GOVERNMENT OF INDIA MINISTRY OF RAILWAYS … by Checked by JE/DESIGN/RDSO DSE/TPL/RDSO Draft for...

Prepared by Checked by

JE/DESIGN/RDSO

DSE/TPL/RDSO

Draft for internal use of RDSO

GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

DRAFT

SPECIFICATION FOR DEVELOPMENT

OF SINGLE PHASE TO THREE PHASE

HOTEL LOAD CONVERTER

FOR WAP4 LOCOMOTIVE

Specification No:RDSO/2011/EL/SPEC/0109_Ver’0’

Issued on: 31.05.11

Issued by:

ELECTRICAL DIRECTORATE

RESEARCH DESIGNS AND STANDARDS ORGANISATION

MANAK NAGAR LUCKNOW-226011

Page 2 of 34 Issued on - 31.05.11 RDSO/2011/EL/SPEC/0109_Ver’0’


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S.N. Date of Revision Page No. Revision Reasons for Revision

1. 2.

3. 4.



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Contents

Abbreviations PAGE -

Definitions and Interpretations PAGE -

CHAPTER 1 General Description PAGE -

CHAPTER 2 Operating and Environmental Conditions PAGE -

CHAPTER 3 Technical Requirements PAGE -

CHAPTER 4 Scope of Supply PAGE -

CHAPTER 5 Tests PAGE -

Annex-1 Transformer details PAGE -

Annex-2 Hotel load details PAGE -

Annex-3 Loco circuit PAGE -

Annex-4 Space envelops PAGE -

Annex-5 Burn-in test



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Abbreviations

The following abbreviations are used in this Specification:

Abbreviation Full Name

AC Alternating Current

BOM Bill Of Material

CFD Computational Fluid Dynamics

CLW Chitranjan Locomotive Works

DA Diesel Alternator

DC Direct Current

ELS Electric Loco Shed

EOG End On Generation

HOG Head On Generation

IR Indian Railways

OHE Over Head Equipment

OEM Original Equipment Manufacturer

RDSO Research Design and Standards Organisation



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Definitions and Interpretations

Terms or words not defined in this Specification shall be governed by the definitions contained in the standards applicable. In this Specification, the following words and expressions shall, unless repugnant to the context or meaning thereof, have the meaning hereinafter respectively assigned to them:

Term Definition

BLHO Shall mean switch at driver’s desk to operate hotel load converter;

Hotel Load shall mean electrical loads of coaches of a train such as lights, fans and air conditioning, pantry etc. as detailed in Annex-2;

Design Concept shall have the meaning set forth in Clause 1.5.1;

Design Package shall have the meaning set forth in Clause 1.5.2;

Inspecting Officer

shall mean the person, firm or department nominated to inspect the hotel load converters or the representative of the inspecting officer so nominated;

LHB shall mean coaches manufactured in accordance with design of Linke Hossman Busch.

Purchaser shall mean the President of the Republic of India as represented by the IR organisation entering into the contract;

Supplier shall mean the firm or company with whom the order for supply of the hotel load converter(s) WAP4 locomotive has been placed; and

Tenderer shall mean firm or company participating in the tender for supply of hotel load converter for WAP4 locomotive.



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Chapter 1

General Description

1.1 Introduction

1.1.1 IR is manufacturing tap changer based WAP4 locomotives which are utilized for passenger train

operations. These locomotives take power from OHE through pantograph to traction transformer.

This traction transformer is provided with a hotel load winding to cater for the power supply to

coaches (also referred to as Hotel Load). The capacity of this winding is 1000 kVA, which gives

750 volt single phase at 50 Hz at 22.5 kV supply voltage with rated maximum current of 1333 A.

The details of transformer are provided in Annex-1.

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

electronics, control system and power supply systems, IR has decided to adopt an energy efficient

power supply system for feeding to the coaches referred to as HOG for Rajdhani/Shatabdi trains,

presently having EOG system. LHB type of coaches are best suited for adoption of HOG scheme

as the rake integrity with these coaches is expected to be maintained due to the specific design of

their inter vehicle mechanical coupling.

In EOG system the Hotel Load in the coaches of Rajdhani and Shatabdi express trains are fed

from the power cars placed at either ends of the rake. Each power car is installed with 2 DA sets

generating 3-phase power supply at 750 Volts 50 Hz and the same is transmitted to entire rake

through two cable feeders, running through the whole length of the train. This electric power

supply is tapped at each coach through a 50 kVA transformer in Conventional Coaches and 60

kVA transformers in LHB coaches and is converted to 415 Volts for feeding the equipment

working at this voltage and further transformed down to 110 Volts AC single phase for feeding the

equipment working at that voltage. Since the power cars are placed at either end of the rake, the

system is termed as EOG.

1.1.2 In HOG scheme power is fed from the electric locomotive to the train to cater for the Hotel Load

of the train. In WAP4 locomotives, power is taken from the OHE through pantograph to traction

transformer of the locomotive which is provided with a hotel load winding of 1000 kVA, at

nominal voltage of 750 V single-phase, which varies with the OHE voltage variations. This 750

Volts single-phase supply will be fed to hotel load converter, which shall give 750 Volts 3-phase

50 Hz supply as output, for feeding the Hotel Load of the train. Converter output will further be

stepped downed to 415 V, 3-phase AC by existing transformers provided in every coach. This

electrical power will be used to operate the lights, fans, air conditioning, water raising apparatus of

the coaches and the pantry car equipment.

1.2 Scope and Object

This Specification covers the technical aspect of the IR’s requirement for the IGBT based hotel

load converters for the WAP4 locomotives, to cater for the Hotel Load. It explains the interface



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requirement of the converter with the locomotive, and lays down the desired performance and

testing methodology.

1.3 Supplier’s Responsibility

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

1.3.1 The Supplier shall supply the hotel load converter conforming to the various operational and

functional requirements specified in this Specification. The Supplier shall supply detailed

instructions for proper installation of the converter in the WAP4 locomotive. For this purpose the

Supplier shall also depute his representative during installation of the first set of hotel load

converter in the WAP4 locomotive at CLW.

1.3.2 The Supplier shall suggest and carry out all the modifications/re-organizing of the equipment

required for providing the hotel load converter on the WAP4 locomotive in association with

CLW/ELS for the first set of hotel load converter which shall be subsequently done by CLW in

regular production. The Supplier shall submit the drawings for all the changes required to be

carried out as part of Design Package.

1.3.3 The Supplier shall also be responsible for interfacing the hotel load converter with power car.

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

1.3.5 The Supplier shall be responsible for supply of special tools, testing jigs, portable

diagnostic/troubleshooting tools preloaded with suitable latest operating system and application software and instruments, which may be required for troubleshooting and maintenance of the hotel load converter.

1.3.6 The Supplier shall be responsible for supply of a suitable software “if applicable” for off-line analysis of diagnostic data downloaded from the hotel load converter.

1.4 Training

The Supplier shall arrange for training of IR personnel on the following subjects at OEM’s work

place under the guidance of OEM’s engineers:

• Assemble, testing, commissioning of hotel load converter;

• maintenance, repair and troubleshooting of the hotel load converter; and

• fault diagnostic analysis and software parameter setting.

Five days training for six persons at CLW and in any ELS shall be organised by the Supplier.

1.5 Documentation and Design Approval



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1.5.1 The Tenderer shall submit, including but not limited to following along with the offer for evaluation, as part of Design Concept:

a) Schematic Circuit;

b) functional description;

c) system design concept;

d) protection concepts;

e) communication protocol and software structure description along with the interface with the locomotive control system;

f) cooling design;

g) mechanical interface diagram and compliance to existing mechanics;

h) clause by clause compliance;

i) calculation and simulation results of system behavior;

j) credentials with details of supply made of such items;

k) data sheets for devices and other equipment proposed along with detailed description of supply proposed;

l) salient features and advantages of the offered system;

m) details of technical support and training offered;

n) recommended list of spares for 5-year maintenance after warranty along with full drawing/design and details of OEM;

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

p) logistics proposed for warranty support within India;

q) declaration for long-term support by the Tenderer;

r) guaranteed values of efficiency of devices/subassemblies and assemblies;

s) calculation to withstand short circuit current under fault conditions;

t) details of short time rating of the converter;

u) expected efficiency with respect to load along with calculations; and

v) IRIS/ISO 9000 certification.

1.5.2 The Supplier shall submit, including but not limited to the following, as part of Design Package to

RDSO for approval, before commencing manufacturing. Only on getting the approval from RDSO

in writing shall the production begin.

a) Technical documentation explaining the complete scheme, characteristics, diagnostics, protection and control etc. including electric schematic circuits;

b) Interfacing and control scheme of hotel load converter with power car;

c) detailed drawings of each system/sub-system with interface details;

d) design calculations for selection of devices, cooling systems and various subsystems, establishing the adequacy of the components selected;



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e) details of output contactor and output filter;

f) complete BOM / technical specification of components with source of supply;

g) cooling system design description, data and cooling fluid data;

h) mechanical drawings, mounting arrangement, weight, details of mounting accessories;

i) procedure for parameter alteration, software downloading, diagnostic uploading, analysis etc.;

j) schedule maintenance activities with periodicity;

k) maintenance, trouble shooting and repair manual in English language only in soft form and hard copy;

l) all calculations evaluated on the basis of software simulations shall be supported by sample calculations; and

m) details of tools and plants with design/drawings and name of probable suppliers.

Approval of design means approval of general design features. Notwithstanding the approval, the

Supplier shall wholly and completely be responsible for the performance of the hotel load

converter.

For the purpose of technical decisions on improvement / modifications etc. on the hotel load

converter, RDSO shall be the final authority from Purchaser’s side.

1.6 IR’s Responsibility

IR shall be responsible for followings:

a) The cabling required in the WAP4 locomotive; b) the cable for connecting volt free contacts to control and diagnostic system of the WAP4

locomotive;

c) any equipment re-layout and mounting platform on the locomotive necessary for installation of hotel load converter shall be done by IR in association with the Supplier;

d) labour, consumables and electricity required for erection, testing and commissioning of

hotel load converter; and e) the wages and allowances as well as the cost of the travel to and from the place of training

for IR personnel.

1.7 Infringement of Patent Rights

The Supplier shall submit a signed undertaking to IR in the following format as part of Design

Concept and while entering the contract:

“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 and development of

hotel load converter 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 Supplier”.



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1.8 Reference to various Standards

1.8.1 This Specification is based on the following normative references:

Standards Title

IEC 60077-1 Railway applications – Rolling Stock General Rules

IEC 61287-1 Railway applications – Power converters installed on rolling stock

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

IEC 61373 Railway applications – Rolling stock equipment – shock and vibration test

IEC 60310 Traction transformers and inductors on board rolling stock

EN 50121-3-2

(CENELEC)

Railway applications – Electromagnetic compatibility

Part 3-2: Rolling stock - Apparatus

EN 50121-2

(CENELEC)

Railway applications – Electromagnetic compatibility

Part 2 : Emission of the whole railway system to the outside world.

EN 50153 Railway applications – Rolling stock – Protective actions against electrical hazards

EN 60529 Protection classes of cases (IP-Code)

EN 50126/ IEC 62278

RAMS

EN 50238

EN 50264

Table 1 - Standards

1.8.2 The latest version of the aforesaid standards, which have been published at least 60 (sixty) days before the last date of bid submission shall be considered applicable.

1.8.3 Where the aforesaid standards are based on ambient and environmental conditions which are less onerous than those stated in this Specification, the conditions stated in this Specification shall be applied in the design and testing of the hotel load converter and sub-systems; and the requirements of the aforesaid standards shall be adjusted accordingly.

1.8.4 Alternative Standards

The requirements listed in this Specification are the minimum. The Supplier may adopt alternative internationally recognised codes, standards and specifications if it can demonstrate to the Purchaser that such alternative is superior or more pertinent to the hotel load converter than the standards specified in this Specification. The Supplier shall seek the prior approval of the RDSO for any alternate standards proposed to be used.

1.9 Reliability, Availability, Maintainability and Safety (RAMS)

1.9.1 General



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The Supplier shall design the hotel load converter to ensure high degree of reliability, availability and high degree of safety in order to provide a dependable service. The optimization of the system with respect to reliability, availability, maintainability and safety shall form an integral element of this Specification.

The plan for reliability, availability, maintainability and safety shall conform to EN 50126/ IEC 62278. Reliability of electronic components shall conform to IEC 61709.

1.9.2 The Supplier shall develop RAMS targets both for the hotel load converter and for the major sub-systems such as rectifier module, DC link, inverter module, contactors, control electronics etc., such that it shall provide a high level of dependability. The RAMS targets shall be defined in Design Package.

1.9.3 The Company shall establish and operate a detailed reliability, availability, maintainability and safety (RAMS) assessment system in support of the design, manufacture and subsequent testing, commissioning, operation and maintenance of the hotel load converter.



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Chapter 2

Operating and Environmental Conditions

2.1 Power supply system

The power supply system adopted is 25 kV, 50 Hz single phase AC with following features:

Nominal supply voltage 22.5 kV (rms), 50 Hz, single phase, AC

Normal variation in supply voltage 19 kV to 27.5 kV (rms)

Occasional maximum voltage 31 kV (rms)

Occasional minimum voltage 16.5 kV (rms)

Normal variation in frequency ± 8% (46 to 54 Hz)

Types of Neutral sections (i) 41 m in length having insulated over lap on both end and neutral wire in between which is not earthed; and

(ii) Short neutral sections of approximately 4.61 m and 9.6 m length having an insulated portion (of PTFE) on both sides and middle portion of neutral section which is solidly earthed.

There shall be power interruptions at neutral sections varying from 12 seconds to 20 seconds..

Pantograph bounce Up to 45 ms

Table 2 – Power supply system

Note: The occasional maximum and occasional minimum voltage may persist for 15 minutes.

2.2 Climatic and Environmental Conditions

The climatic and environmental conditions prevailing in India are the following:

� Atmospheric temperature

Maximum temperature: 50 degree Celsius

Maximum touch temperature of metallic surface under the Sun: 75 degree Celsius and in shade: 55 degree celsius

Minimum temperature: - 10 degree celsius ( Also snow



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fall in certain areas during winter season)

� Solar radiation 1 kW/m2

� Humidity 100% saturation during rainy season

� Altitude 160 m above mean sea level

� Rain fall Very heavy in certain areas.

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

� Coastal area humid and salt laden atmosphere with maximum pH value of 8.5, sulphate of 7 mg per liter, maximum concentration of chlorine 6 mg per liters and maximum conductivity of 130 micro siemens / cm

� Vibration The vibration and shock levels recorded on various sub-systems in existing locomotives of IR are generally more than the limits given in IEC 61373.

� Electromagnetic pollution

High degree of electromagnetic pollution is anticipated in WAP4 locomotive machine room, where the hotel load converter shall be mounted.

Table 3 – Climatic and environmental conditions

2.3 EMC

2.3.1 The hotel load converter shall comply with the EN 50121 series of Railway Electromagnetic

Compatibility standards and EN 50238.

2.3.2 The Supplier shall prepare, implement and maintain an EMC management plan in accordance with

the standards referenced in Clause 2.3.1 of this Specification. The EMC management plan shall be

defined in Design Package.



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Chapter 3

Technical Requirements

3.1 The hotel load converter shall be completely IGBT based. The control shall be microprocessor/microcontroller based having diagnostic features.

3.2 Power quality of the hotel load converter output at any load from 0% to 100% shall be as under:

� Output Voltage phase to phase :750V ± 5%, 3Ø sine wave AC

� Output voltage between phase to earth of feeder : less than 1.0 kV

� Rated output power :375 kVA at unity power factor for all supply voltage variations in accordance with clause 2.1 of this Specification

� Output Frequency : 50Hz ± 2%

� Short time current overload rating : 125% for 20 sec.

� Total harmonic distortion (THD) : Less than 10% in output voltage

� Voltage unbalance : Less than 1 %

� Expected current unbalance in load current : Up to 15% of rated output current

� Current harmonics at full load : Less than 5% up to 20th harmonic up to 1000 kHz

� Input power factor :Shall be close to unity at full load with normal input parameters

� Efficiency at full load :Not less than 96% at rated input voltage

� Direct on load starting of converter :Minimum 150 A (steady state current) of induction motor load

3.3 Two such hotel load converters shall be provided in one WAP4 locomotive.

3.4 It shall not be possible to regulate the duty cycle of the loads.

3.5 The variation of hotel load power from the transformer with supply voltage is given in Annex-1.

3.6 Approximate total Hotel Load to be attached with the converter is given in Annex-2.

3.7 The operation of the hotel load converter shall be done by the loco pilot (driver) by pressing spring loaded BLHO switch provided on the driver’s desk. The circuit from transformer winding to the input of hotel load converter is shown in Annex-3. The BLHO switch, current sensor and earth fault protection system shall be interfaced with input contactor..

3.8 If any information is required to be shared with the power car for better operation of the hotel load converter the complete arrangement like supply of cables, connectors, jumper cables, control panel or any other item required for the same shall be within the scope of supply of the Supplier.



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3.9 Suitable three pole output contactor for the hotel load converter shall be provided at the output of the hotel load converter.

3.10 Suitable filter circuit shall be provided at the output of the hotel load converter.

3.11 Protection

The devices used in the hotel load converter shall be protected against high rate of rise of voltage and current, line transient surge, switching surges etc.

The converter shall be protected against following:

• Open circuit in hotel load winding;

• ground fault in AC input circuit;

• ground fault in 3-phase output, limits for earth fault detection should be not more than 30 mA per coach;

• converter phase fault, line to line short circuit due to dead short at load terminal;

• thermal over loading;

• high / low voltage in DC link;

• failures of power supply to control electronics;

• DC link short circuit;

• input over voltage / under voltage;

• input over current;

• single phasing in load;

• output over voltage and under voltage; and

• output over current. The details of such protection shall be submitted by the Supplier for approval as part of Design Package.

3.12 Indications

3.11.1 At driver’s desk a simple indication ‘LSHO’ shall be provided which will indicate the health of the hotel load converter.

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

• Main contactor stuck ON/OFF;

• input over current;

• input earth fault.

• input available;

• output available;

• converter healthy;

• converter faulty; and



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• output earth fault.

3.13 Fault Diagnostic

The following messages shall be recorded in the memory of hotel load converter for the purpose of fault diagnostic: (To be updated as per SIV specification and after discussions with

manufacturers)

3.14 Interference

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

Interference Current Limit

1.0 Psophometric current 10.0 A

2.0 DC component 4.7 A

3.0 Second Harmonic component (100 Hz) 3.0 A

4.0 1000 Hz up to 5000 Hz 400 mA

5.1 >5000 Hz up to 32000 Hz 270 mA

5.2 39500 Hz up to 43500 Hz 270 mA

The Supplier shall undertake FFT (Fast Fourier Transformation) analysis of the total current from

1000Hz to 5000Hz and 5kHz to 50kHz separately to find out the frequencies which produce the

highest currents within each bandwidth. In the frequency bands >32000Hz to <39500Hz and

>43500Hz to 50000Hz the frequencies at which the current values exceed 270mA shall be

identified. This test shall be included within the tests listed within Chapter 5 and the results shall

be provided in type test report.

EN 50238 is currently under revision and shall include interference current limits for track circuits and axle counters. Where these overall interference current limits are more onerous than those stated above these limits shall be applied. The Supplier shall submit the simulated values of these interference currents as part of Design Package.

3.15 Mechanical Dimensions and Weight

3.12.1 There is space constraint inside WAP4 locomotive. On board air compressors have been shifted to under slung to create space inside machine room. There is some space available on roof and some space in under frame, which shall be utilized for fitment of the hotel load converter. The details of space envelops available are given in Annex-4. The Supplier shall ensure that the hotel load converter along with all accessories shall fit in the space envelops specified in Annex-4. The



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weight of the hotel load converter and its accessories shall be specified separately in Design Package and the overall weight of hotel load converter system shall not exceed _______ Kgs.

3.12.2 A gap of at least 50 to 100 mm shall be maintained between roof and the converter in the machine room of the locomotive and cooling system design shall be done accordingly.

3.12.3 The enclosure for electronics shall be free from dust and moisture. The hotel load converter shall be protected against dust and water in accordance with IP54. The panel sheets used for fabrication should be of SST grade 321 as per ASTM-A240 of minimum 3 mm thickness.

3.16 Cooling

Suitable and efficient cooling system shall be adopted keeping in view the location of hotel load converter and space constraint inside the locomotive. CFD analysis indicating effectiveness of cooling system shall be submitted as part of Design Package.

3.17 Safety

Indication of presence of high voltage ( voltage indicator ) shall be provided in each hotel load converter cubicle for human safety.

3.18 Safety Factors

3.15.1 In the circuit configuration, 25% safety margin in the rating of both voltage and current under worst conditions shall be ensured. This shall be established in the Design Package with calculation.

3.15.2 A minimum thermal margin of 10ºC for junction temperature under worst operating condition for the power devices shall be required. Over load margins and duration shall be furnished as part of Design Package.

3.15.3 Current density of the bus bars shall be 4A / sq. mm. 3.15.4 Acoustic noise generated by circuits and components shall be less than 80 dB (A) at a distance of

1m from the equipment. The measurements shall be conducted in accordance with ISO 3381. 3.15.5 The electronic cards shall be provided with LED indication to show the health of cards, to assist

maintenance and operating personnel in trouble shooting. 3.15.6 The power portion of the hotel load converter shall be suitably protected to prevent accidental

contact. The shields and screens shall be properly earthed. 3.19 Marking

3.16.1 The major equipments/subassemblies shall bear marking and serial number. The equipments/subassemblies shall contain serial number and make of manufacturer.

3.16.2 All equipments / cubicles shall contain name plates of anodized aluminum with engraved / punched letters.



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3.16.3 The inverter rating plate shall be marked with the following information:

(i) Type / Make

(ii) Contract/purchase order number

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

(iv) Rating -- KVA -- Input voltage range -- Output voltage, frequency and wave shape

3.16.4 Cable

The use of wires / cables shall be reduced to minimum. Bus bars shall be of high grade copper, insulated bus bar shall be preferable. The wires / cables shall be of high grade copper with halogen

free thin walled insulations. The insulation/sheathing material shall be fire survival type according to EN 50264.All the cable terminations shall be made through crimped sockets / lugs. The circuit diagram shall be furnished in Design Package. Each cable / wire shall be numbered at both ends for easy identification. The use of pre-insulated lugs suitable for double crimp for insulation and conductor is recommended. Current collection through threads shall be avoided and terminals of adequate size shall be provided.



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Chapter 4

Scope of Supply

The following shall be scope of supply:

SL

No.

Item Description Quantity

1. IGBT based hotel load converter with its control system. 2 nos. per locomotive

2. Circuit in accordance with Annex-3 and indication to driver in accordance with Clause 3.11.1 of this Specification.

01 set per locomotive

3. Interfacing of hotel load converter with power car as per RDSO modification sheet _____________

Full ordered qauntity

4. Portable data logging and processing unit pre-loaded with Windows XP or later for downloading the software, viewing and changing the parameters, trouble shooting, in hotel load converter along with user license.

01 no. per 5 locomotive sets of converter or part

thereof

5. Testing and commissioning of the above equipment 01 locomotive 6. Installation drawings and installation manual (hard copy in A4 size paper

and soft copy both) in English language only 3 sets for full

ordered Quantity. 7. Training 60 man days

8. Special tools and jigs for maintenance. 01 set per 5 loco sets of converter or

part thereof.

9. Inter Vehicular Couplers (IVC) in accordance with specification number EDTS105-Rev.’E’

04 nosnumbers per locomotive

10. UIC coupler 04 numbers per locomotive

11. 3 Pole Output contactor for Hotel Load inverter (refer Clause 3.9 of this Specification)

2 nosnumbers per locomotive

12. Maintenance and operation manual in hard copy in A4 size paper and in English language only

1 set per 5 loco sets of converter or part

thereof. 13. Maintenance and operation manual (in English language only) in soft copy

with suitable software to read and edit it 1 set per 5 loco sets of converter or part thereof.Lump sum

Installation and commissioning shall be the responsibility of the Supplier. The special tools, machines, instruments and other facilities, which are required for installation and commissioning of the hotel load converter and are not available with IR, shall be supported by the Supplier.



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Chapter 5

Tests and Trials

Type Test

5.1 Prototype tests shall be performed on one unit (manufactured as per design) to verify that product to meet

the requirements specified and agreed upon between the Purchaser and the Supplier. Series manufacture shall commence only after successful completion of prototype tests.

Type test shall be repeated in following cases. � First time supply to IR; � modification of equipment, which is likely to affect its function; � failure or variations established during type or routine test; and � at the time of indigenisation, if the Supplier has supplied the product with foreign collaboration

originally.

5.2 The hotel load converter shall be tested in accordance with IEC 61287 (including all optional tests) and the control electronics shall be tested as per IEC 60571 [including the following optional test –

performance test (clause 10.2.2), dry heat test (clause 10.2.4 to be done at 80 °C), damp heat cyclic test (clause 10.2.5) , salt mist test ( clause 10.2.10)].

5.3 The list of tests (as per IEC 61287) to be carried out is as follows:

Sl.

No

Clause no. Description

Remarks

1. 4.5.3.2 Verification of Dimensions and Tolerances

2. 4.5.3.3 Weighing 3. 4.5.3.5 Cooling system performance tests

4. 4.5.3.5.3 Check of effectiveness of air filers Xa 5. 4.5.3.6 Tests of mechanical and electrical protection and

measuring equipment

6. 4.5.3.8 Test of the degree of protection Xa

7. 4.5.3.9 Commutation Test 8. 4.5.3.10 Acoustic Noise Measurement

9. 4.5.3.11 Temperature Rise Test

10. 4.5.3.12 Power loss determination 11. 4.5.3.13 Supply over voltage and transient energy

12. 4.5.3.14 Sudden variation of load Xa 13. 4.5.3.17 Partial Discharge Test Xa

14. 4.5.3.18 Safety Requirements 15. 4.5.3.19 Vibration and Shock

16. 4.5.3.20 Electromagnetic compatibility

17. 4.5.3.21 Step change of line voltage test 18. 4.5.3.22 Short-time supply interruption test



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19. 4.5.3.23 Current-sharing Test Xa

Xa = The execution of the test is subject to agreement between the Supplier and the Purchaser.

5.4 The prototype units shall be inspected and tested jointly by the representative of CLW/ RDSO at the

manufacturer’s premises or at mutually decided venue where all the facilities shall be made available for carrying out the prototype test. The first set of hotel load converter shall be kept in field trials for 50,000 Kms. The RDSO/ CLW engineers shall associate and witness the tests in the locomotive also till they are successfully completed. Any defects noticed / design improvement found necessary as a result of the test / trial shall be carried out by the Supplier in the least possible time. Serial production shall only start after successful trial run on locomotive and clearance to this effect given by RDSO.

ROUTINE TEST

5.5 Routine tests shall be carried out to verify that properties of the product corresponding to those measured

during type tests. Routine test shall be carried out by the Supplier on each equipment.

5.6 The converter shall be routine tested in accordance with IEC 61287 (including all optional tests) and the control electronics shall be tested as per IEC 60571 [including the following optional test –dry heat test (Cl.

10.2.4 to be done at 80 ° C), damp heat cyclic test (Clause 10.2.5)].

5.7 The list of tests (as per IEC 61287) to be carried out is as follows:

Sl.

No Clause

no. Description Remarks

1. 4.5.3.1 Visual Inspection 2. 4.5.3.4 Marking Inspection

3. 4.5.3.5.4 Leakage Test 4. 4.5.3.6 Tests of mechanical and electrical protection

and measuring equipment

4. 4.5.3.7 Light Load Test

5. 4.5.3.15 Insulation Resistance Test Xa

6. 4.5.3.16 Dielectric Test

Xa = The execution of the test is subject to agreement between the Supplier and the Purchaser.

Other points to be followed

5.8 The suppliers shall submit complete test programme for type and routine test to RDSO as part of Design

Package. The Supplier shall carry out the test as per mutually agreed test programme at his own cost.

5.9 Investigation tests are intended to obtain additional information regarding the performance of the product. They shall be specially requested either by the Purchaser or the Supplier.

5.10 Authorised representative of IR may conduct surprise check on manufacturing process and quality control

along with any of the test to ensure quality of product and its conformance to specification.

5.11 Instrumentation



JE/DESIGN/RDSO

DSE/TPL/RDSO


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

(b) Value of the fundamental component and total Harmonic Distortion (THD) of hotel load converter output shall be measured by power analyser during the prototype test at various mutually decided preset points in traction and braking modes. True value of output voltage shall also be measured for record.

(c) Input power factor and the efficiency shall be measured using power analyzer at rated load. 5.12 Clarifications with respect to certain tests are given below

(a) Visual inspection –The objective of visual inspection is to check that the equipment is free from defects and the equipment is as per approved drawing. Bill of materials shall be submitted as part of Design Package. The make, rating of equipments, subassemblies shall be checked with the details as per approved Design Package. If a change is needed in make or rating of important equipments, sub-assemblies, it shall be intimated and shall have approval of RDSO. All the important dimensions shall be measured and shall be in permissible tolerance.

(b) Power loss determination test – This test shall be done at voltage corresponding to 22 .5 kV in OHE.

The efficiency shall be measured at full and 80 % of load. (c) Earth fault – Simulate the earth fault by connecting a suitable resistor between cubicle frame and

output phases. The hotel load converter shall not trip and earth fault indication shall be in “OFF” state till the leakage current is less than limit approved as part of Design Package submitted by the Supplier.

(d) Burn in test -- The electronic cards used on the equipment shall be subjected to burn-in 80 hours as per the temperature cycle in Annex-5. The cards shall be kept energized during the test. Functional test of each card shall be carried out after the burn in test. (please refer clause 10.2.13 of IEC 60571). This shall be part of internal test by manufacturer, whose results shall be submitted during routine test.

(e) Cooling test – The purpose of this test is to verify the cooling of various components / assemblies.

The parameters for measurement to check efficacy of cooling system shall be decided based on scheme proposed as part of design proposal.

(f) Insulation resistance and dielectric test – The insulation resistance with 1000 V megger shall not be

less than 100 M ohms at 70 % RH for all the circuits. The dielectric test shall be carried out after shorting semiconductor device, pulse transformer earthed, earthed special cards if necessary before applying dielectric voltage. The level of dielectric voltage shall be as per IEC 61287.

(g) Temperature rise test –The hotel load converter shall be loaded to full load for 6 hours with input OHE

voltage of 19 kV and with 50% blockade of the inlet filters, if used. The temperature rise shall be recorded by temperature detectors mounted at the specified reference points on the body of semiconductors, capacitors, and other components as agreed between purchaser and manufacture. The maximum recorded temperature under worst condition shall be corrected for 60 degree C and compared with maximum permissible temperature. (for power devices at junction). The thermal margin available shall be compared with the safety margin declared by the manufacturer. The temperature of the power devices shall have a margin of minimum 10 degree C.

h) Damp heat test – Functional test of each electronic card shall be carried out after the damp heat test.



JE/DESIGN/RDSO

DSE/TPL/RDSO


5.13 Signalling and Interference tests

Tests to determine the levels of interference with the traction power supply and signal and telecommunication equipments and facilities to prove that these are within acceptable limits (reference to clause 3.11), shall be done after provision of hotel load converters in the locomotive.



JE/DESIGN/RDSO

DSE/TPL/RDSO


Annex-1

Important Data of Transformer

SN Details Ratings

1.0 Rating of the transformer- 1.1 Primary 6670 KVA

296 A 22.5 kV

1.2 Secondary 5400 KVA

2 x2700 A 2x1000 V

1.3 Auxiliary 270 KVA 760 V or 830V

1.4 Hotel load 1000 kVA 1333.33 A

750 V, 50 Hz ± 3%

2.0 Percentage impedance 2.1 Main circuit 10%

2.2 Auxiliary circuit 3 % to 5% 2.3 Hotel load circuit 3 % to 5%

3.0 Magnetizing current At 22.5 KV

2.5 A

Supply voltage (kV) Hotel load voltage (V) Hotel load power (kVA)

31 1033.333 1377.743

30 1000 1333.3

27.5 916.6667 1222.192

25 833.3333 1111.083

22.5 750 999.975

20 666.6667 888.8667

19 633.3333 844.4233

18 600 799.98

17.5 583.3333 777.7583

17 566.6667 755.5367

16.5 550 733.315



JE/DESIGN/RDSO

DSE/TPL/RDSO


Annex-2/1

Power Requirement With Different

Coach Combinations with HOG System

TYPE COACH

COMBINATION

EXISTING CONNECTED

LOAD(IN KW)*

POWER REQUIREMENT AT 0.8 DIVERSITY FACTOR(IN

KW)

24 COACH RAJDHANI

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

932 745.6

19 COACH RAJDHANI

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

742 593.6

12 COACH SHATABADI

AC-9,POWER CAR-2,PANTRY-1

440 352

* Considered power factor for inductive load is 0.7.

The types of load in detail for each and every type of coaches are given below:

S.NO.

CONNECTED LOAD CALCULATION FOR LHB TYPE COACHES 1-AC

COMPONENT POWER QUANTITY

TOTAL

CONNECTED LOAD

IN (WATTS) IN (WATTS)

1. ANTI-SKIDDEVICE 48 1 48

2. FAN

2.1 EXHAUST FAN 132 2 264

3. PANTRY EQUIPMENT

3.1 HOT CASE 1200 1 1200

3.2 BOTTLE COOLER/ 800 1 800

3.3 REFRIGERATION

4. SWITCH BD CABINET 500 1 500

5. COACH LIGHTING

5.1 LIGHTINGS 40 WATTS 40 9 360

5.2 LIGHINGS 20 WATTS

SINGLE COMT.+

VASTIBULE 20 17 340



JE/DESIGN/RDSO

DSE/TPL/RDSO


+DOORWAY

5.3 READING LIGHT 10 24 240

5.4 TOILET OCCUPIED

LIGHT 16 4 64

5.5 LAV. LIGHT 16 4 64

6. AC SYSTEM

6.1 AC UNIT 13600 2 27200

6.2 CONTROL PANEL 140 1 140

7. SANITARY SYSTEM

7.1 WC CONTROL SYSTEM (24 V)

40 4 160

7.2 WATER PUMP 220 1 220

7.3 MAGNETIC VALVES 8 6 48

7.4 ELECTRIC SHAVER

SOCKET 20 4 80

8. PA SYSTEM

8.1 LOUDSPEAKER EQUIPMENTS

60 1 60

9. ELECTRIC CAR

EQUIPMENTS

9.1 BATTERY CHARGER 6160 1 6160

37948

TOTAL LOAD 37.95 KW

S.NO.

CONNECTED LOAD CALCULATION FOR LHB TYPE COACHES 2-AC

COMPONENT POWER

(WATTS) QUANTITY

TOTAL

CONNECTED LOAD

(WATTS)

1. ANTI-SKID DEVICE 48 1 48

2. FAN

2.1 EXHAUST FAN 132 2 264

3. PANTRY EQUIPMENT



JE/DESIGN/RDSO

DSE/TPL/RDSO


3.1 HOT CASE 1200 1 1200

3.2 BOTTLE COOLER/ REFRIGERATION

800 1 800

4. SWITCH BD CABINET 500 1 500

5. COACH LIGHTING

5.1 LIGHTINGS 40 WATTS 40 9 360


SINGLE COMT.+

VASTIBULE + 20 15 300

5.3 READING LIGHT 10 52 520

5.4 TOILET OCCUPIED

LIGHT 16 4 64

5.5 LAV. LIGHT 16 4 64

6 AC SYSTEM

6.1 AC UNIT 13600 2 27200

6.2 CONTROL PANEL 140 1 140

7 SANITARY SYSTEM

7.1 WC CONTROL SYSTEM(24 V)

40 4 160

7.2 WATER PUMP 220 1 220

7.3 MAGNETIC VALVES 8 6 48

7.4 ELECTRIC SHAVER

SOCKET 20 4 80

8 PA SYSTEM


60 1 60

9 ELECTRIC CAR

EQUIPMENTS

9.1 BATTERY CHARGER 6160 1 6160

TOTAL 38188

TOTAL 38.2 KW



JE/DESIGN/RDSO

DSE/TPL/RDSO


CONNECTED LOAD CALCULATION FOR LHB TYPE PANTRY CAR (HOT

BUFFET)

S.NO. COMPONENT POWER

IN

(WATTS)

QUANTITY

3-PH

AC/415 V

1-PH

AC/240V

1-PH

AC/110V

DC/110

V

WATTS WATTS WATTS WATTS

1 ANTI-SKIDDEVICE

48 1 0 0 0 48

2 FAN

2.1 EXHAUST FAN 132 2 264 0

0

3 PANTRY

EQUIPMENT

3.1 HOT CASE,FOR 140MEAL

1500 1 0 1500 0 0

3.2 BOTTLE COOLER 90 LTRS

200 1 0 200 0 0

3.3 REFRIGERATOR, 310LTRS

300 1 300

3.4 DEEP FREEZER, 230 LTRS

400 1 400

3.5 OVEN TOSTER GRILL

1200 2 2400

3.6 WATER BOILER-1,2 &3

3000 3 9000

3.7 ELECTRIC BURNER-1

2000 2 4000

3.8 ELECTRIC BURNER-2 & 3

2000 2 4000

3.9 ELECTRIC BURNER-4

5100 1 5100

3.10 ELECTRICAL CHIMNEY-1,2 & 3

300 3 900

3.11 INSECT KILLER

20 2 40

3.12 WATER FILTER

200 1 200

SUB TOTAL OF PANTRY

EQUIPMENTS 28040

4 SWITCH

BOARD

CABINET

500 1 0 0 0 500

5 COACH

LIGHTING 0

5.1 LIGHTINGS 40 WATTS

40 9 0 0 360 360



JE/DESIGN/RDSO

DSE/TPL/RDSO



0

5.3 SINGLE COMT.+ VASTIBULE +

20 15 0 0 300

5.4 DOORWAY 0

5.5 LAV. LIGHT 16 2 0 0 32 0

5.6 TOILET OCCUPIED LIGHT

16 2 0 0 0 32

6 AC SYSTEM

6.1 AC UNIT 13600 2 27200 0 0 0

6.2 CONTROL PANEL

140 1 0 0 0 140

7 SANITARY

SYSTEM

7.1 WC CONTROL SYSTEM(24 V)

40 2 0 0 0 80

7.2 WATER PUMP 220 1 220 0 0 0

7.3 MAGNETIC VALVES

8 6 0 0 0 48

7.4 ELECTRIC SHAVER SOCKET

20 2 0 0 0 40

8 PA SYSTEM


60 1 0 0 0 60

9 ELECTRIC

CAR

EQUIPMENTS 0

9.1 BATTERY CHARGER

6160 1 6160 0 0 0

SUB

TOTAL 33844 28040 392 1608

TOTAL Watts 62276

TOTAL (KW) 62.276



JE/DESIGN/RDSO

DSE/TPL/RDSO


Annex-3



JE/DESIGN/RDSO

DSE/TPL/RDSO


Annex-4/1

A B C



JE/DESIGN/RDSO

DSE/TPL/RDSO


Annex-4/2

A. Free Space after removing Compressor-1 and Compressor-2 in machine room.

1800 mm

650 mm = 1300 mm 1150 mm 600 mm

B. Free Space for Contactor Panel between RSI panel and ATFEX transformer.

380 600

RSI Panel

ATFEX Transformer

Approximate height 1340 mm (with non modular loco

duct)

Approx. height= 1450



JE/DESIGN/RDSO

DSE/TPL/RDSO


Annex-4/3

C. Free space on roof near pantograph

2055

350 (w)

350

Space in under slung

After shifting control reservoir (between TM3 and transformer), available free space is: 1350 mm 480 mm

Approx. Height = 700 mm

Approx. height= 650



JE/DESIGN/RDSO

DSE/TPL/RDSO


0 C0

+25 C0

+70 C0

-25 C0

On

Off

1.4 2.1 5.2 5.5 9.1 9.4 12.5 13.2 15

Time (Hrs)

0.1=10 Min

1.55 5.27 5.42 9,17 9.32 12.57 13.12 14.41

Temperature CycleTemperature

in Degrees

BURN-IN TEST

Annex-5

Date post:	08-Apr-2018
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