GOVERNMENT OF INDIA MINISTRY OF RAILWAYS · • IEC-60850 - Supply voltages of traction systems •...

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Issued on……….. Spec. No. RDSO/2012/EL/SPEC/0112, Rev. ………

Prepared by Checked by Issued on …

GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

Main Transformer of 6500KVA with Steel tank for 3-Phase drive locomotives Type WAG-9

Specification No. RDSO/2012/EL/SPEC/0112, Rev. ………

2012

Approved by Signature Sr EDSE

ELECTRICAL DIRECTORATE

RESEARCH DESIGNS & STANDARD ORGANISATION

MANAK NAGAR, LUCKNOW- 226011

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Status of Revision

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

1. - All 0 First Issue

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Index

Clause No.

Description Page Nos.

Abbreviations 4 1.0 FOREWORD 5 2.0 Scope 5 3.0 Climate & Environment Conditions 5-6

4.0 Standards 6 5.0 Description 7-8 6.0 Technical Data 9-13 7.0 Tank 14 8.0 Reliability Requirements 14 9.0 Tests 15-22

10.0 Quality Assurance Plan 23 11.0 Bill of Material 23 12.0 Documentation 23-24 13.0 Scope of Supply 24-25 14.0 Documents to be supplied by Bidder 25 15.0 Technical Documents to be supplied by Contractor 25 16.0 Declaration for Infringement of IPR by Vendors 25

17.0 Note 25 Technical data to be supplied with the offer(Annexure-A) 26-32

Additional data to be submitted by the Contractor(Annexure-B) 33-36

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Abbreviations

The following abbreviations are used in this specification:

Abbreviations Full Name

CLW Chittaranjan Locomotive Works.

OEM Original Equipment Manufacturer.

RDSO Research Design and Standards Organisation.

Bidder Shall mean firm or company participating in the tender to manufacture

of the item.

Contractor Shall mean firm or company with whom the order to manufacture the

item has been placed.

Supplier The successful tenderer for supply of the equipment.

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1.0 Foreword

This specification covers broad features, requirement and testing of the main transformer

for 3-phase drive locomotive type WAG-9 for working with IGBT based power converters

having switching frequency 450 Hz. This locomotive is presently being manufactured by

CLW with LOT 6500 KVA capacity transformers as per their original design provided

with GTO based power converters. As on electric locomotives GTOs are getting

obsolete, IGBT based traction converters are now being provided in phased manner.

Finally, all the new locomotives are expected to be provided with IGBT based Converters

in future

The main transformer type LOT 6500 for WAG 9 locomotive compatible to work with

IGBT based converters is to be manufactured with steel tank having identical outlines

drawing to that of LOT 6500 KVA transformer. The technical parameters of

Auxiliary(BUR) winding and filter winding are almost identical with existing design of LOT

6500/7500 KVA transformer.

2.0 Scope

The scope of this specification is to design, develop, manufacture and supply traction

transformer type LOT 6500 KVA with One HV winding, Four traction windings, One filter

winding, One Auxiliary winding for used on WAG 9 locomotives with the same

dimensional envelop and mounting arrangement to that of the existing LOT 6500

transformer. The new transformer shall be designed using the latest world-wide

technology to work in conjunction with IGBT based power converters.

3.0 Climate & Environment Conditions

� Atmospheric temperature

Metallic surface temperature under Sun: 75o C max. and in

shade: 55o C max.

Minimum temperature: - 10 °C (Also snow fall in certain

areas during winter season)

� Humidity 100% saturation during rainy season.

� Reference site conditions

i) Ambient Temp.: 50o C

ii) Humidity: 100%

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iii) Altitude: 1776 m above mean sea level.

� Rain fall Very heavy in certain areas. The locomotive shall be

designed to permit its running at 10 kmph in flood water

level of 102 mm above rail level.

� Atmosphere during hot weather

Extremely dusty and desert terrain in certain areas. The

dust concentration in air may reach a high value of 1.6

mg/m3. In many iron ore and coalmine areas, the dust

concentration is very high affecting the filter and air

ventilation system.

� Coastal area Locomotive and equipment shall be designed to work in

coastal areas in humid and salt laden atmosphere with

maximum pH value of 8.5, sulphate of 7 mg per litre, max.

concentration of chlorine 6 mg per liters and maximum

conductivity of 130 micro siemens /cm

� Vibration The equipment sub-system and their mounting

arrangement will be designed to withstand vibrations and

shocks encountered in service as per IEC : 61373 unless

otherwise prescribed.

� Electromagnetic Pollution

High degree of electromagnetic pollution is anticipated in

locomotive machine room, where the equipment will be

mounted. Necessary precaution should be taken in this

regard.

� Wind speed High wind speed in certain areas, with wind pressure

reaching 150 kg/m2

4.0 Standards

The following specifications shall generally be followed for manufacture and testing of the

transformer:-

• IEC-60310 - Rules for traction transformers and reactors

• IEC-60076 - Recommendations for power transformers

• IEC-60077 - Rules for Electrical Traction Devices

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• IEC-61373 - Vibration & shock

• IEC-60038 - Standard voltages

• IEC-60296 - Transformer Oil

• IEC-60529 - Degree of protection provided by enclosures.(IP-code)

• IEC-60085 -Thermal evaluation and designation

• IEC-60850 - Supply voltages of traction systems

• EN-10025-2 - Non alloy structural steels

5.0 Description

5.1 Each loco requires one transformer for feeding supply to traction converters/ traction

motors, to auxiliary converter for supplying to auxiliary machines and to supply Hotel load

of train. This transformer will consist of Primary winding, 04 Traction windings, Auxiliary

winding (BUR). In addition, it has a FILTER winding which is connected on locomotive to

passive filter.

5.2 The transformer tank also contains 02 series resonant chokes (one for each converter) & 03 Auxiliary Converter double chokes (one for each of the 03 auxiliary converters).

5.3 The transformer has also provision of 01 additional reactors for Auxiliary(BUR) winding.

This reactor is provided to ensure the impedance of auxiliary winding similar to their

existing rating (in LOT 6500 KVA transformer with Aluminium tank) and shall be

connected internally in series with the winding and therefore, bushing terminals for this

reactor is not required on the tank cover. However, the provision of these 01 additional

reactor in the transformer is provisional and their actual requirement will be decided

based on testing results of the prototype unit.

5.4 Transformer is forced oil cooled and external cooling of the oil is designed with two independent oil circuits with cooling units of capacity 120 KW each located within the machine room of locomotives. However, the cooling units / circuit component do not form part of transformer supply.

5.5 L.V. and H.V. bushings mounted on the top shall be in line with the existing bushing

mounted on the LOT 6500 KVA transformer. 5.6 The transformer main tank and its two conservators shall be made of standard steel. The

proposed outlines of the LOT 6500 KVA transformer shall have identical interfaces as described in HSTN 003359(original outlines of LOT 6500 KVA transformer). The

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transformer is under slung mounting and therefore, the steel tank should has a provision of 04 nos. safety chain for its fixation with under frame.

5.7 The mounting arrangement drawing of LOT 6500 KVA transformer with steel tank shall

be submitted to CLW for approval before undertaking manufacturing and prototype testing.

5.8 Design document is required to be approved by RDSO before going for manufacturing of

the LOT 6500 KVA transformer. 5.9 Technical data to be furnished by the tenderer with the offer is given in Annexure-A.

5.10 Additional technical data to be furnished by the successful tenderer is given in

Annexure-B.

5.11 The special features of the transformer are

� Transformer is mounted under slung on under frame

� Transformer is designed for feeding IGBT based Power and Auxiliary converter load. The transformer is designed to work with 450 Hz inverter’s switching frequency.

� Approx. 30% impedance between primary & traction windings. � Very high magnetic de-couplings between traction windings � Use of continuous transposed conductor for windings � Transformer and conservator tank of Standard Steel S 355J2N(EN 10025-2)/equivalent

IS

� Rapid action coupling between transformer and conservators in oil circuit

5.12 Additional apparatus of the transformer

� Overflow valve (In case of over pressure, the tank must not be damaged and overflowing oil shall be drained off the transformer cover)

� Oil drain tap, oil level screw

� Temperature sensor

� Slide of oil intake and drainage

� Transformer tank fastening

� Two conservator tanks including

� Air dehumidifier including valve

• -Oil level gauge

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• -Connection to the transformer including rapid action coupling

• -Oil filler tap

• -Oil drainage screw

� Earthing

5.13 General arrangement drawing of the transformer shall be in line with CLW Drawing

No.CLW/ES/3/SK-1/0456 for LOT 6500 KVA transformer for WAG9 locomotive.

6.0 TECHNICAL DATA

6.1 Catenary Voltage:

- Nominal - 25 KV

- Maximum - 30 KV

- Minimum - 17.5 KV

6.2 Frequency(Hz) - 50 Hz ± 6%

6.3 Ratings for WAP 5/WAP 7 Locomotives Transformer

WINDING POWER (KVA) VOLTAGE (V) CURRENT (A)

HV 1 x 6130* 25000 245

TRACTION 4 x 1450 4 x 1420 4 x 1021

BUR 1 x 334 1 x 1000 1 x 334

FILTER 1 x 400 1 x 1150 1 x 348

* The filter power is only reactive. HV only feeds the losses of the filter winding and

therefore, the HV current is defined on the 6130 KVA base.

6.4 Percentage Impedance:

HV to Traction winding 1, 2, 3 or 4 : 30 % ± Tolerance as per IEC:60310

(at 1450 KVA)

HV to Auxiliary winding : 10 % ± Tolerance as per IEC:60310

(at 334 KVA)

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HV to Filter winding : ≤ 4 %

(at 400 KVA)

6.5 Series resonant choke type 2 SOD 240

i) Inductance per choke : 2 x 0.551 mH (±15%) Linear to I peak = 1391A

ii) Thermal current ITh : 2 x 984Aeff

iii) Resonant frequency : 100 Hz

iv) Voltage stress between

a. terminals max. : 482 VAC b. to earth max. : 3471 V

v) Separate voltage withstand capability : 10 KV

vi) Losses(KW) : 12.5 KW + IEC Tol.

6.6 Auxiliary converter choke type 6 GOD 120

(i) Inductance per BUR-choke :

0A : 30 mH

120A : 30 mH

155A : 26 mH

190A : 20 mH

(ii)Tolerances : -0%, +free

(iii) Frequency : 100 Hz

(iv)Current rated : 155 A

max. : 190 A

(v)Ripple nom. : 38.6%

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max. : 50.2%

(vi)Voltage to earth rated : 1153 V

max. : 2000 V

(vii)Separate voltage withstand

capability : 10 KV

viii)Losses(KW) : 12 KW + IEC Tol.

6.7 Auxiliary converter choke type 6 GOD 22 (Provisional)

i. Quantity : 2

ii. Inductance per choke : 2 x 0.3 mH (±15%)

iii. Thermal current Irms : 2 x 330 A

iv. I max : 2 x 700 A(Peak)

v. Frequency(Hz) : 50 Hz

vi. Resistance(RDC) at 85 °C : 2 x 3.9 mohm ±10 %

vii. Total Losses : 1.5 KW ±15 %

viii. Electrical connection : In series with Auxiliary

(BUR) winding internally

ix Voltage Class : Compatibility as per

Auxiliary(BUR) winding

6.8 No load magnetization current (A)

at 25 KV : 0.7%(approx.)

6.9 Transformer losses at 25 KV

i) No load loss - 4 KW + IEC Tol.

ii) Load losses, harmonic losses, reactor losses and stray losses –192 KW

iii) Total transformer losses shall be approx. 196 KW.

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6.10 Transformer overall efficiency

At 25 KV : ≥ 97 %(approx.)

6.11 Permissible and designed temperature rise

(i) Oil (°C) : 45 °C [ IEC 60310-20 °C]

(ii)Winding (°C) : 55 °C [IEC 60310-20 °C]

6.12 Type of Cooling and cooling medium

OFAF. Inhibited mineral Transformer Oil as per IEC: 60296

6.13 Class of Insulation

(i) on conductors : Enamel of class H and nomex insulation of class H

(ii)Cooling medium : Class A( Mineral inhibited insulation oil as per IEC:60296)

6.14 Dielectric levels Primary Traction Aux. Filter

(i) Induced voltage withstand (KV) 60 - - -

(ii) Separate source withstand (KV) 10 10 5 5

(iii) Impulse voltage withstand (KVp) 150 - - -

6.15 Transformer Rating Plate

Each transformer shall be provided with a rating plate showing at least the items

indicated below, unless otherwise agreed between user and manufacturer:

� Manufacturer’s name

� Manufacturer’s serial number

� Date of manufacturing

� Connection diagram

� Principal tappings

� Rated power and voltage of each winding

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� Rated frequency

� Cooling medium and type

� Volume of cooling medium

� Identification of cooling method

� Total mass.

6.16 Inductor Rating Plate

Each inductor shall be provided with a rating plate showing at least the items

indicated below, unless otherwise agreed between user and manufacturer:

� Manufacturer’s name

� Manufacturer’s serial number

� Type of inductor

� Rated current(r.m.s. value, or mean direct current for smoothing inductors)

� Value of inductance(at one or more specified reference current values)

� Rated frequency

� Cooling medium and type

� Identification of cooling method

� Total mass.

7 Tank

Transformer main tank and its two conservator tanks will be of Standard Steel

S 355J2N(EN 10025-2)/or its equivalent IS. Outline of the tank will be identical to

HSTN003359(original outline drawing of LOT 6500 KVA transformer)

7.13 Total Weight

Weight of the transformer shall be - 9000 ± 3% kg

7.14 Mounting Dimensions

External dimension(overall) including cooling unit shall be according to HSTN003359.

Length-2866 mm

Width – 1970 mm

Height – 1339 mm

7.3 FEM Analysis of Tank

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FEM analysis of tank shall be conducted considering the vibration and shock

requirement mentioned in the IEC:61373. Tank shall be structurally stable for

mounting in under frame of 25 KV AC 3-ph drive electric locomotives.

8.0 Reliability Requirements

8.1 Life time/Operational Time

Daily : Approx. 16 hours(at approx. 330 days/year)

Yearly : 5280 hours

Within 40 years : 211200 hours

8.2 Reliability

Under operational conditions as per clause 8.1 above, MTBF of 11 x 106 hours is

expected.

9.0 Tests

9.1 Transformer Including Filter Winding

The Type and Routine Tests shall be carried out on the transformer as per Table-1 below

which also stipulates the category of the tests and the clause to which the reference is to

be made. Tests on the chokes which can not be disassociated from the transformer shall

be carried out together with the latter.

TABLE-1

Test Description Clause or Sub Clause

Type Routine

Preliminary checks 9.1.1 9.1.1

Measurement of winding resistance 9.1.2 9.1.2

Measurement of voltage ratios 9.1.3 9.1.3

Measurement of no-load primary current and losses 9.1.4 9.1.4

Measurement of impedance voltages 9.1.5 9.1.5

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Measurement of load losses 9.1.6 9.1.6

Determination of total losses 9.1.7 9.1.7

Temperature Rise 9.1.8 -

Measurement of Insulation Resistance of windings

- before and after the HV test

9.1.9 9.1.9

Dielectric :

- full wave impulse voltage withstand

- induced voltage withstand

- separate source voltage withstand

9.1.10

9.1.11

9.1.12

-

9.1.11

9.1.12

Short-circuit test 9.1.13 -

Measurement of Frequency Response Analysis 9.1.14 9.1.14

Measurement of Transformer noise 9.1.15 -

Pressure and Leakage test on Tank 9.1.16 9.1.16

Measurement of weight 9.1.17 9.1.17

9.1.1 Preliminary Checks (IEC 60310- Clause 10.2.3)

Visual inspection and identification of the circuit diagram, terminal meetings, polarities &

particulars on the rating plate shall be carried out.

9.1.2 Measurement of Winding Resistance (IEC 60310- Clause 10.2.4)

Resistance of each winding shall be measured with direct current at ambient temperature

and the values thus obtained corrected to 85 deg.C.

9.1.3 Measurement of Voltage Ratio (IEC 60310- Clause 10.2.5)

Voltage ratio shall be measured between primary winding and all secondary windings

individually. Voltage ratio shall also be measured between primary winding & Bur

winding, Filter winding & Hotel load winding .

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The measured values shall be with-in ± 0.5% of the design values.

9.1.4 Measurement of No load primary current & losses (IEC 60310 -Clause 10.2.6)

No load primary current and losses shall be measured with 50 Hz sinusoidal voltage

applied to high voltage winding. However, this measurement can also be carried out by

energising Bur winding. No load current and losses for the primary winding shall be

measured at 17.5 KV – 27.5 KV in steps of 2.5 KV.

The measured no load losses at 25 KV shall not exceed 4 KW + IEC 60310 Tol..

9.1.5 Measurement of Impedance Voltage (IEC 60310- Clause 10.2.7)

Impedance voltage between each pair of the windings shall be measured at rated

frequency using approximately sinusoidal voltage supply.

The short circuit impedance between primary winding and each of the traction

windings shall be with-in ± 15% of the design value.

9.1.6 Measurement of Load Losses (IEC 60310- Clause 10.2.8)

Load losses between HV winding and traction windings, filter, Bur winding and Hotel load

winding (for WAP-5/WAP-7 locomotives transformer) shall be measured and corrected to

85 deg.C. The corrected losses shall not exceed the limit specified at clause No. 6.10.

9.1.7 Determination of total losses of transformer (IEC 60310 -Clause 10.2.9)

The total losses of the transformer at reference temperature of 85 deg. C shall be

computed as under:-

(a) Load losses of HV to all Traction windings (b) Load losses of HV to Filter winding (c) Load losses of HV to BUR winding (d) No load losses

(e) Harmonic losses

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Since all the windings are very high magnetic de-coupled, the total transformer losses will

be the sum of (a), (b), (c), (d) & (e) above.

The total transformer losses shall not exceed 240 KW.

9.1.8 Temperature rise test (IEC60310- Clause 10.2.10)

This test on the transformer shall be carried out by short circuit method to determine

temperature rise of oil, average temperature of air at the blower entrance, average

temperature of air at cooler exit, average temperature of oil at transformer exit, average

temperature of oil at cooler exit and winding temperatures including windings of the two

reactor units.

DGA & BDV of Oil must be performed before and after the temperature rise test.

For temperature rise test, thermocouples shall be provided at locations as under:

• Top oil pocket - One

• Air entrance on top of the blower – Two, one on each blower

• Air exit under the cooler – Two, one on each cooler

• Oil exit from the transformer – Two, one on each exit

• Oil containers – Three, located at about 3 m from the transformer

9.1.8.1 Oil Temperature Rise

For this test, with the auxiliary winding and filter winding left open circuited, the primary

winding shall be short circuited and all traction windings connected in series and

energized such as to feed losses in the transformer determined in clause 9.1.7 above

and reactor losses measured in Clause 9.2.3. These losses fed in the transformer shall

be maintained till oil temperature stabilizes. The oil temperature measured and

temperature rise calculated.

The temperature rise of oil shall not exceed 45 deg.C.

9.1.8.2 Winding Temperature Rise

• HV Winding

For this test, the primary winding shall be short circuited and supply given to four series

connected traction windings so as to feed 245 Amps. in HV winding for a duration of 60

min. At the end of 60 min., blowers shall be switched off and hot resistance of the HV

winding measured.

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• Traction Winding

For this test, with blowers on, series connected traction winding shall be short circuited

and supply given to HV winding to feed 1021 Amps. in traction winding for a duration of

60 min. The blowers shall be switched off and hot resistance of the traction winding

measured.

• BUR Winding

For this test, with blowers switched off, the Bur winding shall be short circuited and

supply applied to HV winding with 334 Amps. in Bur winding for a duration of 60 minute

at the end of which hot resistance of the winding shall be measured.

• Filter Winding

For this test with blowers switched off, the filter winding shall be short circuited and

supply given to HV winding with 348 Amps. in the filter winding for a duration of 60

minutes at the end of which hot resistance of the filter winding shall be measured.

• Series Resonant Choke Windings

For this test, with blowers switched off, 1144 Amps. at 50 Hz shall be given to the two

series connected reactor windings for a duration of 60 min. at the end of which hot

resistance of the reactor windings shall be measured.

• Aux. Converter Choke Windings

For this test, with blowers switched off, 127.4 Amps. at 50 Hz shall be given to the six

series connected reactor windings for a duration of 60 min. and the end of which hot

resistance of the reactor windings shall be measured.

From the measured hot resistance of the windings, the temperature rise of the different

windings of the transformer & reactors shall be determined.

The temperature rise of windings shall not exceed 55 deg.C.

9.1.9 Measurement of IR value (IEC 60310 -Clause -)

Measurement of IR value of individual windings to Tank and Earth and between windings shall be carried out at room temperature. The values obtained after 60 seconds shall be

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corrected to 30 deg. C. For HV winding 5kV and all other windings 1kV megger shall be used. These measurements shall be taken before and after HV test.

9.1.10 Impulse voltage withstand test (IEC 60310- 10.2.11.3)

The HV winding shall be subjected to impulse voltage test of 150 KVp, 1.2/50 micro

second wave.

The winding shall withstand the test voltage.

9.1.11 Induced Voltage Withstand Test (IEC 60310- Clause 10.2.11.1

All traction and filter windings shall be connected to tank and earth. Test voltage will be

applied to Auxiliary(Bur) winding in order to induce 60 KV voltage in HV winding.

Frequency of the applied voltage shall be more than 100 Hz and accordingly duration of

the test may be decided.

The winding shall withstand the test voltage.

9.1.12 Separate source voltage withstand test (IEC 60310-Clause 10.2.11.2 )

Single phase 50 Hz, separate source voltage of amplitude as given below shall be

applied for 1 minute between each winding to be tested and all other windings connected

together to tank and earth:-

(i) primary winding and all other windings to earth 10 KV

(ii) Traction winding to all other windings and earth 10 KV

(iii) Filter winding to all other windings and earth 5 KV

(iv) Auxiliary winding to all other windings and earth 5 KV

The windings shall with stand the test voltage.

9.1.13 Short-Circuit test (IEC 60310 -Clause 10.2.12)

Short Circuit test shall be carried out as per IEC:60310. The test voltage shall be 27.5

KV and all the secondary traction windings are to be subjected to short circuit test.

Variation in % impedance before & after the short-circuit test shall not differ

more than ±1%. After the test, the transformer to be removed from the tank and no

observable deformation, movement or slackening of any winding, insulation over

clamping devices should be revealed.

9.1.14 Measurement of Frequency Response Analysis

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Frequency response analysis of the transformer winding under different configurations

shall be measured and recorded for future reference.

9.1.15 Measurement of Transformer noise Noise of transformer and associate equipments in different operating conditions will be measured in accordance with ISO3744.

9.1.16 Pressure & Leakage Test on Tank (IEC 310 -Clause -)

The transformer tank shall also be tested with a water/ oil pressure of 0.6 Bar for a

period of 12 Hours to detect any leakage.

There shall not be any leakage during or at the end of the test.

9.1.17 Measurement of weight (IEC 310 -Clause -)

The weight of the Transformer filled with oil and provided with its accessories shall be

measured.

The measured weight shall be approx. 9000 ±±±±3% kg

9.2 Series Resonant Choke, Auxiliary Converter Choke and other additional reactors

The Type and Routine Tests shall be carried out as per Table-2 below which also

stipulates the category of the tests and the clause to which the reference is to be made :-

TABLE-2

TESTS Type Routine

Preliminary checks 9.2.1 9.2.1

Measurement of winding resistance 9.2.2 9.2.2

Measurement of losses 9.2.3 -

Measurement of inductance 9.2.4 9.2.4

Temperature Rise 9.2.5 -

Separate source voltage withstand 9.2.6 9.2.6

Measurement of IR of windings 9.2.7 9.2.7

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9.2.1 Preliminary Check (IEC 60310- Clause 10.3.3)

A check shall be made on the terminal marking, the polarities and the particulars on the

rating plates of both the reactors.

9.2.2 Measurement of Winding Resistance (IEC 310- Clause 10.3.4)

The resistance of each choke coil shall be measured with a dc current at ambient

temperature. The measured values shall be corrected to 85 deg.C.

9.2.3 Measurement of Losses (IEC 310- Clause 10.3.5)

The losses of each choke coil shall be measured at rated current and ambient

temperature and corrected to 85 deg.C.

The total losses of the two series resonant chokes shall not exceed 12.5 KW +

15%.

The total losses of the three auxiliary converter chokes shall not exceed 12.0 KW +

15%.

9.2.4 Measurement of Inductance (IEC 60310 - Clause 10.3.6)

The series resonant choke coils shall be fed at rated current of 984.0 amps at 50 Hz and

impedance / inductance measured.

The inductance of the coils measured at the rated current shall be within ±15% of

the designed value of 0.551 mH.

The inductance of the aux. converter chokes shall be measured at the rated current of

155 Amps. for each coil. Inductance curve shall also be drawn as a function of current

over the entire operating range from 17 Amps. to 190 Amps. rms.

The inductance of the each coil at the rated current shall not be less than 30 mH.

9.2.5 Temperature Rise Test (IEC 60310 - Clause 10.3.7)

Temperature rise test shall be conducted as per Clause 9.1.8 above.

9.2.6 Separate Source Voltage Withstand Test (IEC 310 – Clause 10.3.8.2)

50 Hz AC voltage shall be applied for 01 minute between the winding and earth and

between windings. The test voltage shall be 2.25 U + 2000 volts, where U is the rated

voltage of the windings.

The winding shall withstand the test voltage

9.2.7 Measurement of IR of windings

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This test shall be conducted as per Clause 9.1.8 above.

10.0 Quality Assurance Plan

Quality Assurance Plan as per the requisite format of RDSO/CLW is required to be

submitted for approval.

11.0 Bill of Material (BoM)

Bill of Material (BOM) as per the requisite format of RDSO is required to be submitted for

approval.

12.0 Documentation

12.1 Contents

12.1.1 Drawings, Tracing and Description

All drawings and description which are necessary for design, assembly and

commissioning of the Transformer. A part list / composition list of each drawing has to

be given. Within the individual Lists all parts of the corresponding drawing have to

mentioned, including consumable items. A family tree has to be given, including all

drawings, arts lists and other relevant documents which are part of the

documentation. Also a complete list of all documents and a complete list of all

components (“Bill of Material”).

12.1.2 Manual

The manual includes all necessary information for correct operation, maintenance,

faultfinding and repair of the transformer. Including spare parts catalogue and

instruction for assembly, dismantling and replacement of the individual components.

12.1.3 Language

All documents, including reference documents, shall be in English.

12.2 Structure

12.2.2 Drawing, Tracing and Descriptions

The documentation shall be structured by the following order:

1. Family Tree

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2. List of drawings (sorted by Indent-NO.)

3. Bill of materials (sorted by Indent-NO.)

4. Drawings, etc. (sorted by subassembly components, corresponding to the family

tree).

All documents have to be given in proper folders. Loosen documents Will be not be

accepted.

12.2.3 Manual

An overview of function and work order has to be given. The chapters of the Manual

must belong to the individual sub-assembly components. All drawings and

documents, which are used as reference documents, have to be given as annexure to

the manual.

12.2.4 Standards / Units

Only IEC – Standards or internationally recognized standards shall be accepted. Only

SI Units will be accepted.

12.2.5 Drawings, Tracing and descriptions

4 Sets of hard copies and one set of softcopy of complete design document,

Drawings, BoM, etc.

12.2.6 Manuals

4 sets of copies

13.0 Scope of Supply

Qty / Loco

Transformer : 1 No.

Series Resonant choke : 2 Nos.

D.C. Link circuit choke aux. converter : 6 Nos.

High Voltage bushing mounted on Transformer : 1 Set

RTD – PT 100 mounted on Transformer : 1 No.

Conservator tank with Breather : 2 Nos.

Hose with nipple (3EHP431215R0001) : 2 Nos.

Connecting Hose complete with nipple (3EHP431217R0001) : 1 No.

Connecting Hose complete with nipple (3EHP431253R0001) : 2 Nos.

Quick Couplings as per drawing no.-CLW/ES/3/SK-4/0456 Alt.F : 6 Nos. ( set consists of one male and one Female )

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Elbow Union as per drawing no.-CLW/ES/3/SK-5/0315 Alt.H : 2 Nos.

Transformer Oil- As per IEC:60296

The Transformer and conservator tank should be completely filled with Oil. One-

barrel (209 liters) to be separately provided for filling in oil pipes and other

accessories.

Set of Transformer fixing bolts and plates as per Spec no. CLW/ES/3/SK-1/0315 Alt.H : 1 Set Scope of supply of this transformer should be in line with drawing no.-

CLW/ES/3/SK-1/0456 Alt.F to CLW/ES/3/SK-5/0456 Alt.F which is for LOT 6500

KVA transformer.

Additional auxiliary reactor for Auxiliary winding(provisional) : 2 No.

.

14. 0 Documents to be supplied by bidder:

The tender shall integrate the following along with the quotation.

i) Clause wise comments on the specification and Test Program.

ii) Detailed drawings.

iii) Past experience with supporting papers (if Any)

iv) Quality Assurance Program

v) Machinery & Plant for Such Job.

vi) Technical data as per Annexure-A

15.0 Technical documents to be supplied by Contractor:

The following documents shall be supplied by the supplier as a part of the contract.

i) Type Test reports

ii) Routine Test reports along with each set

iii) Maintenance manual

iv) Design data calculation and drawings of transformer submitted by that

supplier to CLW and RDSO during design approval.

v) Technical data is to be submitted as per Annexure-B.

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16.0 Declaration for Infringement of IPR by Vendors:

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

Design Concept and while entering the contract:

“Indian Railways shall not be responsible for infringement of patent rights arising due to

similarity in design, manufacturing process, use of similar components in the design

and development of hotel load converter and any other factor not mentioned herein

which may cause such a dispute. The entire responsibility to settle any such

disputes/matters lies with the Supplier”.

17.0 Note

1. Standard fasteners of M/s TVS, M/s un-brako and Spring washers of M/s Forbes make

only to be used.

2. Firm should provide Min/Max Oil level scale in Conservator tanks.

3. For other references, if any, RDSO or CLW may be approached.

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Annexure-A

TECTNICAL DATA TO BE SUPPLIED WITH THE OFFER

TRANSFORMER

1. Make

2. Type

3. Standard

4. Primary Voltage (kV)

i) Nominal ii) Maximum iii) Minimum

5. Continuous rating at 22.5 kV

Winding Primary Traction Auxiliary Filter

(secondary)

No. of windings

No load voltage (V)

Current (A)

Capacity (kVA)

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6. Percentage impedance voltage

7. Percentage impedance voltage of

- Auxilliary winding (%) - Hotel load winding (%)

- Filter winding(%)

8. No load magnetization current

i) at 22.5 kV (A) ii) at 27.5 kV (A)

9. Flux density in the core

i) at 22.5 kV (Wb/m²) ii) at 27.5 kV (Wb/m²)

10. Current density at rated current

i) Primary (A/mm²)

ii) Traction (Secondary) (A/mm²)

iii) Auxiliary (A/mm²)

iv) Filter (A/mm²)

11. Transformer losses At 22.5kV At 27.5kV

Core (kW)

Copper (kW)

Total (kW)

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12. Transformer overall efficiency

i) at 22.5 kV (%)

ii) at 27.5 kV (%)

13. Permissible and designed temperature rise separately

(i) Oil ( °C )

(ii) Winding ( °C )

(By resistance method)

14. Type of cooling and cooling medium

15. Class of insulation

a) On conductors b) Cooling medium

16. (i) Material of insulation on the conductor

(ii) Material of the cooling medium

(iii) Thermal and electrical characteristics of conductor insulation.

(iv) Thermal and electrical characteristics of cooling medium.

17. Dielectric levels Primary Traction Auxiliary Filter

(a) Induced voltage

withstand (kV)

(b) Separate source

voltage withstand (kV)

(c) Impulse voltage

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withstand (Kvp)

18. Construction

i) Type of core : Core type/Shell type

ii) Type of winding : Concentric coils/sandwich coils

iii) type of winding

construction (single coil or more coils in series/parallel)

- Primary - Secondary - Auxiliary

- Filter 19. Weight of transformer and oil

i) Without cooling equipment ii) 'with cooling equipment

20. Overall dimensions of the transformer

i) Without cooling equipment

ii) With cooling equipment (Attach drawings)

21. Oil

i) Weight ii) Volume

22. Data on additional equipment

i) oil circulating pump

a) Motor - Make

- Type

- Rating

- Insulation class

- Weight

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b) Pump - Make

- Type

- Speed

- Quantity & head

- Weight

ii) Fluid circulating blower

a) Motor - Make

- Type

- Rating (kW)

- Voltage (V)

- Current (A)

- Speed (RPM)

- Insulation class

- Weight

b) Pump - Make

- Type

- Speed (RPM) (Max)

- Air Quantity (m3/hr) & head (mm WG)

- Weight (kg)

iii) Radiator - Make

- Type

- Rating (kW)

iv) Current transformer

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- Type

- Make

- Ratio

- Burden (VA)

- Accuracy class

- Insulation class

v) Overload relay

- Type

- Make

- Ratio

- Burden

- Accuracy class

- Setting value

vi) Oil flow relay

- Type

- Make

- Range

- Setting

vii) Oil temperature indicator

- Type

- Make

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- Range

- Setting

viii) Silicagel

- Type

- Make

23. The following drawings/curves/calculations shall be submitted by the tenderer along with

the offer :

Outline and general arrangement drawing of the transformer,

24. The contractor shall also furnish detailed drawings showing core arrangement, winding/coil

arrangement, insulation arrangement, cross sectional drawings, rating plate etc. for

transformer.

25. Overload Vs. duration curve of the transformer with sample calculations for the same.

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ANNEXURE-B

ADDITIONAL DATA TO BE SUBMITTED BY THE CONTRACTOR

TECHNICAL DATA OF MAIN TRANSFORMER

1. Rating:

1.1 Primary Volts Amps. kVA

1.2 Traction (Secondary) Volts Amps. kVA

1.3 Auxiliary Volts Amps. kVA

1.4 Filter

1.5 Magnetising current(%) 1.6 Core losses:

- 22.5 kV

- 27.5 kV

Primary Traction Auxiliary Filter

(Secondary)

_______ _______ _______ _______

1.7 Copper losses 1.8 Total losses 1.9 Resistance (%) 1.10 Reactance (%) 1.11 Current density

2. Winding details Primary Traction Auxiliary Filter

______ ______ ______ ______

2.1 Total No. of turns

2.2 No. of windings

2.3 No. of coils

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2.4 Sections per coil

2.5 Turns per coil

2.6 Turns per layer

2.7 No. of layers

2.8 Size of conductor

2.9 Total sectional area

2.10 No. of parallel conductors.

2.11 Mean length of

winding (mm)

2.12 Weight of copper wire(kg)

2.13 Coil dia (inner)

2.14 Coil dia (outer)

2.15 Depth of winding (radial)

2.16 Height of section

2.17 Conductor insulation

2.18 Winding method

2.19 Inter connection of sections

2.20 Inter connection of coils

2.21 Clearance between HV&LV

3. Magnetic Circuit Details

Primary Traction Auxiliary Filter

______ ______ ______ ______

3.1 Grade (silicon sheet steel)

3.2 Thickness (mm)

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3.3 Space Factor (%)

3.4 Core constructional arrangement (2 or 3 limb)

3.5 Sectional area

- Gross ( cm²)

- Nett ( cm²)

3.6 Flux density at :

- 22.5 kV (wb/m²)

- 27.5 kV (wb/m²)

3.7 Volt/turn at : - 22.5 Kv

- 25.5 kV

3.8 Mean core length (mm)

3.9 Dimensions of windows (mm)

3.10 Outer dimensions

4. Ancillary Data

4.1 Operating pressure of explosion vent

4.2 HV and LV bushing Specification

4.3 Weight (kg) i) Core and coils ii) Tank and fittings iii) Fluid (lit.) iv) Cooler and pump

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v) Fluid vi) Total weight of Transformer block

5. Calculations

5.1 Temperature rise calculations for rated load and overloads.

5.2 Reactance calculations for different windings for arriving at designed value.

5.3 Calculations for thermal and mechanical effects under 3 second short circuit.

5.4 Calculations for arriving at the regulation characteristics of the transformer alongwith

the regulation curve (dc voltage vs dc current)

GOVERNMENT OF INDIA MINISTRY OF RAILWAYS · • IEC-60850 - Supply voltages of traction systems •...

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Transcript of GOVERNMENT OF INDIA MINISTRY OF RAILWAYS · • IEC-60850 - Supply voltages of traction systems •...