GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

I

ELECTRICAL DIRECTORATE

RESEARCH, DESIGNS & STANDARD ORGANISATION

MANAK NAGAR, LUCKNOW - 226011

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

1. July'12 6, 9, 30, 31, 32, 33, 1 Definition of Company and34, 35, 36, 37, 39, Procured revised; clauses 1.2.440, 42, 44, 45 and (item5), 4.6.1, 4.6.12, 4.9,48 4.10, 4.14, 4.15.1, 4.16,

4.17.1, 4.18, 4.19.2 4.22,4.26, 4.27.4, 4.27.6, 4.31.4,4.34 and 5.5 revised

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4.

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ABBREVIATIONS 4DEFINITIONS .. '" 61. GENERAL DESCRIPTION 82. OPERATING AND SERVICE CONDITIONS 133. PERFORMANCEREQUIREMENTS 184. TECHNICAL REQUIREMENTS 245. INSPECTION, TESTING AND TRIALS ........................................................•............... 476. ANNEX 1 507. ANNEX 2 578. ANNEX 3 58

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Abbreviation Full Name

AC Alternating Current

ASIC Application Specific Integrated Circuit

BS British Standard

CLW Chittaranjan Locomotive Works

CSC Constant Speed Control

DC Direct Current

EMC Electro-magnetic Compatibility

EMI Electro-magnetic Interference

EN Euro Norm (European Standard)

GPS Global Positioning System

GTO Gate Tum-Off Thyrister

HP Horse Power

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

HV High Voltage

IC Integrated Circuit

IEC International Electro Technical Commission

IEEE Institution of Electrical and Electronic Engineers

IGBT Insulated Gate Bipolar Transistor

IP Ingress Protection

IR Indian Railways

IS Indian Standard

ISO International Standard Organization

LED Light Emitting Diode

OHE Over Head Equipment

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PCB Printed Circuit Board

PTFE Polytetrafl uoroethylene

RAMS Reliability, Availability, Maintainability and Safety

RDSO Research Designs & Standard Organisation

SMI Special Maintenance Instruction

MS Modification Sheet

TC Technical Circular

STR Schedule of Technical Requirement

UHF Ultra High Frequency

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

VCB Vacuum Circuit Breaker

VCU Vehicle Control Unit

VHF Very High Frequency

WAG Wide Gauge AC Goods locomotive

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In this Specification and Standard, the following words and expressions shall, unless repugnant tothe context or meaning thereof, have the meaning hereinafter respectively assigned to them:

Term Definition

Company Shall mean firm or company with whom the order for supply of Locomotiveshas been placed or intended to be placed.

Category Book shall mean list of equipments procured by CLW from trade for manufacturingof WAG9 locomotive containing equipment name, specification/drawingnumber, quantity required per loco and other details

Design Package shall have the meaning set forth in Clause 1.5.3 of this Specification andStandard

FBcubicle shall mean filter cubicle

Government President of the Republic of India as represented by the IR entering into thecontract

HB cubicle shall mean auxiliary cubicle

IP shall mean degree of protection provided by enclosures according to IEC60529

Locomotive(s) shall mean IGBT based WAG9 locomotive(s) manufactured in accordance withthis Specification and Standard

L-10 shall mean life of bearing in accordance with ISO 281

Manufactured shall mean system/subsystem/equipment manufactured by the Company afterthe clearance given by the Government after capacity and capabilityassessment by ROSO/CLW to verify that the Company complies withROSO's/CLW'sSTRwhere ever applicable; and after successful type tests. Thisshall be only applicable for the items where the Company is not an approvedsource of RDSO/CLW

Procured shall mean system/subsystem/equipment purchased by the Company inaccordance with CLW'sor ROSO'sspeCification from latest approved sources ofCLW or ROSO. The latest approved sources are available on RDSO's officialwebsite www.rdso.indianrailways.gov.in and CLW's official websitewww.clw.indianrailways.gov.in. This shall be only applicable for the itemswhere the Company is not an approved source of RDSO/CLW. In case theCompany is approved SOurce of RDSO/CLW, it can use its own makesystem/subsystem/equipment

Propulsion shall mean traction converter, auxiliary converter, vehicle control unit alongwith associated cooling systems, driver display and traction motor speed

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Equipments sensor

RoutineTests shall have the meaning set forth in Clause 5.1.2 of this Specifications andStandard

SB cubicle shall mean control cubicle

Tests shall mean the tests set forth in Chapter 5 to determine the conformity of theLocomotive with the provisions of this Specifications and Standard

Type Tests shall have the meaning set forth in Clause 5.1.2 of this Specifications andStandard

Unlessspecifically identified to the contrary all obligations in this Specifications and Standard shallbe obligations of the Company and for the avoidance of doubt where in this Specification andStandard it states that the Locomotive or any constituent parts shall or will meet a certainrequirement, the achievement of this requirement shall be an obligation of the Company.

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1.1.1 This Specification and Standard define the design, manufacture, delivery,testing and commissioningof the Locomotive.

1.1.2 The purpose of this Specification and Standard is to develop additionalindigenous sources for manufacture of electric locomotives. It is the intentionto develop Locomotives generally similar in structure and construction toWAG9 type, the manufacture of which is being done at CLW. The Companyshall ensure identical or same design of superstructure, bogie, electricalequipments etc. and proposeeqUivalentsand alternate designs only where theexisting sourcesof equipment are inadequate.

1.2.1 The standards/legislation applicableand relevant to the Locomotivesand to thePropulsionequipments shall be:

(c) EN;

Cd) UIC;

(e) AAR;

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

1.2.3 For the avoidance of any doubt, in case of any conflict between therequirements of these standards and Specification and Standard, thestipulations of this Specification and Standard shall have preced~nce.Clarification of any conflict shall be sought from the Governm~nt.

1.2.4 The Propulsion Equipments shall comply with and enable the Locomotive tocomply with the follOWingstandards:

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Item No Standard Title Standard No

1. Railway applications - Rolling Stock - IEC 61133Testing of rolling stock on completion ofconstruction and before entry into service

2. Railway Applications - Power Converter IEC 61287installed on board rolling stock -characteristics and test methods

3. Electronic equipment used on rail vehicles IEC 60571

4. Electronic traction - Rotating electrical IEC 60349 -2machines for rail and road vehicles - Part2: Electronic convertor-fed alternatingcurrent motors

5. Railway application - rolling stock - Part IEC 61377-33: combined testing of alternative currentmotors, fed by an indirect convertor, andtheir control system

6. Electric railway equipment - Train bus - IEC 61375-1Part 1: Train communication network

7. Rotating electrical machines - Part 18: IEC 60034-18Functional evaluation of insulation systems

8. Railway applications - electromagnetic EN 50121compatibility - emission and immunity ofthe signalling and telecommunicationsapparatus.

9. Railway applications - electromiilgnetic EN 50121-3-2compatibility - Part 3-2: rolling stock -Apparatus

10. Railway applications - electromagnetic EN 50121-2compatibility - Part 2: emission of thewhole railway system to the outside world

11. Railway applications - compatibility EN50238between rolling stock and train detectionsystem

12. Railway applications - Traction IEC 60310transformers and inductors on boardrolling stock

13. Low-voltage switchgear and control gear - IS 3231 / ICE

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Item No Standard Title Standard No

Part 1: General rules 60947

14. Conductors of insulated cables lEC 60228 / IS10810

15. Railway applications - rolling stock lEC 61373equipment - shock and vibration test

16. Programmable controllers - Part 3: lEC 61131Programming languages

17. Railway applications - electric equipment lEC 60077for rolling stock

18. Railway application - rolling stock lEC 61991protective provisions against electricalhazards

19. Rotating electrical machines lEC 60034

20. Shunt capacitors for a.c. power systems lEC 60871having a rated voltage above 1000 V

21. Environmental testing - Control cubicle lEC 60068

22. Degree of protection prOVidedby lEC 60529enclosures (IP Code)

23. Railway applications. Rolling stock. Rules EN 50343for installation of cabling.

24. Electronic components - Reliability - lEC 61709Referenceconditions for failure rates andstress models for conversion

25. Railway applications - Specification and En 50126/ lECdemonstration of reliability, availability, 62278maintainability and safety (RAMS)

26. Railway applications - Rolling stock lEC 61881equipment - Capacitors for powerelectronics

1.2.5 The latest version of the aforesaid standards which have been published atleast 30 (thirty) days before the date of opening of tender shall be consideredapplicable.

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1.2.6 Where the aforesaid standards are based on ambient and environmentalconditions which are less onerous than those stated in this Specification andStandard, the conditions stated in this Specification and Standard shall beapplied in the design and testing of the Product and the requirements of theaforesaid standards shall be adjusted accordingly.

1.2.7 The requirements listed in this Specification and Standard are the minimumrequirements. The Company may adopt alternative internationally recognisedcodes, standards and specifications if it can demonstrate to the Governmentthat such alternative is more onerous or more pertinent to the Products or theLocomotive than the standards specified in this Specification and Standard.The Company shall seek the prior approval of the Government for anyalternate standard which is proposedto be used.

1.3.1 All materials (including surface coatings, metals, insulants, adhesives, fluids,grease etc.) used in the construction of the Locomotive shall not give rise tohealth hazards for crew and staff. The materials shall also be suitable forstandard repair operations such as those currently used by the Government(e.g. welding, cutting etc.) without the need for staff to be protected by otherthan standard means.

1.3.3 Materials used for the Locomotiveshall be appropriate for achieving the DesignLife of the Locomotive.

1.3.4 The welding of the locomotive shell shall be undertaken in accordancewith theWelding Procedure Specification numbers A0326-0001 to A0326-0030 candA0713-0001 to A0713-004 (which are referenced in Annex 1 of thisSpecification and Standard) or equivalent procedures developeq in accordancewith internationally recognisedstandards.

1.4.1 The Company shall conduct a RAMSassessmentfor the Propulsion Equipmentsin accordance with the requirements of EN50126, to demonstrate that thetargets and requirements stipulated in Chapter-3 of this Specification andStandard have beensatisfied.

1.4.2 The Company shall produce all necessaryreliability, availability, maintainabilityand safety documentation to address the requirements of EN50126 and toassist the Government to maintain the performance of the Products over theentire Design Life of the Locomotives.

1.5.1 The Company shall produce to the Government, the Design package within 120(Onehundred and twenty) days of the date of the Agreement.

1.5.2 The Design packageshall contain sufficient design documentation to demonstratehow the Company proposes to satisfy the requirements of this SpeCificationsand Standard. As a minimum this packagewill include the follOWing.

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Clause by Clause commentary against the Specifications andStandard describing the proposed design of the PropulsionEquipments;

list of standards applied to the design and construction ofPropulsionEquipments;

a list of any single point failures that will cause a loss of power of1/6th (one sixth) or greater of the tr<;lctionpower (as per Clause3.12.2 of the Specificationsand Standard;

all design documentation necessary to verify compliance with theSpecifications and Standard, including the specific requirementsdetailed in Annex 3 of this Specificationand Standard;

Inspection plan and bill of material for raw material required forManufactureditems;

1.5.4 All deSigns and drawings shall be supplied in hard copy, in duplicate, and inelectronic form on compact disk (CD) / digital video disk (DVD), along with thesoftware and two sets of hardware to read and edit the same. All drawingsshall be prOVidedin auto cad format.

1.5.5 One set of maintenance and operating manual shall be supplied per 05 (five)Locomotivesin hard copy.

1.5.7 Approval of design shall be given by RDSOwithin 60 (sixty) days of submission ofall design details in accordance with this Clause 1.5 of this Specification andStandards.

1.5.8 Approval of design means approval of general design features. NotWithstandingthe approval, the Company shall wholly and completely be responsible for theperformance of the Locomotive.

1.5.9 For the purpose of technical decisionson improvement / modifications etc. on theLocomotive, RDSOshall be the final authority from Government's side.

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CHAPTER-2

OPERATING AND SERVICE CONDITIONS

2.1 The Locomotives shall achieve the safety and reliability targets defined in Chapter-2 ofthis Specification and Standard whilst satisfying the operating and service requirementsdetailed in this Chapter-2 of this Specification and Standard.

2.2 Whilst the majority of the interfaces and environmental conditions are described in thefollowing clauses, the Company shall independently ensure that all interfaces, operatingand service conditions are considered.

2.3 The environmental conditions described in this Chapter-2 of this Specification andStandard shall override any environmental conditions described in any specificationsreferenced in Annex-1 of this Specification and Standard.

The existing WAG9 locomotive is permitted to operate on all 25kV electrified routes inIndia. The Locomotive shall be able to operate on these routes under the operating andservice conditions described in this Chapter 2 of this SpeCificationand Standard.

The Products and in particular the locomotive shell and any externally mounted equipmentshall satisfy the requirements of RDSODrg No. SKEL-3917.

2.6.1 The overhead line power supply conditions within which the Locomotives shalloperate are:

Description Values

Nominal supply voltage 22.5 kV, 50 Hz, single phase, AC

Normal variation -in supply voltage------19 kV to 27.5 kV

Occasionalmaximum voltage 31 kV

Occasionalminimum voltage 16.5 kV

Variation in supply frequency ± 8% (46 to 54 Hz)

Neutral Sections After every 25 to 50 Km

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

(ii) Short neutral sections ofapproximately 4.61 m and 9.6 m

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Description Values

length having an insulated portion (ofPTFE) on both sides and middleportion of neutral section which issolidly earthed.

Pantographbounce Up to 45 ms

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

2.7.1 The tracks are equipped with DC track circuits, 83113 Hz AC track circuits aswell as other AC track circuits at higher frequencies. Similarly, other devicessuch as axle counters, block instruments and points machines may also beemployed. On the communication network, control circuits, teleprinter circuits,as well asVHF/UHFand micro-wave circuits are employed.

(a) by compliance with Clause 2.8.3 of this Specification and Standard, becompatible with the signalling and telecommunications systems on theoperating routes identified in Clause 2.4 of this Specification andStandard or on adjacent lines and shall not affect the safe operation ofthese systems even under fault conditions of the Locomotive; and

(b) not place staff working on signalling and telecommunication equipmentunder personal risk even under fault conditions of the Locomotive.

2.7.3 The Locomotive shall not cause electrical interference exceeding the levelsspecified below at any point on the operating routes identified in Clause 2.4 ofthis Specification and Standard or on adjacent lines under all modes ofoperation (induding multiple operation), including failure modes:

No Interference Current Overall Limit

1.0 Psophometriccurrent ACtraction 10.0A

2.0 DCcomponent in AC mode 4.7 A

3.0 Second l'iarmonic component (100 Hz) and 8.5 A83113 Hz component in AC traction

4.0 1400 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

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(Note: The measurement of the interference current shall be taken in the trackreturn current circuit of the Locomotive.)

2.7.4 The Companyshall undertake FFT(Fast FourierTransformation) analysis of thetotal current from 1000Hzto 5000Hz and 5kHz to 50kHz separately to find outthe frequencies which produce the highest currents within each bandwidth. Inthe frequency bands >32000Hz to <39500Hz and >43500Hz to 50000Hz thefrequencies at which the current values exceed 270mA shall be identified. Thistest shall be included within the tests listed within Schedule 7 and the resultsshall be prOVidedin a Type Test report.

2.7.5 EN 50238 is currently under revision and shall include interference currentlimits for track circuits and axle counters. Where these overall interferencecurrent limits are more onerous than those stated in Clause 2.7.3 of thisSpecification and Standard these limits shall be applied subject to provisionsmade in Clause 1.2.6 of this Specificationand Standard.

2.8.1 The Locomotive shall comply with the EN 50121 series of RailwayElectromagneticCompatibility standards and EN50238.

2.8.2 The Company shall prepare, implement and maintain an EMC ManagementPlan in accordance with the standards referenced in Clause 2.8.1 of thisSpecification and Standard.

2.9.1 The Locomotive shall remain fully operational across the following ambienttemperature range:

2.9.2 The maximum temperature of any exposed surfaces shall be limited throughthe application of suitable measures to ensure the reliable operation of theProducts and eliminate hazards to operating and maintenance staff and otherthird parties.

(a) the existing WAG9locomotive experiencestouch temperatures of 75 0C(degrees CelsiUS)in direct sunlight and 55 0C (degrees CelsiUS)in theshade;

(b) the temperature inside the existing WAG9 locomotive reaches 70 0C(degrees CelSius) in summers when standing in direct sunlight in un-energisedconditions; and

(c) the temperature inside the existing WAG9 Locomotive adjacent to theelectronic cards reaches 65 °C (degrees CelsiUS) in summer whilstoperating in service.

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It shall be possible to operate the Locomotive through extremely dusty terrain (includingdeserts), where the dust concentration may reach a high value of 1.6 mg/m3 and have ahigh saturation of conductive particles.

The Locomotive shilll remain fully operational dUring the rainfall typicallyexperienced across the operating routes identified in Clause 2.4 of thisSpecification and Standard.

The Locomotiveshall be able to operate at 10 km/h in flood water of 102 mmabove rail level.

The Locomotives shall remain fully operational during the snowfall which may beexperienced on any part of the operating routes identified in Clause 2.4 of thisSpecification and Standard.

The Locomotivesshall be required to operate in a humid and salt laden atmosphere withpH value of 8.5, sulphate of 7 mg per litre, concentration of chlorine 6 mg per litre andconductivity of 130 micro Siemens/em. The design of the Propulsion Equipments shallfully consider the risk of corrosion and measures shall be implemented to ensure andmaintain the Design Life of the Locomotive.

The Locomotive shall be exposed to solar radiation and the design of the PropulsionEquipments shall take this into consideration to ensure that this does not have adetrimental effect on the operation of the Locomotive. A minimum value of 1kW/m2 shallbe applied.

The altitude at which the Locomotive shall operate shall vary from sea level to 160mabove mean sea level.

The vibration and shock levels recorded on the traction motors fitted to theexisting WAG9 locomotive are generally more than the limits given in IEC61373. High level of vibrations above 30g and 39g have been measured at thetraction motor rotor and stator respectively, which occasionally increase up to300g and 89g respectively with worn gear-pinion.

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a) Main starting resistance on level tangent track (including accelerationreserve) = 4.0 (in kg/tonne)

b) Mainrunning resistanceon level tangent track = 0.6438797 + 0.01047218V + 0.000073;23v2 (in kg/tonne), whereV is speedin Km/h

Ii) Graderesistance= 1/G x 1000 (in kg/tonne), where G is gradient (e.g. G=200 incaseof 1 in 200 gradient)

b) Runningresistanceon level tangent track = 0.647 + 13.17/W + 0.00933V+ 0.057/WN x V2 (in kg/tonne)

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3.1 The Locomotive shall achieve the performance requirements contained in this Clause 3 ofSpecification and Standard.

3.2 Unless explicitly stated in this Clause 3 of Specification and Standard the performance ofthe Propulsion Equipments and the subsequent performance of the Locomotives shallsatisfy the performance requirements stated in this Clause 3 of SpeCificationand Standardacross all likely combinations of operating and service conditions stated in Clause 2.4, 2.6and Clause 2.9 to 2.17 inclusive of this Specification and Standard.

3.3 Where speCificrequirements relating to the performance of the Propulsion Equipments arenot prOVidedin this Specification and Standard the performance shall be at least as goodas the current design of the Existing WAG9Locomotive.

3.4.1 The outline dimensions of the Locomotives shall be as per the existing WAG9locomotive.

3.4.2 The outline dimensions of the Locomotives shall also meet the requirements ofClause 2.5 of this Specification and Standard.

3.5.1 Across the range of 21.5 kV to 27.5 kV line voltage and with half worn wheels,the Locomotivesshall be capable of the following performance.

Parameter Requirement

(I) Starting tractive Not less than 510 kNeffort under dry railcondition up tospeed not less than10 Km/h

(ii) Continuous rated Not more than 50speed (constant Km/hpower)

(iii) Max. deSignspeed 110 Km/h - with fullyworn wheels

(iv) Max. operating 100 Km/h - with fullyspeed worn wheels

(v) Continuous rated Not less than 4.5 MWpower at rail at all speeds from

continuous ratedspeed to maximum

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I I I design speed

Table 5 - Locomotive Performance

3.5.2 There shall be no significant reduction in the starting tractive effort from thatstated in Table 5 of this Specification and Standard across the voltage rangespecified in Clause2.6 of this Specificationand Standard.

3.5.3 The efficiency of the traction converter (line side converter and drive sideinverter) shall not be less than 97% under full load and at the continuous ratedspeed. Similarly the efficiency of the auxiliary shall not be less than 96% underfull load. In each case the efficiency shall be computed from parametersmeasuredat conditions correspondingto full load and governed by lEe 61287-1 for traction converter and auxiliary converter.

3.5.4 In inching mode, at a constant speed settable by the driver in steps of 0.1Km/h, in the range of 0.5 to 1.5 Km/h, it shall be possible for the WAG9DLocomotive to haul loads up to 7500 tonnes on a gradient of 1 in 1000 orflatter.

3.5.5 In shunting mode at speeds up to 15 Km/h it shall be possible for theLocomotive to haul loads up to 7500 tonnes on a gradient of 1 in 1000 orflatter.

3.6.1 The performance of the regenerative brake of the Locomotive shall satisfy thefollowing requirements

Parameter Requirement

RegenerativeBrake Force Not less than 260 kN overthe speed range of 10Km/h to 62 km/h withoutsliding, and as close aspossible to 260 kN athigher speeds

3.7.1 The starting tractive effort of the Locomotiveshall be applied gradually withoutproducing jerks in the train being hauled by the Locomotive.

3.7.2 For the existing WAG9locomotive the rate of changeof tractive effort is limitedto 20 kN/second. This level of control shall be applied to the Locomotiveand itshall be maintained throughout the tractive effort curve.

3.7.3 For the existing WAG9 Locomotive the rate of change of breaking effort islimited to 100 kN/second. This level of control shall be applied to theLocomotiveand it shall be maintained throughout the braking effort curve.

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The noise level inside the cab shall not exceed 70 dB(A) with allauxiliary equipment including cab air conditioner operating at itsgreatest noise output. The noise level shall be measured in the cabalong the centre line between 1200 mm and 1600 mm above the floorand at a distance of 600 mm from the front of the cab. Themeasurement shall be conducted in accordancewith ISO 3381.

The noise level inside the cab, when the Locomotive is running at themaximum speed shall not exceed 80 dB(A) with all auxiliary equipmentincluding the cab air conditioner operating. The noise level shall bemeasured in the cab along the centre line between 1200 mm and 1600mm above the floor and at a distance over 600 mm from the front ofthe cab. The measurement shall be done according to ISO 3381.

3.8.2 All noise levels listed above in Clause 3.8.1 are in decibels referred to 20 micropascals, as measured with "A" weighting network of standard Type 1 soundlevel meter with time weighting "F".

Parameter Requirement

Bogieconfiguration Co-Co

Axle load--~--

22 tonnes ± 2%

Number of axles 6

Locomotive weight (fully 132 tonnes ± 1%*equipped andoperational)

Centre of gravity of the As per the Existing WAG9 Locomotivelocomotive shell with all (including ballast).the mounted equipmentinstalled (Products and Note: the centre of gravity calculations reportCLWComponents) IB18-05.3 and drawing IB031-00318 for the

Existing WAG9 Locomotive (without theballast) are referenced in Annex 1 of thisSpecification and Standard.

Buffing load The Locomotive shall be designed towithstand static buffing load of 400 tonnes atthe buffers

Lateral forces The lateral force measured at axle box levelshall be <= 4.0 tonnes

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