MP.0.24.00.45 (Rev03) Sep16 For Spec-3Phase-DEMU-1600HP
MP.0.24.00.45 (Rev03) Sep16 For Spec-3Phase-DEMU-1600HP
MP.0.24.00.45 (Rev03) Sep16 For Spec-3Phase-DEMU-1600HP
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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
Issued by
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RESEARCH DESIGNS AND STANDARDS ORGANISATION
MANAK NAGAR, LUCKNOW – 226011
RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
0.0 Foreword
0.1 Diesel Electric Multiple Units are self-propelled units consisting of Driving
Power Car and Trailer Cars. They have been developed to give faster
service for sub-urban areas where traffic density is high. These have
operational features of fast acceleration and fast braking enabling them to
function as a stopping train while maintaining the average speeds of fast
Mail/Express trains.
0.2 At present, Diesel Electric Multiple Units (DEMUs) are manufactured with
AC-DC transmission system. Indian Railways has successfully introduced
AC-AC technology on mainline 4000HP diesel-electric locomotives. A recent
development has been introduction of 3-phase AC-AC technology on EMUs
and a large number of AC-AC EMUs are in service in Mumbai suburban
area. AC-AC transmission system provides improvement in reliability,
haulage capability and maintenance. Considering the future trend and its
advantages, it is proposed to manufacture 1600HP DEMUs based on 3-
phase AC-AC technology.
0.3 This specification has been prepared for development of a proven and
modern 3-phase AC-AC transmission system with microprocessor based
controls for the Indian Railways 1600HP BG Diesel Electric Multiple Units.
0.4 AC-AC transmission system and allied microprocessor based controls shall
be used with diesel engine and allied mechanical/electrical systems to
manufacture 1600HP AC-AC BG DEMU.
0.6 Easy access for inspection and maintenance requiring minimum attention
shall be given special consideration in the design of the electrical equipment
and the layout of DEMU.
Page 1 of 25
RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
0.7 The manufacturer is expected to provide all the items required for proper
functioning of the equipment in accordance with the best current
international practices, whether included in this specification or otherwise.
0.8 The specification has been prepared for general guidance of the
manufacturer. Any deviation from specification intended to improve the
performance, reliability and efficiency of the equipment as a whole or part
thereof may be proposed for consideration. All such proposals shall,
however, be accompanied with complete technical details and justification
for proposed deviation.
0.9 Performance of 3-phase AC-AC DEMU shall largely depend upon design of
traction inverter and microprocessor based control system. Therefore, it may
be noted that irrespective of whatever has been stated in this specification,
complete integration (electrical, mechanical as well as software controls) of
the offered equipment with the other equipment fitted on the DEMU shall be
sole responsibility of the successful tenderer. Successful tenderer shall
provided required supervisory support for proper mounting, installation and
shall be responsible for commissioning and satisfactory performance of
DEMU in the field trials.
0.10 Offers from only those tenderers, who have developed and have experience
in manufacture and integration of equipment for 3-phase AC/AC traction
system shall be accepted. Therefore, tenderers must submit the evidence of
successful track record of manufacture and integration of equipment for 3-
phase AC/AC traction system along with the offer. Preferably, tenderer shall
also submit detailed indigenization plan with the offer.
0.11 Tenderer shall have manufacturing, assembly and testing facilities for the
equipment being offered for 3-phase AC/AC DEMU viz., Traction control
converter, microprocessor based Vehicle Control System, traction
machines, control equipment etc.
0.12 All the provisions contained in RDSO‟s ISO procedures laid down in
Document No. QO-D-7.1-11 dated 19.07.2016 (titled “Vendor-Changes in
approved status”) and subsequent versions/amendments thereof, shall be
binding and applicable on the successful vendor/vendors in the contracts
floated by Railways to maintain quality of products supplied to Railways.
1.1 DEFINITIONS
Page 2 of 25
RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
1.1.7 „UIC‟ means Union International Des Chemins defer (International Union
of Railways)
1.1.8 „IRS‟ means Indian Railway Standard.
1.1.9 „IR‟ means Indian Railways.
1.1.10 Throughout this specification the words:
1.1.11 Horse Power (HP) shall be taken as metric horse Power, i.e. 75 kg
metre/sec.
1.1.12 Tonnes (T) shall be taken as metric ton i.e. 1000 kg.
2.0 SCOPE
Page 3 of 25
RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
13. PC/Laptop based software tool for downloading the fault 1 no.
data packs, viewing and changing the user settable
parameters along with user license.
14. Inter Vehicle Couplers alongwith end wall terminal panels 1 set
for power, control & data communication with cable
assembly. Inter Vehicle couplers required for DPC & TCs of
one basic unit (1 DPC + 4 TC) are in the scope of tenderer.
Inter Vehicle Coupler shall be user-friendly and generally
confirm to ICF Spec. No. ICF/Elec/133 latest revision.
15 Driver cab FRP interior paneling. 1 set
16 Installation, testing and commissioning charges. (to be
Installation includes all the above items except item no – quoted)
9&10. Item no.9&10 will be installed by ICF.
OPTIONAL:
17 GPS based PAS/PIS system for one basic unit (1 DPC + 4 1 set
TC). (See details given in Para )
18 Close Circuit cameras (CCTV) in the Driver's cabin and 1 set
Ladies compartment along with Digital Video Recorder.
(One camera at Driver's cab & two in Ladies compartment)
19 All Power cables, control cables and special cables like 1 set
Optic Fiber cables for one basic unit (1 DPC + 4 TC).
20 Fuel oil level sensor 1 set
21 Junction boxes, ducts and filters 1 set
22 Any other item not covered in the above breakup and scope (to be
of supply, but essentially required to buind up the rake. quoted)
2.2 The Tenderer shall supply above items to ICF and fitment of these equipment
along with testing and commissioning of the complete DEMU shall be done
at ICF under the supervision of successful tenderer. Tenderer shall arrange
for special instruments, tools etc. required for installation and commissioning
of the DEMU which are not available at ICF.
OPTIONAL:
The contractor shall supply above items to ICF and fitment of the equipment
and accessories along with testing and commissioning of the complete
DEMU shall be done by the contractor. The contractor shall also supply
hardware required for all the equipment, stainless steel air ducts required for
traction motor, Traction inverter, auxiliary converter, vent fan and radiators,
Fuel piping between fuel tank and engine, and any special instruments and
tools required for installation and commissioning of the DEMU. Assistance
for transport and loading of heavy equipments with electric/ pneumatic
power connection will be arranged by ICF.
Page 4 of 25
RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
a) All power and control cables shall be E-Beam type conforming to RDSO
Spec. no. ELRS/SPEC/ELC/0019(latest). All data cables shall be
confirming to CLW Spec. no. CLW/ES/3/0459(latest). RDSO approved
sources for power and control cables and CLW approved sources for
data cables shall only accepted. However, prior approval shall be
obtained from ICF.
b) All cables shall be supplied in pre-harnessed form as per harness chart
issued by ICF which can be obtained after finalization of design with
ICF. Pre-harnessed cables shall be supplied in proper packed
condition before delivery to ICF. The packing condition shall be
approved by ICF before commencement of supply.
c) Terminal boards and MCBs required for termination of Train line cables
on the end wall of all the coaches shall be supplied in pre-
wired and assembled form. Terminal blocks and MCBs of
ICF/RDSO approved makes shall only be accepted.
3.1 The complete microprocessor based vehicle controls and inverter systems
shall be required to work continuously at full load under following
atmospheric conditions:
Maximum temperature (i) 70 ºC (under sun)
(Atmospheric) (ii) 47 ºC (in shade)
(Temperature inside DEMU may reach 60 ºC.)
Minimum temperature -20 ºC.
(Atmospheric)
Humidity 90 % (Up to 100% during rainy season as per
IEC 60721-3-5.
Altitude Max. 1200 meter above mean sea level
Reference site conditions (i) Ambient temp. 47 ºC
(ii) Temp. inside engine compartment 55 ºC
(iii)Altitude 160 m.
Page 5 of 25
RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
4.1 The supplier shall state the value of maximum starting tractive effort,
continuous tractive effort and continuous speed values that shall be
developed under dry rail conditions and also under all weather conditions,
which shall be demonstrated during testing. Supplier shall try to improve the
performance beyond above stated values.
Page 6 of 25
RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
4.2 The tenderer shall clearly specify the minimum guaranteed reliability of the
equipment in terms of km/failure.
4.3 The tenderer shall clearly specify the efficiency of various equipment and
also the overall transmission efficiency.
4.1.1 Microprocessor based control system shall be provided with state of the art
adhesion improvement system. The system should be able to optimize the
adhesion for all weather conditions - dry rail, wet rail conditions- and all track
conditions - mainline, branch line and station yards- and operating
conditions (starting, running, braking).
4.1.3 Tenderers are required to indicate the expected level of adhesion in various
conditions. The proposed inverter and vehicle control system shall achieve
far better adhesion performance compared to existing DEMUs which are
based on AC/DC transmission system.
4.2.1 The DEMU shall be working under 25 kV, 50 Hz, OHE system also.
Electronic signals generated inside the traction inverters and vehicle control
systems shall not be affected by this and DEMU shall work without any
adverse performance.
4.2.2 The tracks over which the offered system shall work may be equipped with
DC track circuits, 83-1/3 Hz track circuits as well as track circuits at higher
frequencies. Harmonics generated by the inverter system should not affect
signalling gears like audio frequency track circuits and axle counters which
work in the range 0-5 kHz with a limit of 400 mA. On the communication
network, control circuits, teleprinter circuits as well as VHF/UHF and
microwave circuits are employed. The psophometric voltage induced on
communication circuit running by the side of track should not exceed 1 mV.
4.2.3 The electric and electronic equipment used in the inverters and Vehicle
Control System shall comply emission and immunity aspects of EMC to
CENELEC standard EN-50121-3-2. The internal EMC shall cover a
combination of earthing, shielding and isolation of interference sources so
that conducted and radiated noises are properly segregated or suppressed
and no other equipment is affected due to operation of inverter. The
following interference current in the output current waveform shall not be
exceeded at any point in the operating envelope of the DEMU:
Page 7 of 25
RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
Psophometric current<=5 A
100 Hz - 400 mA
1700 50 Hz - 300 mA
2000 50 Hz - 300 mA
2300 50 Hz - 300 mA
2600 50 Hz - 300 mA
5100 50 Hz - 100 mA
All the equipment offered shall fit within the space available in various
sections of the DEMU. Layout drawings (RDSO drg. Nos. CG–K6004 and
CG-K6014) of the proposed 1600 HP DEMU are enclosed at annexures IV
& V respectively for guidance. The total weight of the AC-AC equipment
offered shall preferably not exceed the weight of the existing AC-DC
equipment. The break up of weight of various components/ equipment of the
system shall be furnished by the tender.
5.1 The Power car shall be powered by fuel efficient diesel engine capable of
producing approx 1600 HP at 1800 rpm under standard conditions. The
engine shall be adjusted to deliver 1450 hp to the alternator under site
conditions.
5.2 The rectified traction alternator output shall be fed to traction inverter(s)
through a DC link. Traction inverter system shall be used to generate 3-
phase variable voltage-variable frequency (VVVF) output to be fed to four 3-
phase asynchronous traction motors connected in parallel. Inverter output
voltage and frequency shall be matched to traction requirements over the
entire speed range of the DEMU and shall be continuously regulated.
5.3 Solid state Auxiliary Power Control (APC) shall be provided to cater to
battery charging, controls lighting, Electric motor driven Engine room
ventilation fan and electric motor driven compressor requirements.
5.4 The 3-phase propulsion equipment should be offered such that alternator
excitation and engine HP for idle and intermediate notches are so chosen
that the engine is operated at the optimum SFC points.
5.5 All electrical equipment shall comply with relevant latest IEC/AAR/IEEE
standards. Tropical humid weather conditions prevailing in India shall be
kept in view in the design of all electrical components. The successful
tenderer /supplier shall submit detailed information about traction machines
and equipment used as per annexure - II.
Page 8 of 25
RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
6.2 The traction alternator shall be coupled with fuel efficient diesel engines
capable of producing approx 1600 HP at 1800 rpm under standard
conditions. The engine shall be adjusted to deliver 1450 hp to the alternator
under site conditions.
6.3 The traction alternator offered shall be directly coupled with the engine. The
mounting arrangement of the engine with alternator shall be decided
mutually between engine manufacturer and tenderer. No any modification
shall be carried out in the engine/engine block for the purpose of mounting
the proposed traction alternator. If any modification is required for successful
mounting of the proposed traction alternator, it should be carried out in
traction alternator only. Any changes in the mounting design should be
approved by RDSO.
6.4 The main terminal box shall be mounted at suitable location such that
connection / disconnection can be made easily. The neutral connection shall
preferably be available for ground fault detection, if required.
6.5 The alternator shall be designed for a high voltage low current operation
such that the alternator voltage at rated engine output is sufficient for proper
operation of the system.
6.6 The alternator efficiency with rated output shall not be less than 95%. The
efficiency curve for the alternator over the entire speed range shall be
furnished. The alternator shall be designed such that its output when
rectified by a three-phase bridge rectifier does not result in a ripple factor
more than 5%.
7.1 A suitable traction motor matching with the entire system shall be offered.
The traction motor shall be of AC 3-phase squirrel cage asynchronous type.
It should have a three phase stator winding suitable for voltage of wide
frequency range from inverter.
7.2 The traction motor shall be self-ventilated type with axle hung nose
suspension arrangement. The motor shall be fitted with roller suspension
bearings.
7.3 Suitable arrangement for sensing of the motor temperature shall be provided
to allow microprocessor based controls to sense and take required action to
prevent motor failure.
Page 9 of 25
RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
7.6 The traction motor shall operate satisfactorily over the entire range of
loading with ripple/harmonic currents imposed from the supply system
(comprising of alternator, rectifier, inverter, etc.). The manufacturer shall
conduct necessary tests on the traction motor to establish compliance with
this requirement.
7.7 The traction motor shall be of a high voltage and low current design such
that it is compact. The maximum voltage rating of the traction motor shall be
commensurate with the alternator/inverter voltage rating.
7.9 The motor efficiency at continuous rating shall not be less than 93%.
7.10 The weight of the traction motor should be approximately 2 tons.
The gear case shall be of sturdy and lightweight construction and shall be
adequately supported through the traction motor frame to prevent dropping
down under the most severe vibration that may be generated due to adverse
track conditions.
8.1 The insulation scheme for Traction alternator and traction motor should be
class 200 or above.
8.2 The machine shall be designed such that the 'hot spot' temperature under
any condition of loading in stator winding does not exceed the average
temperature of that winding (measured by resistance method) by more than
15 deg. C.
Page 10 of 25
RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
The Engine room radiator fan shall be hydrostatic drive/ electrically driven.
10.1 The power rectifier shall be a 3-phase bridge using silicon diodes suitable for
rectifying the 3-phase AC output of traction alternator throughout the range
of operation of the alternator. More than one bridge units may be connected
in parallel depending upon requirement.
10.2 Proposed rectifier shall have sufficient margin in continuous / short time
ratings and surge withstanding capability. Also, it shall have adequate
margin to withstand internal short circuits due to string failure condition and
short circuit across DC link. Cooling air requirement for the rectifier shall be
indicated by the tenderer in the offer.
10.3 The devices used in the rectifier assembly shall preferably be of a standard
type of a reputed make such that, in case of urgency, the purchaser can
interchange these devices with commercially available devices of another
make.
10.4 The layout of components inside the rectifier assembly shall provide for easy
accessibility and replacement of the failed components during maintenance
without having to remove large number of other healthy components. Each
component shall be clearly marked to indicate type, nomenclature and
rating.
10.5 All the components such as diodes, heat sinks, fuses, micro switches,
snubber capacitors/resistors etc. and their mounting arrangement shall be
designed to withstand vibrations and shocks as specified in IEC-60571.
11.0.1 Proposed traction inverter system may preferably have four inverters using
one inverter individually for each motor. Alternatively, a configuration of two
traction inverters may also be offered. In this case each traction inverter
shall drive traction motors on one bogie. Input supply for all the traction
inverters shall be the same DC link.
Page 11 of 25
RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
11.0.2 The basic control philosophy for the induction motor shall be such as to
achieve best suited results for traction application like minimum device
losses, high dynamic response, stable constant speed operation, fast acting
slip/slide control etc. Direct Torque Control, Vector Control, Slip Frequency
Control etc. are some of the popular control strategies used for traction
drives. Vector control system is not used in the existing DEMUs. The
tenderer shall furnish the details of control strategy duly describing its
merits.
11.0.3 The software of the inverter control system shall be fully compatible with the
Vehicle control software including closed loop propulsion control, slip slide
control, exchange of temperature data, fault diagnosis etc. The inverter
system should have its own protection and control logic, which it should also
be able to communicate with the vehicle control software in the event of a
fatal failure to initiate a protective shutdown of the DEMU. Damage to IGBT
devices of the inverter shall be prevented in case of a short circuit at the
load end.
11.0.4 Motor or bogie cut out facility shall be provided to isolate defective traction
motor(s) in case of any fault. In case axle control philosophy is followed,
each defective traction motor can be isolated individually. In the event of
bogie control system and in case of inverter cut out, inverter control system
shall be designed to automatically reduce DEMU power adequately so that
remaining inverters and motors are not overloaded and the DEMU is able to
reach up to destination with reduced power. DEMU power shall be reduced
in proportion to the number of traction motors cut out at that time.
11.0.5 Inverter Protection System shall be used to protect the inverters from over
voltage and over current conditions on supply as well as load side.
Protection shall be achieved by turning OFF the traction alternator excitation
by vehicle control system in case current or voltage exceeds a pre-set value.
An alternative proven and reliable protection system may also be offered by
the tenderers giving full justification of the offered scheme.
The traction inverter system shall be designed for following protection class:
11.0.7 The main power semiconductor device used for switching shall be Insulated
Gate Bipolar Transistor (IGBT) with sufficient PIV rating. The IGBT module
may contain external or internal protection circuits and gate drive circuits.
Page 12 of 25
RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
11.0.10 Preferably forced air cooling shall be used for inverters. It is preferable
that cooling requirement of complete inverter system be met by blowers that
are located inside the inverter cabinet(s) itself. Alternative cooling method
for the main inverter can be proposed by the tenderer and cleareance shall
be obtained from RDSO.
11.0.11 The weight of the Inverter & rectifier combined should be approx. 2 tons.
11.1.1 Inverter shall be of PWM type with high switching frequency to obtain near
sinusoidal waveform and reduce current harmonics even in the lower speed
region of traction motor. The harmonics of the output waveform of inverter
shall be controlled to minimize the traction motor torque pulsations, traction
motor heating and also to provide constant and high adhesion between
wheel and rail throughout the operating speed range of the DEMU.
11.1.2 The components and technology used shall ensure very high efficiency of
the inverter system. Typical efficiency of about 98% is preferred.
Manufacturer shall furnish the expected efficiency with respect to DEMU
load/speed.
11.1.3 For semi conductor devices a safety margin of 25% on the ratings for
current and voltage under worst operating conditions shall be provided and
established through calculations.
Page 13 of 25
RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
(a) In case of axle unit system, one axle can be cut-out in the event of major
faults with the inverter. Similarly in case of bogie control, traction motors
of a bogie may be cut out in the event of an inverter fault. In either case,
it must be ensured that journey is completed with defective equipment
isolated.
(b) Suitable margin shall be provided in the equipment rating such that
under emergency conditions with isolation of single traction unit such as
inverter, traction motor(s), etc., there is no necessity to reduce trailing
load on level track and the journey can be completed at reduced
speeds, if adhesion conditions are satisfactory. The one-hour ratings of
the equipment shall not be exceeded under such operations. The
successful tenderer/supplier shall submit short-time ratings of the major
equipment.
11.1.6 Features of data logging for monitoring fault conditions. Facility for
interfacing PC / laptop for upload / download of data for fault diagnostics and
further analysis shall be provided. A real time clock unit is to be provided
along with the fault logs so that tripping time can be co-related with the
operating conditions of the DEMU. The fault codes should be in text format
which shall be comprehensible for the operating and maintenance
personnel. Faults should be stored in permanent memory with a buffer
battery. Minimum fault log size should be 50 faults with ring buffer. It should
be possible to download the fault log using a lap top computer and interpret
it through a separate common PC application such as MS EXCEL etc.
Important parameters of the equipment at the time of occurrence of the fault
should be recoverable for fault analysis and must include the following:
a) Identification of the fault & its brief description in text and coded form.
b) Identification of components and sub assemblies involved.
c) Time and date of fault occurrence.
Page 14 of 25
RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
For smoothing the voltage ripple of the rectifier output and for supplying the
reactive power for inverter switch-over and traction motor excitation, a
capacitor bank of optimal value shall be provided keeping considerations of
permissible ripple voltage in the intermediate circuit on one hand, and the
space occupied and the current to be controlled in the event of a short
circuit on the other.
13.0.1 All the digital input signals of Switches, Relay Contact Feedbacks, Contactor
Feedback contacts, etc shall be electrically isolated before being given to
the Vehicle Control Computer through a Digital Input Interface. All such
Digital Input interfaces should be provided with reverse polarity and surge
protection to prevent damage to the computer circuits against inadvertent
wrong connection.
13.0.2 All driving output signals for the Relays, Contactors, Lamps, etc shall
preferably be driven through a MOSFET based circuit of adequate rating.
These outputs shall be electrically isolated from computer circuits and shall
be provided with protection against short circuit and reverse polarity.
13.0.3 All the analog input signals that are received from the various Sensors e.g.
Voltage, Current, Temperature, Pressure etc, shall be conditioned and
electrically isolated with Isolation Amplifiers before being used by computer.
Similarly all the analog outputs shall be electrically isolated from CPU and
shall have short circuit protection.
Page 15 of 25
RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
13.0.5 The CPU shall consist of a 32 bit micro controller running at minimum
40MHz along with its programmed software, various peripheral and interface
circuits e.g. Real Time Clock, Non Volatile Memory, etc. All other circuits
that are meant for processing either input or output signals shall be
controlled through commands from this card. The CPU shall continuously
monitor all the inputs and control all the outputs of the system based on the
software program. Provision shall be made to configure the control system
through Laptop for using the system with different types of traction
equipment/DEMUs, through user programmable parameters, loaded in Non
Volatile Memory of CPU. The details shall be finalized in consultation with
RDSO.
13.0.6 A removal type of non-volatile memory module shall be provided for storing
the Event Data. This data shall be logged during running of the DEMU. This
memory module shall be prevented from unauthorized access by a Lock
and Key arrangement. The details of the data to be stored shall be finalized
in consultation with RDSO.
Page 16 of 25
RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
Traction Control
Wheel Slip Control,
Control of Auxiliaries,
On line Fault Diagnostics
Speed recording
Display of operating status, faults in the traction equipment/electronics.
Communication with Traction Control computers
All displays shall be on LCD TFT monitor not more than 10.4”. There shall
be two display screens on the control desk for use by the driver (one is for
redundancy). Same displays can also be used as maintenance display
which shall continuously display important data such as loco speed and
tractive effort, MR pressure and BP pressure in analog gauge picture form
whereas the other one (on the vehicle control microprocessor unit) also a
digital display showing turbo, lube, fuel, load meter data etc. on recall
through an alphanumeric keypad.
The display on the vehicle control microprocessor unit shall be MENU driven
and shall be made user friendly. It shall display operational status of DEMU,
fault messages and data packs, running totals etc. Any fault, Alarm
condition, etc shall be shown on the display with suggested action, if any,
and sounding of audio alarm for the benefit of the Driver. It shall be possible
to conduct self tests on various equipments, by using a key pad to be
provided on the display unit. It shall also be possible to conduct self load
test on the engine and Traction Alternator through the keypad. The details of
the various Display Screens, Text Messages, etc shall be finalized in
consultation with RDSO.
Page 17 of 25
RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
14.1 After placement of order, the manufacturer shall furnish complete relevant
data and dynamic system details pertaining to proposed traction
alternator/auxiliary generator required for carrying out torsional vibration
calculations. The manufacturer shall also furnish complete set of
dimensional drawings required for the calculation of mass elastic data i.e.
mass moment of inertia, stiffness of different shafting, etc. Material
specification and the permissible vibratory stress values of different shaft
sections of the proposed system shall also be indicated by the
manufacturer. Dynamic system details of the diesel engine and other auxil-
iary attachment of DEMU shall be supplied by RDSO to the manufacturer to
assist them in deciding the dynamic system details by some approximate
analysis. The details indicated here shall be submitted by the manufacturer
to RDSO, well in advance of the actual manufacture, for scrutiny and
approval.
14.3 The manufacturer shall be prepared to carry out modifications in the design
of offered equipment if considered necessary from the torsional matching
considerations.
15.0 DOCUMENTATION
15.1 Following documents shall be submitted by each tenderer along with the
offer for evaluation:
Page 18 of 25
RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
16.2 In general, traction inverter shall be tested in accordance with IEC-61287 &
control electronics of inverter and Vehicle Control System shall be tested as
per IEC-60571 whereas traction alternator and traction motors shall be
tested as per IEC-60349. Type and routine tests on other equipment shall
generally be conducted in accordance with relevant IECs as mentioned at
annexure- III. However, if the tenderer proposes a different test scheme,
the same can be examined by RDSO on provision of alternative test
procedures submitted by the tenderer.
16.3 The supplier shall submit detailed type and routine test programs to RDSO
for approval. RDSO may also decide to carry out some tests on any one or
all the equipment, which are not covered by relevant IEC specifications.
Tests shall be carried out as per mutually agreed test program and the total
cost shall be borne by the manufacturer.
Page 19 of 25
RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
16.6 Type test shall be performed on one prototype unit of given design to verify
that product meets the specified design requirements. However, routine
tests shall be carried out on each equipment.
16.8 Subject to agreement between RDSO and manufacturer, some or all the
type tests shall be repeated on sample basis so as to confirm the quality of
the product. This shall be part of revalidation of vendor approval. Type test
may also be repeated in any of the following cases:
Major modification of equipment, which is likely to affect its functionality
or performance.
Failure or major performance variations established during type or
routine testing.
Resumption of production after an interruption of more than two years.
16.10 INSTRUMENTATION
(a) All the instruments used for testing should be duly calibrated. The
calibration certificates are to be shown to RDSO representative(s) on
demand.
(b) Value of the fundamental component and THD of traction inverter output
shall be measured by power analyzer during the prototype test at
various mutually decided pre-set points. True RMS value of output
voltage is also to be measured for record.
17.0 WARRANTY
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RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
18.1 In case of any failures, the details of failure and action taken to arrest re-
occurrence of similar failure in future with failure analysis report etc. is to be
submitted to RDSO.
18.2 In case of repeated failures, necessary changes in design on the units put in
service or in production line are to be made by the manufacturer.
Investigation tests, if considered necessary, are to be arranged/conducted
by the manufacturer.
19.1 Each equipment shall bear for identification ICF order number, batch/lot
number, serial number, type, year of manufacture, manufacturer‟s name as
well as important nominal and short time ratings.
19.2 All equipment of the complete system shall be suitably packed in strong
water proof boxes to prevent any damage during transit and handling.
21.0 TRAINING
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RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
Annexure-I
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RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
Annexure - II
1. Alternator
Make and type, drive arrangement, one hour and continuous ratings, maximum
design/test/service speeds, maximum output voltages at no load and full load,
maximum output current, Characteristic curves, details and data of windings
including method of impregnation and varnish used, estimated temperature rise,
cooling arrangement, rating under natural cooling, details of insulation.
Motorette test results, evaluation criteria and test programme, results of type
and routine tests(if conducted), details of exciter and rectifier assembly, details
of bearings including L10 life and lubrication scheme, mounting arrangement,
fits and clearances adopted, overall dimensions and weight.
2. Traction Inverter
Make and type, number of inverter cubicles, nominal input voltage and current,
continuous output rating, maximum phase to phase output voltage at nominal
input voltage, nominal output current at nominal input current, maximum output
frequency, arrangement and details of IGBT devices (Manufacturer's data sheet
shall be furnished), declared duty cycle rating, thermal characteristics of devices
and heat sinks, details of cooling requirements/arrangement, maximum
operating junction temperature of devices under worst operating conditions,
safety margin, evaluation criteria and type test programme, protection and
indication scheme, overall dimensions and weight.
Technical details of DC link capacitors and any other filter/choke offered by the
tenderer for fitment at the DC link .
3. Traction motor
Make and type, continuous rating, one hour rating and short time rating,
design/test/service speeds, starting current and duration, current ratings for
various operating voltages, gear ratio, traction motor characteristics under
different voltage conditions, details and data of windings including method of
impregnation and varnish used, estimated temperature rise in windings,
bearings etc., cooling arrangement including ducting details, rating under natural
cooling, details of insulation, design of the bearings including L10 life and
lubrication scheme, details of data for motorette test, evaluation criteria and test
programme, results of type and routine tests (if conducted), fits and clearances
adopted, overall dimensions and weight of traction motor, detailed design
features of suspension roller bearings(if provided).
4. Auxiliary Power Control (APC)
All relevant details as in case of main traction inverter. The auxiliary power
requirement catered to by this inverter as well as the reserve available for use in
future shall be clearly stated.
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RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
6. Master Controller
Make and type, rated current, making and braking current, position of reverser
and throttle handle, details of cam and auxiliary interlocks, overall dimensions,
weight, mechanical and electrical endurance test data.
7. Contactors
Make and type, rated voltage and current, making and braking capacity, number
of auxiliary contacts with control circuit voltage, magnet valve and coil details,
overall dimensions, weight, mechanical and electrical endurance test data.
8. Relays
Make and type, rated current and voltage, range of setting, rated control voltage,
rating of contacts, details of material of the contacts, type of enclosure,
temperature rise limit, indication system provided, overall dimensions, weight
and mechanical and electrical endurance test data.
9. Microprocessor Controls
Make and type, details of traction alternator excitation controls, analog / binary
inputs / outputs signals, vehicle bus, train bus interface, CPU details and power
supplies for electronic systems. Details of interface with the traction inverter
system and braking system. Details of protection and indication system. Details
of adhesion control system. Overall dimension / weight and redundancy.
Basic rack, number of teeth, module, pressure angle, helix angle (if any), profile
displacement (x.m), center distance between mating gears, quality & accuracies
of gear teeth and other related information.
Heat treatment process adopted for hardening the gears i.e. case hardening /
through hardening /induction hardening.
Hardness at tip, flank and root of the gear teeth. Case depth of case hardened
gears and hardness distribution of cross section in case of induction hardened
gears shall also be furnished.
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RDSO SPEC. No.MP.0.2400.45 (Rev.- 03) Sep.‟16
Annexure - III
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