GOVERNMENT OF INDIA MINISTRY OF RAILWAYS vuqla/kku …

of 74 EL/0.6.2/PC/Main File RDSO/PE/SPEC/AC/0084-2020 (REV. 2)

Prepared by

SSE/ Alternator

Checked By

Director/MRVC

Hkkjr ljdkj

jsy ea=ky;

GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

vuqla/kku vfHkdYi ,oa ekud laxBu

RESEARCH DESIGNS AND STANDARDS ORGANISATION

SPECIFICATION FOR 400 336 KW DIESEL ALTERNATOR SET FOR POWER CAR

vkj-Mh-,l-vks-@ih-bZ@fof’kf"V@,-lh-@0084 & 2020 ¼ifj’kks/ku-*2*½

RDSO / PE / SPEC. / AC / 0084-2020 (Rev ‘2’)

S.NO. Details of Amendment

Revision Page Number

Reasons for amendment

1. Complete spec. revised 1 Nil Revised as per field requirement

2. Complete spec. revised 2 Nil Revised as per field requirement

vuqeksfnr

APPROVED

dk;Zdkjh funs’kd@ih ,l ,.M bZ ,e ;w

ED/PS &EMU

Formatted: Indent: Left: -0.31", First line: 0.31"


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

INDEX

S. No Description Page no.

CHAPTER No 1

1.0 Forward 3

1.1 Scope 3

1.2 Scope of supply 3

1.3 Governing specification 3

1.4 Service requirement 4

1.5 General requirements 5

1.6 Test and performance 8

1.7 Guaranty / Warranty 11

1.8 Infringement of patent rights / 11

1.9 ISO 9000 accreditation 11

1.10 Cartel formation 11

1.11 Marking & packing 12

1.12 Training 12

1.13 List of spares and list of special tools 13

1.14 Documents to be submitted for approval 13

1.15 QAP to be followed 14 CHAPTER NO.2 Technical requirement of diesel engine

15-22

CHAPTER NO.3 Technical requirement of alternator

23-32

ANNEXURE-A Schedule of technical data sheet to be furnished by the

manufacturer along with the tender and type test for diesel engine 33-38

ANNEXURE-B Schedule of technical data sheet to be furnished by the manufacturer along with the tender and type test for alternator

39-43

ANNEXURE-C1 Schedule of technical data sheet to be furnished by the

manufacturer along with the tender and type test for radiator system/ventilation system

44-45

ANNEXURE-C2 Schedule of technical data sheet to be furnished by the manufacturer along with the tender and type test for ventilation

arrangement for engine room.

46-47

ANNEXURE-D List of drawings and specification Undertaking for cartel formation 48

ANNEXURE-E Undertaking for cartel formation Fire retardant test

49

ANNEXURE-F Fire retardant test List of documents to be submitted alongwith design details

50

ANNEXURE-G Format for quality assurance plan Feedback 51-52

ANNEXURE-H Noise level mapping Declaration on fire safety of DA set 53

Formatted: Font: Not Bold, Complex ScriptFont: Not Bold

Formatted Table

Formatted: Centered, Indent: Left: 0.5",Space After: 10 pt, Line spacing: Multiple1.15 li

Formatted: Font: (Default) Arial, 11 pt,Complex Script Font: Arial, 11 pt

Formatted: Font: 11 pt, Not Bold, Nounderline, Complex Script Font: 11 pt

Formatted: Font: 11 pt, Not Bold, Nounderline, Complex Script Font: 11 pt


Prepared by

SSE/ Alternator

Checked By

Director/MRVC


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

CHAPTER-I

GENERAL DESCRPTION 1.0 FORWORD

The power supply system with axle generation has limitations for services where the electrical requirement is very high. For such trains, the system of end on generation with diesel engine driven sets mounted in power cars at the two ends of the train has been evolved and selectively adopted on the Indian Railways. At present, Rajdhani Expresses, Shatabdi, and Garth Rath services are provided with End-On-Generation (EOG) system.

Presently the rakes of Rajdhani / Shatabdi express trains are working on end on generation system of power supply and are provided with two power cars each fitted with two DAG sets of 500 kVA 336 KW each.

1.1 SCOPE 1.1.1 This specification covers supply, assembly, installation, commissioning, performance, testing

requirement of Diesel Alternator set of electrical power output 400 336 KW, 750 Volt AC, 3-phase, ventilation system, instrumentation, protective devices and accessories, including fuel pipe line, water pipe line, engine air intake pipeline, exhaust piping etc in High Capacity Power Car.

1.1.2 This specification supersedes the Section-II of RDSO specification no. ELPS / SPEC. / EOG / 02

issued in Nov.1994. However the DA set will meet General functional requirement for diesel engine and alternator system for power car as per the specification for EOG / ELPS / SPEC. / EOG / 02 issued in Nov.1994.

1.2 SCOPE OF SUPPLY Manufacturer / supplier shall supply the DA set along with items as per Bill of material

(BOM)given in clause no 2.13 & 3.11. Control panel shall be supplied as per RCF specification EDTS : 103 (REV. ‘D’) or latest revision. However, control panel is not part of scope of supply of specification.

Manufacturers shall ensure that engine supplied to Indian Railways must be complying to latest applicable CPCB norm for emission on the date of supply.

1.3 GOVERNING SPECIFICATIONS: 1.3.1 Following standards, regulations as far as they can appropriately be applied to the coaches for Indian Railways shall be applicable. IEC : 60571-1998 or latest Rules for electronic equipment used on the rail vehicles.

UIC: 564-2 Regulation relating to the fire protection and the fire fighting measures in passenger carrying railway vehicles or assimilated vehicle used on international services.

UIC: 567 General conditions for coaches.

Formatted: Indent: Left: 0.38"


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

IEC : 61373 Railway application- Rolling stock equipment- shock & vibration test.

IEC :349 Rotating electrical machines for rail and road vehicle.

IEC :101 Rules for auxiliary machines on motor vehicles.

IEC : 61000 series Electromagnetic compatibility (EMC) Pt. 4, testing and measurement

technique-section 4. Electrical test transient/burst immunity test.

BS : 5514 Part-I-1996 &

ISO 3045-1 1995 or latest

Reciprocating internal Combustion Engine performance Part-I standard

reference condition de-ration. of power fuel and lubricating oil consumption

and test methods.

BS : 5514 Part-3-1990 &

ISO 3045-3 1989 or latest

Reciprocating internal combustion engine part-3 specification for test

measurements.

BS : 5514 Part-4-1997 & ISO 3045-4 1997 or latest

Reciprocating internal combustion engines part-4 speed governing.

BS : 5514 Part-5-1979 &

ISO : 3045-V 1978 or latest

Reciprocating internal combustion engines part-5 for torsional vibration.

BS : 5514 Part-6-1992 &

ISO : 3045-6 1980 or latest

Reciprocating internal combustion engines part-6specification for over speed

protection.

BS : 5514 Part-7-1996 & ISO : 3045-7 1995 or latest

Reciprocating internal combustion engines part-7 Code for engine power.

IS: 10000-1980 Pt-9 or latest Methods of tests for internal combustion engine (Endurance test).

IS : 4722-2001 or latest Specification for rotating electrical machines.

IS : 7132-73 or latest Guide for testing synchronous machine.

IS : 7306-74 or latest Methods for determining synchronous machine from tests.

IS : 4889-68 or latest Methods of determining of efficiency of rotating electrical machines.

IS : 1460-2001 or latest Automotive diesel fuels.

IS : 13730 Pt-13 or latest Particular types of winding wires part-13 polyester or polyester-amide over coated with polyamide-amide enameled round copper wire clause 200.

ELRS/ Spec. / ELC / 0019 (Rev.4 2) or latest.

Thin walled electron Beam halogen free irradiated cable with copper conductors for powered Rolling Stock applications. E-beam halogen free cable with copper conductors.

RDSO spec. ELPS / Spec. /

EOG / 01 or latest

Spec. and code of practice for wiring in 750V EOG system coaching stock.

RDSO specification no. ELPS / spec. / EOG / 02 Nov., 1994

Specification for broad-gauge high capacity power car for 750 V EOG system.

IS : 13847-1993 Pt-I or latest Specification for low voltage switchgear and control gear – Pt-1, general

requirements.

IS : 13778-1993 Pt-1 - 6 or

latest

Method of test for winding wires thermal properties.

IS : 1239 Pt-2-1982 or latest Mild steel tubes, tubular and other wrought steel fitting of Pt-2 mild steel tubular and other wrought steel pipe fittings.

IS : 649 or latest Stator and rotor stamping.

IS : 7624 or RDSO specification

Lead acid battery for starter battery.

ISO 8528 part 9 & 10 vibration and noise test of DA sets

Note: Latest version of the above specifications/standards shall be applicable and shall be available with the manufacturer before commencing the prototype type test.


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

1.3.2 The supplier shall furnish the details of all the international standards viz UlC/ lEC/ DIN / VDE / EN to which the equipment shall conform.

1.4 SERVICE CONDITIONS: The generating sets fitted in power car shall be suitable to operate continuously under the following varying climatic conditions existing throughout India normally encountered on the Indian Rolling Stock: 1.4.1 Environmental Conditions: - Minimum ambient temperature : - 5 ° C - Maximum ambient temperature : + 55° C - Humidity : : 95% - Altitude : Max.1200 1600 metresmeters above sea level. - Atmosphere : Extremely dusty foggy, desert weather. The dust contents in

the air may reach as high as 1.6 mg / meter³ - Annual rain falls : Very heavy in certain areas between 1750 to 6250 mm. The equipment shall be designed to work in coastal area, humid salt laden and corrosive atmosphere. The maximum values of the condition shall be as under: - Maximum pH value : 8.5 - Sulphate : 7 mg / litre - Max. Concentration of chlorine : 6 mg /litre - Max. Conductivity : 130 micro Siemens /CM I.4.2 Train Speed : 200 Km/hr max. 1.4.3 Vibration & Shunting Shocks: The coaches are expected to run upto a maximum speed of 160 km/h and is planned to be increase up to 200 kmph in future in varying climatic conditions existing throughout India. DA set as well as all accessories to be mounted on the coach shall be designed to withstand service vibrations and buffing shocks. i) Maximum vertical acceleration : 3 g ii) Maximum lateral acceleration : 3 g iii) Maximum longitudinal acceleration : 53 g (corresponding to shunting shocks) (“g” being the “value of acceleration due the gravity) 1.5 GENERAL REQUIREMENT:


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

1.5.1 The Diesel Alternator set shall consist of approved make diesel engine coupled with an approved make alternator both mounted on suitable common base frame.

1.5.2 The diesel alternator set shall generally conform to the details indicated below:

Electrical output power of diesel engine-

alternator DA set at NTP site condition of 55

deg C ambient and 200 m altitude (20ºC & 1

atmospheric pressure) and altitude 600 meter

Minimum 400 336 KW

System Voltage & Frequency 750V, AC, 3 phase & 50 Hz ± 3%

Power factor 0.8

Arrangement and mounting of DA set shall confirm to RCF drawing no. 1 11012 0 89 300 001 and

1 11012 0 89 300 002. Overall dimension of DA DG set shall be within the envelope as being used

presently. OGA drawing, mounting dimension and overall Wweight of complete DA set system

shall be approved by ICF/RCF PUs before prototype test is undertaken.

1.5.3 Suitable anti-vibration mountings (AVM) of proven design with cast steel top bearing plate as

recommended by the supplier shall be provided between the mounting base frame and the coach

under frame at mounting location to absorb the continuous vibrations and shocks encountered

during service. The supplier shall furnish the design calculation for the base frame together with

selection of AVMs before fabrication to achieve following conditions alongwith design document.

Vibration level measurement in all three axis x, y & z at front and rear foot of diesel engine and

alternator shall be taken as per ISO : 8528 pt. -9 or IS 4729and to be provided by PUs/RDSO

1.5.31.5.4 The firm shall critically check the dimensions and the positioning of various load bearing

members of the power Car coach and design placement and fitment of the DA set in a manner

that load is transferred to the coach on load bearing members directly.

1.5.41.5.5 The firm shall submit the following PUs approved drawings along with the offer of the DA

Set:

i. All three views of DA set with radiator placed in the coach and with footprint on the coach floor.

ii. Silencer assembly with fitment of the roof on coach.

1.5.5 The proposal of the DA set supplier shall be acceptable after having validated the offer by RCF PUs validation using computer simulation etc. alongwith submitting the drawings of RDSO.

1.5.6 1.5.61.5.7 The DA set should be compact, robust and light in weight.

Formatted: Font: (Default) Tahoma, Fontcolor: Auto, Complex Script Font: Tahoma

Formatted: Font: (Default) Arial, Font color:Black, Complex Script Font: Arial

Formatted: Outline numbered + Level: 3 +Numbering Style: 1, 2, 3, … + Start at: 1 +Alignment: Left + Aligned at: 0" + Tab after: 0.5" + Indent at: 0.5"


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

1.5.71.5.8 The firm shall make his own arrangements for welding sets, welding rods and welders for

fabrication work to be done suit for commissioning at site.

1.5.81.5.9 One Two sets of maintenance and operation manuals shall be supplied free of cost separately with each diesel engine and Alternator set.

1.5.91.5.10 Once a prototype approval for a make, type and rating of the diesel engine and alternator has been granted, based on the type tests results, the design of the same shall not be changed without the specific and written approval of RDSO. In the event of any of the parameter that have bearing on the performance, deviating from the type values, beyond the permissible tolerance, RDSO reserves the right to repeat the type tests.

1.5.101.5.11 A certificate to the effect that after sales service will be rendered for diesel engine and alternator at all the cities where EOG trains originate along with the name, address and telephone nos. of the service personnel shall be furnished. This information shall also be included in the maintenance manuals.

1.5.111.5.12 The firm shall furnish complete information as per Annexure -‘A’ for the diesel engine and Annexure-‘B’ for the alternator along with detailed design documents.

1.5.121.5.13 The firms shall furnish detailed drawings of radiator indicating the overall and mounting dimensions and other details to facilitate installation of the radiator separately. Technical particulars of the radiator like minimum air flow required through the radiator at 55º C (ambient), its total heat rejection capacity shall also be furnished alongwith submission of design document .

1.5.131.5.14 The engine electrical schematic wiring system with the details of components used (protections, solenoids contractors, switches, gauges etc.) shall be submitted by the firm alongwith submission of design document.

1.5.141.5.15 The interlocking system schematics along with wiring diagram with functional description of the complete system shall be submitted by the firm alongwith submission of design document.

1.5.151.5.16 Calculation for adequacy of diodes selected with their characteristics shall be submitted for the approval by the firm alongwith submission of design document.

1.5.161.5.17 The harness specific to the control switchgear required for the DG DAset shall be supplied by the manufacturer. Cable shall be e-beam irradiated copper cable as per RDSO specification no. ELRS / SPEC. / ELC / 0019 (REV-2 4) - Feb., 2011 with latest amendment / revision and shall beprocured of approved make of RDSO.

1.5.171.5.18 Cable shall be crimped at both ends with suitable lugs. Heat shrinkable PVC transparent sleeve of RDSO approved make shall be provided over all the lugs and joints so that sleeves do not dislodge.



Prepared by

SSE/ Alternator

Checked By

Director/MRVC

1.5.18 Computer generated cable markers of reputed make shall be provided for identification of cables. 1.5.19 Clearance and creepage distance shall be maintained as per IS : 13947 (latest).

1.5.20 The firm shall associate during testing and commissioning of the DA set and its interface with the

switchboard cabinet in the power car.

1.5.21 The equipments working above 110V supply shall be provided with danger plate as per IS : 2551.

1.5.22 Earthing symbol plate shall be provided at all the locations.

1.5.23 Electronic components, if used, in diesel engine or alternator or elsewhere shall confirm to IEC : 60571.

1.5.231.5.24 Colour of DA Set:- The DA Set shall be finished in the colour code no. 108 air craft blue of

IS:5-1961 “Colours for ready mixed paint”. Painting shall be in accordance with specification and “Code of Practice” issued by RDSO for Raw materials , hardware, and anti-corrosive treatment of train-lighting equipment.

1.5.24 The diesel- alternator set is also capable to work on 110 % over-load for one hour once in 12 hour period of operation under service conditions prescribed above.

1.5.25 Engine shall require only indigenous lubricant oil of reputed make.

1.5.26 Soft copies of design details, Circuit diagrams, detailed drawings of diesel engine and alternator, type test results, field trial reports, drawings in auto cad should also be given along with hard copy.

1.5.27 'Maintenance Schedule' and 'Activities' in Each schedule should be submitted during design approval .

1.5.261.5.28 Ventilation equipment and Panel filter for power car shall be tested as per Annex C - 2

1.5.271.5.29 All component used in DA set assembly shall be fire retardant.

1.5.281.5.30 All pipe lines i.e. fuel, lube, coolant etc. should be metallic, covered by fire sleeve, properly clamped and secured.

1.5.291.5.31 Noise reduction features ( Optional): DA set layout shall be in such a way that minimum noise is transmitted outside the power car in the platform area. Firm may reorient/redesign radiator motor, ventilation system, provide acoustic panel and use residential silencer to achieve noise reduction, in such a way that there shall be marginal / minimum increase in the overall weight of the complete system. Acoustic material if used shall be fire retardant. Technical details of complete noise reduction scheme shall be

Formatted: Indent: Left: 0.25", No bulletsor numbering

Formatted: Indent: Left: 0", Hanging: 0.5"

Formatted: Font: Bold, Complex Script Font:Bold


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

submitted to RCF/RDSO. Noise level shall be measured as method prescribed in ISO 8528 Pt. 10 fg-4 and should comply CPCB norms i.e. 75 DB. . Firm shall take prior approval of RDSO/PUs for each noise reduction feature w.r.t. mounting dimensions, OGA dimension & weight. Residential silencer, if provided shall have at least 25dbA noise suppression. Firm shall submit test certificate from NABL accredited lab in this regard. The engine room temperature shall be maintained within the limits prescribed in clause no. 2.11.1, even after adopting the noise reduction measures. RCF/ICF may decide to go for power car with reduced noise level as compared to present. Present level of noise mapping is enclosed in Annexure - H. In such a case firm shall submit details of noise reduction measures for prior approval of RDSO / ICF / RCF. DA set layout shall be in such a way that minimum noise is transmitted outside the power car in the platform area. Firm shall reorient / redesign radiator motor, ventilation system, provide acoustic panel and use residential silencer to achieve noise reduction. Acoustic material used shall be fire retardant. Noise level shall be measured as method prescribed in ISO : 8528 pt.- 10 fig - 4. Firm shall take prior approval of ICF/RCF for each noise reduction feature with respect to mounting dimension, OGA dimension and weight. Residential silencer if provided shall have at least 25 dBA noise suppression. Firm shall submit test certificate form NABL accredited lab in this regard.

1.6 TESTS AND PERFORMANCE:

1.6.1 General

a) DA set prototype shall be done by the Engineers of RDSO & RCF at the works of the manufacturer. After successful type testing and commissioning of DA set on power car, it will put under extensive field trials of 1000 hours for six months.

b) After successful completion of field trials as reported by the Railways, the prototype approval

shall be considered. In case of unsatisfactory performance in the field re-prototype testing either

in full or part can also be done earliest by RDSO for which all the necessary facilities shall be

provided by the DA set manufacturer free of cost.

b)c) All type tests mentioned in table A & B in clause 2.12.2 and 3.10.2 shall be carried out on Diesel engine and alternator at the works of the manufacturer.

c)d) Any defect noticed / design improvement found necessary as a result of these tests / trials shall

be carried out by the manufacturer in the least possible time.

Formatted: Justified


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

d)e) All the system to be supplied against the tender shall incorporate without any extra cost, all the

modifications carried out in the first type tested unit after the field trials of the system. e) All expense on labor, material and fuel during the type test, acceptance test & commissioning test

shall be borne by firm.

1.6.2 TYPE TESTS:

The proto type test shall be undertaken either totally or in part on DA set as per clause 2.12 & 3.10 under the following conditions without any additional at cost of the firm:

a. A manufacturer undertakes to manufacture for the first time as per this specification.

b. A new variant of engine or alternator is introduced by existing manufacturer.

c. A fundamental change in design is introduced and modification of equipment likely to affect

its function.

c. Failure or variations established during type test.

d. Resumption of production after an interruption of more than two years.

e. Specification is amended or revised.

1.6.3 ACCEPTANCE TEST:

All acceptance tests mentioned in table A & B in clause 2.12.2 and 3.10.2 shall be carried out on

Diesel engine and alternator DA Set by an inspecting authority nominated by the purchaser at the

works of the manufacturer.

1.6.4 ROUTINE TEST:

Routine tests mentioned in table A & B in clause 2.12.2 and 3.10.2 shall be carried out on Diesel engine and alternator by the manufacturer at his premises to ensure compliance with the specification and the drawings. Authority nominated for acceptance test shall verify routine test record of each Engine & Alternator.

1.6.5 SPECIAL TEST ON COMBINED DIESEL ALTERNATOR DA SET DURING PROTOTYPE APPROVAL:

1.6.5.1 Firm should have a test bed for complete DA set along with radiator and ventilation arrangement simulating power car condition. Following test shall be conducted on combined set of diesel - alternator under following condition:


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

i) 100 % load with radiator in un-choked condition.

ii) 100 % load with radiator in 30% choked condition.

iii) 110 % load with radiator in un-choked condition.

iv) 110 % load with radiator in 30 % choked condition.

v) Measurement of Speed (RPM) of Engine.

vi) Measurement of alternator Currents, Voltage, Power of DA set (KW in all 3-Ø).

vii) Measurement of Frequency (Hz).

viii) Measurement of Specific fuel consumption (gm/kwh).

ix) Measurement of main Lube oil Pressure (kg / cm2).

xi) Measurement of inlet & outlet temperature (deg C) of lubricating oil.

xii) Measurement of inlet & outlet water temperature (deg C) of coolant engine.

xiii) Measurement of inlet & outlet air temperature of Radiator.

xiv) Measurement of exhaust temperature.

xv) Calculation of torque.

xvi) Appropriate sensors to be incorporated to monitor temperature of cladding of exhaust

manifold, turbo heat shield, exhaust elbow . Theseand temperatures should be

monitored by electronic control panel.

1.6.5.2 ENDURANCE TEST:

Endurance test shall be conducted on DA set on test bed for 96 hours (6 cycles of 16 hours

each). DA set shall be loaded in each cycle as per clause 2.1 of IS : 10000 pt-9.

1.6.6 COMMISSIONING TESTS:

1.6.6.1 For Prototype:


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

These tests are to be conducted after commissioning of DA sets in Power car at production units

i.e. ICF / RCF In case of prototype these tests are to be conducted in presence of PUs, RDSO

and firm. These tests shall comprise of following:-

a) a) Full load test at specified BHP for till stabilization of temperature and minimum of 3 4 hrs.

b) Continuous running after above 4 hours for 96 hours on continuous rating as declared by Firm

(not less than 70% of full load) during commissioning test (Prototype only).

b) Temperature rise in Engine room at full load over ambient till stabilization.

c) Power and control connection sequence test.

d) Checking of bill of material as per specification.

e) Tuning of Engine RPM and alignment

f) Vibration level at base rail with the help of strain gauges/transducers

g) IR and HV test

h) Phase sequence test

i) Functional / operational aspects of each sub-component as well all protection test.

j) Engine room ventilation in terms of air exhaust through ventilation fans.

k) Checking of sealing of Radiators, Fresh air filter, ventilation fan bellows, and

proper tightening of screws etc. and mechanical interfaces.

l) Visual inspection and checking quality of workmanship

m) All protection of engine and alternator shall be verified

n) Test on panel filter as per Annex C2 clause 2.3.

o) Working of fuel flow meter.

p) Checking of termination of cables not more than 2 at one terminal.

q) Checking of Insulation resistance of starter motor to be more than 2 M ohm before and

after temperature rise.

Formatted: Indent: Hanging: 0.29"

Formatted: Font: (Default) Tahoma, ComplexScript Font: Tahoma

Formatted: List Paragraph, Numbered +Level: 1 + Numbering Style: a, b, c, … + Startat: 1 + Alignment: Left + Aligned at: 0.39" +Indent at: 0.64"


Formatted: Indent: Left: 0.44", Hanging: 0.5"


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

r) Checking of manual isolation switch with fuse to isolate the DA set starter motor from the

battery after start of DA set to be mounted in coach side wall for each DA set.

Firm shall make complete booklet of these test conducted on first power car jointly signed

with concerned Electrical Production unit and RDSO of ICF/RCF and shall send the

commissioning report to RDSO. For Subsequent DA set it should be submitted to CEE of PUs.

1.6.6.2 For other than prototype, all DA sets shall be subjected to above tests except for 1.6.6.1 (b).

1.6.7 The alternator and diesel engine shall be tested at ambient condition. However, the test results

shall be extrapolated to on site condition to check the compliance to declared parameters.

1.7 GUARANTEE / WARRANTY: 1.7.1 Guarantee/Warranty obligation of the equipment shall be as per IRS condition pf contract

1.7.2 The supplier shall be responsible for carrying out all the modifications at his cost on any part of

the equipment during the period or warranty required for satisfactory operation of the

equipment as per technical specification. For any technical decision the final authority from the

purchaser’s side is RDSO.

1.7.3 Warranty: The supplier shall be responsible for any damage to equipment provided in power car

of Indian railway due to defective design, materials, and workmanship to a period as per IRS

condition prevalent at the time of tendering. The period of warranty will be extendable in case of

recurring problems attributable to defective design, material or manufacturing. The supplier’s

liability in this respect of any complaints defects and/or claim shall be limited to the furnishing and

Installation of replacement parts free of any charge. Further, should any design modification is

required to made in any part of the equipment the guarranty period shall commence from the date

when the modified part is commissioned in service. If during the guarantee period, the equipment

is out of commission on firms account the period of guarantee will be extended by the period for

which the equipment remained out of commission.

1.8 INFRINGEMENT OF PATENT RIGHTS:

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 & development of this 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 manufacture r/ supplier. Details/ design/ documents given by them are firm should not infringing any IPR and they are responsibly in absolute and full measure instead of railways for any such violations Data,




Prepared by

SSE/ Alternator

Checked By

Director/MRVC

specification and other IP as generated out of interaction with railways shall not be unilaterally used without the consent of RDSO and right of Railways/RDSO on such IP is acceptable to them.

1.9 ISO 9000 9001 ACCREDITATION:

The firm seeking RDSO’s approval for manufacture and supply of diesel alternator set conforming to this Specification shall have ISO: 9001 accreditation to ensure its conformance to quality systems laid down in the standard for design and manufacturing processes at different stages.

1.10 CARTEL FORMATION

The firms shall not engage in cartel formation with other firms and will also submit a

declaration in this regard as per Annexure - ED attached.

1.11 MARKING & PACKING

1.11.1 The Diesel - Alternator shall be provided with suitable name plates, on which the following shall

be marked / engraved:

a) Manufacturers name and trade mark.

b) Rated capacity of the machine (alternator KVA/Diesel engine BHP etc.).

c) Voltage and current rating.

d) Class of insulation.

e) Weight of alternator / Diesel Engine / Radiator.

f) PO Number

g) Name of PUs

fh) Engine must be affixed with a conformance label meeting the following requirements

i) Statement that “this engine conforms to the environment (protection) rule 1986”

ii) Type approval certificate number

The label shall be affixed on part necessary for normal operation of the engine and not normally

requiring replacement during the life of the engine.

1.11.2 The serial number of the machine shall be marked/engraved/ embossed as under:-


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

First two digits : Year of manufacture

Next two digits : Month of manufacture

Next two / three digits: No. of machine manufactured in the particular Month e.g. Serial

No.08 02 0001 denotes machine manufactured in February 2008

with Serial number of 0001.

1.11.3 The equipment and its sub assembly shall be packed with wooden box of sufficient strength

and the empty space shall be filled with suitable filling material.

1.11.4 Manufacture shall provide a screen-printed schematic diagram of power and control circuit at

suitable place.

1.11.5 Manufacturer shall provide printed DO’s and Don’t Do’s

1.12 TRAINING:

A) The supplier shall arrange for training to Indian Railway personnel in maintenance and

trouble shooting of the system supplied. Ten man-days training in operation, maintenance &

trouble shooting aspects will be provided. The supplier will provide detailed technical write-up to

all the trainees. The syllabus for training will have to be approved by the user/ purchaser. The

venue of training will be mutually agreed. Training will be arranged free of cost. Suitable training

material will be supplied to the participants.

B) If the firm in involved in operation of power car also in future it should ensure to give a

competency certificate to trained operators. Such operations should not be below ITI in

Mechanical/Electrical trade. Record of such competencies should be kept available with the firm

along with the issue date & validity.

1.13 LIST OF SPARES AND LIST OF SPECIAL TOOLS:

The Firms shall submit recommended list of spares for diesel alternator set and list of special

tools if required any.

1.14 Apart from details as per Annexure A, B , C1 & C2 , following documents shall also be

submitted to RDSO for approval before type test:

1.14.1 Diesel engine:

a) General description of diesel engine with the list of protection devices, gauges and

sensors.


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

b) Heat balance diagram and heat load calculation.

c) Lube oil circulating diagram.

d) Radiator water circulating diagram.

e) Detailed drawing of radiator indicating the overall and mounting dimension.

f) Air duct design details and drawing to avoid back turbulence.

g) Details of electronic governor including circuit diagram.

h) Anti vibration mounting design details with calculation.

i) Design calculation for base frame with detailed drawing.

j) Starter battery selection calculation.

k) De-ration calculation for engine at site conditions.

l) Design of Cladding of exhaust manifolds and turbo charger with metallic shield.

m) Material details of fire sleeve hoses on rubber tubes.

n) Functional, detail of electronic control panel.

o) Design, detail of parker or equivalent fittings.

p) Class of insulation & circuit diagram of starter motor

q) Detail of remote monitoring system.

r) Number of joints.

ls) Any other design related details.

1.14.2 Alternator

a) Diagram of electrical connections together with assembly drawing showing full

particulars of Exciter / stator and numbers of turn, sections, weight and length per coil. b) Circuit diagram of AVR. c) Shaft design stress calculation. e) Bearing life and lubrication interval calculation. f) Insulation scheme. g) Diode selection calculation.


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

h) Dimensioned part drawings with full details of tolerance of dimensions. Finish, material specification. i) Design detail and Circuit diagram of AVR. jh) Any other design related details. 1.15 QAP TO BE FOLLOWED DURING MANUFACTURING FOR DA SET:

Manufacturer shall comply RDSO ISO document No. QM-RF-8.1-3 latest version to for Quality

Assurance Plan as per ANNEXURE—G

1.15.1 Since the quality of the equipment bears a direct relationship to the manufacturing process

and the environment under which it is manufactured, the manufacturer shall ensure Quality

Assurance Program of adequate standard.

1.15.2 The material purchased from outside agencies shall conform to the relevant Standard

Specification as specified in RDSO / IS Specification. The certificate conforming to RDSO /

IS Specification should also be made available for each lot of machines . It is also preferred that

in-house test facilities for purchased items should be developed by the firm so that testing of these

materials can be done within the factory premises so that check can be exercised by the Inspecting

Authority in case necessary, otherwise, the testing of these materials should be done by NABL

accredited Testing Agency.

1.15.3 Firm shall submit all the technical documents i.e drawings, design calculation, layouts, circuit

diagrams etc in soft copy as well.

1.16 Schedule of technical requirement:

Schedule of technical requirement for this assembly of DG set shall be RDSO/PE/STR/AC/0037-

2012 (Rev 0)

Formatted: Indent: Left: 0", Hanging: 0.5",Tab stops: 0.56", Left


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

CHAPTER 2

TECHNICAL REQUIREMENT OF DIESEL ENGINE

2.0 DIESEL ENGINE:

The Diesel engine shall be of robust and reliable design, turbo charged and water-cooled. Engine

shall be able to deliver power minimum power of 585 BHP for getting and minimum electrical

power output from alternator of 336 400 KW. Firm should declare power deration chart with

temperature and altitude up to at site condition of 55 º C and 200 1600 m altitude at 1500 RPM.

Firm shall declare the BHP rating of engine at standard reference condition as per BS 5514 part-1

i.e at total barometric pressure=100 kPa, Air temperature=25 º C Relative humidity 30 % and

charge air coolant temperature 25 º C. Accordingly, deration curve if any shall also be submitted.

Manufacturers shall ensure that engine supplied to Indian Railways must be complying to latest

applicable CPCB norm for emission on the date of supply. Engine shall be capable to work on 110

% overload for one hour in 12 hour period of operation.

2.1. ENGINE COOLING SYSTEM:

2.1.1 The engine shall be water cooled and shall be supplied with Radiator. The radiator shall be

suitable for separate mounting at a remote location to facilitate cooling by a fan to be driven by

suitable capacity, 3- phase, 415 volts, and squirrel cage induction motor. The engine shall also be

supplied with suitable circulating water pump, lubricating oil heat exchanger, lubrication oil pump,

interconnecting pipes, silencers, and exhaust pipes.

2.1.2 The drawing for the location of the radiator with respect to the face of the engine and its

mounting and the ventilation arrangements shall be submitted by firm for prior with approval of

RDSO / RCF PUs.

2.1.3 The cooling equipment (Radiator, water pump, pipe lines etc.) shall be of adequate capacity such

that the water temperature is maintained within the specified range with the engine operating at

the full rated load at site conditions with radiator clogged to 30 %.

2.1.4 The air duct design with guided flow to avoid back turbulence shall be designed by the firm and

shall be submitted by firm shall be got with approved by RDSO / RCF PUs in order to reduce the

noise level (Supply of duct shall be in scope of tenderer as per firm’s drawings).

2.1.5 The operating range of water temperature, under full load shall not exceed 985 º C

maximum. If water temperature exceeds 95º C alarm should are with high water

temperature and if it exceed 98º C engine should trip.



Prepared by

SSE/ Alternator

Checked By

Director/MRVC

2.1.6 Water level indication shall be provided on the radiator top tank at a visible location. If water level

falls below permissible limit engine should trip with low water level alarm in crew compartment.

2.1.7 The Firms shall furnish detailed drawings of the radiator indicating the overall and

mounting dimensions and other details to facilitate installation of the Radiator separately.

Technical particulars about the radiator, like minimum Air flow required through the radiator at

55 ° C ambient, its total heat rejection capacity, the pressure drop across the radiator etc. shall

also be furnished.

2.2 AIR FILTER:

2.2.1 The engine shall be equipped with air filter of adequate capacity suitable for operation in service

conditions given in clause no. 1.4. The filters shall be supplied alongwith DA set as per Engine

Manufacturer’s recommendations by the manufacturer.

2.2.2 Drawing for fresh air inlet to air cleaner and turbo charger shall be submitted by firm for prior

approval of RDSO / RCF PUs. FEA of turbo charger should be conducted & report submitted to

RDSO.

2.2.3 The air filter location shall be selected in such a way that crew cabin staff shall be able to check

the filter condition for clogging and its attendance. To facilitate this, suitable restriction indicator

will be provided. Additional engine tripping mechanism shall also be incorporated in the engine

electronic control panel control circuit which will trip the engine in case filter gets choked beyond

permissible limit with high air filter chocked alarm in crew compartment.

2.3 FUEL PIPE LINE:

2.3.1 The scope of supply includes the supply and erection of seamless stainless steel heavy duty pipes

grade SS 316 and flexible hoses (SAE 100 R1 or better) of appropriate size and length with

necessary pipe and end fittings, isolating cocks, union sockets etc. as needed. The exact quantity

shall be as required at site. Rubber hose shall not be used in fuel circuit. No banjo type fitting to

be used as it is leakage prone. All joints should have Stainless steel parker fittings or Stainless

steel equivalent fittings. Only metallic rigid/ flexible fuel & lube oil pipe lines should be used.

Number of joints have to be minimal in fuel & lube oil pipe lines. Number of joints should be

declared.

2.4 FUEL / LUBE OIL:

2.4.1 The engine shall normally be required to operate on diesel fuel whose properties standard shall

be as per IS 1460-2000 or latest. The diesel engine shall be tested with Bharat Stage II fuel oil



Prepared by

SSE/ Alternator

Checked By

Director/MRVC

in type test. Even though diesel engine being Bharat stage III compliant, it shall be capable of

operating with Bharat Stage-II CPCB conforming fuel oil in case of emergency.

2.4.2 Drawing for Fuel oil suction and return from the engine pump to engine shall be submitted by

firm for prior approval of RDSO / RCF PUs.

2.4.3 Required amount of lube oil and diesel oil for all the test during type testing and commissioning

tests shall be arranged by firm.

2.4.4 Bye pass circuit filter to be designed in such a way that frequency of lube oil change is not less

than 500 hrs. Firms may use centrifugal lube oil filter in bypass circuit instead of Paper filter.

2.4.5 Engine shall require only indigenous lube oil which is presently used by Indian Railways.

2.4.6 All lube/fuel oil pipe line should be away from high temperature zones as for as possible.

2.5 FUEL CONSUMPTION METER:

2.5.1 Fuel consumption meter shall be provided for monitoring the fuel oil consumption. Its working

shall be monitored during 6 months field trial.

2.6 SILENCER:

2.6.1 The silencer shall be suitable for location on the coach roof exposed to atmosphere. Adequate length of the pipes, elbows etc for carrying the exhaust hot gas in the silencer to the atmosphere shall be supplied and erected by the firm. Provision shall also be made to prevent water entry into the silencer. The portion of the exhaust pipe inside the coach and from its manifold shall be suitably and adequately cladded. The supplier shall submit design of silencer both with single silencer and more than one silencer unit serially connected to reduce the diameter and the design shall be got approved from RDSO/PUs.

2.6.2 Cladding:

Cladding of exhaust manifolds and turbo charger with metallic shield to ensure surface

temperature within safe limit not exceeding 80 C. Appropriate sensors to be incorporated to

monitor temperature of cladding of exhaust manifold and turbo charger and temperature

monitored by electronic control panel. Events of failure should be generated and recorded as

fault, though engine is not required to be tripped.

2.6.2 Drawing for general arrangement of silencer and exhaust system mounting arrangement

shall be submitted by firm for prior approval of RDSO / RCF PUs.


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

2.6.3 The turbocharger, exhaust manifold and the exhaust pipe lines shall be thermally insulated and

cladded with galvanized steel sheets or aluminum SS sheets and firmly secured so as to ensure

that there is no excessive heat in the engine room.

2.6.4 Noise level to be measured as per ISO 8528 part 10 and should comply CPCB norms.

2.7 ELECTRONIC GOVERNOR: 2.7.1.1 The engine shall be supplied with Electronic governor conforming to International

standard like BS / IEC / ISO. The governor should be suitable for transport application. Electronic

governor should be directly mounted on the engine varying of the speed from idling speed to

maximum load speed and also in the Crew compartment.

2.7.1.2 There should be Electronic control panel & governor for Engine to improve regulation of

RPM and frequency, monitoring of engine parameters. The device shall be easily accessible and

preferably in crew area. The electronic control panel shall display the following information:-

a) Lubrication oil pressure& temperature.

b) Water outlet temperature.

c) RPM of engine.

d) Battery voltage.

e) Two bank difference of temperature (if 'V' type engine)

f) Surface temperature of cladding of exhaust manifold and turbocharger.

g) Fuel consumption in liter.

h) Exhaust gas temperature

i) Engine output in KW

j) Alternator output voltage and current in each pahse and line

k) Date and time.

l) Performing duration in hours.

m) Alternator output power in kW

n) Power factor.

o) Frequency of Alternator

p) Ambient Temperature in power car

q) Fault’s are displayed directly or fault codes are displayed.

Formatted: Style, Indent: Left: 0", First line: 0", Pattern: Clear (White)

Formatted: Indent: Left: 0", First line: 0.5",Space After: 0 pt, Line spacing: 1.5 lines

Formatted: Font: (Default) Arial, ComplexScript Font: Arial



Prepared by

SSE/ Alternator

Checked By

Director/MRVC

It should have memory to store & access the last 50 faults data (minimum). Firm shall give

details of the system along with Overall General Arrangement (OGA) drawings & circuit diagram.

2.7.1.3 Data shall be downloadable by USB Pen Drive of reputed make without aid of laptop or any other software. This data should be directly openable in MS Office applications like Excel/Word.

2.7.1.4 Memory shall have sufficient capacity to contain minimum 7 days data with a resolution of one

minute apart from cumulative data of last 7 days and fault data. 2.7.1.5 Transferring of the Journey data: The data stored in the portable USB pen drive unit shall be

transferred directly to the PC or laptop having USB port. 2.7.1.6 Reporting Format: Recording interval shall be one minute and minimum duration of

recording shall be running seven days. The format of reporting shall be as follows: Format A

Date Time Output Voltage

Output Current

Cumulative SFC

Exhaust gas temperature

Ambient temperature in power car

R Y B

Format B for failures:

Date Time Type of Faults Remarks

2.7.2 REMOTE MONITERING SYSTEM:

Power factor

Output

power in

kW

Lube oil pressure in bar

Surface temperature of

cladding of exhaust manifold and turbo charger

Fuel consumption in litre/hrs

Water outlet temperature

Engine RPM

exhaust manifold

turbo charger

Exhaust Elbow cladding

Formatted: Font: Arial, English (U.K.)


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

Provision of remote monitoring device for health of DA set shall be provided by firm. Arrangements for communication i.e. SIM should be made by Railways. Electronic Control Panel should have provision of Remote monitoring also. All the data

which is downloadable as mentioned above should be able to transmitted in real time through a SIM (3G and above) to another device. Arrangement of SIM shall be in scope of Railways, maintaining it. The software/ App over which the data can be accessed shall be provided free of cost to user Railways. The software /App should have feature to integrate any number of DA Set/ Power Cars to be monitored by division or zonal railways or both. The display system should have ease of monitoring events and concerns should be shown in flashing red colors.

2.8 STARTER MOTOR:

2.8.1 Diesel engine shall be equipped with a starter motor working from 24 V DC battery supply and

associated accessories like starter solenoid, fuel start Solenoid etc. for cranking the engine. The

motor shall be of adequate rating to crank the engine to firing speed under the service conditions

specified in Clause 1.4, without exceeding the temperature rise limits for the class of insulation.

The entire engine wiring shall be non-grounded. Starter motor shall be Delco Remmy, Lucas or

reputed make with prior approval of RDSO / RCF.

2.8.2 It shall not be possible to energise the starter motor, when the engine is running at speed

above the minimum firing speed. Suitable cranking protection shall be provided.

2.8.3 Insulation resistance of starter motor should be more than 2 M ohm on both terminals, during

commissioning.

2.8.4 Manual isolation switch with fuse to isolate the DA set starter motor from the battery after start of

DA set to be mounted on coach side wall for each DA set provided by PUs.

2.9 STARTER BATTERY:

2.9.1 A 12 cell (3 mono blocks each comprising of 4 cells) 24 volts tubular lead acid battery of 290 AH

capacity to IS: 7624 (latest) or RDSO’s specification shall be provided by the supplier

separate for each DA sets to feed power to the engine starter. The firm shall certify the

adequacy of the battery. The battery shall be suitable for high discharge starting current and shall

be taken from OEM directly.

2.10 SAFETY DEVICES, GAUGES / INSTRUMENTS:


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

2.10.1 The engine shall be provided with fuel solenoid and safety devices like high water temperature

cut-out, low lube oil pressure cut-out, air filter choke cut-out, low water level cut-out, radiator air

loss cut-out, exhaust gas temperature Max 600ºC, , two bank difference temperature (if ‘V’ type

engine) maximum 50ºC, phase unbalance, phase sequence change and over speed cutout etc.

to facilitate automatic tripping of engine. The gauges and meters as required shall also be

supplied with minimum suitable length of leads. Complete protection scheme shall be submitted

to RDSO /PUs RCF for approval

Important Engine Parameters from safety point of view:

S.No. Parameters Reference value

1 Radiator

i) Coolant temperature Max 98 deg. C

(Engine to shut down with indication should

come on Electronics control panel.)

ii) Low water coolant

level

Engine to shut down with indication should

come on Electronics control panel.

iii) Radiator Air loss Engine to shut down with indication should

come on Electronics control panel.

2 Lube Oil

i) Max. lube oil

temperature

Max 130 deg. C

(Engine to shut down with indication should

come on Electronics control panel.)

ii) Low lube oil pressure 2.5 Bar min.(Engine to shut down) (Engine to

shut down with indication should come on

Electronics control panel.)

3 Two bank difference of

temperature (if ’V’ type engine)

Maximum 50ºC (Engine to shut down with

indication should come on Electronics control

panel.)

4 Exhaust gas temperature Max600ºC (Engine to shut down with indication

should come on Electronics control panel.)

Formatted Table


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

5 Air filter chocking at 60% Engine to shut down with indication should come

on Electronics control panel.

6 Emergency stop Engine to shut down with indication should come


7 Phase sequence change Engine to shut down with indication should come


8 Over voltage Engine to shut down with indication should come


9 Under voltage Engine to shut down with indication should come


10 Over frequency Engine to shut down with indication should come


11 Under frequency (Engine to shut down with indication should come

on Electronics control panel.)

12 High ambient temperature in

side of power car

Maximum 70ºC (Engine to shut down with

indication should come on Electronics control

panel.)

2.10.2 The performance monitoring of electronics control panel (remote gauges panel) shall be mounted

in side the crew cabin to facilitate monitoring/starting of Diesel engine from the cabin itself. The audio and visual alarm for the fault shall also be provided in the crew cabin & audio alarm

for guard cabin itself so that fault can be understood and attended promptly by cabin crew staff. The inter connecting cables, if any shall be supplied by the firm. The electronics control panels shall also have the lockable starting switch and push button for operating the engine and a ‘ STOP PUSH BUTTON ’.

2.10.3 During the emergency and other failures, stopping of the engine shall be by De - energizing the

fuel “Shut-Off valve” only or tripped through engine control Unit.

2.10.4 In emergency and other failure stopping of the engine shall be through Electronic governor actuator or through engine ECU.


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

2.10.5 The panel shall also have the starting switch for operating the engine and an EMERGENCY

ENGINE STOP push button for stopping the engine.

2.11 VENTILATION SYSTEMS:

2.11.1 The ventilation system shall be such that in actual service operating conditions, with the diesel

engine and alternator operating at their full rated capacity, the temperature of the engine room

shall not be more than 5 ° C, over the maximum ambient temperature. Engine room ventilation

shall consist of blower assembly complete with fan, motor and housing / brackets suitable

mounting.

2.11.2 Ventilation fan motor shall be IP - 65, Class-H insulation of M/S ABB, M/s Laxmi Hydraulic, M/s

Crompton, M/s Siemens, M/s Kirlosker Electric make only. The motor shall conform to IS :325.

2.11.3 Ventilation aspects relating to Radiator cooling and Engine Room are given in Annex.-C 1 & C 2.

2.12 FIRE SEFTY :

Fire safety is a serious concern of Indian Railways. Manufacturer has to give design input in enhancing features in engine and alternator, so that there is no likelihood of fire due to leakage of fuel, lube, fuel/lube under pressure mixed with air, short circuit, insulation failure, over voltage, over current beyond permissible limit, surface temperature being too high, joints faling during service, proximity of joints to hot areas and battery etc. Since the DA set is installed in a rolling stock having continuous vibrations, besides own vibration of DA Set, there are chances of it impacting wiring, joints in under pressure lube, fuel tubes, assembly etc. Therefore a shock and vibration test at a NABL accredited lab/ Government lab is to be conducted at the prototype before commissioning test. Following are some check points for the inspector conducting prototype to enhance fire safety.

i) Any high pressure/ low pressure pipe line should be for away from the high temperature zone like as exhaust manifold, turbocharger compressed air line.

ii) Metallic collector with proper drainage arrangement below fuel & lube oil pipe lines. iii) Provision of adequate clamps on pipe lines for better handling of vibrations. iv) Minimal number of joints in fuel & lube oil pipe lines to be used. v) No Aluminum Sheets or plates shall be used with DA Set or during installation of DA Set in

Power Car.” In lieu SS or GI sheets of suitable thickness may be used. vi) All joints should have stainless steel parker fittings or equivalent stainless steel fittings. vii) Only metallic rigid/ flexible fuel & lube oil pipe lines to be used.

viii) Provision of fire sleeve hoses on rubber tubes if use is inevitable.

ix) Fuel lift pump, water separator filter, fuel filter and flow meter to be away from body of engine

(on other side of battery).

x) Minimum number of filters to be used..

Formatted: Indent: Left: -0.19", Hanging: 0.44", No bullets or numbering

Formatted: Font: (Default) Arial, Font color:Red, Complex Script Font: Arial


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

xi) Cable harness route to be shortest possible and with proper clamps. Cable harness component

of approved source shall be used.

xii) Cladding of exhaust manifolds and turbo charger with metallic shield to ensure surface

temperature within safe limit. Appropriate sensors to be incorporated to monitor temperature of

cladding of exhaust manifold and Turbo charger and temperature monitored by electronic

control panel. The engine will shut down in any incident of excess exhaust temperature max

600ºC or in the event the limit (50±10ºC) for variation in exhaust temperature on either bank is

exceeded (if ‘V’ shape engine).

xiii) All safety check will be done.

2.132 TESTS ON DIESEL ENGINE:

2.132.1 Prototype, acceptance, and routine tests as mentioned in the table given below shall be

conducted on the diesel engine:-

2.12.2 2.13.2 TABLE FOR TESTS ON DIESEL ENGINE – A :

Sr.no Tests Type test Accepta-nce test

Routine Test

Cl. Of Relevant Standards

1 Verification of dimensions

of all major assemblies and

sub-assemblies and weight

of Diesel Engine and

Radiator

Yes Yes - As per PUs

approved

drawings.As per this

specification

2 Performance test of 11

hours rated BHP and 1

hour 110% overload

during prototype test

and during acceptance

test 4 hours rated BHP

and 1 hour 110%

overload

Yes Yes no As per this

specification

32 Rating test at simulated

site condition. During the

S. No. 2, test the following

recordings shall be made

Clause no. 15.5.2

(Engine group-3) of

BS : 5514 pt- 1 1996

or latest

international

standard. a) Fuel consumption rate. Yes Yes Yes

Formatted: No bullets or numbering


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

b) Lube oil pressure. Yes Yes Yes Table -5 list -A test

measurements S.N.

A 1 to A 19 Tabte-7

list C and Table -8,

list D

CPCB

certification as per the latest guidelines

/ norms will have to

be provided by the manufacturer to

substantiate the compliance of

emission norms

c) Lube oil consumption. Yes No -

d) Cooling water inlet and

outlet temperature.

Yes No No

e) Exhaust gas

temperature.

Yes Yes No

f) Smoke test. Yes Yes Yes

g) Torque Yes Yes Yes

h) Speed. Yes Yes Yes

43 Governing test Yes No No BS : 5514 Part-4

1997 and ISO :

3046-4 or Latest

International

Standard

54 Specific fuel consumption

(SFC) test Yes Yes Yes Clause no. 15.5.2

Table 6 list B of BS :

5514 part-I or latest international

standard. Specific fuel consumption (SFC) test shall be within 220 g/kWh.

6 Radiator capacity test (at simulated or equated site

conditions 55 º C)

Yes No No Annexure –C1 of this

specification for

reference only.

7

Special test:

Clause no. 15.5.2

(Engine group-3) of

BS 5514 Pt-I 1996 or

latest International

Standard

Table-5 list A test

measurements S.No.

i) Engine heat balance Yes No No

ii) Sound level Yes No No

iii) Exhaust-gas emission Yes No No

Formatted: Font: (Default) Arial, 11 pt,Complex Script Font: Arial, 11 pt


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

characteristics A 1 to A 19

Table-7 list C and

Table - 8 list D

8. Environmental test on

Electronic governor and electronic control panel.

Yes No No Clause 120.2.3,

120.2.4, 120.2.5,

120.2.6, 120.2.7,

120.2.8, 120.2.9,

120.2.10, 120.2.11,

12.2.12 of IEC :

60571-201206 or

latest.

9. Endurance test (Internal testing )

No No No Manufacturer shall

submit internal test

results to RDSO

for 32 cycles as

per clause 2.1 of

IS: 10000 pt.-9 .

10. Shock and vibration test Yes No No Shock and

vibration test on

complete Diesel

Engine shall be got

conducted from

any NABL or Govt.

labs or lab which

has been

accredited by an

accreditation

agency as per

category 1 class B

of IEC 61373

before

commissioning test

to establish impact

on joints of fuel

pipe line, exhaust

manifold,

turbocharger,


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

cables and wires

etc. and report

submitted to

RDSO.

11 Starter motor test Yes Yes Yes As per clause no.

2.8 of this

specification.

12 Safety devices, gauges/instruments

Yes Yes Yes As per clause no.

2.10 of this

specification.

13 Ventilation system Yes Yes Yes As per clause no.

2.11 of this

specification.

14 Clearance and creepage test

Yes Yes Yes As per clause no.

1.5.19 of this

specification.

15 Remote monitoring test Yes Yes Yes As per clause no.

2.7.2 of this

specification.

16 Safety check Yes Yes No As per clause no.

2.12 of this

specification.

17 Special Test Yes Yes No As per clause no.

1.6.5 of this

specification.

18 Data downloading Yes Yes Yes As per clause no.

2.7.1.6 of this

specification.

19 Commissioning test During commissioning in every coach. As per clause no.

1.6.6 of this

specification.


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

Note: The values of the test for SFC, Lube oil consumption, Lube oil temperature, lube oil pressure, shall be kept for record for future reference of acceptance test. A tolerances of 3 % should only allowed.

2.13 BILL OF MATERIAL

S.

No.

Description Qty/DG set

i) Diesel Engine as approved by RDSO for on board application in Engine room of

power cars along with following accessories:

1 Set

a Fly wheel with housing 1 No.

b Engine air cleaner mounted on Engine with the duct for collecting air from the

side wall opening of the coach.

1 No.

c Flexible coupling duly machined to match with alternator shaft. 1 No.

d Lube oil cooler 1 No.

e Fuel filter and lube oil cleaner 1 No.

f Exhaust piping complete with metallic flexible pipe, rigid pipes elbows, flanges,

cladding of the exhaust pipes, and silencer with clamps (quantity as required at

site).

1 lot

g Fuel circuit piping including seamless stainless steel pipes, metallic flexible pipe

hoses, pipe fitting (brass). Non-return valves (as required at site).

1 lot

h Engine monitoring panel provided with the radiator water temperature gauge,

lube oil pressure gauge, Techno-hour meter, engine off push button, lube oil

temp. gauge, tripping of the engine due to failure of HWT, LOP,OS along with the

parallel remote annunciator for the same, tripping of engine due to air- filter

choking, tripping due to low water level ,tripping due to air loss from radiator

motor etc.

1 set

i Set of gauges for remote mounting on the power and control electronic control

panel circuit panel for monitoring radiator water temperature, lube oil pressure,

lube oil temperature, fuel consumption meter etc.

1 set

j Safety devices (cut outs) for automatic tripping of engine in the event of high

water temperature, low Lube oil pressure and over speed mounted on the engine,

low water level, air-filter chocking, tripping due to air loss from radiator motor etc.

1 set


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

k Starting equipment 24 V dc consisting of adequate starter motor (not exceeding

10 KW), Starter solenoid & fuel start solenoid.

1 set

l Electronic governor with engine control and display panel. 1 no.

m Base frame for diesel alternator set complete, as per approved drawing with anti-

vibration mounting (clause 2.2). Firm shall keep the mounting arrangement of the

base rail common with the existing design i.e. keeping the mounting hole same to

avoid minimum changes.

1 set

n Coolant piping with fittings connected between radiator and engine. As per

requirement

n

(i)ii

Radiator assembly complete with radiator, water level indicator, blower fan, drive

motor frame work, fan housing, AVMs etc as per approved drawing.

n

(ii)iii

12 cell ( 3 mono blocks each comprising of 4 cells) tubular lead acid battery of

290 AH capacity to lS:7624(latest) or RDSO’s specification complete with inter-cell

connectors to feed power to the engine starter motor for cranking the engine

1 set

n

(iii)iv

Engine room ventilation consisting of blower assembly complete with fan, motor

and housing / brackets suitable for mounting. Motor shall be of M/s ABB /

Siemens / Kirlosker electric / Laxmi Hydraulic/ CGL make.

1 set

n

(iv)v

Dry type, fire retardant, removable and reusable panel type of approved make by

RCF/RDSO.

As per

requirement

n

(v)vi

Anti vibration mounting pads of M/s Resistoflex or M/s Metalastik or any other

with prior approval

1 Set

n

(vii)

Fuel consumption meter along with its accessories 1 no

o Remote monitoring system 1 set

p Maintenance manual 1 set


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

CHAPTER-3

TECHNICAL REQUIREMENT OF ALTERNATOR

3.0 ALTERNATOR:

3.1.1 Alternator shall be rated at minimum 400 336 KW , 1500RPM, 750 V, 3 - Phase, 50 Hz , 0.8 pf

and should work at site condition of 55 º C and 200 1600 m altitude. Firm shall also declare the

rating of alternator at standard reference condition as per IS : 4722 Accordingly, deration curve if

any shall also be submitted. Alternator shall have 10 % overload capacity for one hour in a span

of 12 hours.

3.1.2 Alternator shall be of the self-excited, self regulated and self-ventilated brush less design

confirming to duty continuous class S 1 as per IS : 4722-2001 and shall have 3- phase star connected

winding with 4 terminals brought out for external connections. The terminal shall be located in a

terminal box, provided on alternator body.

3.1.3 The alternator shall be capable of catering to at least 30 % of unbalanced load in anyone or two

of the phases with the current in any of the phases not exceeding the rated current with the

regulation maintained at 5 % or less and 2.5 % or better in manual and AVR mode of operation

respectively.

3.1.4 Stator and rotor stampings shall be CRNGO steel sheet M-45 grade with C 6 coating. Stamping

shall be tested as per IS : 648 and IS : 649. Firm shall procure stamping from M/s SAIL, M/s

Nippons steel or any other make with prior approval of RDSO.

3.2 VOLTAGE REGULATION:

3.2.1 Voltage regulation of the alternator shall be of the dual control type i.e. both electric and

electronic. The electric control shall be through compound transformer or magnetic amplifier open

loop excitation and electronic regulation through solid- state automatic closed loop excitation

voltage control both sensing from all the three phases. The combined regulation shall be within

2.5 % or better. There shall be “Stand-by” facility to ensure regulation within 5% even in the

event of failure of the automatic electronic voltage regulator and this “Stand-by” facility shall

automatically cut in, with the help of an over-voltage / under voltage sensing device which would

also indicate through LED indication regarding failure of AVRs.

3.2.2 AVR (automatic voltage regulator) shall be modular type suitable for remote mounting in power

and control panel in crew room. Interconnecting cables and coupling arrangement between

alternator and AVR shall also be in the scope of firm. Dimensions and layout drawing of AVR shall

be got approved by RDSO / PUs RCF before submission of internal test report. Firm shall submit


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

wave-form of field supply at no load and full load and also provide percentage (%) THD in field at

various load conditions.

3.2.3 The cables required for manual stand-by control device, leading from the alternator to the Over

Voltage / under voltage sensing device provided externally shall be in the scope of firm. Cables

shall be e-beam of RDSO approved make.

3.2.4 The input leads to the AVRs shall have fuse protection with appropriately rated fuse of Siemens /

L & T make. The AVRs shall be of the plug-in type. AVR and over voltage sensing device shall

meet the environmental condition as per IEC : 60571-1998 in respect of dry Heat, Damp Heat,

Voltage Surge, insulation resistance test & vibration etc.

3.2.4.1 Local control panel (AVR/OVR) should be mounted on coach sidewall on the side of

radiator & ventilator panels or alongwith terminal board.

3.2.5 Complete details of the Alternator alongwith AVR/OVR (along with schematic diagram) shall be

submitted by the manufacturer during submission of internal test report.

3.2.56 The rotating diodes used for supplying DC power to the main field winding shall be of current

rating equal to at least 2 times the loading on them under full load of the alternator. They shall

be of minimum 1000 V PIV rating. Under the full load operating conditions the case temperature

of the diodes shall be at least 20 ° C below the limit recommended by the manufacturer.

Provision of appropriately rated fuses / MOV on the input side of the rectifier bridge is desirable.

3 2.7 Firm shall submit details of harmonics content at various load condition to RDSO for approval.

This is very essential to limiting neutral current at design stage. There shall be no need of any

neutral current limiting reactor.

3.2 8 In layouts, where the rotating diodes are located at the hot air exit end, the current rating of

diodes shall be at least 3 times the loading.

3.2.9 Calculation for adequacy of the diodes selected with there characteristics shall be

submitted for approval to RDSO / RCF.

3.3 TERMINAL BOX:

3.3.1 The terminal box shall be located at the non-drive end. Suitable cut-away with a cover plate

having cable entry holes (suitable for 150 sq.mm e-beam cables) for output power. Cables shall

be provided as per RDSO specification no. ELRS / SPEC. / ELC / 0019 (REV.’42’), Feb., 2011 or

latest.

3.3 2 The internal and external cable terminations shall be on fiber glass DMC / SMC terminal board

located across each other without crisscrossing and suitable for crimped terminations connected


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

palm to palm. The spacing between terminals shall be minimum 75 mm between phases and

phase to neutral. The head of the terminal studs (preferably hexagonal) shall be embedded on

the rear of the terminal board and be further secured on top by a nut. For securing cable lugs,

nuts, lock nuts, flat and spring washers shall be provided.

3.3.3 The air clearance between un-insulated live parts and body of alternator shall not be less than

75 mm.

3.3.4 FIRE RETARDANT TEST: Fire retardant test for terminal board shall be done as per

Annexure —EF

3.4 ALTERNATOR VENTILITION:

In order to prevent dust ingress, the cooling air will be drawn from the inside of the engine room

or through the side walls through dry type air filters and ducts. The firm shall submit the

drawings for general arrangement of ducting for approval by RDSO / RCF PUs. The overall

dimensions of the various ducts and their orientation shall be mutually discussed and finalized in

consultation with production units.

3.5 INSULATION & WINDINGS:

3.5.1 The alternator shall have stator insulation of class ‘H’, rotor insulation of class ‘H’ and exciter

insulation of class’ H’ . Slot liners and slot wedges used in stator, exciter rotor and exciter field

shall be of class ‘H’ and minimum 4 kV (mm) breakdown voltage. Coil insulation, head insulation,

aeration wedge etc. used in main rotor shall be of class ‘H’ and minimum 4 kV (mm) breakdown

voltage. All sleeves shall be of class ‘H’ insulation. All winding wires used in main stator, exciter

and main rotor shall be insulated with class ‘H’ insulation by vacuum pressure impregnation

process. Temperature rise limit for Class “H’ insulation by vacuum pressure impregnation process

shall be not more than 115 deg. C at 55 deg C ambient temperature.

3.5.2 The manufacturer shall submit the insulation scheme of the alternator with details of thermal and

electrical insulation properties of the material used with relevant standard specification.

3.5.3 WINDING WIRE:

3.5.3.1 The main field winding wire which shall he on the rotor shall be strip conductor having

enameled glass covered insulation conforming to IS : 13730 Pt- 13- 1993 or latest better with

class 200 of insulation “H”.

3.5.3.2 The test on enameled winding wires shall be conducted as per IS : 13778 Pt. 1 to 6. The

manufacturers shall maintain separate documentation for these tests, indicating the winding

wire supply particulars. Winding wire shall be from RDSO / CLW approved sources.


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

VACUUM PRESSURE IMPREGNATION PROCESS (VPI): All the windings used in the

alternator shall be impregnated through Vacuum Pressure impregnation process (VPI). The

winding shall be subjected to pressure impregnation as per recommended procedure of varnish

manufacturer. Varnish used shall be FT 2005 of M/s Dr. Beck.

3.5.3.3 VACUUM PRESSURE IMPREGNATION PROCESS (VPI): All the windings used in the

alternator shall be impregnated through Vacuum Pressure impregnation process (VPI). The

winding shall be subjected to pressure impregnation as per recommended procedure of varnish

manufacturer. Varnish used shall be FT 2005 of M/s Dr. Beck.

The test on enameled winding wires shall be conducted as per IS : 13778 Pt. 1 to 6. The

manufacturers shall maintain separate documentation for these tests, indicating the winding wire

supply particulars. Winding wire shall be from RDSO / CLW approved sources.

3.6 HARMONIC DISTORTION:

3.6.1 Alternator shall be designed so that the total harmonic distortion is below 5 % of the rated

capacity.

3.6.2 Firm shall arrange to test the quality of power supply in actual service condition with rake for

voltage, frequency and harmonic contents.

3.7 BEARING:

The type, size and make of bearings used in the alternator shall have the prior approval of RDSO

before submission of internal test report.

a) The alternator shall be fitted with of SKF / FAG bearing.

b) Firm shall submit the calculation of L 10 bearing life at 1500 rev. / mm, life in hours and

lubricating interval should be declared.

3.8 SHAFT DESIGN:

Special care shall be taken in regard to design and manufacture of rotor shafts. The detailed

manufacturing drawing of the shaft shall be got approved by RDSO before submission of internal

test report. The supplier shall ensure that the raw material for the shaft is EN 24 hardened and

tempered. At change of sections, smooth ground finish should be obtained after giving maximum

possible radius with form tool. Finished shafts shall be subjected to ultrasonic (100%) to detect

internal flaw. The ultrasonic testing shall be conducted on each rotor shaft and certificate of the

same shall be attached with each lot at the time of inspection.

3.9 ROTOR:




Formatted: Font: (Default) Arial, ComplexScript Font: Arial


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

The Rotor of alternator shall be dynamically balanced separately on a balancing machine. The

residual unbalance shall not be more than 2.5 gm-cm/kg in any case to balancing quality grade of

G 2.5 to IS / ISO 1940 -1 : 2003. The dynamic balancing of rotor shall be checked individually on

a balancing machine. During acceptance test, test certificate may be verified.

3.10.4 3.10.0 MEASUREMENT OF STATOR AND FIELD RESISTANCE OF ALTERNATORS:

It shall be measured by suitable resistance measuring device when the alternator is at ambient

temperature. Ambient temperature at the time of carrying out the test shall also be recorded. The

stator and field resistance at 20 ° C shall be averaged for first 5 machines. The resistance of any

stator or any field winding shall not vary by more than +7 % from the declared value.

3.10.51 TEMPERATURE RISE TEST:

The alternator in conjunction with the Automatic voltage regulator (AVR) shall run at rated

current & voltage at 1500 rev/min speed till the temperature stabilizes. Temperature of the stator

winding, field windings, bearings, terminals, inside AVR, AVR PCBs and frame shall be

measured. The temperature rise above the ambient of 55 ° C shall not exceed the following

values under full load condition as well one hour over load (110%) conditions: -

Class of insulation Temp. rise limit Method of measurement

H 115 ˚ C Resistance /Ohm meter or better

The temperature rise of terminals, frames etc. shall be as low as possible. The maximum bearing

temperature at the highest ambient temperature of 55 °C shall not exceed 100 ° C. The

temperature measurements on all location shall be made by point contact pyrometers unless

otherwise specified or agreed to.

3.10.5.21.1 The temperature rise of main diodes shall be less than designed temperature limits of each

component under worst operating conditions.

3.10.1.2 While accepting the first lot of the machine, after the approval of prototype, temperature

rise test shall be carried out on 5 machines and the temperature rise shall be averaged. This

average, temperature rise shall serve as basis of acceptance or rejection of subsequent

machines. The temperature rise of the windings of subsequent machines shall be regarded as

satisfactory if it does not exceed by more than 8% from the average temperature rise value or

100C, whichever is higher but within the limits specified in clause 3.10.0 for the class of insulation

used. If after the production has stabilized and consistency in production and performance has

Formatted: Indent: Left: 0", Hanging: 0.49",Tab stops: 0.49", Left

Formatted: Line spacing: 1.5 lines


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

been achieved and with the approval of RDSO, the temperature rise test is not conducted on all

the machines, the temperature rise shall not exceed by 80C above the average temperature.

Further if the temperature rise is observed to be less by more than 50C in 3 lots continuously, re-

averaging of temperature rise shall be done by conducting temperature rise tests on five

machines again and the revised values shall hold good for subsequent lots.

3.10.2 TESTS ON VENTILATI’ON EQUIPMENT AND FILTERS SHALL BE AS PER ANNEXURE-’C2’

3.10.63 INSULATION RESISTANCE TEST:

3.10.47.1 The insulation resistance shall be carried out on all the circuits, before and after high voltage

test between all live terminals shorted together and body with a megger. The meggering

voltage and values of the insulation for the various circuits shall be as under:

Sno Rated circuit voltage Meggering voltage Insulation resistance value

1. 750V AC 1000 V DC Not less than 100 mega Ohms






3.10.57 HIGH VOLTAGE TEST:

Immediately after the temperature rise test, an AC potential of 3 KV 1500 V rms at 50 Hz shall be

applied between all external terminals of the alternator shorted together and the frame for a

period for 1 minute. The test shall commence at a voltage of less than one third the test voltages

and shall be increased gradually to the full test voltage. The leakage current shall not exceed

30mA for the above tests.

3.10.68 MECHANICAL OVER SPEED TEST:

3.10.86.1 The test is to be conducted as soon as possible after the temperature rise, test, while the

alternator is still hot. The alternator shall be subjected to 20 % over speed (1800 rpm= 60 Hz.

for 4 pole construction) for a period of 2 minutes.

The test is to conducted as soon as possible after the temperature rise test or load test, while the alternator is still hot. The alternator shall be run for a period of 2 minutes with the main output terminal open-circuited and field excited separately at the level corresponding to maximum field


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

current during load testing at a speed of (1800 rpm=60 Hz. For 4 pole construction). No part of the alternator shall show any sign of damage deterioration.

3.10.79 SHORT CIRCUIT CHARACTERISTIC TESTS:

The output terminals of the alternator shall be short circuited with an ammeter in circuit before

starting this test and excitation shall be adjusted in such a way that 25%, 50 %, 75 %, and

100% and 125% of full load current flows through the armature windings at the 1500 rpm. The

test shall be carried out at various speeds covering complete speed range. The speeds selected

for this test shall be same as selected for open circuit test. Varying the output current up to 150

percent for various field current, a number of readings are taken of field current and output

current. Curves shall be plotted at different speeds for field current versus short circuit current.

This test shall be carried out on a cold machine.

3.10.8 OPEN CIRCUIT TEST:

The alternator shall be run at 1500 rpm. The field shall be separately excited and the excitation

varied over the range up to saturated voltage of main stator output terminal. Excitation changes

should be made in gradual steps from zero to a value corresponding to at least 130 percent of

the rated voltage of the machine under test with the excitation current equal to zero, the residual

voltage of the machine under test is measured. The output voltage at the alternator out put

terminal corresponding to each setting of field excitation shall be recorded and curves plotted.

3.10.910 OVER VOLTAGE PROTECTION:

In case of failure of AVR, relay of the over voltage sensing device should be actuated and

manual by pass of the system to be checked.

3.10.101 EFFICIENCY TEST:

3.10.101.1 The efficiency test shall be conducted on 50%, 75 % 100% 110% load. The efficiency at

1500 rev/min shall not be less than 92 % at full load at full load. Efficiency of alternator shall be

measured with the help of torque meter and output measurement.

.

3.110 TESTS FOR ALTERNATOR:

3.110.1 Test Instruments: The indicating instruments used in electrical measurement shall

conform to relevant Part of IS : 1248 of 1984 or latest. Instruments with the following accuracy

shall be used:

a. For type, acceptance and routine tests instrument of class 0.5 accuracy.


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

b. For surge protection test, the amplitude and duration of the surge voltage shall be measured

by oscilloscope and stop watch.

c. Stator resistance shall be measured by a micro ohmmeter or Ammeter Voltmeter method.

3.110.2 Type, acceptance and routine tests as mentioned in the table given below shall be carried

out on the alternator in accordance with IS : 4722-1868, in conjunction with lS : 7132-1973, lS

: 7306-74 and IEC-115 to check for adequacy of the design to meet the stipulations in respect

of designs, workmanship and materials.

SAMPLING:

3.10.12 The sampling for conducting various tests shall be done as per the following table.

S.

No

.

Classification of

Test

Qty. Of each type of alternator covered in Purchase Order.

Qty. Upto 49 From 50

to 149

From 150 to

299

300 and

above

(a) Prototype As specified by RDSO

(b) Type 1 2 3 4

(c) Routine All All All All

(d) Acceptance 10% (minimum 2

nos.)

10% 10% 10%

3.130.3 TABLE FOR TESTS FOR ALTERNATOR-B

Sno Tests Type

test

Acceptance

test

Routine

test

Clause of relevant IS / IEC

1. Verification of dimensions of alternator assembly

Yes Yes Yes As per PUs approved

drawings As per approved

drawing

2. Measurement of resistance

Yes Yes Yes As per Cl. 3.10.0 of this

specification Clause 8 of IS :


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

7132-73

3. Phase sequence test

Yes Yes Yes Clause 11 of IS : 7132-73

4. Regulation test Yes Yes Yes As per Cl. 3.2.1 of this


7306-74

5. Measurement of leakage reactance & potier reactance.

Yes Yes No Clause 5.2 & 5.3 of IS :

7306-74

6. Measurement of OCC (open circuit characteristics)

Yes No No As per Cl. 3.10.8 of this


7132-73

7. Measurement of short circuit Characteristics



7132-73

8. Efficiency test Yes Yes No As per Cl. 3.10.10 of this

specification Clause 6.2 of IS

: 4889-68

9. Temperature rise test for windings.


specification Clause 25 of IS:

7132-73 & Cl.11 of IS : 4722-

2001 or latest.

10. Temperature rise test on rotating Diodes

Yes No No 10.2.4, 10.2.5 of IEC-60571-

2006 or latest

11. Overload test Yes Yes No Clause 16 of IS : 7132-73 &

Cl. 12 of IS : 4722-68 and as

per Cl.3.10.1 of this

specification the diesel

alternator is also capable to

work on 110 % overload for

one hour under service

conditions prescribed above.

12. Mechanical Oover speed test.

Yes Yes No As per Cl.3.10.6 of this



Prepared by

SSE/ Alternator

Checked By

Director/MRVC

7132-73 & Clause 24 of IS :

4722-2001 or latest

13. Insulation resistance test

Yes Yes Yes As per Cl.3.10.4.1 of this


4722-2001 or latest

14. High voltage test Yes Yes Yes As per Cl.3.10.5 of this


7132-73 & Cl. 21 of IS :

4722-68

15. Determination of wave form deviation factor

Yes No No Clause 12.1 of IS : 7132-73

16. Determination of wave form distortion factor


17. Determination of harmonic factor


18. Test for manual by pass with automatic change over arrangement.

Yes Yes No As per Clause 3.2 of this

specification

19. Test on AVR for environment

Yes No No Clause 120.2.3, 120.2.4,

120.2.5, 102.2.6, 102.2.7,

120.2.8, 102.2.9, 120.2.10,

120.2.11 ,12.2.12 of IEC :

60571-201206 or latest.

20. Test on over-voltage sensing device for environment

Yes No No Clause 12.2.3, 12.2.4, 12.2.5,

12.2.6, 12.2.7,12.2.8,

12.2.9,12.2.10,

12.2.11,12.2.12 of IEC :

60571-2012 or latest.

21. Endurance test on over voltage sensing device 500 operation at 30 sec. ON & 30 Sec. OFF.

Yes No No No part of the over voltage

sensing device shall show

any sign of damage

deterioration or failure.

Formatted Table


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

22. Test for verification of the total harmonic distortion.

Yes Yes No As per Clause 3.6 of this

specification

23. Checking dynamic balancing of rotor.

Yes No Yes As per Clause 3.9

24. Unbalance load Yes Yes Yes As per Cl. 3.1.3 of this

specification

25. Fire retardant test Yes Yes No As per Annexure-E of this

specification

26. Over voltage protection

Yes Yes Yes As per Cl. 3.10.9 of this

specification

3.141 THE BILL OF MATERALS OF ALTERNATOR SHALL BE AS PER THE DETAILS GIVEN

BELOW:

S.

No.

Description Quantity/DG

set

1 Self excited, self regulated self ventilated brushless 400 336

KW alternator at NTP site condition of 55 deg C and 200 m

altitude.

1 set

2 Crimping sockets for copper cable of sizes 150sqmm, 120

sq. mm., 16 sq. mm. to specn. EDTS 200 and Crimping

sockets for copper cable of sizes 6 sq mm and 1.5 sq mm to

specification no EDIS 201.

1 set

3 e-beam cables of various sizes as required of RDSO

approved make and as per RDSO specification No. ELRS /

SPEC/ ELC / 0019 (Rev.’4’).

1 set

4 Set of special tools required for maintenance (list to be

submitted during tendering stage

As per

requirement 1

set

Formatted Table


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

5 Computer generated cable marker of reputed make As per

requirement

6 AVR (automatic voltage regulator) modular type

interconnecting cables and coupling arrangement between

alternator and AVR

1 set

7 Plug- in type fuse protection with appropriately rated fuse of

M/s Siemens, M/s L&T , M/s Ferraz make for AVRs

As per

requirement

8 The rotating diodes for supplying DC power to the main field

winding of current rating equal to at least 2 times the

loading on them with minimum 1000V PIV rating

As per

requirement

9 M/s SKF / FAG / NSK make of bearings approved by RDSO

used in the alternator

As per

requirement

10 Fiber glass DMC / SMC terminal board with box cover

approved by RDSO

As per

requirement

11 Flexible coupling for engine and alternator. 1 set

12 Relays/contactors of M/s ABB/Siemens/ Schenider/L&T

make

As per

requirement

4.0 COMBINED SYSTEM TEST:

After having completed satisfactory test of Diesel Engine and Alternator Individually, both the

prototype sets are to be coupled and offered for Combined System Test by the firm. Test is to

be conducted as per clause number 1.6.5.2.

3.12 5.0 ENCLOSURES:

S. No. Annexure No. Description

Formatted: No bullets or numbering


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

1. Annexure-A Technical data sheet for diesel engine 2. Annexure-B Technical data sheet for alternator 3. Annexure-C1 Technical details for radiator system 4. Annexure-C2 Technical details of ventilation arrangement

for engine room 5. Annexure-D List of drawings and specifications 6. Annexure-ED Cartel formation certificate 7. Annexure-FE Fire retardant test 8 Annexure-G Format for Quality Assurance Plan 8. Annexure-F List for Submissions by firm list 9. Annexure-G Feedback 10. Annexure-H Declaration about fire safety.

Formatted: Indent: Left: 2"


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

ANNEXURE –‘A’

SCHEDULE OF TECHNICAL DATA SHEET OF DIESEL ENGINE (PARTICULARS TO BE SUPDLIED BY THE

MANUFACTURER AT THE TIME OF REGISTRATION /PROTOTYPE TEST.)

1.0 Following particulars pertaining to diesel engine and auxiliary equipment shall be submitted by the

tenderer to RDSO/RCF:

1.1 Diesel Engine

1.2 Continuous duty(load in percentage).

A-1 General Data

A-1.0 The particulars for diesel engine.

a) Make & Model & No.

b) Weight and dimension of diesel engine with accessories.

A-1 .1 Fuel consumption of the engine at

a) 100 %, 110 %, 75 %, 50 % in Litre Kg/hr.

A-1.2 Lube oil consumption of the engine at

a) 100 %, 110 %, 75 %, 50 % in Litre Kg/hr.

A-1.3 DESIGN DETAIL:

1. Rated output of the engine at NTP and site condition.

2. Rated engine speed.

3. Number and arrangement of cylinders.

4. Cylinders bore.

5. Cylinders material composition

56. Piston stroke

7. Piston material composition

86. Compression Ratio


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

97. Mean Piston Speed

108. BMEP (Break Mean Effective Pressure) at rated output

119. Normal no load idling speed

120. Peak firing pressure

131. Full test result and data pertaining to engine tests.

142 Specific fuel consumption at half, full and 10% overload conditions with tolerance band under

NTP and site conditions. Indicate the lower calorific value of the fuel used in arriving at the

specific fuel consumption figure. Maximum specific fuel consumption (SFC) 220 g/kWh shall be

permitted.

153. Fuel oil consumption at idle speeds (normal & low)

164. Lube oil consumption at rated output as percentage of fuel oil consumption.

175. De-rating calculation for site condition

186. Safety devices provided:

i) Over speed ii) Low lube oil pressure iii) High cooling water temperature iv) iv) High lube oil temp. v) Two bank difference temperature vi) Exhaust gas temperature vii) Air filter chocking viii) Emergency stop ix) Phase sequence change x) Over voltage xi) Under voltage xii) Over frequency

xiii) Under frequency

xivv) Any other

197. Weight of engine excluding oil and water. 2018. Volume and weight of water contained in the engine. 2119. Volume and weight of oil contained in the engine


Formatted: List Paragraph, Indent: Left: 0.5", Hanging: 0.44", Numbered + Level: 1 +Numbering Style: i, ii, iii, … + Start at: 1 +Alignment: Left + Aligned at: 0.25" + Indentat: 0.75"

Formatted: List Paragraph, Indent: Left: 0.5", Hanging: 0.44", Numbered + Level: 1 +Numbering Style: i, ii, iii, … + Start at: 1 +Alignment: Left + Aligned at: 0.25" + Indentat: 0.75"




Prepared by

SSE/ Alternator

Checked By

Director/MRVC

2220. Weight of major equipment:

i) Turbocharger ii) After-Cooer iii) Cylinder block iv) Piston and connecting rod v) Cylinder liner vi) Cylinder head

2321. Temperature of exhaust gas at tube inlet at rated output under NTP and site conditions. 2422. Method of starting giving details of equipment. 2523. Periodicity of overhauling the following critical items:

i) Turbocharger ii) Piston and piston rings iii) Air and exhaust valve iv) Main bearings v) Connecting rod bearings vi) Fuel injection pump vii) Fuel injectors

2624. General arrangement and dimensional details. 2725. Characteristic curves for torque, output and specific fuel consumption for different loads. 2826. The curve of fuel consumption against load. 2927. Power consumption of various auxiliary devices under full load condition 1500 rpm.

3028. Radiator capacity in terms of air flow rate and air velocity through radiator.

3129. Heat balance diagram of diesel engine.

3230k. Heat dissipation characteristic of radiator under operating conditions power consumption

of radiator fans motors.

A-2 Fuel Injection System:

1. 1. Type of fuel injection system 2. Fuel pressure in bar in external pipe line if any.

A-3 Turbocharger:


Formatted: List Paragraph, Numbered +Level: 1 + Numbering Style: 1, 2, 3, … + Startat: 1 + Alignment: Left + Aligned at: 0.5" +Indent at: 0.75"


Formatted: List Paragraph, Indent: Left: 0.75", First line: 0"


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

1. Number of turbocharger used for engine. 2. Make and model. 3. Air flow at rated output 4. Speed of turbocharger at rated output. 5. Types of bearings. 6. Details of lubrication. 7. Whether pre and post lubrication provided. 8. Booster pressure at full load. 9. Life of turbocharger.

A-4 Air Cooler:

1. Type of cooler. 2. Details of mounting indicating whether cooler can be removed without removing turbocharger.

A-5 Exhaust System:

1. Type of exhaust system 2. Number of exhaust gas entry segments. 3. Whether the exhaust manifold is shrouded/insulated.

A-6 Piston and Rings;

1. Material specification of piston and rings. 2. Method of cooling 3. Shape of bowl in piston crown 4. Number and configuration of piston rings.

A-7 Valves:

1. Material specification of valve 2. Single/composite type. 3. Whether valve rotators used. 4. Recommended tappet clearance 5. Angle of valve and seat

A-8 Cylinder Head:

1. Material


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

2. Coolant flow distribution 3. Weather reclaimable by welding

A-9 Cylinder Block:

1. Material 2. Whether cast for fabricated 3. Is the mounting rigid or on resilient pads 4. Experience regarding block distortion

A-10 Crankshaft:

1 Material specification 2. Type of bearings calculate bearing loads 3. Particulars of vibration damper

A-11 Cylinder Liner:

1. Material 2. Dry of wet liners 3. Water sealing arrangement between liner and cylinder block

A-12 Connecting Rod and Bearings:

1. Material of connecting rod 2. Material composition of bearing shells.

A-13 Electronic Governor and electronic control panel control panel:

1. Make and type 2. Minimum idle speed. Rated full load speed and droop characteristics. 3. Torque available on the output shaft 4. Control/safety feature provided.

A-14 Cooling Water System:

1. Detail of cooling circuit 2. Type of water pump and its characteristic viz delivery vs flow resistance. 3. Is the cooling system pressurized? If so, up to what pressure? 4. Max permitted cooling water temperature at inlet & outlet of circuit 5. Normal cooling water temperature at full load under NTP and site conditions.


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

6. Radiator construction and dimensional details. A-15 Lube Oil System:

1. Details of oil circuit with flow diagram 2. Lube oil pressure at full & idle speed 3. Max temperature at hottest point 4. Lube oil pump characteristic and power absorption at various points. 5. Details of all filters used in the lube oil circuit. 6. Efficiency of filtration and periodicity of attention.

A-16 Fuel System:

1. Schematic fuel oil circuit. 2. Details of fuel oil lift pump and its drive 3. Details of filters used in fuel oil circuit. 4. Periodicity of attention.

A-17 Intake Air System:

1. Details of engine intake air system. 2. Type of primary and secondary stage filters and their efficiency. 3. Pressure drop permitted at the operating point for periodicity of attention.

A-18 Other items: A-18.1 Make Type & capacity of cooling equipment. A- 18.2 Power consumption of radiator fan at nominal speed. A-18.3 Normal and maximum permissible lubricating oil temperatures A-18.4 Normal and maximum cooling water temperature. A-18.5 Make, type & HP of engine starter motor. A-l8.6 Overall dimension and Weight of Diesel engine A-18.7 Overall dimensions with mountings of diesel engine as per ROSO specification and as per PUs

approved drawings. A-18.8 Exhaust gas temperature at turbo inlet




Prepared by

SSE/ Alternator

Checked By

Director/MRVC

A-I 8.9 Capacity of lube oil sump. A-18.10 Design calculation for the base frame together with selection of AVMs to limit the vibrations

as stipulated in clause-4 .2. A-18.11 The water pump capacity of radiator cooling. A-18.12 Total heat rejection capacity of radiator minimum air flow required end pressure drop across the

radiator. A-18.13 Noise level in db(A) at 1m and 2m distance when DA set is working on full load at 0.8 p.f. A-18.14 Heat load calculation for complete scheme with selection of radiator fan, ventilation fan, radiator

motor fan capacity and ventilation fan motor capacity.

4-18.15 Class, type and make of electronic governor and electronic electronic control panel control panel.

A-18.16 Interval between the successive overhauling.

A-18.17 Whether the engine supplied has been type tested by ROSO.

ANNEXURE A2.


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

General details of engine

1. General Arrangement drawing of engine: The drawing shall indicate important dimensions & details like:

I. Nominal output & rpm

II. Max. length, max. width and max. height,

III. Height of centre line of crankshaft,

IV. Location of C.G.,

V. Direction of rotation with respect to observer’s position,

2. Layout of lube oil system, fuel oil system, cooling system, air intake and exhaust system along with their capacities.

3. Is the engine provided with priming pump? Provide details.

4. Is ECM provided? Provide details.

5. What is the emission standard proposed engine? Provide certificate.

6. Other technical details

A) Provision for gauges/indicators for engine for the following

i. Engine rpm

ii. Engine hour meter

iii. Engine lube oil pressure

iv. Engine lube oil temperature

v. Engine lube oil level

vi) Engine cooling water temperature

vii) Engine cooling water level

viii) Fuel level

ix) Any other gauge/indicator

B) Provision of Safely of engine against the following

i) Low engine lube oil level

ii) High engine lube oil temperature

iii) Low cooling water level

iv) Low fuel level


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

v) Engine over load

vi) Emergency engine stop

C) Ensure following for engine

i) Crank Case Breather

ii) Oil/Water Leakage protection

iii) Fuel tank drain provision

iv) Provision of draining of lube oil from sump

v) Flushing arrangement for coolant

vi) Fuel filling arrangement from both side of coach

vii) Protection from spillage of oil

viii) Heat insulation to hot surfaces / exhaust pipes

ix) Number of air intake filter

x) Number of lube oil filter

xi) Number of fuel filter

xii) Coolant filter, if any.

xiii) Lube oil filling point

xiv) Oil relieving port

xv) Provision of vacuum indicator with air intake system

xvi) Provision of thermostat with radiator

xvii) Type of coupling between engine & alternator

xviii) Provision of fire detection & suppression system


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

ANNEXURE-B

SCHEDULE OF TECHNICAL DATA SHEET FOR ALTERNATOR

(PARTLCULARS TO BE SUPPLIED BY WE MANUFACTURER AT THE TIME OF REGISTRATION /

PROTOTYPE TEST.)

B-1.0 Alternator:

B-1.1 Make & Model.

B-1.2 Rating (continuous) at NTP

a) Output ………..KVA

b) Current ……….. Amps.

c) voltage / phase ……….. Voltage

d) Frequency …….Hz.

e) Power factor at full load.

f) De-rating factor at on site condition

o) Speed of Alternator in ………… RPM

B-1.3 Number of poles.

B-1.4 Class of insulation. (Specified H class)

a) Stator winding

b) Rotor winding

B-1.5 Excitation system

a) Type of excitation.

b) Excitation system voltage

c) Excitation current.

B-1.6 Efficiency


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

a) Full load …………%

b) Three/fourth(3/4) …………%

c) Half load(1 /2 ) ………..%

d) 110% of full load ……..%

B-1.7 Weight of alternator with exciter DA set

B-1.8 Over all dimensions with drawing (alternator).

B-1.9 Overall dimension of complete se. with drawing.

B-2.0 Over voltage sensing device-make.

B-2.1 Diesel engine electronic control panel control panel with details of instruments and interlocks.

B-2.2 Setting of trip at - Volts

B-2.3 Rating of contacts - Amps.

B-2.4 Rating of contacts - Volts.

B-2.5 Circuit diagrams.

B-3.0 The details of the regulating system and schematic diagrams.

Make,

Dimensions ( length x width x height) in mm.

Weight in . ---kg.,

Voltage adjustment range ---

Current adjustment range ---

B-4.0 Calculations for the adequacy of the diode selected with their characteristics.

B-5.0 Calculation & test results of harmonic content of power supply in actual rake load condition.

B-6.0 Alternator Shell particulars

(a) Material of the shell


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

(b) Length of the shell

(c) Outer dia of the shell

(d) Inner dia of the shell

(e) Drg. of the Shell with all tolerances and manufacturing process

B-7.0 Alternator Stator particulars

(a) Inner dia of stamping

(b) Outer dia of stamping

(c) Thickness of stamping

(d) No. of stampings used

(e) Wt. Of stator core

(f) Grade of magnetic material used

(g) Supplier’s name

(h) Power loss per kg

(i) Material specification

(j) Details of locking arrangement of stator core of both side.

{k) Pressure used to install the lamination in position

(I) Checking methods adopted to ensure true-bore of stator

(m) Total length of stator lamination.

B-8.0 Alternator Rotor particulars:

(a) Total length of rotor shaft

(b) Material of rotor shaft

(c) Inner dia of stamping

(d) Outer dia of stamping


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

(e) Total length of stamping

(f) Thickness of stamping

(g) No. of stampings used

(h) Wt. Of rotor core

(i) Grade of Magnetic material used

(j) Supplier’s name

(k) Power loss per kg

(I) Material specification

(m) Details of locking arrangement of rotor stamping on both side

(n) Pressure used to install the lamination in position

(o) Checking methods adopted to ensure outer dia of rotor

(p) Finished shaft drawing clearly indicating bearing seat, dimension on shaft and dimension of bearing with tolerances. (q) Both ends end-shield manufacturing drawing

(r) Rotor skew angle

B-9.0 Windings of alternators:

(a) Size of copper wire (Stator with specification and maker)

(b) Size of copper wire (Field with specification & maker)

(c) No. of turns per coil (stator)

(d) No. of turns per coil (field)

(e) Type of varnish used for impregnation

(f) Method of impregnation used

(g) Type of slot insulation used

(h) Type of wedge insulation used


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

(i) Type of insulation used on overhang

(j) Details of lead wire

(k) Method of lead and winding wire joint.

(I) Type of winding used.

B-10 Shaft details

(a) Material of shaft

(b) Dimension of shaft

(c) Die of shaft

B-11 Bearing

(a) Make and type of bearing

(b) Drive end & Non- drive end bearing

B-12 Recommended grease (specify IOC brand)

(a) Frequency of greasing including quantity.

(b) Method of greasing

B-13 Data shoot for selection of power diodes

(a) Type of diodes

(h) AV Current

(c) Av. Voltage

(d) Permissible junction temperature

(a) Av. Forward voltage drop

(f) Weight of diodes

(g) Any other parameters


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

ANNEXURE C- 1

SCHEDULE OF TECHNICAL DATA SHEET FOR RADIATOR SYSTEM (PARTICULARS TO

BE SUPPLIED BY THE MANUFACTURER AT THE TIME OF REGISTRATION

/ PROTOTYPE TEST.)

C-1.0 Radiator System:

C-1.1 The radiator and its cooling system layout should be designed in such a way that it should

transmit minimum noise on the Railway plate form.

C-1.2 The power required for radiator cooling should be as low as possible and in no case should be

more than 30 kW.

C-1.3 The fan shall have an air handling capacity (in cu. meter /hour) of at least 20% more than the

minimum requirements of the radiator to maintain the engine cooling water temperature at the

specified level under continuous full rated load of the engine at site conditions. The fan shall

deliver the air volume at a minimum static head of 50 mm W.G

C-1.4 Suitable louvers/sound attenuator are to be provided in front of the radiator to facilitate air flow

and prevent Sound leakage.

C-1.5 Suitable louvers /sound attenuator are to be provided in front of the radiator to facilitate air flow

and prevent Sound leakage.

C-1.6 Tests:

C-1.6.1 Blower motor shall be subjected to type and acceptance tests in accordance to relevant IS

specification.

C-1 6.2 Radiator capacity test (at simulated or equated site conditions at 55˚ C )

Testing procedure is given below:

i) Under this test diesel engine is connected to the radiator designed for use in the high capacity

power car and operated at 100% and 110% load. This test is conducted with the radiator in the

free and 30% choked condition. For the later the surface area of the radiator is blocked in a

distributed manner for 30% of the area. During this test the inlet and outlet temperature and the

flow of water and air are measured.


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

ii) The water temperature, the heat transferred through water and air are computed and

compared with the declared heat balance characteristics.

iii) If the radiator inlet air is preheated to 55 ° C (for simulation) then the test is conducted in the

prevailing ambient temperature and the water temperature at the equated site conditions is

determined. The radiator inlet water temperature recorded shall be well below the maximum

permissible temperature by the value equal to the difference between 55˚ C and the test ambient

temperature. LAT (Limited ambient test) shall be more than 55°C at rated load during combined

test.

LAT=Maximum allowable Temp.-coolant Temp+ Ambient temp.

iv) For the purpose of the test, thermostat regulating the water flow through the radiator shall be

kept open

C-1.6.3 Capacity of the blower for radiator cooling shall be specified.

C-1 .6.4 The firm shall create a mockup at their works to simulate the service conditions.

Formatted: Indent: Left: 0.75", First line: 0"


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

ANNEXURE C- 2

SCHEDULE OF TECHNICAL DATA SHEET FOR VENTILATION SYSTEM (PARTICULARS TO

BE SUPPLIED BY THE MANUFACTURER AT THE TIME OF REGISTRATION / PROTOTYPE

TEST.)

C-2.1 For the purpose of engine room cooling/ventilation, two numbers of centrifugal type fans with

dual radial outlets are to be mounted on each DA set, at the cant rail level in roof. The cooing

air shall be drawn through the two louvered openings of size 600 x 1600 mm with filter

panels and through the engine room bottom circular inlet of the blowers, exhausted through

the louvered openings of size 475 x 300 mm, provided on the curved portion of the roof. The

rating of the motor shall not exceed 5.0 KW.

C-2.2 Blower motor shall be of M/s ABB/ Siemens/ KEC/Crompton/Laxmi hydraulicKirlosker make

with terminal connections suitable for Star-Delta starter.

C-2.3 he selection of blower shall be such that its capacity is at least 10% more than the

requirements to meet the Engine room temperature conditions specified. In deciding the

static pressure to which the blower rating is to be designed the same conditions given in

clause 2.0 shall be taken into account.

C-2.2.4 The impellers of the blower should be fully welded. Stiffening arrangement has to be provided

for the impellers to eliminate the distortion due to service conditions.

C-2.2.5 The blower design and motor shall be in accordance with clause 1.3 of Annexure-C 1 and

tests shall be performed on blower as per para 1.6 of Annexure-C 1.

C-2.2. Panel Filters:

C-2.2.1 The panel filters used shall be of the panel mounted type. The filter media shall consist of

three layers of graded density fire retardant glass fiber pads and a layer of woven fiber-glass

cloth at the outlet side, all sandwiched together and stitched securely. The filter media shall

be given a spray of dust trapping oil (servo friz-68 or equivalent) on the inlet face. The filter

media pleats shall be properly sealed and secured with the frame to prevent air leakage and

media migration. These filters shall give a service life of maximum six months before choking.

All metallic parts shall be properly painted. The design of the filter shall be got approved in

advance from RDSO. The filters shall be of RDSO approved make.

C-2.2.2 The pressure drop across the filter shall not be more than 5 mm of WG when new and 18

mm of WG when in fully clogged condition.


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

C-2.2.3 The filter shall be capable of filtering out dust particles of size greater than 20 microns.C-

2.3.4 The material used for housing the filter element shall be either electro-galvanized or

shall be of non-corrosive material.

C-2.2.5 The type of filter to suit the dimensions for two nos. of panels provided in coach shall be

clearly furnish by the firm.

C-2.3 Tests for filter:

At least one filter panel shall be subjected to type tests in accordance with the relevant IS specification and the remaining will be checked for dimensions and physical damages.

C-2.3.1 The capacity of blower for engine room cooling, calculations to establish their adequacy,

rating of the motor, filter details, overall dimensions, weights etc, shall be furnished along with the tender.

C-2.3.2 Fire safety: Due to short circuit joint free cable shall be used in blower motor circuit.


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

ANNEXURE -D

LIST OF DRAWINGS

A) GENERAL ARRANGEMENT OF DIESEL ENGINE

B) RADIATOR MOUNTING DRAWING

C) VENTILATION MOTOR MOUNTING

D) RAIL BAFE FRAME DRAWING


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

ANNEXURE -DE

UNDERTAKING AGAINST CARTEL FORMATION

We……………………………….. hereby, give an undertaking that as a Registered Vendor

for manufacture and supply of………………………………….. will not be a part of a cartel with other

vendors and will be quoting competitive rates in the tenders invited by the Indian Raiiways/Pus

We ……………………………………………..are aware of the fact that the Registering Authority i.e. RDSO may

de-list the name of our firm from the Master List of Approved Vendors if complaint is received about such

cartel formation from any of the Railways/Production DA sets.

.

Seal and signature

(Authorized signatory of the firm)

Date:

Place:

Seal:

Formatted: Justified


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

ANNEXURE -EF

FIRE RETARDANT TEST

1.0 A piece of terminal board of alternator measuring about 150 x 25 mm or nearest to this size shall

be subjected to the luminous batswing flame, preferably supplied by a Bunsen burner. The

specimen shall be held with the flat side up at an angle of 45° to the horizontal. The flame shall

be of 25 mm. in width across the tips.

2.0 The flame shall be applied to the specimen at the lower end for 30 seconds and removed for 30

seconds and then applied again to the same end for second period of 30 seconds and then

removed again.

3.0 Should be the specimen get ignited, it shall not continue to burn for more than 50 seconds after

the flame has been removed.


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

ANNEXURE –F1

List of documents to be submitted alongwith design details of RDSO

S.No. Clause No. Description

1 1.5.3 OGA drawings

1.5.4 Suitable anti-vibration mountings (AVM)

1.5.13 Annexure-A1, A2 &B

2 1.5.14 Detailed drawing of Radiator

1.5.15 Engine electrical schematic wiring diagram

1.5.16 The interlocking system schematics along with wiring diagram with

functional description of the complete system.

1.5.17 Calculation for adequacy of diode selection.

1.5.27 Mainteanace schedule and Activities

1.5.29 Documents.

1.5.33 Noise reduction features

1.14.1 Diesel Engine details

1.14.2 Alternator details

1.15 QAP

3 2.0 Declare derating power

2.1.2 Engine cooling system

4 2.1.4 Duct design

5 2.2.2 Air Filter

6 2.4.2 Fuel oil suction/return

2.6.1 Design of silencer

7 2.6.3 Drawing for general arrangement of silencer


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

8 2.7.1.2 Data format and downloading

2.10.1 Safety devices, gauges/instruments

2.13 Fire safety

2.15 Bill of Material (BOM)

9 3.2.2 Dimension and layout of AVR

10 3.2.5 Complete details of the Alternator with AVR/OVR (along with

schematic diagram)

3.2.7 Submit details of harmonics content

11 3.2.9 Calculation for adequacy of the diodes.

3.4 Alternator ventilation

12 3.5.2 Insulation scheme

13 3.7 (b) Bearing

14 3.8 Alternator shaft

3.14 Bill of Material (BOM)

15 Annexure-D

16 Annexure-G


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

ANNEXURE –F2

List of documents to be submitted alongwith design details with approval of PUs

S.No. Clause No. Description

1 1.5.3 OGA drawings

1.5.4 Suitable anti-vibration mountings (AVM)

2.1.2 Engine cooling system

2.1.4 Duct design

2.2.2 Air Filter

2.4.2 Fuel oil suction/return

2.6.3 Drawing for general arrangement of silencer

2.8.4 Manual isolation switch

3.4 Alternator ventilation

ANNEXURE -G

FORMAT FOR QUALITY ASSURANCE PLAN

1 Organization:

The firm shall submit the organizational chart, along with the qualification and experience of key

persons in management involved in quality assurance program.

2 Documentation:


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

The manufacturer shall maintain all necessary documents and data that will help him have

consistency in producing quality product.

3 Purchase of raw material:

Raw material/equipments shall be procured only from well-proven sources, conforming to

relevant standards. Critical components shall be procured from reputed OEM or their accredited

agents.

4. Quality Control-Process:

Screening of critical electronic component/devices shall be carried out as a part of process quality

control method adopted should be clearly explained.

5 Inspection and Testing:

(i ) Receiving Material: The manufacturer shall ensure that incoming material is not used for

processing until it has been inspected and verified as confirming to specified requirements.

Verification shall be in accordance with quality plan or laid down documented procedures.

(ii) In process inspection and testing: Inspect, test and identify product as required by the quality

plan or documented procedures evolved on the basis of RDSO specification and other relevant

specification/standard.

(iii) The supplier shall carryout all final tests and inspection in accordance with the quality plan or

documented procedures evolved on the basis of RDSO specification and specified standard to

complete the evidence of conformance of the finished product.

6. Testing / Measuring Instruments.

The instrument and equipment used for testing, and inspection shall be of the required accuracy.

7. R & D Organization:

The firm shall indicate the organizational structure of their R&D wing along with qualification of

the personnel. Firm should have at east one Engineering Graduate design engineer with

experience of more than 3 years in the field of Mechanical and Electrical engineering

8. Laboratory Test House: The manufacturer shall have a well equipped Laboratory/Test House

to carry out various tests on the raw material, stage inspection and inspection of the finished

product.

Formatted: Right: -0.5"


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

9. Traceability of components used: Manufacturers shall elaborate the procedure being

followed for ensuring traceability of critical components used, and in house test performed on

each critical components, sub assembly & complete equipments individually.

10. Handling /Storage/Delivery: The manufacture shall have proper facilities for handling and

storage of raw material and finish product. The supplier shall control packing presentation and

marking process so as to ensure conformity to the railway requirement.

* * * * *


Prepared by

SSE/ Alternator

Checked By

Director/MRVC

Annexure- G

FORMAT FOR FEEDBACK GIVEN BY USER RAILWAYS REGARDING PERFORMANCE OF

DA set of power car

S. No. Parameter Check/ Test to be Done Remarks

1. a) Date & Place of fitment b) Coach No. c) No. of days completed after fitment. d) All electrical parameter as per clause No.

1.6.6 of this Specification. e) Fitment Report.

2. Any other remarks.



Prepared by

SSE/ Alternator

Checked By

Director/MRVC

Annexure-H

DECLARATION ON FIRE SAFETY OF DA SET

I---------------(Name), -------------------------------------------------(designation)

On behalf of ------------------------------------------------------(firm name) hereby declare

following:-

1) The materials used in manufacture of Diesel Engine/Alternator/DA Set is fire retardant.

2) Fire safety has been considered in design of Diesel Engine/Alternator/DA Set.

Date:

Name

Signature

(Note:- This is to be given by Diesel Engine,/Alternatorand /DA Set registering vendor

applicant.

GOVERNMENT OF INDIA MINISTRY OF RAILWAYS vuqla/kku …

Documents

Transcript of GOVERNMENT OF INDIA MINISTRY OF RAILWAYS vuqla/kku …