii. Better environment. iii. Modification can be done within existing envelope of EMD Loco.

1.2 This kit shall be designed as an emission control system which shall be fitted on

existing locomotives as well as newly under manufacturing EMD engines to achieve EPA Tier ‘0’ emission level or better.

1.3 The engine components of proposed emission kits shall be fitted on exiting

envelop / assembly and replace the original one. No change shall be permitted in other engine subassemblies/components to accommodate the kit.

2. General Information about the Engine General Information about the Engine of IR’s EMD Locomotives:

i. Engine Model: 710G3B ii. Number of Cylinders: 16 iii. Engine Type: Two‐Stroke, Turbocharged iv. Cylinder Arrangement: 45° “V” v. Compression Ratio: 16:1 vi. Displacement per Cylinder: 11 635 cm3 (710 Cu in) vii. Cylinder Bore: 230.19 mm (9‐1/16”) viii. Cylinder Stroke: 279.4 mm (11”) ix. Rotation (Facing Flywheel End): Counter clockwise x. HP at Rated RPM: 4500 HP at 954 RPM xi. Normal Idle Speed: 269 RPM xii. Low Idle Speed: 200 RPM

3. Operational Requirements:

i. Reduction of emission level to the level of Tier ‘0’ norms as per EPA’s 40 CFR part 1033.



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ii. There should not be adverse effect on SFC of engine. For this purpose at the stage of prototype testing on the engine test bed, SFC level of engine fitted with conventional power assembly & emission level after retro-fitment of the emission kit on the same engine shall be compared at rated hp and at duty cycle. Duty cycle to be followed for the purpose is attached as Annexure - I.

iii. Retro-fitment of Emission kit shall not result in reduction of BHP of the engine.

iv. Emission kit should fit within envelope of existing EMD loco.

4. Requirement for up-gradation of emission norms: The emission level as Tier ‘0’ norms as per EPA’s 40 CFR part 1033 which is to be achieved shall be as per following values or better for Line-Haul Locomotive.

Year of original manufacture

Tier of standards

Standards (g/bhp-hr) NOX PM HC CO

1973-1992 Tier 0 8.0 0.22 1.00 5.0

5. Scope of Work:

i. The suppliers shall be responsible to finalize the design of the equipment in consultation with production unit and RDSO.

ii. Procurement of the emission kit mainly includes power assembly and injectors.

iii. Other standard parts such as blowers, turbocharger, governor, camshafts and after-coolers, to be supplied from Indian Railway stocks.

iv. One prototype emission kit will be fitted on a engine test bed at RDSO for testing. The testing shall be carried out jointly with the representatives of firm, production unit of IR and RDSO.

v. After successful testing of the kit, the prototype emission kit will be fitted on loco engine at DLW, Varanasi.

vi. The supplier shall install the kit on loco. Retro-fitment of the kit proposed by supplier shall be carried out in consultation with production unit of Indian Railways and RDSO.

vii. Remaining emission kit will be supplied to DLW Varanasi for fitment on locomotive engine.

viii. Technical experts of equipment supplier shall be available, during the commissioning of the kits & testing of the engines, for troubleshooting of any technical problems.

ix. Statutory clearance related to emission kit, if required shall be taken by equipment supplier.



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6. Deliverables: Contractor will have to deliver the following:

i. Detailed project report w.r.t. emission level, SFC & BHP

ii. Drawings/ part no. along with detailed bill of materials (BOM) of relevant components which are part of kit.

iii. Details of modifications required for future up-gradation of locomotive 7. Condition:

i. Modification shall be done within existing envelope of EMD Loco.

ii. Up gradation of emission shall require minimal structural layout changes in

existing WDG4/WDP4 locos.

iii. Life of the kit items shall be equal or higher than the present components / assemblies.

iv. EPA Tier ‘0’ emission should be achieved on the existing EMD710 engines.

v. The supplier should submit the details of the emission kit alongwith test results of the kit w.r.t. emission level, SFC & BHP for approval of RDSO. After approval of RDSO, the supplier shall offer one loco set prototype kit for inspection at manufacturer’s premises.

vi. One prototype kit, duly inspected by RDSO, to be supplied to Engine Development Directorate, RDSO, Lucknow, which will be fitted and tested on engine test bed at Engine Development Directorate / RDSO.

vii. During the test the supplier shall optimize the emission kit and control settings to achieve EPA Tier ‘0’ emission level.

8. Inspection:

i. After approval of details & firm’s internal test results, the tenderer will offer one kit loco set prototype kit to RDSO, for inspection at manufacturer’s premises.

ii. After fitment of prototype kit, the performance of the locomotive shall be monitored for three months.

iii. On the basis of successful performance, clearance shall be given, after which the tenderer will offer inspection of balance quantity to RDSO.

9. Warranty:

The warranty shall be decided by production unit of Indian Railways as per standard IRS conditions.



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Annexure – I

Duty cycle for the purpose of comparison SFC

Notch Duty cycle of Locomotive

Idle 42.5

Coasting 18.5

1 5.8

2 4.0

3 3.5

4 3.3

5 3.3

6 3.8

7 3.3

8 8.5

DB 3.8

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