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HSRAmdt
HSRAmdt
DIRECTORATE OF ELECTRICAL
ENGINEERING
EED-Q-267
ISSUE-1 MAR 03
ISSUING AUTHORITY
(NAVAL HEADQUARTERS)
1
(ii)
ISSUE 1 MAR 03
REQUIREMENT FOR
The issue and use of this Specification is authorized on behalf of the Indian
Navy
By
Promulgated by:
2
INTRODUCTION
3
(iv)
CONTENTS
Authorisation (i)
Introduction (ii)
Contents
1. Scope
1
2. Related Documents
2
3. Definition 3
9. Scope of Supply 23
13. Appendix
4
SECTIONI
SCOPE
0101. This EED-Q-267 covers the design, manufacturing, testing and onboard
commissioning of the (a) 28 V DC system 12 KW (b) 200 V, 400 HZ, 3 PH AC
system 30 KVA and (c) Their associated sub assemblies. The rectifier
designed as per the specifications mentioned in EED-Q-267 should be
suitable to start ALH, Seaking, Chetak and KM-28.
5
SECTION II
RELATED DOCUMENTS AND APPLICABLE STANDARDS
(i) MIL STD 704E and DEF STAN 61-5 Part 5 - Characteristics electric
power for aircraft
(ii) NES-536 - Requirement of static conversion equipment
(xix) NES 526 Requirement for cables, electric Rubber insulated LFH
sheathed for
general services
6
(xx) NES 642 Requirement for Aircraft starting and servicing cable
assemblies.
7
SECTION III
DEFINITIONS
0301. For the purpose of this EED-Q, the definitions that apply in addition to
the general terminology are contained in succeeding paragraphs.
0305. Crest Factor. The crest factor is the absolute value of the ratio of
the peak to the RMS value for each half cycle of the voltage waveform
measured over a one second period under steady state conditions.
8
0310. Electric Starting Operation. Electric starting operation is a
specialized case of normal electric system operating conditions where the
normal voltage limits may be exceeded due to the high electric demand.
The voltage limits for normal operation may be exceeded during the
following starting conditions :-
0312. External Power Source. The external power source refers to the
ground or shipboard power source used to provide power to the aircraft’s
electrical distribution system.
9
0317. Over Frequency and Under Frequency. Over frequency and
under frequency are those frequencies which exceed the transient limits for
normal operation and are limited by the action of protective devices.
0318. Over Voltage and Under Voltage. Over Voltage and under
Voltage are those voltages which exceed the transient limits for normal
operation and are limited by the action of protective devices.
11
SECTION- IV
Tender Drawings
12
SECTION- V
ENVIRONMENTAL CONDITIONS
0501. The design of the rectifier/ Rotary frequency converter and their
associated control gears is to be catered for the most adverse of the
environmental and ambient conditions. The conversion equipment and it’s
control equipment shall conform to the following specification: -
CLOSED
SL CONDITION NORMAL
DOWN
1. Temperature
Ambient air 5 to 45 °C
Engine room Up to 55 °C
up to 55 °C
Sea water 2 to 35 °C
2. Relative Humidity at 38 ° C Up to 100% Up to 100%
3. Time Continuous Up to 48 hrs.
0504. The helo starting rectifier, converter & its control gear/panel are to be
designed to withstand their full shock levels without allowing for the
protection afforded by shock mountings.
0505. The equipment shall comply with either of the following shock
standards to be specified in SOTRs:-
(a) Indian Naval shock grade curve “A” ( Appendix ‘A’) in conjunction
with BR-3021. All equipment which affect the ship’s combat efficiency
come under this category.
13
(b) Indian Naval shock grade curve “B” (Appendix ‘B’) in conjunction
with BR-3021. All equipment which do not affect the fighting capability
of the ship, come under this category.
0506. In general, the shaft deflection under designed shock and acceleration
shall not exceed the air-gap dimension.
0508. The fixing position for shock vibration mountings are to be such that
the height of the machine center of gravity above the plane of fixing does
not exceed one half of the minimum span of the mountings.
14
SECTION- VI
Technical Specification
Input
(b) Frequency
15
Output
16
(ae) Total starting period/cut off period: 25 to 60 seconds
depending on OAT & power sources.
Design Requirements.
0606. The harmonic distortion of the input supply due to the design of the
equipment, is to be no greater than the levels quoted in NES 532. The
distortion levels should be minimized where possible and distortion factor
should not exceed 0.035.
Cooling
17
0611. Experience in Fleet use indicates a significant proportion of static
conversion equipment failures occur as a result of overheating. Suitable
exhaust fan be provided in the rectifier to meet the permissible helo rectifier
operating temperature limit.
0612. The DC & AC helo starting system should conform to Spec. MIL STD
461 C/E in respect of EMI/EMC test requirements. Static Conversion
techniques can excite electromagnetic noise and guidance for EMC is to be
sought from NES 515.
0613. Mean Time Between Failure (MTBF). The design of the equipment
shall be such that the estimated mean time interval between failure shall not
be less than 10000 hours.
0614. Self Noise & Vibration. Care is to be taken in the design and
manufacture to ensure that the airborne noise and structure borne vibrations
produced by the transformer rectifier, the self induced airborne noise and
vibration level must not exceed 60 dB. Vibration levels and methods of
taking measurements are given in clause 630 of specification NES-537. The
other general requirements for the design of electro-technical equipment are
given in specification NES-501.
0617. A multi setting overload trip with suitable selection switch in the output
circuit of rectifier be incorporated. Each setting of overload trip will
correspond to the starting current envelope of a particular type of aircraft
and will trip the rectifier in case of overload to preset current value. The
selection switch should be panel fitted and user friendly for ease of
operation. Also the overload trip should have provisions of calibration.
Control Principles
Voltage control
0620. Control Circuit Wiring. LFH (Limited Fire Hazards) cables are to
be used for internal wiring.
19
0622. Remote Starting & Instrumentation Panel. The helo starting
rectifier shall be provided with a remote starting panel along with following
metering facility:-
SECTION - VII
Technical Requirement
0701. The frequency converter shall be designed to meet the input and
output supply characteristics for the appropriate load and duty cycle. The
design is to be catered for the most adverse of the environmental and
electrical conditions. Standstill anti condensation heater suitable for
operation on 230 V, 50 HZ, 1 Ph supply is to be fitted inside the converter to
prevent condensation when the converter is not working. Remote control of
converter is to be fitted in control switchboard panel located in Hangar. The
frequency converter shall conform to specification EED-Q-267 and other
specifications mentioned therein.
Technical Specifications.
Input
(b) Frequency
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(i) Nominal frequency - 50/60 Hz ( as specified
)
(ii) Constant load tolerance - + 0.5 Hz or + 1.0%
(iii) Load range tolerance - +1 Hz or + 2.0%
(iv) Transient - + 2.5 %
(v) Time of recovery - 2 Sec to within 1% of
transient
(vi) Modulation - + 0.25%
Output
General Requirements
0703. The frequency converter should comprise directly coupled three phase
squirrel cage induction /Synchronous motor and a synchronous generator.
21
0704. The frequency converter set is to be of closed air circuit monoblock
type. The frequency converter set design is to permit ready removability of
the item without undue disturbances to the system.
0705. The frame size of M/G set shall be selected from the standard range. In
case of motor alternator, the coupling set must be direct coupled type
only(belt or gear driven not permitted). The specification for design/testing of
motor and its starter/control panel should conform to EED-Q-071 (R2). The
converter for helo starting system shall conform to EED-Q-242(R1) and EED-
S-806.
0706. All other equipment’s necessary for starting and control of the motor
generator shall be provided in a suitable bulkhead mounting panel.
0708. Internal Wiring. Only LFH (Low Fire Hazards) cables are to be used
for internal wiring.
Output Capability
(a) Supplying 110 % rated load at 0.8 power factor for one hour in
any 12 hour period.
0711. Voltage Regulation. Voltage trimmer for both auto voltage regulator
and hand voltage regulator is to be provided for varying the generator
voltage from 5 % below and 5 % above the rated voltage at all conditions of
load and all frequencies within 5 % of the normal.
22
0714. Transient Voltage Performance. The transient voltage performance
of the generator with AVR is to be as mentioned at para 0715 to 0717.
0716. When the frequency converter set is supplying at any load between 25
% and 100 % of rated load at 0.8 lagging power factor and a load equal to 25
% rated load at 0.8 lagging power factor is suddenly removed the
momentary voltage change must not exceed 7.5 % of the rated voltage.
0717. In both the cases, the voltage must be restored to and remain within
0.5 % of the final steady state voltage within 1 second of the instant of load
change.
0718. The short circuit current when in AVR control and with the generator
hot is to be at least three times the rated current and is to be sustained for
at least 3 seconds.
0720. Overall Efficiency. Frequency Converter M/G set over all efficiency
should not be less than 80 % and the same to be indicated in binding
drawings and rating plate.
0721. All the control and protection required for the converter shall be fitted
in a control panel and facility for remote control (Start, Stop, Indication and
hand voltage adjustment (HVR) is to be provided in C & C switchboard or as
specified in the TSPs.
0722. The motor starter shall be of Soft starter type/Star Delta conforming to
EED-Q- 071(R2)
0728. Over Voltage Protection Unit. The generator AVR and OVPU are to
be designed so that the voltage protection unit does not operate under any
of the following conditions:-
0729. Over Load Protection. Over load protection setting should be 125 %
of the full load current and it should be adjustable with calibrating
arrangement.
0730. Single Phase Protection. The control panel shall be provided with
the suitable arrangement for protection of the motor against single phase
protection.
24
0733. Mean Time Between Failure (MTBF). The design of the equipment
shall be such that the estimated mean time interval between failure shall not
be less than 10000 hours.
25
SECTION -VIII
CONSTRUCTION
Mounting of Equipment
0806. The control panel shall be designed suitable for bulkhead mounting.
0807. Number and type of Shock mounts required for rectifier, converter and
control panel are to be supplied along with the main equipment.
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Terminals
0810. Bolted type terminals and crimping sockets of electrolytic copper are
to be provided for all incoming and outgoing cables. Adequate spare terminal
strips are to be provided to facilitate remote control/additional control (if any
) and indication purpose.
0813. Cable Entry Glands. Cable entry glands of mild steel for body and
Naval brass for nut and their sizes shall conform to specification
DGS/EED/VI/1535/R6 for incoming and outgoing cables. The gland nut and
washers are to be left undrilled. Cable glands are to be supplied along with
the main equipment for all incoming and outgoing cables.
27
0820. Material and Workmanship. The equipment shall be made from
approved material as specified in the specification NES 507. Workmanship
shall be of highest quality and to the entire satisfaction of the inspecting
authority. Standard specification and grade of material of each component
used to be indicated in the binding drawings.
MARKING
0824. Size of the tally plate, diagram plate, danger plate, equipment
start/stop, adjustable output etc. and their letters shall conform to NES-723.
Rating plate shall indicate the following
(a) INPUT
(i) Voltage
(ii) Current
(iii) Frequency
(iv) Phase
(v) Power factor
(vi) Converter motor RPM
(b) OUTPUT
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SECTION - IX
SCOPE OF SUPPLY
(a) Transformer- rectifier 28+ 0.5 V DC, 12 kW, 400 A with suitable shock
mounts (04 nos.) conforming to IN shock grade NSS-II.
(b) One number contactor box arranged to take the following cables.
(c) One no. 300 Amps Flight deck socket box fitted with one 300 Amps
socket ( the socket to receive helo starting cable [Patt No: 0564-525-0974(23
Mtrs length)] end connector be fitted on the front panel of the box for ease of
plugging in/ un-plugging of connector) and arranged to take following cables:
S.No Cable Part No. Cable size No. of cables OD(mm) Gland Size
(d) One no. hangar socket box having two 300 Amps sockets and arranged
to take following cables.
S.No Cable Part No. Cable size No. of cables OD(mm) Gland
Size
(f) One no. start/service switch in watertight housing and arranged to take
following cables.
(i) One in number squirrel cage induction motor with soft/star delta
starter for input supply of 415 V, 50 HZ, 3 pH 3 Wire suitable for continuous
operation.
(ii) One in number 30 KVA 200 V, 400 HZ, 3 pH - 3 Wire at 0.8 P.F.
synchronous generator, brushless, electrically controlled, self ventilated
suitable for continuous operation.
(vi) Shock mounts for the frequency converter and control panel
conforming to NSS-II. The manufacturer shall provide details and make of the
S/V mounts.
(xiii) Flight Deck Socket Box 6 pole, 200V 400 Hz, 1 KVA 3 Phase 4 wire
water tight complete with matching plug- 6 nos.
(xiv) Power panel for helo starting and servicing supplies 200V, 400Hz, 3
phase 4 wire- 1 no.
31
SECTION –X
1005. The first of each type of equipment is to be type tested and each
successive unit is to be production tested at the manufacturer’s works. In
addition, extended endurance testing of prototype equipment is required to
be carried out before approval for their use can be granted. The supplier
should also furnish data/information about the methods/measurements
carried out in evaluating the performance of the equipment during the trials.
1008. The schedule for inspection, test & trials should be drawn up in such a
way that all inspections including component level inspection, trials of
subassemblies, etc., should be, as far as practicable performed at the
corresponding stage of manufacturing. Detailed measurements should be
carried out at the appropriate stage of manufacturing.
32
1009. Testing requirements at sea shall be defined in the trial programme for
each ship. The major machinery elements shall be subject to post tests
inspections. All tests required are to be carried out as specified in this
specification.
RECTIFIERS
ENVIRONMENTAL TESTS
1013. All tests (except shock tests) are to be carried out by manufacturer at
his own works, in the presence of an inspecting authority, prior to
dispatching the equipment to the customer.
1014. The inspecting authority shall call for repetition of tests if he is not
satisfied till the representation of the normal performance of the equipment.
34
1015. The manufacturer shall be responsible for the satisfactory performance
during warranty period and would have to undertake any repair if found
necessary.
1017. Environmental Stress Screening (ESS) tests. All the PCBs and
electronic modules fitted in the Helo Starting Rectifier will be subjected to
ESS tests as per MIL STD 2164 mentioned below:-
No. of cycles : 06
Dwell time : 90 min.
Change over : 5 min.
(c) Random Vibration Tests:- The vibration test will be carried out
on X,Y & Z axis at 20-2000 Hz, 0.02 g 2 /Hz for 10 minutes.
(d) Burn in Test. The equipment with PCBs in place will be switched
on at room temperature for 168 hours. OR for 48 hours at full load at 55 ˚C.
The test will comprise of:-
35
SECTION-XI
(a) A layout drawing where more than one cubicle or other auxiliary
is involved.
(b) Main view of the individual cubicles, with part section.
(c) Detailed drawing of principal sub-assemblies.
(d) Circuit diagram, wiring diagrams, wiring schedules and terminal
connection
details
(e) Overall dimensions of the equipment.
Each drawing shall have cross-reference to the other drawings of the series
and to the drawings of the associated apparatus, such as contactor box,
motors and starters etc.
36
SECTION –XII
1201. Spare Gear. The onboard spares, Base & Depot spares and test
equipment is to be recommended by the supplier. Such recommendations
are to be commensurate with the reliability of critical components and
component used in the system. Special tools and test equipment is to be
supplied for onboard maintenance.
1204. Installation. The supplier shall supply one set of installation and
commissioning spares. The manufacturer is required to provide the
necessary representative(s) to assist in carrying out inspection and supervise
the work that is done on the equipment, during the following phases:
37
Appendix-‘D’
Winding Resistance TR TR
Temperature Rise TR T TR
Hot Spot Sensing T T
Dry and damp heat T
Withstand Voltage TR TR
Insulation Resistance TR TR TR
Efficiency T T
Voltage Balance TR
Ripple, harmonic content modulation T
Voltage Range TR
Effectiveness of enclosure T T
Measurement of air gaps TR TR
Bearing grease relief T T
Self induced airborne noise and
vibration
(i) Type Test T T
9 Ship Motion
MIL-STD 461 C
10 EMI/EMC
39
Appendix- ‘F’
TEST SPECIFICATION.
HSR
380V/415V/440V 3 phase
ONLINE
I/P Supply
OSCILLOSCOPE
WITH GRAPHIC
RECORDER
40
TEST SPECIFICATION.
TEST NOs.
(30 mtrs)
Ship's laid Cable Patt No: 521-6824
Cable Patt No: 05645250974(23 Mtrs)
Cable Patt No: 529-5690
Ship I nstalled Socket
Helo Starting Air Craft/
Rectifier
Load Bank
Test procedure Test No. (ii) The Helo starting Rectifier is to be connected to
load with 30 mtrs long specified cable. Using an online graphic Oscilloscope at
the load end, the maximum drop in output voltage and its recovery time within
specified values be recorded during transient load state.
Test Procedure Test No. (iii),(v) &(vii) The Helo Starting Rectifier to be
connected to a 30 mtrs long specified cable as shown above. Using an online
41
Oscillograph the test parameters are to be recorded at load terminal. Tests No. (iii
) & (iv) are to be conducted for the complete starting envelope of the Helo Starting
Rectifier. Test No.(vii) be conducted for minimum duration of 10 sec to obtain
significant transient parameters on graph.
Test Procedure Test No. (iv) The Rectifier output voltage & current be
recorded at load terminal as shown in Figure above for a duration of 20 sec. for
Helicopter servicing/ compressor washing.
TEST SPECIFICATION.
HSR
ONLINE GRAPHIC
OSCILLOSCOPE
I/P Supply
Test Procedure Test No. (ix) Online graphic oscilloscope be connected at the
output terminals of the rectifier. Switch on the rectifier and using the output
voltage trimmer decrease the output voltage of rectifier to operate the U/V trip of
42
the rectifier. Similarly, using the voltage trimmer increase the rectifier output to
operate the O/V trip. Operation of both U/V and O/V relays be online recorded.
TEST SPECIFICATION.
Ship's laid Cable Patt No: 521-6824 Cable Patt No: 529-5690
Ship I nstalled Socket
Helo Starting Air Craft/
Rectifier
Load Bank
43
44
Tele : 23014405 Integrated headquarters
Ministry of Defence(Navy)
New Delhi – 110 011
EE/03/5181 23 Dec 09
45
4. EEDQ267 has thus been amended to factor in these requirements and
list of amendments being incorporated have been tabulated and is placed at
Enclosure. Copy of amended EEDQ267 is being forwarded by eMail to all
addressees.
5. HSRs complying with EED Q267 is applicable for Seaking, ALH and
Chetak helicopters. Specific requirement to start other helos like KA 28, KA31
etc will have to be addressed separately on a case to case basis.
sd
(Amit Rastogi)
Captain
Director of Electrical Engineering
Copy to:
The Director
Indian Naval Ship Maintenance Authority
Mumbai
46
The Commodore Superintendent
Naval Ship Repair Yard,
C/o FMO, Port Blair
The Director
ETMA
FMU/SS Complex
C/o Fleet Mail Office
Mumbai – 400 001
47
Encl to IHQ MoD(N)/DEE letter No.
EE/03/5181 dated 23 Dec 09
48
08 0612 Pertains to CE 101, 102 The list of
EMI/EMC test CS 101, 114, 115 EMI/EMC tests to
requirements RE 101, 102 be conducted on
RS 101, 103 each equipment
has been
specified. In
addition, it needs
to be brought out
that the first
rectifier of each
type should be
subjected to the
relevant EMI/EMC
tests.
09 0619(d) Pertains to design Following protections to
of protective be provided:
arrangements AC
Under Voltage
Over Voltage
Single phasing
DC
Under Voltage: Tripping at
18+ 0.5v with delay of 5
sec
Over Voltage: Tripping at
32+ 0.5v with delay of
1sec (settable)
Overload: Tripping when
the load exceeds the
specified output current
Short Circuit to be
checked during FATs only
49
50