May - 2015 SPECIFICATION FOR IGBT BASED 3X130KVA AUXILIARY CONVERTER FOR THREE PHASE LOCOMOTIVES Specification No: CLW/ES/03/IGBT/0485, Alt-C Total No. of sheet-33 | “SPEcrIcATION FOR Isr sAseD SAGO KVA AUHUARY (HEOKED By SEEDED vA CENTRE FOR DESIGN & DEVELOPMENT | (CHITTARANUAN LOCOMOTIVE WORKS. WEST BENGAL INDIA 3 TOBEUSED FOR No: CLWESOWIGST/ONS PHASE ccties | SEE ] Dy. CEEDED * {es |‘TABLE OF CONTENTS Page 2 of 33 Clause No. Description Page No. 1. Foreword. 5 1A Scope & Object. 5 12 ‘Supplier's Responsibility. 5 13 Railways Responsibility. 7 14 Reference to Various Specifications. 7 15 Documentation. 8 16 infringement of Patient Rights. 40 2 ‘Technical Specification... "1 a Climatic & Environmental Condition. 2 4 ‘Scope of Supply. 2 5. Tests. Pxy 6. ‘Appendices. 29-33 61 Annexure-1 29 6.2. Annexure-2 32 6.3. Annexure-3 33 ET al ieee, |S dose SK 130 KVA - tae | rte ieee oe tes guns | NO AB een ce oes ee ie FE mee lePage 3 of 33 Alteration Record Sheet ‘Amendment | Date of | Page | Alt Changes clause no. | amendment | No | 422 | 47-10-2011_| 05 | A _| - Test & field tail joindy with CLW & RDSO. | 128 | 47-40-2011 | 05 | A_|- Warranty clause modified. 134 | 1740-2011 | 06 | A | - Clause 1.3.4 has been deleted. 14 [17-40-2011 | 06 | A_| = Clause 1.4 various standards are added. 15 [17410-2011 | 07 | A | - Clause 1.5 as been modified and more information required being included. | 23 47-40-2017 [42 | A |= Some Parameter value changes ike | - frequency .OHE voltage variation etc | 233 | 17-40-2011 | 42 | A |= The contractors are controlled by Auxiliary | Converter control electronics. 25 | W7-10-2011 | 13 | A | - Frequency steps for multiple operations is modified and about L |_ output connector is added. 26 | (A021 | 14 | A | Control & communication of Auxiliary Converter with MICAS ‘S2 control electronics will be done through software. 3___[r-i0-2011 | 21 A |= IEC sub-clause updated. 423 | 1208-2014 | 04 | B | - Clause 1.2.3has been modified _ 47 [12-08-2014 [21 |B |- Clause 4,7 has been deleted. 4.0 | 24-05-2015 | 05 | C | Clause modified 12.10 | 24-05-2015_|06_| C | Clause modified — 2.2(a) | 21-05-2015 | 11 | C |= Inputvoltage changed from 22.5KV 025 KV 2.2() (b) | 21-05-2015 [12 | C_|- Output frequency modified from 50Hz:3% to S0HZE2% | “244 | 24-05-2015 | _14_| C_|- Protection clause modified. 26 | 21-05-2015 | 15 | C_|- Initazing time has been added and modified 282 | 21-052015 | 15 | C |- Clause modified. _ 290 | 21-05-2015 | 16 | C_|- Clause 2.9 D has been added and modified. [2412 | 24-05-2015 | 16 | C_ |= Clause modified to comply IP-54 as per |EC-60529) [212 [21-05-2015 [46 |-C|- Cooling clause modified, [2146 [21-06-2018 [48 | C_|- Reliability clause modified. = 214.11 | 21-05-2015 | 19 | C_|- Ciause fitment of MCB-100 has been added [24412 [21-05-2015 [19 | C_| Clause mechanical integration has been added : [24413] 21-05-2015 [20 |"C |= Clause control equipment integration has been added [24414 [21-05-2015 [20 | C_| Clause no.3.9 shifted to clause no.2.14.14 214.15 | 21-05-2015 | 20 | C | Clause no.3.10 shifted to clause no. 2.14.15 [45 [2-05-2015 [22 | C|- Clause modified, Chapter | 27-05-2015 | 23 | C_|- Type and Routine test segregated (clause sino. changed) | 53 | 21-05-2015 | 23 | C |- 1EC411 5 deleted | 5A(20,21,20 | 21-05-2015 | 24 | C | - IEC61287 clause TAIT AIT AAT ASR TAG added. | 23,28830) - 1EC80571 clause10.2.3 added ('5.4(24,25,26 | 21-05-2015 | 24 | C |- Testrefered to IEC411 5 deleted 827) 54(20,838 | 2-05-2018 | 24 | C | 1EC61671 is replaced with IECBOST 1 L_34) I ESRC ror | pnersr. crx ay ate [eo [sur © Bee (YY | 4qc- | SR SoBe USED NEST BENGAL NOMA na no. cLEsea/ ames voioutmies [oreo CC URu— ar [a fo fePage 4 of 33 | 5.4(37) 21-05-2015 24 C_| - New clause IEC60571 clause 10.2.13 added | 5.14(e) 21-05-2015 a C | - Requirement of RH is deleted, leakage current criteria and | correction temperature modified. 5.140) 21-05-2015 27 C_| - Max. temperature correction modified from 55°C to 60°C. |= 5.14(j) 21-05-2015 28 C_| - Clause vibration and shock test added. 5.14 (k) 21-05-2015 28 C_|- Clause bum-in-test & dry heat test added. CONVERTER AA GATTARAUAN LOCOMOTIE WOKS = | = =. woecuomnes Jorcesp cH ar a le fePage 5 of 33 CHAPTER - 1: GENERAL 1.0 FOREWORD Auxiliary Converters are used to supply 3-Phase Auxiliary Loads (Auxiliary Motors Blowers Compressors & Pumps) and Battery Charger. The Auxiliary Converter units are mounted in the machine room and are forced cooled. The Auxiliary Converter electronics will be mounted in the converter cubicles and shall have the necessary interface with the vehicle control electronics. The auxiliary converters shall be supplied in two preassembled units The tenderer is expected to study in detail the existing interface of the GTO based Auxiliary Converter with the remaining equipments (ie.VCU,cooling arrangement, oll pumps.tracton motor blowers.cll cooler blowers, scavenge blowers,compressor& battery charger, efc.). The tenderer is also expected to study the existing machine room layout, ducing, cable routing etc. in detail.Site visit, if required,shall be arranged on prior intimation to CLW. Submission of the offer shall deem that all the aspects are known atthe time of making offer. IR intends to go for open control system for vehicle control and would like to integrate, in future. The auxiliary converter with the vehicle control electronics on a bus system conforming to Published open standard. The design of auxiliary converter should keep this aspect in view, ‘though itis not covered in the present scope of supply 14.4 SCOPE & OBJECT: This specification covers the technical aspect of the Rallway’s requirement for the three numbers 130kVA IGBT based auxliary converters for three phase locomotives of the type WAG-9,WAG-SH,.WAP-7 & WAP-S5. It explains the interface requirement ofthe equipment with the locomotive and traction system clarifies the load pattern on the auxiliary converters and lays down the desired performance and testing methodology. Relevant /ECs will be the governing specification except for what is mentioned inthis specification 1.2. SUPPLIER'S RESPONSIBILITY The supplier's responsibilty shall be extended to the following: 1.21 The supplier shall supply detailed instructions for proper installation of the equipment on the locomotive. For this purpose the supplier should also depute his representative during installation ofthe auxiliary converter in the locomotive at each location (Shed/CLW). 1.22 The supplier shall be responsible for commissioning, testing & field trials of the prototype equipment in service and depute team of engineers for this purpose. The supplier shall arrange to carry out detailed test & field trial jointly with CLW & RDSO. 1.23 The supplier shall also quote for special tools, testing jigs and instruments, which may be required for troubleshooting and maintenance of the auxiliary converter separately. aT FOR ‘PREPBY. CHECKED BY scotStsco | Sepa S00 xonare | \¢ | _ceurre on oesen veve.orvet CONVERTER ws CCTTARANJAN LOCOMOTIVE WORKS. ‘eeeuses WEST eeNGAL OA re xo eesn earnas sface_ | BEDE wocowomes | oreo I lar la fe lePage 6 of 33 1.24 The supplier shall quote for spares, which may be required for satisfactory maintenance of the equipments for a period ofS years. 4.25 The supplier shall also submit on demand repair charges for the canis. The repaired card should have warranty of one year. A separate contract will be executed by the Raiiways with the contractor for the repairs. 1.2.6 The supplier shall supply suitable software “if applicable” for offine analysis of diagnostic data downloaded from the Auxiliary converter. 1.27 The design shall be developed as per requirement given in the specification. The detailed design shall be submitted to CLW and RDSO for scrutiny and approval before commencing of the manufacturing. Here “approval” means the “approval of design features’ only. The suppliers shall be responsible for performance of complete Auxiliary Converter. 1.2.8 Warranty: The supplier shall warrant that everything to be furnished under the contract shall be free from defects and faults in design, material, workmanship and manufacture, and shall be of the highest grade and consistent withthe established and generally accepted standards for stores of the type ordered and in full conformity with the contract and samples, if any, and shall, if operable, operate properiy according to the contract. The warranty forthe stores to be supplied under this contract shall be 42 months from delivery ‘or 36 months from date of satisfactory commissioning and acceptance test of the stores, whichever is earier. The contractor shall immediately on receipt of notice of defect depute his engineer to start action for rectification of defects under warranty. In the eventuality of major design modifications during the warranty period, the warranty for such components shall be extended for such period as is mutually agreed. 1.29 The supplier shall be responsible for carying out all the modifications at his own cost on any part of the equipment supplied during the period of warranty requited for satisfactory operation of the equipment as per technical specification. 1.210 Training : The supplier shall organise for training to IR personnel at CLW and at their factory premises for Railways (RDSOICLW & Zonal Railways) inthe field of maintenance & trouble shooting of the system, Five days training for six persons per 10 Loco set is to be offered in the field of maintenance & trouble shooting of Auxiliary Converter on mutually agreed location between manufacturer and CLW. 1.2.11 The supplier shall supply free of cost the elaborate manual for maintenance and troubleshooting to IR for easy maintenance of the Auxiliary Converter 1.2.12. The supplier shall submit detailed system's design manual of the system. ‘SEGFICATION 1 CHECKED ay ‘S508 TORE USED ‘CENTRE FOR DESIGN DEVELOPMENT ‘CHTTARANJAN LOCCMOTIVE WORKS WEST BENG, NDIA von No: Cuwesna Gerdes PHASE SUED BY LocouoTives | DY. CEE/DaD ar la fe fe XuO RA AUUARY ‘CONVERTERPage 7 of 33 1.3 Railways’ Responsibility: Railways will be responsible for following: 1.3.1 System interface design in terms of hardware & software and changes associated with them in the locomotive control system will be dane by Railways. 1.3.2. The cabling in loco for modified load distribution and protection. 1.3.3. The isolation and switching arrangement for auxiliary motors. 134 Deleted 1.35 Any equipment relayout on locomotive which is necessary for installation of Auxiliary Converter shall be done by the Railway. 1.36 All labour consumable materials, electrical energy for erection, testing & commissioning of ‘Auxiliary Converter will be provided by the IR free of cost. 1.3.7 The wages and allowances as well as the cost ofthe passage to and from the place of training for the railway personnel. 1.4 REFERENCE TO VARIOUS SPECIFICATIONS This Particular Specification is based on the following Normative References. Only those revisions shall be taken, which are valid on the date of signing the contract. In addition to the following, relevant ToT documents shall also be referred wherever required, ‘Standards Tile EC 6007-1 __| Rallway applications — Rolling Stock General Rules TEC 61287-1 | Railway applications - Power converters installed on roling stock TEC60571 | Speciic ules concerning the electronic control part of converters. | IEC 61373 allway applications — Rolling stock equipment — shock and vibration test | IEC 60310 Traction transformers and inductors on board rolling stock | EN60121-3:2 | Railway applications - Electromagnetic compatiblity (CENELEC) _| Part 3-2: Roling stock - Apparatus | EN50121-2 | Rallway applications - Electromagnetic compatibility | (CENELEC) —_| Part 2: Emission ofthe whole railway system to the outside world. | 1EC-61375-1 | Electric Railway Equipment-Train Bus Part =1 : Train communication network | | EN 50153 | Railway applications — Rolling stock — Protective actions against electrical hazards. EN 60529 Protection classes of eases (IP-Code) FEREATON Poa | PREPBY croc 8v lost snse0 rd se5010 Se0Kve - CENTRE FOR DES A CEVELOPMENT Goreme | NY ey Siraaaanwoeanenons TOBEUSED WEST BENGAL NDA FOR no: Cues ETON apse | ROUEDBY ocowornes | OF CEE/DHD — far ja fe fePage 8 of 33 4.5 DOCUMENTATION: v ‘The tenderer must submit the following information with the offer in printed form and neatly compiled in a booklet form. Offer with incomplete information may not be considered, Detailed specification of the offered converter, major equipments lke transformer, chokes, and DC link capacitors as well as MCCBs & fuses etc. > Details of semiconductor devices used their specification and data sheet > Design calculations including the calculation of safety margin in voltage, current, thermal (for junction temperature) along with the limit value of power devices. Detailed calculation of cooling system design and its efficiency are to be furnished. Minimum airflow rate, which will give the desired cooling, should be mentioned. > Mechanical drawings of complete cubicles as well as major subassemblies / rack with details of dimensions, mounting arrangement and weight, which are required to be taken out for ‘maintenance. > Details of protection provided and their effectiveness / proposed set values and range and working principle, Details of implementation. > ‘System description, power circuit diagram along with bill of material of major ‘equipments, circuit description, working principle and salient features. The detals of microprocessor t microcontroller used, functional block description of PCBs used, control system hierarchy, protocol used and interfacing. » Detail operation of panel and function of each switch, indications and fault diagnostic feature. > QAM (Quality Assurance Manual). > Declared output voltage and current waveform, THD and regulation. > Test protocol with procedure of testing, > Data sheet of major components duly filled, » {SO 9000 certification. > ‘Schematic Circuit ea Functional Description > Mechanical interface diagram and compliance to existing mechanics. > Clause by clause compliance. [aomerroW Fa | excrov cere 8 iBT BASED | SSEINSD ‘SEEDED pe \ - ‘CENTRE FOR DESIGN 8 DEVELOPMENT fone tA (CHTTARANUAN LO2OMOTIVE WORKS ToBEUED eT GAL ND. a 1p cavesen brats SPHASE 1SSUEDBY voecuorives | bv c2/080 ar la |e |eS os v A 7 AP 7 v v Page 9 of 33 Calculation and simulation results of system behaviour, including interference to the S&T cirouits. Credentials with details of supply made of such/similar ites. Salient features and advantages of the offered system. Details of technical support and training offered. Recommended list of spares with cost for 3-year maintenance after warranty along with full drawing/design and details of OEM. st of special tools, jigs and fixtures needed for assembly, testing, commissioning, maintenance and repair along with full technical specifications and probable suppliers. Logistics proposed for warranty support within India. Declaration for long-term support by the tenderer. Guaranteed values of efciency of devicesisubassemblies and assemblies. Calculation to withstand shor circuit current under fault conditions. Details of short time rating of the converter. Expected efficiency. Technical documentation explaining the complete scheme, characteristics, diagnostics, protection and control etc Detaled drawings of each system/sub-system with interface details, Complete BOM(bill of material) / technical specification of components with source of supply. Procedure for parameter alteration, software downloading, diagnostic uploading, analysis et. Schedule maintenance activites with periodicity. Maintenance, Trouble shooting and repair manual in soft form & hard copy. All calculations evaluated on the basis of software simulations shall be supported by sample calculations, The tenderer shall wholly and completely be responsible for the performance of the complete equipment. > Details of Tools and Plants with design/drawings and supplier. SPEORETON fom | prepay cyecxen By sear nse 0 Seu ping S CENTRE FOR DES &DEVELOPUENT convenes CHTAPanUMN LocONTNE ORNS ‘oes WES ENGL BOA ro no caves rns arise [Siar vocouornes | ovceron = Cy, far fa fa fePage 10 of 33, 4.6 INFRINGEMENT OF PATENT RIGHTS Indian Railway shall not be responsible for infringement of patent rights arising due to similanity in design, manufacturing process, components used in design, development and manufacturing of inverter and any other factor which may be cause such dispute. The responsibilty to settle any issue lies with the manufacturer. SSN TT | enero ceo vcafarseo | SSe08D oa ise - oma cee ron ce5r DEVEL -NENT anette | NS ‘Surana cosowotns Wares ‘elseunes Wee SEAL ND fon no HSH ers sfuce [Rear —_——Page 11 of 33 CHAPTER - 2: TECHNICAL SPECIFICATION 24 The auxiliary at AC input may use thyristors or IGBTS. The inverter should, however, be with IGBTS. The control should be microprocessor / micro-controller based with diagnostic facies. The specication has been drawn for three auxiliary converters identical in all respects each with 130 KVA capacity and battery charging unit (details in 2.2) constitute one loco set of equipment, however, for sake of clarity unless otherwise specified following applies to each of the converters which may be refered as BUR’, BUR2 and BUR3 respectively housed in two cubicles, cubicle-1 shall have BURY and cubicle-2 shall have BUR2 & BUR3. 2.2 Converter Ratings (BUR1, BUR2 & BUR3) INPUT (2) Vottage : 1000 V single phase at a catenary voltage of Nominal Voltage = 25 KV AC Maximum Voltage = 27.5 KVAC Minimum Voltage ~ 49kV AC Occasional Maximum -31kV Instantaneous Minimum ~16.5KV ‘Supply Frequency ~ 50Hz# (8%) The occasional maximum and instantaneous minimum voltage may persist for 30 min. (b) Frequency 50 Hz + 8% (c) Power factor 0.8 or more (at full load) between OHE voltage 19 kV to 27.5 kV and min. 0.55 above 27.5 kV. (d) (THD) Total Harmonic To be kept to minimum, manufacturer will indicate Distortion (Current) the optimized value at full load (e) Winding Details 334 KVA / 5.82% Impedance / 268.58 m2 a Ss wits Bh cw le eePage 12 of 3 OUTPUT (i) AC 3-Phase (2) AC voltage (L-L) A15VE5% (b) Nominal Output Frequency 50Hz+2% (c) KVA output 130 KVA (2) Short time current rating Same as overload rating of the exsting GTO based 3 X 100 KVA auxiliary converter i.e approximately 450 A for 4 to 6 sec. (@) Total harmonic distortion (THD) in Less than 10% ‘output voltage to the 3-phase motor. ( dviat Less than 500V/Microsecond (@):. The auxiliary converter shall be suitable for generating 3-phase AC out put at multiple voltages and frequencies as detailed in para 2.5 below (ii) Dc OUTPUT (a) 40V, 80A with current ripple less than 5% and voltage regulation 45%, with battery current maximum of 110A (b) The Battery Charger characteristic should be suitable for charging the existing 199 AH Ni-Cd battery & supplying the 110 V load in 3-phase locomotives (iv) EFFICIENCY: Effciency at rated output :—-‘Minimum 92% at rated load (190 KVA) of 0.8 pf Note: Rated capacity of 130 KVA is expected for input voltage range of 1$kV to 30KV. However, degraded performance in terms of lower output voltage or frequency is acceptable below 19kV and manufacturer will specify the extent of degraded performance. It will not be possibie to regulate the duty cycle ofthe loads. The existing smoothing choke which is rated at 155A (Max.190A) shall be explored for adoption in the improved design of Auxiliary Converter (3X130 KVA). In the event of inadequacy of the existing choke, the tenderer shall offer alternative choke design, Keeping in mind that this choke will be provided in the machine room and may lead to increase of machine room temperature. The detalls of the existing smoothing choke are given below. EGFIOATION (HEoKED BY SED | CENTRE FOR DESIGN DEVELOPMENT (CHTTARANIAN LOCOMOTIVE WORKS WEST BENGAL, NDIA NO-CLVESIG/ GETOAES her fur da fe fe SK130KVA AURILARY CONVERTER TOBEUSED FOR PHASE LocowoTivesPage 13 of 33 Pos. 313 — ] Ty 6GODI20 | ‘Quantity 1 Three-Phase Choke Location Inside Transformer Tank Data Refer to Specification No. 3EHE 428048 __ Inductance values of each BUR choke at different currents OA [30 mH | 120A 30 mil (20a 30m 155A 26 mH 190A 20 mH ‘Terminal Notation: xB13 xel4 OS and 3033 os xail xpi. xBaL XB XBSL XB? BURI BUR2 BUR3 Each choke consists of a magnetic frame. The chokes are arranged in a stack. Since asymmetric voltages are applied across these, the chokes are decoupled. The DC ink ‘elements are designed for a nominal power of 100 kVA. 23 Load pattern The normal & emergency loadings are shown in Annexure-1 234 Three phase auxiliary load: Auxliary loads on individual BUR, in normal and fautt conditions shall be distributed as detailed in Annexure. Auxliary converter should be in a postion to soft start the loads using variable voltage. variable frequency control 2.3.2 DC load: The locomotive control circuit, loco head light, flasher light tc. are fed through 110V DC circuit containing locomotive battery 23.3 Reconnection of the loads under emergency: If one of the auxiliary converters fails then the provision is made for continued operation with reconnection of loads. The reconnection of loads is done with the help of contactors with interlocking feature. See Annexure-| for the proposed connection. These contactors are OR | ererar. eee veofensen | seman Seow aban . centRe Fon OESTGN DEVELOPNENT cOWERTER CHNTTARANAN LOCOMOTIVE WORKS oucusD EST BENGAL RO FOR no cuesou GoTo spuse | RUB EY Locowotives | OY. CEE/DED at [a {e |cPage 14 of 33 controlled by the Auxiliary Converter control electronics. The necessary actions for reconnection will be taken by vehicle control electronics. 24 — Protection: 24.1 The devices used in the auxiiary converter shall be protected against high rate of rise of voltage & current, lin transient surge, switching surges etc. The converters shall be protected against (2) Open circuit in auxiliary winding (0) Ground faultin AC input circuit () Ground faultin 3-phase load (@) Auxiliary converter phase fault (@) Line tone short circuit due to dead short at motor terminals () Thermal over loading (9) Fuse failure in converter (h) High / low voltage in DC link () Failures of power supply to control electronics 0 DC link short circuit (K) Input over voltage / under voltage (0) Inputover current (m) Single phasing in load (n) Output over current ‘The details of such protection shall be submited by the successful tenderer for review during design stage. The equipments shall be protected against intemal transient, spikes and surges as per limit laid down as per IEC 60571 (2006-12) 2.14.14 Multiple voltage / frequency operation: The energy conservation feature through multi level ventilation! coofng, as existing in the present 3X100 kVA GTO based Auxiliary converter and IGBT based auxlary converter shall be retained. At least two frequency steps should be provided for this purpose ie 37 Hz and 50 Hz. The methodology of implementation shall be finalized at the design approval stage. Based ‘on the ventilation requirement the auxiliary converter shall be required 'o be operated at 50 Hz even in case of isolation of one of the auxiiary converter. Therefore the output connector shall be suitably modified to cary full load as per Annexure-| SFEORCATION ron | Pray crecxeo sv GBT BASED aD Se00 SisoWwa ~ ALAR ; CENTRE FOR DESI DEVELOPMENT wie, | NS CHTTARANUAN LOCOMOTIVE WORKS Ste useD WEST EENAL INDIA FR no: cLWESes Gauss PHASE ISSUED BY T tocoworves | br.cespin = Ya ar ja [edePage 15 of 33 2.6 Integration with Vehicle Control Electronics: The Auxiliary converter has to work with the existing Vehicle Control Unit, which is based on MICAS S2 control & communication (C&C) system of Mis. Bombardier Transportation. The tenderer shall give a suitable interface to the existing VCU. All the control and communication functionalties of the existing Auxiliary Converter shall be met by the proposed IGBT based auxilary converter. Modified software suitable for the converter shall be within the scope of supply The Auxliary converter shall be ready for use with upcoming TCN compliant VCU which is as per CLW specification No.-C-D&D/TCNIVCUIHWIMICAS-S2VER3 with latest. Specification shall be made available tothe tenderer at CLW on demand, The initialization time for IGBT based Auxiliary Converter should be kept < 30 sec. 2.7 Fault Indication, Diagnostics and Trouble Shooting: ‘A suitable fault diagnostics and trouble-shooting arrangement as per functional requirement of 3-phase locomotive shall be provided locally on the auxiliary converter. The faults shall be down loadable on a laptop computer through a standard port /interface. Large capacity of storage of faults along with the background data should be provided, so that data pertaining to at least 90 days are kept stored. Details of the fault diagnostics and indication of faults / health status shall be finalized during the design approval stage. 28 Safety: Following shall be provided in each Auxiliary converter cubicle for human safety 28.1 _ Indication of presence of high voltage ( Voltage Indicator) 282 All the equipments shall be adequately earthed, insulated, screened or enclosed. It ‘should be provided with essential safety interlock and keys on front panel and is to be integrated with existing key multiplier system as may be adequate to ensure the protection of the equipment and safety of those concemed with its operation and maintenance. 29 Mechanical dimensions The spaces for retrofitment of Auxiliary converter in place of existing equipment are mentioned under. The changes, if any, are to be agreed to between Raiways and the Auxiliary Converter's manufacturer. Its also to be ensured that the above equipment could be fited in existing types of Locos of IR namely WAPS, WAG, WAG-SH & WAP7. Envelope size of the space available in the locomotive for mounting the equipment (all dimensions are in mm) for retrofitment on WAPS / WAG / WAGSH / WAP7 Locos shall be as under: ‘SECRICATION FOR PREP BY, ‘CHECKED By iosteaseo | SSE08D ‘SEEDED Abney CENTRE FOR OES DEVELOPUENT cowenter CATTAPANUIN LOCOMOTIVE WORKS Sones WES BENGAL ROA = No: cues IeaTIONas spuase [SUEY tocowotves | Dy. CEE/DED ar ja [ea fePage 16 of 33 Overall Size Mounting Dimension () Cubicle 1 4460 «1020%1860 (LxD*H) 4420900 (LxW) (i) Cubicle 2 +1820 x1020%1860 (LxDxH) 4480x900 (LxW) Note: 'A. Agap of 50 to 100mm only is available between roof and equipment in the locomotive and hence cooling system design should be done accordingly. B. Each cubicle houses fully identical 130 KVA converter as described in 2.1. C. Offer should include power loss calculation considering existing cooling system. . The panel sheets used for fabrication of enclosure shall have minimum thickness 2.0 mm and shall be made either of steel as per IRSM 41-7 with corrosion resistance coating or $6304.To have a light weight door, aluminium alloy may be used. The number of fxing bolts to be restricted to maximum 5-6 nos. per door. The drawing of the front door fixing arrangement is given at Annexure-2, 2.40 Weight: ‘The weight ofthe existing auxiliary converter cubicles are approximately Cubicle -1 (BUR-1) -608 Kg Cubicle -2 (BUR-2&BUR-3) - 1130 Kg 2.11 Enclosure: 2114.4. This would be as per TOT design documents for auxiliary converter of 3 phase loco. Any altemative design meeting functional requirement can be offered with full detalis for IR's scrutiny and approval. 2.41.2 The enclosure for electronics shall be free from dust and moisture and shall comply the IP-54 ‘as per IEC-60529.Design of cooling heat exchanger shall be done to ensure temperature difference less than 10 degree centigrade across the heat exchanger. 242 Cooling: ‘The present GTO based Auxiliary Converter uses force air cooling from machine room blowers, a part of the cooling air is quided to the Auxliary Converter. The heat losses in the BUR’s are carried away through the heat exchanger. The ventilation air guiding ducts from the machine room to Auxiliary Converter Cubicle 1 & 2 shall be provided the folowing air values as appended below: RATION for | peers cveoneo BY seorersen | S8g04D Sow StsoKuh ae Centre FoR DESI DEVELOPMENT convene ChTAranut LocoMorne WORKS ose used es BNL ROA ron 1g eawese araas shase _ [RleDar wocsuones force = YR ar fa le fePage 17 of 3 Cubicle 4 Airflow rate Front: 1100 min Rear : 550 mh Airspeed Front: 25mis Rear 5.0 mis Pressure Front: 30Pa Rear : 06Pa Cubicle 2 Airflow rate Front. : 1700 mh Rear 1100 mh Airspeed Front: Smis Rear: Smis Pressure Front : 30Pa Rear : 20Pa The existing arrangements for the ‘cooling of the auxiiary converter shall be preferred However, the tenderer shall furish the detailed altemative arrangement if existing arrangement is found inadequate. 2.13 Locomotive Cable Interface: It is proposed that the cables for connection to the locomotive should be in the bottom of the panel. Following are the sizes of various cables proposed to be used. However, this may change as per the requirements and needs and shall be discussed & finalised after placement of order. EB irradiated cables shall be used for intemal wiring, (a) Transformer auxiliary winding to input of Auxiliary converter pane! ~ 70 mm? cable, (0) Output of auxiliary converter - 50 mm2cable. (4) Battery charger to battery base ~ Two 10 sq mm cable. Control cables are connected from upper side of the cubicle through a circular connector. However, finalisation of cable outlets shall be done during design approval after award of contract Location of input & out put terminal should be same as the one in existing Aux converter to provide for interchangeability of different makes of Auxiliary Converter. EORCATION FOR PREP. CcHEoKED By ioat ease | SSEDSD SEEDS Anu CENTRE FOR OES DEVELOPUENT covers | NS CHHTAFUnuN\ LocauOTWe WORKS ‘ose sed WEST NAL RO FOR No: cuWestH IGsTIONS spiase | BSUEBBY Locouorives | DY. CEE/DED at fa [a fePage 18 of 33 2.14 General design featur 2.14.1 Safety factor (@) In the circuit configuration, 25% safety margin in the rating of bot: voltage and current under worst conditions is to be ensured. This should be established in the offer with calculation. (b) A minimum thermal margin of 10°C for junction temperature under worst operating condition for the power devices is requited. Over load margins and duration are to be furnished. 2.14.2. Current Density of the Bus Bars : 4A / sq, mm 2.14.3 Acoustic Noise : Acoustic Noise generated by circuits and components should be as low as possible, less than £80 dB (A) ata distance of 1 M from the equipment. 2.14.4 The cards shall be provided with LED indication to show the heath of cards, to assist ‘maintenance and operating personnel in trouble shooting, 2.14.5 The power portion of the equipment should be suitably protected to prevent accidental contact. ‘The shields and screens shall be property earthed 2.146 Reliabi Component to be selected and tested as per interational reliability essurance specication including burn-in test. Tenderer shall submit reliability calculations indicating MTBF of different deviceslequipments ike cards and sub-assembly. Adequate margin shal be provided fo take in to account ambient conditions prevaiing in India. 2.14.7 Maintainabi ‘The use of general purpose ICs should be encouraged and use of ASICs restricted for better maintainablity. Modular system with plug in and easily replaceable control cards with polatization for non-interchange ablity shall be provided. Accessibilty to components / subassemblies requiring frequent maintenance should be ensured. Azcess is available only from the corridor sides, 2.14.8 Marking: ‘The major equipments / subassemblies should bear marking and serial number. The equipment should contain serial number and make of supplier. (@) Allequipments / cubicles shall contain name plates of anodised aluminium with engraved / punched letters. FEGRCATION FOR. PREP ay, crecxen BY vwatsisen | SSEDSD SEEDED DVR joa CENTRE FOR DESI 8 DEVELOPMENT cwenteR “ CGHTTARANUAN LOCOMOTIVE WORKS Tose useD WEST SENSAL NOM no: CVES¥a srodes FoR apse | SUEDEY LocowoTives | DY. CEE/DED ar ja |e fePage 19 of 33 (0) The inverter rating plate shall be marked with the following information: () Type / Make (i) Contract number (ii) Month and year of manufacture / batch no. / Serial no. (iv) Rating —KVA ~ Input voltage range ~- Output voltage, frequency and wave shape 2149 Cables: ‘The use of wires / cables shall be reduced to minimum. Bus bars will be of high grade copper and insulated bus bar is preferable.The wires / cables shall be of high grade, copper with halogen free thin walled insulations. All the cable terminations shall be made through crimped sockets / lugs and wires with circuit and diagram furnished. 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 must be avoided and terminals of adequate size shall be provided. 2.14.10 Cable grommets / glands of suitable size as required for input and output cables shall be provided at cable entry / exit. 2.14.11 Fitment of MCB-100: MCB 100 (Circuit Breaker for Battery Charger).f required, should be provided on the front/ left side wall (neat_machine room blower-2) of Auxiliary Converter-2 such that it should be easily accessible by the Loco Pilot and maintenance staf the output of MCB-100 shall be connected directly to the input of battery charger. Mounting of MCB-100 should be such that it should be Possible to operate it without opening the front door of Auxiliary Converter-2. While opening the door of Auxiliary Converter-2 during maintenance it shall be ensured that the position of MCB- 100 is not disturbed 2.14.12 Mechanical Integration: IGBT based Auxiliary Converter shall be retro-ftment of the exiting GTO based Auxiliary Converter.So the mounting arrangement of the IGBT based Auxiliary Converter shall be kept unchanged to the existing GTO based Auxiliary Converter. FECTION ton | prep ciecxeo ev vectansen | SeE080 Seea0 Sx1soKve xb cenmeronce@rsSeLonENt < CATARINA Loe Sous | NO WEST BENGAL NOMA oR no cuesou eras sense |S vooouotves | ovcesios = A, ar Ja fe fePage 20 of 33 2.14.13 Control Equipment Integration: ‘All the connectors for control system of the of IGBT based Auxiliary Canverter's bus station shall be similar to one used in the existing GTO based Auxiliary Converter. Suppliers has to Use the same connector for control signals of the IGBT based Auxiliary Converter. Details shall be available from CLW. 2.14.14 Input Power Interface: @ () © (a) e) The auxiliary converter will be supplied through the auxiliaries winding of the locomotive transformer. 'A RéC snubber is placed across the auxiliary winding with R = 220, 320W and C = 0.66uF, 2000V. In addition, toroid cores are inserted in the input cables to minimise the dit and interaction between multiple converters across same winding. The tenderer has to study the present scheme and to ensure thet offered converter is protected in all operating conditions, ‘The catenary voltage can vary from 19 kV to 30 KV. However, voltage may dip down to 465 KV which may lasts for upto half an hour. Input power frequency: 50H228% Panto bouncing duration should be up to 45 ms (limit of zero pressure contact) and it should not affect Auxiliary Converter with or without loads. 2.14.45 Signal and telecommunication installation: ‘The tracks over which the locos will run may be equipped with 83-1/3 Hz track circuit as well as ‘rack circuits at higher frequencies. Similarly, other devices like axle counters, block instruments, point machines etc., may also be employed. On the communication network, control circu, tele-printer circuit as well as VHF / UHF and micro-wave circuits are employed SFEORORTON Toe | oneay creo By soa nse 60 SeeeD Scisve ~ Aon ‘ CENTRE FOR OES DEVELOPVENT coMVERTER ® CGATTARANIAN LO®OMOTWE WORKS Toe used WEST BEKGAL NDI ron vee BTS spuse_ | GDR 7 ocouarives | OY. cEE/D8D hur ar fA I ©Page 21 of 33, CHAPTER - 3 : CLIMATIC & ENVIRONMENTAL CONDITION 34 Temperature: Maximum temperature inside stabled Locomotive under sun =70 deg. C Maximum temperature inside working loco 55 deg. C Minimum temperature O deg. C The equipment shall be able to startup at the maximum specified temperature inside the locomotive without ny pre-cooling requirement 3.2 Humidity: Upto 100% during rainy season, 3.3 Altitude: Up to 1000 m above mean sea level. 34 Rainfall: Very heavy rainfall in certain areas. So the Auiary Converter shall be designed suitably 3.5 Atmosphere During Hot Weather. Extremely dusty and desert terrain in certain areas. The dust concentration in ir may reach a high value of 1.6 mglcub. In many ion ore and coalmine areas, the dust concentration is very high affecting te fiter and air ventilation system, 38, Coastal Area: The equipment shall be designed to work in coastal area in humidity and salt laden and corrosive atmosphere. The maximum values ofthe condition shall be as folows: @) Maximum pH value 85 8) Sulphate 7 mg per tre. ) Maximum concentration of chlorine. : 6 mg perlite 4) Maximum conductivity 130 micro siemens CM 37. Vibration The equipment shal be designed to withstand the vibrations and shock encountered in service satisfactory 2s specied in IEC 61287 and 60671 publication forthe converter and electronic. ‘equipments respectively and relevant IEC’s as applicable to other equipment. 38 Electromagnetic Pollution: High degree of electromagnetic pollution is anticipated in locomotive machine room, where the equipment shall be mounted, Necessary precaution shal be taken in this regard SSRN oR | eserar cnecreo ay @ ‘ca anc Seo cS wn (CENTRE FOR DESIGN & DEVELOPMENT deme |S | 49--| Sage one sr Bent nO ae no civese® Bere coconotves | orcs = yy ar ] ale |ePage 22 of 33 CHAPTER - 4 : SCOPE OF SUPPLY 44 The scope of supply covers design and development ‘of complete set of 3 nos. 130 KVA IGBT based auxiliary converter for 25KV AC 3 phase locomotive, including battery charger to meet the 110V DC load requirement. Contactors as provided on the existing locomotives for switching and transferring of loads shall be retained. 42 ‘Supplier shall supply suitable software for offine analysis of diagnostic data downloaded from the auxiliary converter. 43. The Auxiliary Converter should have provision for cab air conditioning, which may be adopted in future. The tenderer should also submit the complete proposal consisting of related hardware and software. 44 Commissioning of complete set of 3 nos. 130 kVA IGBT based auxifary converter on the locomotive. 4.5 The supplier shall organise for training to IR personnel at CLW and at their factory premises for Railways (RDSO/CLW & Zonal Railways) in ‘the field of maintenance & trouble shooting of the sysiem. Five days taining for six persons per 10 Loco sets to be offered in the feld of ‘maintenance & trouble shooting of Auxiliary Converter on mutually agreed location between manufacturer and CLW. 46 Detailed operation and maintenance manual 47 Deleted. 48 List of spares for 5 years maintenance. 49 Repair charges for the PCBs. 4.10 deleted. ‘Tenderer shall separately quote for the item mentioned under clause no. 48-49 EET Ta | exceor ieoxs By sstsen Sos isn Somat come ron or Dev 0F.E" CONVERTER X ‘CHITTARANJAN LOCOMOTIVE WORKS. ‘aes Wes STA eu ; no yest Gras aa ities [oreo YO a fa |e lePage 23 of 33 CHAPTER - 5: TEST 5.1. The individual equipments, system and sub-system of Auxiliary Converter shall be type tested and routine tested in accordance with relevant IECs, > TYPE TEST OF AUXILIARY CONVERTER: 5.2. Prototype test shall be performed on one unit (manufactured as per design) to verify thatthe product meets the requirements specified and agreed upon between users & manufacturer. Series manufacture shall commence only after suocessful prototype test. ‘Type test shall be repeated inthe following cases: © Firsttime supplier to IR. ‘© Modification of equipment, which is likely to affects function. ‘© Failure or variations established during type or routine test. ‘© Resumption ofthe after an interruption of more than two years. ‘At the time of indigenisation, if the supplier has supplied with foreign collaboration in product originally. ‘Type test shall be carried out for the equipment/sub-assembly indigenised. The type test on the full unit in case of indigenisation shall be considered only if there is major design change. 5.3. The converter shall be tested in accordance with IEC61287 and the control electronics shall be tested as per IEC80571 5.4. The list of tests to be carried out are as follows: S.N. | IES with clause no. Description [1 [16061287 clause 45.3.1 _| Visual inspection 2. | 1061267 clause 4.5.3.2 | Verfication of dimension & Tolerance 3. | 1EC81287 clause 4.5.3.3 | Weighing 4, 6. | I | I | 4. | 16061287 clause 4.5.3.5 | Cooling system performance tests 1061287 clause 4.5.36 | Test of mechanical and electrical protection and | measuring equipment 1EC81287 clause 4.5.3.8 | Test of the degree of protection 7, [1E081287 clause 45.39 | Commutation test SEROTON ro | meray ceo By vcsttisco | Seow | Sous Ao CENTRE FOR DESION& DEVELOPMENT comeren | WY Gira Lorouorne wom Settee eT BENG RO ron vo ESE eBTas store [Seber vobaiories. | br cet — far fa fo fePage 24 of 33, 16061287 clause 4.5.3.10 ‘Acoustic noise measurement | 9. | 16061287 clause 4.5.3.1 Temperature-ise test 10. | 1061287 clause 4.5.3.12 Power loss determination 11, | 16081287 clause 4.5.3.13 ‘Supply over voltage and transient energy 42 | 1EC61287 clause 4.5.3.14 ‘Sudden variations of load 143, | 1EC61287 clause 4.5.3.17 Partial Discharge test 14, | IEC81287 clause 453.18 | Safety requirements | 45, | 1EC61287 clause 4.5.3.19 | vibration and shock 46 | EC81287 clause 45:3.20 | Electromagnetic compatibility 47, | \EC61287 clause 453.21 Step change of line voltage test 19, | IE061287 clause 45.322 Short time supply interruption test 49 | 1EC81267 clause 45.3.23 | Current sharing test 20 | 1EC61287 clause 7.4.1 | Output characteristics test. | 21 | 1EC61287 clause 7.4.2 __| Starting and restarting test. 22 | 1EC61287 clause 7.4.4 _| Voltage and frequency range verification [_ 23 [1061267 clause 7.45 | Rated load test. [aq [CHS dause438 | Deleted ) 25 | 1411.5 clause 4.3.11 | Deleted 26 |IEC4115clause427 | Deleted 27 |I6C411.5clause4.33 | Deleted | 28 | 1E061287 clause 7.4.6 | Overload capacity test 29. | |EC60571 clause 10.22 _| Performance test by fault simulation 30 | 1€C60571 clause 10.2.3, Cooling test on control electronics. | 31 | 1EC60571 clause 10.2.4 Dy heat on control electronics | 32. | |EC60571 clause 10.2.5 Damp heat on control electronics 33 | IEC80671 clause 102.62 Voltage surge on control electronics 34 | 1EC60571 clause 10.264 Electrostatic discharge test on control electronics 35 | IEC60571 clause 10.2.7 ‘Transient burst susceptibility test on control electronics 36 _| |EC60571 clause 10.2.8 Radio interference test on control electronics 37 | 1EC60571 clause10.2.13 Burnin test of the cards as per temperature cycle described in Annexure-3. ‘SECFIEATION FOR PREP BY. onsen By Isr Basen D SEEDID SKID KA > BUKLARY (CENTRE FOR DESIGN & DEVELOPMENT ‘CONVERTER ‘CHITTARANAN LOCOMOTIVE WORKS, ‘TOBE USED WEST BENGAL, NDA FOR Noa rae PHASE ois [Sao Oe [ar Ja [eoPage 25 of 33 5.5. The prototype units of Auxiliary Converter shall be inspected & tested by the engineers of CLW and RDSO at the factory premises or at mutually decided venue where all the facilities should be made available for carrying out the prototype test. The equipments shall be kept in field trials for a period of six months. The RDSO engineers shall be associate and witness the tests in the Locomotive also til they are successfully completed. Any defects noticedidesign improvement found necessary as a result of the test / tril shall be carried out by the tenderer in the least possible time. Serial production shall only starts only after the successful trial run (on Loco and prototype clearance to this effect will be given by RDSO. > ROUTINE TEST OF AUXILIARY CONVERTER: 5.6. Routine test are to be carried out to verify that properties of the product correspond to those ‘measured during type tests. Routine test are to be carried out by the manufacturer on each equipment. 57. The Converter shall be routine tested in accordance with IEC 61287 and the control electronics shall be tested as per IEC 6057’. 5.8. The list of tests to be carried out are as follows: SN | IEC with clause no. Description [4 |1€061287 ciause 45.3.1 | Visual inspection 2.__|1E061287 clause 45.3.2 __| Verification of dimension & Tolerance 3._ | 1EC61287 ciause 45.3.4 | Marking Inspection ] 4, | 1EC61287 clause 4.5.36 | Test of mechanical and electrical protection and measuring equipment 5. |1EC81287 clause 453.7 | Lightload test 6. | 1EC61287 clause 4.5.3.15 | insulation resistance tests | 7, | 1EC61287 clause 453.16 | Dielectric test [8 | 1EC60571 clause 10.2.2 _| Performance test by fault simulation > OTHER POINTS TO BE FOLLOWED: 5.9. The suppliers shall submit complete test programme for type test to CLW & RDSO and routine test to CLW before the test for its approval. Authorised representative of CLW may also decide SPECICATION FoR | PREP. oxen By soar saseo sD SEEDID aia CCaNTREFOR ESIGN &DEVELOPUENT CONVERTER YS ‘CHITTARANJAN LOCOMOTIVE WORKS ‘TORE USED y ‘WEST SENGAL IDK FoR noveesna/ armeas SPHASE ISSUEDBY vocowanives | OF.czz/DD YO ar ja fe |cPage 26 of 33 to carry out certain special tests on the ‘equipment, which are not covered by relevant IEC specification. Supplier shall carry out the test as per mutually agreed test programme at his ‘own cost. 5.10.nvestigation tests are intended to obtain additional information regarding the performance of the product. They shall be specially requested either by the user or the manufacturer. 5:11 .Authorised representative of CLW 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 CLW's specication 5.12.Necessary arrangement should be made by the supplier to carry out certain tests to establish conformance to specified requirements e.g. dvidt, THD etc. 5.13, Instrumentations: (2) Al the instruments used for testing should be duly calibrated. The calibration certificates are to be shown to inspecting authority on demand. (0) Value of the fundamental component and THD of inverter output wil be measured by power analyser during the prototype test. True value of output veltage rms is also to be ‘measured for record. (©) Input power factor and the efficiency will be measured by usng power analyser at rated load of 130 KVA at 08 pf 5.14. The following clarifications are issued on the tests included in 5.4 & 58 (a) Visual Inspection - The object of visual inspection is to check that the equipment is. free from defects and the equipment is as per approved drawing. Bil of materials shall be submitted. The make, rating of equipments, subassemblies shall be checked with the details as per approved design proposal submitted in design proposal. if a change is needed in make or rating of important equipments, sub-assemblies, it should be inimated and should have approval of RDSO. Auxiliary converter with modified equipments, subassemblies will be given separate revision number. All the important dimensions will be measured and should be in permissible tolerance. (b) Power Loss Determination Test - This test will be done at vltage corresponding to 22.5KV in OHE. The efficiency will be measured at full and 80% of load at 0.8 pf. The performance at different input votage will be monitored. The measurements will be taken at 17.5KV, 19KV, 22.5KV, 25KV, 27KV and 30 kV. SEGRCATION FOR PREP, HexD 8 \garBaseD D ‘SEBDID Xx 1DKVA AURLARY R ‘CENTRE FOR DESIGN & DEVELOPMENT comerter | YQ ‘GATTARANIAN LOCOMOTIVE WORKS TOBE USED WEST BENGAL, NDIA FoR No LIVES GBTINES spuse_ [Supe vocouories | Dv. C080 ar a |e fe© @ 0 Page 27 of 33 Earth Fault - Simulate the earth fault by connecting a suitable resistor between cubicle frame and output phases. The inverter should not trip and earth fault indication will be in “OFF” state fil the leakage current is less than 10mA. If the leakage current will ‘exceed 50mA, the earth fault will occur. Cooling Test - The purpose of this test is to verify that the cooling of various components / assemblies. The air flow rate will be measured to confirm compliance with that claimed by the manufacturer. Insulation Resistance and Dielectric Test - The insulation resistance with 1000V megger shall not be ess than 100M ohms for all the circuits. The dielectric test shal be carried out after shorting semiconductor device, pulse transformer earthed, earthed special cards if necessary before applying dielectric voltage.The corresponding voltages are given below. The folowing are the voltage and leakage current seting © Input circuit -- the test is to be done at 3.3kVrms for 60sec. The leakage current to be less than 50mA. © 110V control side — 1.5KV AC for 60 sec. The leakage current will be less than 10mA. © 24V electronics side - S00V AC for 60 sec. The leakage current to be less than 10mA ‘© Battery charger ~ (4415V side) 2kV for 60 seo. The leakage current to be less than 10mA. ‘Temperature Rise Test: The Auxiliary converter shall be loaded to full load for 6 hours with input OHE voltage of 19kV and with 50% blockade of the inlet fiters, 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°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°C. The inverter shall also be subjected for short time rating after continuous loading to ensure the temperature rise in within the permissible limit. The maximum temperature rise of the electronic devices on the PCBs should not exceed approximately 20°C above its ambient. In case it is exceeding the limit, use of mil-grade component can be considered keeping CLW and its authorised representative informed. Damp Heat Test: Function test of electronic rack will be carried out after the damp heat test. PEOFICATION FOR \caT BASED ‘X10 HVA AUKUARY. CONVERTER TOBE USED FOR S PHASE. Locoworves PREP BY. ceo BY 2 SEBDED - CENTRE FOR DESIGN DEVELOPMENT (CHITTARANUAN LOCOMOTIVE WORKS. WEST BENGAL IND No. CLES GETIDASS TSSUEBEY pres CY = far fa fa foPage 28 of 33 (h) DC Link Discharge: The DC link voltage should come down below 50V within 5 minutes. @ ‘Short Time Rating: Short time current rating shall be same as existing GTO based 3X 100 KVA auxiliary converters. (Vibration and Shock Test: The panel used during the vibration and shock test shall not be allowed to be used for series supplies against the contract as vibration and shock test is destructive test. The panel shall be kept with manufacturer. No item of this panel would be allowed to be used for supplying spares to any Railways, (k) Burn-In-Test & Dry Heat Test: The cards used in the Auxiliary Converter shall be ‘subjected to burn-in- test as per the temperature cycle described in Annexure-3 for at least 5(five) cycles. Functional test of each card shall be carried out after the bum-in- test( Refer 1EC60571 clause no.10.2. 143). This shall be part of intemal test by manufacturer whose results shall be submitted during routing test Besides this dry heat test on cards shall be done at 80°C as per clause no.10.2.4 of IEC60571. FEET FENN neoay ceo 8 ee , ‘cenTaE FOR ES & DEVELOPMENT fate | NS 4b | CGATTARANAN LOCOMOTIVE NORKS, sonerTER Meat oot HOA a | ese ras ottttSies [RR aCe ns [a fo fePage 29 of 33 CHAPTER - 6: APPENDICES Annexure-1 6.1 Existing load distribution of the Three Auxiliary Converters: Following are the load distribution. However, IR reserves right to redistribute the load as per its Tequirement. This shall be finalized with the successful tenderer. This distribution is for 3x130 KVA concept. BUR4 Ollcooler bower 2KW Oilcooler blower-2 [25 KW Total 50 KW. BURZ - 7 Traction motor Blower 1 25KW Traction motor blower -2 7 25 KW {Oi pump transformer = 1 47 KW il pump transformer = 2 47 KW Oil pump converter — 1 KW Oil pump converter = 2 [at KW Total aa KW BURS L Scavenge blower= 1 [3KW ‘Scavenge blower— 2 3KW Compressor - 1 15 KW L Compressor - 2 15 KW Battery charger 12 KVA Total [as KW | When BUR-t ISOLATED BUR2 Traction motor blower =1 2 KW Traction motor blower-2 25KW Cilcooler blower ~ 1 25KW Oil cooler blower = 2 25 KW ‘Scavenge blower— 1 3KW ‘| Scavenge blower=2 3KW Total 06 KW EGREATOR FOR PREP By, cuEoxeD By IceraaseD 80 SEEDED atau \ CENTRE FOR DESIGN 8 OEVELOPUENT CONVERTER WS ‘CHITTARANJAN LOCOMOTIVE WORKS Soeeuseo WEST BENGAL MOA FoR NO: CL WES BETIS spuse | BSED BY Locouotives | Dy. cEE/D8D ar la fa |ePage 30 of 33 BURG Oil pump transformer - 1 a7 KW il pump transformer — 2 4.7 KW Oil pump converter =1 KW. Oil pump converter =2 Tt KW Compressor - 4 TEKW. ‘Compressor — 2 16 KW | Batlery charger 12 KVA { Total [74 KW When BUR-2 ISOLATED BURA _ ‘Traction motor blower 1 KW. Traction motor blower 2 25 KW | Cilcooler blower = 1 25 KW Oil cooler biower = 2 KW sz; Scavenge blower - 1 3 KW - ‘Scavenge blower 2 3KW [Total 706 KW a BURS Oiipump transformer = 4 a7 KW (Oil pump transformer = 2 AT KW. | (il pump converter - 1 11 KW ai il pump converter = 2 +1 KW ‘Compressor = 1 15 KW | ‘Compressor = 2 15 KW { Battery charger [92 KVA Total 734 KW When BUR-3 ISOLATED BUR4 - —_] L ‘Traction motor blower -1 25KW Traction motor blower -2 25 KW Oil cooler blower = 1 25 KW Oil cooler blower = 2 25 KW Scavenge blower = 1 3KW ‘Scavenge blower — 2 [-3kW Total 106 KW SFERATON FOR | prepay. creo sy ioat Basen SeE080 Se 0KVA Aunt CENTRE FOR DESIEN DEVELOPMENT TOBEUSED WEST BENGAL NDIA 7oR or cAWesin GSTs tite [Fw ee [elf |ePage 31 of 33 BUR-2 (il pump transformer — 1 aK il pump transformer — 2 47KW ‘Oil pump converter - 7 Tt KW CL il pump converter —2 11 KW Compressor ~ 1 415 KW Compressor - 2 _ 15KW Battery charger 12KVA Total 73.4 KW TE Toe asap wie [SE [a cr aes if saePage 32 of 33 Annexure-2 6.2, DRAWING OF FRONT DOOR FIXING ARRANGEMENT: 8 [o} SS, sauarevey | eatery Look FRONT DOOR OF 3X130 KVA IGBT BASED AUXILIARY CONVERTER ‘SPESFICATION FOR PREP By. oseomeD By vearasen | SSEDs0 Steps 3x 130 KV - © AUHLARY ‘CENTRE FOR DESICN 8 DEVELOPMENT CONVERTER < ‘GATTARANIAN LO2OMOTIVE WORKS TOBE USED WEST BENSAL, NDIA NO: CLIESNSLIGBTOWRS FOR SPHASE ISSUED BY isis [RE te |e TeePage 33 of 33 6.3. Burn-in cycle for Auxiliary Converter BURN-IN TEST in Degrees emperature Cycle <7 s28¢| oc ase} 525s 2s 9215 Tea Temecisy yy | TT oaetomin tt tt PT on a Sas ae] eee [| FEORCATION FOR PREP SY. (CHECKED By veareasen | SSEDED SEEDED SK1S0KVA naa CENTRE FOR DESIGN & DEVELOPMENT ‘CONVERTER (CHTTARANLAN LOCOMOTIVE WORKS. ee WEST BENGAL INDIA a No CLMESHN IGETIOASS PHASE ISSUED BY ~ oles [Rito ate + fe |e