Specification for Revision · Specification Title: Micro Controller Based Governor (MCBG) for...

REVISION OF SPECIFICATION / STR

Item Name: Micro Controller Based Governor (MCBG) for application on ALCo/DLW/DMW 16 Cylinder 251 Series D-E locomotives

Specification No: MP-0-1700-01

1. RDSO is reviewing the specification/STR to cater to the latest technological developments in the field, modify clauses not

relevant in the present context and making them more enabling with focus on functional requirements.

2. It is requested that your comments / suggestions with regard to improvements /modifications in specification / STR of the abovementioned item may be submitted in the following format along with the justification for the changes required.

Part A: Basic Information

SN Particulars Information

1. Name

2. Designation

3. Professional Qualification

4. Organization / Firm‟s Name

5. Address for Correspondence

6. Contact No.

7. Email ID

8. Whether firm is registered with RDSO for the subject item. If yes, details like date of registration, current status etc. If no, firm’s experience in manufacturing of subject item or similar item

8. Whether any technical document/Report/Study to support suggested changes is available / enclosed for better appreciation

Part B: Comments / suggestions on the specification

SN Clause No. of

RDSO STR/ Spec Clause, as it exists in RDSO STR/ Spec

Clause , as it should read after incorporation of comments /suggestions in the RDSO Spec / STR

Justification for changes

Comments may be sent to following address within one month from the date of publication on rdso.indianrailways.gov.in

B P S Bhadoria, Joint Director/MP (EC), Mobile No.-9794863120, E-mail ID: [email protected], [email protected] Phone no. : 0522-2450020 Fax No. 0522-2453916

mailto:[email protected]

भा र त स र का र रे ऱ मं त्रा ऱ य

अनु सं धा न अ भिकल्ऩ और मानक संगठन

लखनऊ स्था पि त : 1 9 5 7

Government of India

Ministry of Railways

Research Designs & Standards

Organization

L U C K N O W

E S T T : 1 9 5 7

© RDSO 2020

ALCo/DLW/DMW 16 सिलेंडर 251 श्रृंखला डी-ई

इृंजन ृं के िाथ उपय ग के सलए माइक्र कृं ट्र लर आधाररत

गवननर (MCBG)

MICRO CONTROLLER BASED GOVERNOR

(MCBG) FOR APPLICATION ON ALCO/DLW/DMW 16 CYLINDER 251 SERIES

D-E LOCOMOTIVES

Specification Number MP.0.1700.01 Revision Number 5–final draft Date of Issue 05/10/2020

Brief Description

This document describes the requirements for the development of Microprocessor Based Control Governor for Diesel Electric Locomotives. The complete specification details the functional requirement of the unit, scope of supply and testing of the equipment ensuring reliability and fail-safe operation

FOREWORD

This specification covers the technical requirements and general features of MCBG for ALCO/DLW 16 cylinder 251 series diesel engine on new built or fitment on old locomotives.

DISCLAIMER

This specification is based on the studies and trials conducted by RDSO. Although every care is 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 omissions 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.

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.

ADDRESS FOR COMMUNICATION

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

http://www.rdso.indianrailways.gov.in/

Document No: MP.0.1700.01 Revision No: 05-Draft Date Issued:05/10/2020

Specification Title: Micro Controller Based Governor (MCBG) for application on ALCo/DLW/DMW 16 Cylinder 251 Series D-E locomotives

INDIAN RAILWAYS, RESEARCH DESIGNS & STANDARDS ORGANIZATION

Page 1 of 28

LIST OF AMENDMENTS

S. No.

Amendment Date

Revision Details

1. 1 August 2000 0 First issue

2. March 2002 1 Modification in clause: Clause 4.1 Air Manifold Pressure Bias Fuel Limiter Clause 4.3 Status Display of Engine Parameters Clause 6 Diagnostic and fault logging system Clause 7 Adjustment of various engine parameters Clause 8 Governor output shaft and linkage Addition of new clause: Clause 4.2.1 Mechanical and Electronic Engine Over Speed Trip-Test Facility Clause 9. General arrangement and scope of supply Clause 10. Mounting arrangement Clause 11. Connectors Clause 12. Cables and Clause 21. Training

3. March 2007 2 Modification in clause: Clause 4.3.2 Lube Oil Pressure (LOP) Transducer Clause 9. General arrangement and scope of supply Clause 10.2 Actuator unit Clause 11. Connectors Clause 12. Cables Clause 15.1.1 Environmental tests Clause 19. Literature and maintenance instructions Addition of Annexures: Annexure-1d Fuel limit curve-3300 HP Annexure-1e Fuel limit curve-3600 HP Annexure-3 Mounting arrangement of actuator unit

Document No: MP.0.1700.01 Revision No: 05-Draft Date Issued:05/10/2020



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S. No.

Amendment Date

Revision Details

4. January 2010 3 Modification in clause Clause 4.1 Speed Control Clause 8. Diagnostic and fault logging system Addition of new clause: Clause 5. Interface with MBCS Clause 20. Infrastructure Deletion of clause Clause 9. General arrangement and scope of supply Clause 19. Literature and maintenance instructions Clause 20. Governor testing and calibration facilities Clause 23. Quality assurance plan (QAP) Addition of Annexures: Annexure-3(i) & 3(ii) Annexure-4 Safety features Annexure-5 Display of Engine Parameters on Control unit

(Optional with non-MBCS locomotives) Annexure-6 Methodology for inspection and testing of MCBG Annexure-7 Infrastructure requirements for MCBG

manufacturers

5. April 2018 4 Addition of new clause 23 Title: Vendor Changes in approved status

6. October 2020 5 Annexure-6 Methodology for inspection and testing of MCBG updated. Test Protocol format for prototype test and routine test alongwith Acceptance criteria are incorporated in Annexure 6 of the specification.

Cl. 12. Make of connectors deleted.

Cl 17. Performance feedback format added in heading of Field Trial. RDSO Document no. MP-8.1-1 is referred for field trials Quantity and Quality.

Cl.18 Heading of Approval replaced with heading of Bulk Supply after MCBG becoming Annexure item (Items which can be procured through Open Tender) in Vendor directory.

Clause no. 23, reference of ISO document no. updated.

Clause 24 & 25 for IPR and Confidentiality has been incorporated.

Make in India Policy has been incorporated at Clause no. 26.

Document No: MP.0.1700.01 Revision No: 05-Draft Date Issued: 05/10/2020



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CONTENTS

Clause Description Page no.

1 Introduction 5

2 Scope of specification 5

3 Scope of supply 5

4 Basic functions 5

4.1 Speed Control 5

4.2 Load Control 6

5 Auxiliary features 6

5.1 Air Manifold Pressure Bias Fuel Limiter 6

6 Interface with MBCS 6

7 Safety features 6

8 Diagnostic and fault logging system 7

9 User settable engine parameters 7

9.1 Software 7

10 Governor output shaft and linkage 7

10.1 Stroke 7

10.2 Work Capacity 7

11 Mounting arrangement 7

11.1 Control unit 7

11.2 Actuator unit 8

11.3 Pressure sensor box 8

11.4 Numbering 8

12 Connection scheme 8

13 Cables 9

14 Power supply 9

15 Service conditions 9

16 Inspection and testing 9

17 Field trials 10

18 Approval 10

19 Warranty 10

20 Infrastructure 10

21 Training 11

22 Maintenance spares 11

23 Vendor changes in approved status 11

24 Undertaking by equipment manufacturer 11

25 Declaration of confidentiality of submitted documents by manufacturers

11

26 Preference to Make in India 12




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List of Annexures

Annexure no.

Description Page no.

Annexure-1 Fuel limit table for 3100 HP/3300 HP MCBG locomotives and optimum notch-wise fuel rack limit for 3100 HP/3300 HP MCBG Locomotives

13

Annexure-2 Layout of cutout for mounting controller unit in the short hood side wall of driver’s cab

14

Annexure-3 (i) & (ii)

Input & output cable details of MCBG 15-16

Annexure-4 Safety features 17

Annexure-5 Display of Engine Parameters on Control unit (Optional with non-MBCS locomotives)

18

Annexure-6 Methodology for inspection and testing of MCBG. 19-27

Annexure-7 Infrastructure requirements for MCBG manufacturers 28

Reference: MPTP-15 (PERFORMANCE TEST PROCEDURE AND ACCEPTANCE CRITERIA FOR MICRO CONTROLLER BASED GOVERNOR)




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1. INTRODUCTION:

The Function of the MCBG is notch wise speed control of the Engine and load control and provides other safety feature for satisfactory performance of Engine.

2. SCOPE OF SPECIFICATION:

This specification covers the technical requirements and general features of MCBG for ALCO/DLW 16 cylinder 251 series diesel engine on new built or fitment on old locomotives.

3. SCOPE OF SUPPLY:

i. Control unit, Actuator unit, Pressure sensor box along with mounting arrangement, matching connectors to cable connectors.

ii. Interconnecting cables with connectors as per Annexure-3(i) and 3(ii). iii. Engine Speed Sensor with mounting bracket and interconnecting cables with

connector (Optional). If MCBG is compatible with microprocessor based control system (MBCS), this item is not required.

4. BASIC FUNCTIONS: 4.1 Speed Control: MCBG shall maintain following speed of the engine.

TABLE-1

Notch Position

Wires Energised Engine Speed* (RPM)

free from

hunting with or without

Load

Remarks

3A 7C 12A 15A 1. Time for speed increase from IDLE to FULL shall be from 15 to 20 seconds. For intermediate notch, the time shall be in the same proportion.

2. MCBG shall shut down the engine if the speed increases beyond 1205 RPM. It shall be possible to slowly

SHUT-DOWN ON - - - 0 Low Idle ON - - ON 350

Idle/1 - - - - 400 2 - - - ON 450 3 - ON - - 550 4 - ON - ON 650 5 ON ON ON - 750 6 ON ON ON ON 850 7 - ON ON - 950




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8 - ON ON ON 1050 increase the engine speed above its rated speed for checking the setting of the over speed trip function of MCBG and of Mechanical OSTA.

Dropout voltage of relays if provided, at notch input signals should be within 15-18 Volts & pickup Voltage should be above 30 Volts. 4.2 Load Control: In case of fuel rack travel is in excess of the notch-wise rack

l im i ts given in Annexure-1, MCBG shall give LCP output voltage between 24.4-68.8 VDC.

Load control timing from 24.4 VDC to 68.8 VDC change shall be 8.5-11 sec.

Load control timing from 68.8 VDC to 24.4 VDC change shall be 25-30 sec. 4.3 Locomotive fitted with MBCS all analog (LCP) and digital signals including notch

signals shall be transferred through RS 485 port incase MCBG is integrated with digital communication with MBCS and accordingly cable requirement would get modified. This is with view to reduce complexity and improve reliability.

5. AUXILIARY FEATURES: 5.1 Air Manifold Pressure Bias Fuel Limiter: The MCBG shall limit the fuel rack if

BAP is below the values stipulated in the table given in Annexure-1. A switch shall be available on the front panel of MCBG to manually bypass this feature. However, in case of no BAP signal to MCBG, this feature shall be bypassed and MCBG shall give a message `fuel limit feature by passed' and the event shall get recorded in the error log.

6. INTERFACE WITH MBCS

Following data shall be transferred to MBCS through RS485 port. The communication shall be two way:

FOP, LOP, BAP when battery knife switch is ON, MCBG faults, Fuel rack travel; LCP position (hrs:minutes) and MCBG fault and status messages. MBCS shall also provide LOP data to MCBG. For this Railways shall facilitate between MCBG and MBCS manufacturers.

7. SAFETY FEATURES




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Provision shall be kept for the safety features in the MCBG being offered. Refer to Annexure-4.

8. DIAGNOSTIC AND FAULT LOGGING SYSTEM: 8.1 The MCBG offered shall include suitable fault diagnostic facility to carry out

troubleshooting and to assist maintenance personal in the rectification of the defect/ defects.

8.2 Suitable memory to register fault messages with date and time stamp and their

retrieval on a laptop shall be provided. A facility shall be provided to set the current date and time in the MCBG. It shall be possible to store MCBG faults in MBCS with date and time stamp.

9. USER SETTABLE ENGINE PARAMETERS:

A simple arrangement shall be provided in the software to change the following parameters on the locomotive. (i) Notch wise engine speed (ii) Notch wise minimum lube oil pressure for loco shut down. (iii) Maximum permissible fuel rack at each notch. (iv) Maximum permissible fuel rack in relation to boost air pressure (v) Over speed trip setting (vi) Governor response (vii) Load control timing from max to min. field position of LCP etc. & min. to max.

field position of LCP etc. These adjustments should be possible with a laptop personal computer running in windows environment. A provision shall be made to restrict accessibility to governor adjustments to avoid misuse.

9.1 Software: Necessary software for adjusting the user settable parameters of the

MCBG shall be provided. 10. GOVERNOR OUTPUT SHAFT AND LINKAGE: 10.1 Stroke: The governor output shaft travel shall be of a rotary or linear type and

the total rack travel in MCBG shall be 29 mm approx. 10.2 Work Capacity: The work capacity of the governor output shaft for actuation of

fuel control shaft shall be at least 16.3 Nm (12 ft lb). 11. MOUNTING ARRANGEMENT:




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11.1 Control unit: The dimensions of the control unit will not exceed 328mm x 485mm x225mm. Its weight shall not exceed 30 kg and shall be with matching connectors. Display of Engine Parameters on Control unit (Optional with non-MBCS locomotives): For details refer Annexure-5.

11.2 Actuator unit: The actuator unit shall be suitable for mounting on the existing

Woodward governor base fitted on the engine block. The dimensions of the actuator shall not exceed 269mm (frontal width) x 442mm x 508mm (height). Its weight shall not exceed 60 kg and shall be with matching connectors. These connectors shall be so located that they are easily accessible for inspection and maintenance.

11.3 Pressure sensor box: The dimensions of the pressure sensor box shall not

exceed 293mm x221mm x 63mm. Its weight shall not exceed 5kg and shall be with matching connectors. Boost air pressure (BAP), Fuel Oil Pressure (FOP) and Lube Oil Pressure (LOP) Transducers shall be as below:

Type Working range (kg/cm²) Max temperature encountered

BAP 0 to 3.5 120 ºC FOP 0 to 5 55 ºC LOP 0 to 10 125 ºC

11.4 Numbering: Each control unit, actuator unit and pressure sensor box shall contain

a number plate indicating (a) Serial number (b) Date of manufacturing (c) Name of manufacturer (d) Model number. The major subassemblies going into each unit should also be numbered and recorded with the supplier for future reference.

12. CONNECTION SCHEME: All the connectors at the cable ends shall have one to one connection.

From Control Panel to MCBG (MS3102R-20-29-P+GP)

From MBCS to MCBG for speed signal (MS3102R-12SP-10P+GP)

Connector Pin Loco wire number Connector Pin Loco wire number A 15A A ESS signal 1 B 12A B GND C 7C C 2-24VDC supply to MBCS (Optional) D 3A D ESS signal 2 E 43D F 29A G 50 H 4




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J (Optional with non-MBCS

locomotives)

31L

K (Optional with non-MBCS

locomotives)

31M

13. CABLES: 13.1 No. of cores/length: Refer Annexure 3(i) and 3(ii). 13.2 Specification:

1) Insulation grade: EE (1000VAC, RMS) 2) Inner insulation: PTFE 3) Outer insulation: FRLS (Fire retarded low smoke) 4) Inner conductors: Tin plated copper 5) Shield: Wire mesh with 85% coverage (min) 6) Wire size (no of strands in cores): 15(19/28) AWG (1.5 mm²) 7) No. of twists per meter per pair: 30 nos. min. 8) Capacitance between conductors in a pair: 20 pF per foot max. 9) Dielectric strength 2.5 KV AC, 50 Hz HV for 1 min. between cores, core and

shield and shield and outer insulation. 14 POWER SUPPLY:

The MCBG shall be suitable to work with power supply available on the locomotive as per details given below:

Battery Voltage: 64 to 50 V DC Regulated: 72 + 1V DC (Aux. Generator)

During cranking the engine battery voltage may drop to around 22 V DC for about 0.8 second.

15. SERVICE CONDITIONS:

The MCBG offered shall be capable of working satisfactorily in ambient temperature

up to 55⁰C (the air temperature inside the engine compartment may reach up to 70⁰C), relative humidity up to 95% and shall withstand, without damage, vibrations and shocks encountered in loco.

16. INSPECTION AND TESTING:




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Refer to Annexure-6. 17. FIELD TRIALS:

After successful completion of type tests, required nos. of the equipment shall be subjected to field trials for specified time period. The Quantity and Period for field trials shall be governed by RDSO Document no. MP-M-8.1-1. Feedback shall be furnished by User Railways as per prescribed format as follows: S. N.

Loco No./Type

MCBG make

Date of commissioning of MCBG

Date of failure (if failed)

Date of rectification (if failed)

Feedback/Remark incl. comments on issues related to actuator/control units etc., if any.

1.

2.

3.

During this period, the performance of governor shall be closely monitored and

evaluated by RDSO for:

Operational performance.

Reliability in service under actual environmental operating conditions.

Practical evaluation of maintainability/accessibility of components.

Modifications found necessary as a result of the tests and trials shall be carried out by the vendor at his own cost, after the relevant modifications have been approved by RDSO. The duration of field trials can be increased or curtailed at the discretion of RDSO.

18. BULK SUPPLY: Field trials clearance as applicable for new sources as per RDSO Document no.

MP-M-8.1-1 is prerequisite for bulk supply unless otherwise not specified. 19. WARRANTY:

The supplier shall provide a warranty for the satisfactory performance for a period of 4 years for the Actuator unit while for the Control unit this shall be two years from the date of commissioning.

20. INFRASTRUCTURE: The supplier shall have infrastructure as per Annexure-7.




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21. TRAINING:

The supplier of the MCBG shall impart necessary on-site training to the relevant railway personnel, about the assembly, installation, operation, maintenance, setting of user settable parameters and troubleshooting of the MCBG.

22. MAINTENANCE SPARES:

The supplier is also expected to supply, on cost basis, spares, tools, testing and calibration equipment, which will be required for maintenance and adjustments. The supplier shall ensure continuous availability of spares.

23. VENDOR CHANGES IN APPROVED STATUS:

All the provisions contained in RDSO’s ISO procedures laid down in document no. QO-D-8.1-11, Revision latest (titled: “Vendor changes in approved status”) and subsequent versions/amendments thereof, shall be binding and applicable on the successful vendor/ vendors in the contract floated by Railways to maintain quality of products supplied to Railways.

24. 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.

25. Declaration of confidentiality of submitted documents by manufacturers

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




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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.

26. Preference to Make in India

The Government of India policy on “Make in India” shall apply.

***********




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Annexure-1

FUEL LIMIT TABLE FOR 3100 HP/3300 HP MCBG LOCOMOTIVES:

BAP (kg/cm2

) Fuel rack limit setting (mm)

ABB turbochargers GE and Hispano turbochargers

0 20 20

0.2 23 22

0.4 25 24

0.6 27 26

0.8 28 27

1.0 29 28

1.2 30 29

1.4 32 31

1.6 Max. 32

1.8 Max. Max.

2.0 and above NA Max.

OPTIMUM NOTCH-WISE FUEL RACK LIMITS FOR 3100 HP/3300 HP MCBG LOCOMOTIVES:

Notch Fuel rack limit setting (mm)

1 17

2 19

3 21

4 26

5 28

6 30

7 Max.

8 Max.




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Annexure-2




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Annexure-4 SAFETY FEATURES 1. Low Lube Oil Pressure Shut-Down (LOPS):

A safety feature to protect the engine in the event of low lube oil pressure shall be provided to shut down the engine, whenever the lube oil pressure falls below the following stipulated limits:

Notch Engine low LOP settings (kg/cm2) Low Idle 1.1

Idle/1 1.1 2 1.5 3 1.8 4 2.2 5 2.6 6 3.0 7 3.5 8 4.0

It shall be possible to delay the operation of this device at each notch position. In the event of locomotive engine shutting down due to low lube oil pressure on affecting the low idle feature, the MCBG shall log the fault as “Shut down due to low idle failure”.

A time delay of 40-45 seconds shall be provided in low oil pressure shutdown system at idle/notch-1 speed steps to enable the engine driven lube oil pump to build up the requisite lube oil system pressure while starting the engine. It shall be possible to provide time delay facility at other notches as well. This time delay can be different for different notches. A manual button, which would have to be reset after an LOPS shutdown has occurred, must be provided.

2. Fail-safe Feature:

The MCBG shall be provided with fail-safe feature so as to cause shut-down of the diesel by pulling the fuel racks to “NO FUEL” position in case of malfunctioning of the governing equipment.




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Annexure-5




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Annexure-6

METHODOLOGY FOR INSPECTION AND TESTING OF MCBG

Inspection and testing of the equipment to be supplied by the supplier will be carried out in the following stages. The supplier will provide without any extra charge, the material equipment, tools and any other assistance which the purchaser or his nominee may consider necessary for any test and examination which he or his nominee shall require to conduct at the supplier’s premises and will pay all costs attendant to them.

A. Type Test Plan for Micro Controller Based Governor

(i) Following table summarizes the type test of the equipment/system as per IEC 60571(Latest) or its equivalent to BIS:

S. No Standard Test Name Test Location Test Result/Re

marks

1.

IEC 60571 - 12.2.2 or IS equivalent

Visual Inspection At firm’s premises/NABL Labs

Pass/Fail

2. IEC 60571- 12.2.10.2 or IS equivalent

Insulation Measurement Test

At firm’s premises/NABL Labs

Pass/Fail

3. IEC 60571 - 12.2.10.3 or IS equivalent

Voltage Withstand Test At firm’s premises/NABL Labs

Pass/Fail

4. IEC 60571 - 7.2.6 or IS equivalent

Reverse Polarity Test At firm’s premises/NABL Labs

Pass/Fail


Voltage Variation Test At firm’s premises/NABL Labs

Pass/Fail


Performance Test with Simulator


Pass/Fail


Damp Heat Test At firm’s premises/NABL Labs

Pass/Fail


Cooling Test At firm’s premises/NABL Labs

Pass/Fail


Dry Heat Test At firm’s premises/NABL Labs

Pass/Fail

10. IEC 60571-12.2.8.1 or

IS equivalent

Surge Voltage Test At firm’s premises/NABL Labs

Pass/Fail

11. IEC 60571 – 12.2.12 & IEC61373-Cat.1-Class-B or IS equivalent

Vibration and Shock Test


Pass/Fail


Transient Burst Susceptibility Test


Pass/Fail


Radio Frequency Susceptibility Test


Pass/Fail




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marks


Radio Frequency Emission Test

15. IEC 60571-12.2.11 or IS equivalent

Salt Mist Test At firm’s premises/NABL Labs

Pass/Fail


Water Tightness Test At firm’s premises/NABL Labs

Pass/Fail


Equipment Stress Screening Test


Pass/Fail


Low temperature storage test


Pass/Fail

1. Visual Inspection as per clause 12.2.2 of IEC 60571

a. Physical Dimensional Check

The Physical dimensions are to be measured and recorded as per the RDSO approved drawing.

b. Equipment Number plate verification:

Equipment number plate is to be verified.

c. Power ON check:

This check is to ensure that the system is working normal when the rated input voltage is connected to the system.

2. Insulation Measurement test as per clause 12.2.10.2 of IEC 60571

All the Input / Output pins of the unit are to be shorted together. All the Cards are removed from the respective enclosures.

The Insulation Resistance is to be measured with a 500V DC Megger between the body of unit and above pins.

The value should be >100 Mega ohm.

3. Voltage Withstand (Di-Electric) Test as per clause 12.2.10.3 of IEC 60571

All the Input / Output pins of the unit are to be shorted together.

A test voltage of 1000V ac is to be applied by gradually increasing the voltage amplitude to set limit and is to be maintained at that level for 1 min.

Observations

No disruptive discharge or flash over should occur. The system should work satisfactorily.

IR Test after Dielectric Test

Repeat the “Insulation Resistance Test” after the Dielectric test once again and record the Insulation Resistance Values. Values of insulation resistance should not be less than 100 M ohm.




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4. Reversal of Polarity as per clause 7.2.6 of IEC 60571

The equipment is to be connected with 72V DC in Reverse Polarity at the Power Supply input terminals and is to be kept in that condition for one minute.

The equipment is then to be connected with normal polarity of 72V DC and status LEDs are to be verified

Observations

There should be no damage to the equipment because of reverse polarity.

The equipment is to be working normally after reverse polarity test.

5. Effect of Voltage Variation Test as per clause 5.1.1.2 of IEC 60571

The equipment is to be connected to a variable DC source with normal polarity and the voltage is to be set to 50V DC, (0.7 times of the rated voltage 72V DC).

Status LEDs are to be verified.

Then the voltage is to be slowly increased and set at 90V DC (1.25 times of the rated voltage 72V DC).

Status LEDs are again to be verified

Finally the voltage is to be set to rated voltage of 72V DC.


There should be no damage to the equipment or malfunctioning because of voltage variations.

The equipment should work satisfactorily in all above conditions.

6. Performance Test as per clause 12.2.3 of IEC 60571

Performance test or functionality of the system as per clause 4 to clause 10 of this

specification is to be checked by RDSO on Simulator/test bed at the firm’s

premises.

7. Damp Heat test as per clause 12.2.6 of IEC 60571

Test to be carried out as per IEC 60068-2-30, Test db. With +55°C as upper temperature limit and 2 cycles of 24 hours.

The equipment is to be placed in the test chamber without powering ON.

A functional performance test is to be carried out at the beginning of second cycle.

After test is completed, equipment is to be allowed to recover to ambient conditions.

An Insulation Measurement and Di-electric Test is to be carried out.

Observations

There should be no damage to the equipment or malfunctioning because of Damp Heat.

The equipment is to work satisfactorily during Damp Heat Test.

The Insulation Resistance is to be measured and value should be >100 M Ohms.

There is to be no disruptive discharge or flash over in the Di-electric test.

8. Cooling start Test as per clause 12.2.4 of IEC 60571




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This test is to be carried out in accordance with IEC 60068-2-1

The equipment is to be placed in a cold chamber without any voltage applied condition.

The temperature is to be lowered from ambient to -0±2°C gradually.

Once the temperature in the chamber is stabilized at -0±2°C, the equipment is to be retained in the chamber about 2 hours at that temperature.

The equipment is to be then powered up after approx 5 to 10 minutes.

There should not be any damage to the equipment.


Observations:

There should be no damage to the equipment because of Cooling start test.

The equipment is to work satisfactorily.

9. Dry Heat test as per clause 12.2.5 of IEC 60571

This test is to be carried out in accordance with IEC60068-2-2,

The equipment is to be connected with 72V DC in normal polarity and placed in a hot chamber.

The temperature is to be raised from ambient to 70±2°C.

Equipment is to be kept in this condition for 6 hours, after stabilization of temperature.

There should not be any damages to the equipment after the test.

Observations:

There should be no damage to the equipment because of Dry Heat Test.

The equipment is to work satisfactorily after the test.

10. Surge Voltage test as per clause 12.2.8.1 of IEC 60571

The surge waveform shall be generated and tested using the generator and waveform as specified in IEC 62236-3-2:2008

Surge Voltage is to be applied at BP and BN pins of working equipment.

Status LEDs are to be verified after the test.

There should not be any damage to the equipment.

Observations:

There should be no damage observed to the equipment because of Surge Voltage Test.


11. Vibration, Shock and bump test as per clause 12.2.12 of IEC 60571

The complete cubicle with its mounting arrangements shall be subjected to the tests indicated in IEC 61373.




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There should not be any damages to the equipment after the test.

Observations:

There should be no damage to the equipment because of test.


12. Transient Burst Susceptibility test as per 12.2.8.3 of IEC 60571

Test voltage of 2KV, 5/50 nS, 5KHz as per IEC 62236-3-2:2008 is to be used for testing.

The test is to be carried out in working condition of equipment as per procedure of IEC 61000-4-4.

Observations:

13. There should be no damage to the equipment because of test.

14. The equipment is to work satisfactorily after the test.

15. Radio Frequency Interference Immunity test as per 12.2.9.1 of IEC 60571

Radiated Radio Frequency Interference test and performance with 10V/m (r.m.s) severity as per IEC IEC61000-4-6

The equipment is to be kept energized during the test.

Observations:

For conducted disturbances induced by radio frequencies fields, refer to IEC 62236-3-2:2008 (Table 7 and Table 8).

For radiated disturbances induced by radio frequencies fields, refer to IEC 62236-3-2:2008 (Table 9).

16. Radio Frequency Interference Emission test as per 12.2.9.2 of IEC 60571

Radio Frequency Interference emission test and performance as per IEC IEC62236-3-2:2008

The equipments is to be kept energized during the test.

The test shall be carried out at ETDC/NABL Lab.

Observations:

The equipment shall be tested to the requirements as specified in IEC 62236-3-2:2008 (Table 3, Table 4, Table 5, and Table 6). 17. Salt Mist Test as per IEC 60571-12.2.11

Salt solution

The solution for producing the salt mist shall be prepared by dissolving (50 ± 1) g sodium chloride (NaCl) analytical reagent quality, in distilled or demineralised water to make up(1 ± 0,02) l of final solution at 20 °C; if the pH does not lie between 6,5 and 7,2, the solution shall be rejected.

Test procedure

During the test, the temperature in the test chamber shall be maintained at (35 ± 2) °C.




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The solution and the air used to produce the salt mist shall have a temperature equal to that of the test chamber.

The equipment should be tested in the manner in which they are expected to be used, i.e. protective covers should be in position and the equipment arranged, as nearly as possible, in the position it would occupy in actual use.

The test chamber shall be kept closed and spraying of the salt solution shall continue without interruption during the whole conditioning period.

The period shall be:

– for class ST2: 16 h;

At the end of the test, the equipment shall be washed in running tap water for 5 min, rinsed in distilled or demineralised water, then dried to remove droplets of water and stored under standard atmospheric conditions of the testing area for not less than 1 h, no more than 2 h.

After that, the equipment is to be subjected to a visual examination.

Observations:

There should be no major damage

A performance check shall not show any failure or damage nor any results which are beyond the specified tolerances.

18. Water tightness test as per IEC 60571-12.2.13

As electronic equipment is generally mounted either inside the body of the vehicle or in boxes outside, there is no need to carry out water tightness tests, apart from exceptional cases which is to be defined between user and manufacturer.

19. Equipment stress screening test as per IEC 60571-12.2.14

A screening procedure to be applied to completed equipment or a part of it, for the purpose of eliminating dormant manufacturing or component defects.

Burn-in test




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After mounting of components, the populated PCB cards kept in proper chassis in energized condition shall be burnt in for minimum 45 hrs at +70 deg. C and - 25 deg C as per the cycle at figure above, wherever specified in the main specification. The PCBs will be tested for functionality to the extent possible during the burn-in test. This will be mutually decided. 20. Low temperature storage test as per IEC 60571-12.2.15

This test shall be in accordance with IEC 60068-2-1.

The temperature value for the test shall be –40 °C and the time period shall be 16 h minimum.

After recovery, a performance check shall be carried out at ambient temperature.

Observations:

No damage shall occur,

The functional check should not show any failure or any results beyond the specified tolerances.

(ii) Functional test:

These tests will be carried out under simulated conditions at supplier’s premises to establish that the governor is functioning as per the specification. The detailed functional test plan may vary from vendor to vendor based on their design. Hence, vendor shall submit the detailed functional test plan as per their design meeting the functional requirement of the specification for approval by RDSO before prototype test. RDSO Document no. MP-TP-15 may be referred for guidance. On satisfactory completion of environmental and functional tests, the prototypes will be subjected to Loco Validation tests.

(iii) Loco Validation test

After successful prototype test as given above, the prototype shall be subjected to loco validation test which includes load box test, checking of functional test, Route run trials, MU




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Test, etc. Functional test of the MCBG should be carried out to verify the functional requirements of the specification stated at Clause 4 to 10. The detailed functional test plan may vary from vendor to vendor based on their design. Hence, vendor shall submit the detailed functional test plan as per their design meeting the functional requirement of the specification for approval by RDSO before prototype test. Loco validation test will consist of following:

The maximum instantaneous variation in engine speed expressed as percentage of rated speed, after sudden variation of load from the rated value to zero must not exceed 10% of the rated speed.

Possible faults will be created to test the fail safe features of the governor (to be listed out by the supplier and got approved by RDSO).

On satisfactory completion of the performance tests, the MCBG will be cleared by the inspecting authority for field trials. B. Acceptance Test Plan

This test is to be conducted for the system other than prototype for purchase inspection. This is the subset of type test mentioned above. Following test is required to be conducted for Acceptance test plan. The sampling plan as per IS: 2500, Pt.I, General Inspection Level-II should be adopted for selecting the samples against the lot and determining the acceptance/rejection of lot based on Acceptance test result.


marks


Visual Inspection At firm’s premises/NABL Labs

Pass/Fail


Insulation Measurement Test


Pass/Fail


Voltage Withstand Test At firm’s premises/NABL Labs

Pass/Fail


Reverse Polarity Test At firm’s premises/NABL Labs

Pass/Fail


Voltage Variation Test At firm’s premises/NABL Labs

Pass/Fail


Performance Test with Simulator


Pass/Fail

Note: The Test plan given above is the minimum requirement and strictly governed by IEC 60571. The latest edition of IEC 60571 shall apply mutatis mutandis to this Test plan. The test other than above as specified may also be considered with mutual agreement between vendor and Vendor approving authority, if desired so.

.

Acceptance Criteria for functional test

Ability to maintain desired engine speed at each notch within specified tolerance of ± 3rpm with or without load. Yes/No




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Ability to maintain desired engine speed without speed fluctuations i.e. free from hunting at each notch with or without load. Yes/No

Ability to maintain constant engine power output at each notch. Yes/No

Ability to actuate the fuel control mechanism for rack movement in either direction to regulate fuel supply. Yes/No

Ability to maintain temporary speed change within 10% of the rated speed after sudden removal of rated load. Yes/No

Ability to regulate fuel supply as a function of air manifold pressure (i.e, proper functioning of air manifold pressure bias fuel limiting feature) for optimum combustion. This will be judged from the opacity/colour of the exhaust smoke during rapid notching up of engine speed at the time of load box testing. Yes/No

Proper functioning of safety devices. Yes/No Note : Functional tests will be carried out under simulated conditions at supplier’s premises to establish that the governor is functioning as per the specification. The detailed functional test plan may vary from vendor to vendor based on their design. Hence, vendor shall submit the detailed functional test plan as per their design meeting the functional requirement of the specification for approval by RDSO. RDSO Document no. MP-TP-15 may be referred for guidance.




Page 28 of 28

Annexure-7

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GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

PERFORMANCE TEST PROCEDURE AND ACCEPTANCE CRITERIA

FOR MICRO CONTROLLER BASED GOVERNOR ( WDM2, WDM2C, WDG2, WDP2 )

No. MP. TP-15

SEPTEMBER 2000 (REVISION- 0.00)

.

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RESEARCH DESIGNS & STANDARDS ORGANISATION MANAK NAGAR, LUCKNOW-226 011

PERFORMANCE TEST PROCEDURE FOR MICROCONTROLLER BASED GOVERNOR

The performance of the microcontroller based governor shall be checked at DLW/DCW in two stages (i) Engine test stage (ii) Loco test stage. I. ENGINE TEST STAGE: To ascertain and evaluate the performance of the micro controller based governor, various parameters shall be checked and recorded as under: 1. Dry Run Test :

Rack travel: ----------------- mm

2. Cranking Test:

Time for starting the engine from stationary condition to idle rpm: ------------------ sec

Max. rack travel during cranking: ----------------- mm

3. Normal shutdown Test: Shuts down/not 4. Notch Speed /Stability (No load):

Engine rpm Nominal Actual

Hunting + rpm

Rack LCR Notch

WDM2 WDM2C WDG2 WDP2

IDLE 350 350 1 350 350 2 443 450 3 536 550 4 629 650 5 722 750 6 815 850 7 908 950 8 1000 1050

5. Over Speed Trip Test:

(i) Over speed trip setting of mechanical device

WDM2 (Nominal 1130+20rpm. Aim at 1130 rpm)

WDM2C/WDG2/WDP2 (Nominal 1180 + 20rpm. Aim at 1180 rpm) ------------------ rpm

(ii) Over speed trip setting of built in feature of the micro

1 controller based governor

(10 rpm below mechanical OST setting) -------------------rpm

Note : For testing the over speed trip setting, there shall be provision for freezing the maximum rpm attained during the test on the digital display unit of the governor

6. Engine Performance Test (Load test): Ambient temperature: _________°C

Engine rpm

Nominal Actual

Hunt ing

+ rpm

Rack LCR LOP BAP Water temp.

Vx I GHP Notch

WDM2

WDM2C WDG2 WDP2

IDLE 350 350 1 350 350 2 443 450 3 536 550 4 629 650 5 722 750 6 815 850 7 908 950 8 1000 1050

7. Lube oil pressure during sudden notching down from full load to idle with water at 90 °C:

Min. pressure ---------------kg/cm² Min. engine rpm -----------------rpm Stabilised pressure --------------kg/cm²

8. Exhaust Appearance:

During rapid notching up: Clear/Hazy/Black 9. Temporary speed change test:

The maximum instantaneous variation in engine speed expressed as percentage of rated speed, after sudden variation of load from the rated value to zero:

Max. Speed - Rated speed

Temporary speed change = ------------------------------------ x 100 Rated speed

In order to measure the temporary speed change of engine under the control the governor, the variation of speed after sudden removal of rated load is measured, the engine having previously attained steady operating condition. At rated speed and for the sudden removal of the rated load this temporary speed change must not exceed 10% of the rated speed.

Temporary speed change: --------------rpm

----------------%

2

10. Fail Safe Features test:

Possible faults will be created to test the fail safe features of the governor (to be listed out by the supplier and got approved by RDSO).

11. Specific Fuel Consumption (SFC): --------------gm/GHP hr II. LOCO TEST STAGE: At loco test stage also, all the above parameters with the exception of sfc shall be measured and recorded as under: 1. Dry Run Test:

Rack travel: --------------mm 2. Cranking Test:

Time for starting the engine from stationary condition to idle rpm: --------------sec

Max rack travel during cranking -------------mm 3. Shutdown Test:

(i) With STOP push button: Shuts down/not

(ii)With MUSD switch: Shuts down/not 4. Notch Speed/Stability:

Engine rpm Nominal Actual

Hunting + rpm

Rack LCR Notch

WDM2 WDM2C WDG2 WDP2

IDLE 350 350 1 350 350 2 443 450 3 536 550 4 629 650 5 722 750 6 815 850 7 908 950 8 1000 1050

5. Over Speed Trip Test:

(i) Over speed trip setting of mechanical device

3

WDM2 (Nominal 1130+20rpm. Aim at 1130 rpm)

WDM2C/WDG2/WDP2 (Nominal 1180 + 20rpm. Aim at 1180 rpm) ------------------ rpm

(ii) Over speed trip setting of built in feature of the micro

controller based governor (10 rpm below mechanical OST setting) -------------------rpm

(iii)Check operation of reset switch for OST. ok/not

Note : For testing the over speed trip setting, there shall be provision for freezing the maximum

rpm attained during the test on the digital display unit of the governor. 6. Governor Response:

Check time taken for speed adjustment from: (i) Idle to Full speed

(Nominal 15-20 sec) -----------------sec

(ii) Full to Idle speed (Nominal 8-12 Sec) -----------------sec 7. Load Control Rheostat (LCR): 7.1 LCR operation: Operate the engine at 8th notch with full load, and full rack stop nut adjusted to

hold the rack position around 21-22 mm. The LCR must operate to reduce excitation. LCR Operates/not 7.2 Check load control timing from:

(i) Max. to min. field position: (Nominal 8.5-11 sec) ------------------sec

(ii) Min. to max. Field position: (Nominal.25-30 sec) ------------------sec

8. Engine Performance Test :

Ambient temperature:---------------º C

Notch Engine rpm Hunt Rack LCR LOP BAP Water Vx I GHP

4

Nominal Actual ing +

rpm

temp.

WDM2 WDM2CWDG2 WDP2

IDLE 350 350 1 350 350 2 443 450 3 536 550 4 629 650 5 722 750 6 815 850 7 908 950 8 1000 1050

9. Lube oil pressure during sudden notching down from full load to idle with water at 90 º C: Min. pressure -------------kg/cm2

Min. engine rpm ----------------rpm Stabilised pressure -------------kg/cm2

10. Exhaust Appearance: During rapid notching up: Clear / Hazy / Black 11. Dynamic Braking Test :

(i) With ECS at “run”, throttle at “idle” and reverser handle in “forward” or “reverse” position, movement of selector handle to big “B” position should raise the engine speed to 4th notch rpm.

Confirm: Yes / No

(ii) Engine should shutdown through stop push button both in motoring or in dynamic braking

modes.

Confirm: Yes / No

12. Temporary Speed Change Test:

The maximum instantaneous variation in engine speed expressed as percentage of rated speed, after sudden variation of load from the rated value to zero:

Max. Speed - Rated speed

Temporary speed change = ------------------------------------ x 100 Rated speed

5

Temporary speed change: ----------------rpm ------------------% 13. Safety Devices Operation Test: Test operation of the safely devices provided on the locomotive shall be checked at loco test

stage as under:

(i) Low water alarm (LWA) switch : Actuation of LWA switch should cause shut down of the engine. Confirm: Yes / No

(ii) Ground Relay: Manual actuation of ground relay (GR) should cause power cut off and bring the engine to

idle. Confirm: Yes / No (iii) Hot Engine Alarm: Actuation of this device should bring the engine to idle speed . Confirm: Yes / No (iv) Low Oil Pressure Shutdown Settings:

(To be checked if feasible)

Actuation of this feature should cause engine shutdown in case the lube oil pressure falls below the specified limits.

Function of this device will be checked in the following manner :

During notch up-

Notch LOPS setting Time delay in loco shut down Idle/1 1.1-1.3 kg/cm2 40-45 sec

Idle/1 to notch X

Proportionate value at notch X

10 sec + time taken by the reference speed to reach

notch X rpm

During notch down:

Notch LOPS setting Time delay in loco shut down

Idle/1 1.1-1.3 kg/cm2 40-45 sec Idle/1 to notch

X Proportionate value at

notch X Instantaneous

LOPS values will be as follows:

6

LOPS value (kg/cm2 ) Loco type Idle/Notch 1 Notch 8

WDM2 1.1-1.3 1.1-1.3 WDM22C/WDG2/WDP2 3.9-4.1 4.1-4.4

Check operation of LOPS reset button: Working/not 14. Fail Safe Feature Test : Possible faults shall be created to test the fail safe feature of the governor (to be listed out by

the supplier and got approved by RDSO). 15. Multiple Unit (MU) Operation Test :

Multiple unit operation test shall be carried out as per procedure listed below:

(i) Couple one WDM2/WDG2/WDP2 locomotive having GE or WW or micro controller based governor in MU with the locomotive equipped with micro controller based governor .

(ii) Crank and start both the locomotive engines one by one. (iii) Check notch wise engine rpm of both the locomotives by ascending and descending of

throttle notch positions. (iv) Check for dynamic braking setup of both the locomotives. It should be able to give response

simultaneously. (v) Check MU stop operation : while the engines of the locomotives under MU test are running

at any notch, operate the MUSD switch on the control stand. Both the engines should shutdown.

III. ACCEPTANCE CRITERIA: 1. Ability to maintain desired engine speed at each notch within specified tolerance of +3 rpm with

or without load. 2. Ability to maintain desired engine speed without speed fluctuations i.e. free from hunting at each

notch with and without load. 3. Ability to maintain constant engine power output at each notch. 4. Ability to actuate the fuel control mechanism for rack movement in either direction to regulate

fuel supply. 5.Ability to maintain temporary speed change within 10% of the rated speed after sudden removal

of rated load. 6. Ability to regulate fuel supply as a function of air manifold pressure (i.e. proper functioning of

air manifold pressure bias fuel limiting feature) for optimum combustion. This will be judged from the opacity/colour of the exhaust smoke during rapid notching up of engine speed at the time of load box testing.

7. Suitability to work in Multiple Unit (MU) operation with locos provided with either same /similar or Woodward or GE/EDC type or micro controller based governors.

8. Proper functioning of safety devices. -----------------

7

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