indian railways chittaranjan locomotive...

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SPECIFICATION FOR DUAL MODE SHUNTING

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CENTRE FOR DESIGN & DEVELOPMENT CHITTARANJAN LOCOMOTIVE WORKS

NO: CLW/C-D&D/ES/03/0551

ISSUED BY DY. CEE/D&D ALT

INDIAN RAILWAYS

CHITTARANJAN LOCOMOTIVE WORKS CHITTARANJAN

DRAFT SPECIFICATION FOR

DUAL MODE SHUNTING LOCMOTIVE (DMSL)

SPECIFICATION NO - CLW/C-D&D/ES/03/0551

This specification has been prepared in reference of RDSO

Specification no. RDSO/2017/EL/SPEC/0136 (Rev. 1)

Total no. of pages: 28

(Issued on June– 2018)

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ALTERATION RECORD SHEET

Amendmentin clause no. Date of amendment Page No Alteration Changes - -

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Table of Contents

Chapter No.

Description Page

Abbreviations and Definitions: 4

1 General 5-14

2 Operating and Environmental Conditions 15-16

3 Technical Specification 17-20

4 Salient Information of Locomotive

Appendixes (I- IV)

21-28

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Abbreviations and Definitions:

IR - Indian Railways RDSO - Research Designs & Standards Organisation CLW - Chittaranjan Locomotive Works VCU - Vehicle Control Unit GTO - Gate Turn OffThyristor IGBT - Insulated Gate Bipolar Transistor BOM - Bill of Material Bo-Bo - shall mean one unit of the Locomotive consisting of two bogies, with each

bogie having two wheels with two independent traction motors and the traction motor drive coupled to each wheel;

Co-Co -shall mean one unit of the Locomotive consisting of two bogies, with each bogie having three wheels with three independent traction motors and the traction motor drive coupled to each wheel;

BG - shall mean 1676 mm Broad Gauge used in IR; VCB - Vacuum circuit Breaker TM - Traction Motor CON - Converter Aux - Auxiliaries EMU - Electric Multiple Unit MC - Motor Coach FLG - Fahrzeuleltgert (German) – Engl. VCU - Vehicle Control Unit SLG - Engine Control Unit DCU - Drive Control Unit TE/BE - Tractive effort/Braking effort S&T - Signal and Telecommunication IVC - Inter Vehicular Couplers AFTC - Audio Frequency Track Circuiting OEM - Original Equipment Manufacturer MCB - Miniature Circuit Breaker HB - Auxiliary circuit cubicle TCN - Train Communication Network DMSL -Dual mode shunting locomotive WDS6 -Broadgauge Diesel Shunting locomotive IRAB -Indian Rail Air Brake system Supplier - Firm/companies participating in the tender

Supplier -The person, firm or company with whom the order for supply of the work has been placed.

Sub Supplier -Any person, firm or company from whom the supplier may obtain any materials or fittings to be used for the works

Purchaser -The President of the Republic of India as represented by the Railways organisation entering into the contract

Inspecting Officer -The person, firm or department nominated to inspect the converters or the representative of the inspecting officer so nominated.

ToT documents - Transfer of technology documents.

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CHAPTER 1- GENERAL

1.0 This specification deals with the design, development, supply, installation, commissioning & field validation of Dual Mode Shunting Locomotive (DMSL) for Indian Railways.

1.1 Shunting operations are often performed using diesel locomotives, although these tasks mostlytake place beneath Catenary. The reason for this is usually the last mile, for example Catenary-free tracks at a plant entrance, which cannot be accessed by electric locomotives. Diesel locomotives are more expensive in terms of energy and maintenance costs. Because of noise and air pollution, their use is undesirable especially in populated areas and in tunnels. The dual-mode Shunter Locomotive is basically an electric locomotive with the ability to operate from 25kV ac OHE supply as well as Li-Ion/any other suitable Battery set where yards are not fully electrified. This specification defines the system and performance requirements for the design, development, construction and testing of Dual-mode Shunting locomotives which can work under 25kV Over Head equipments (OHE) as the primary power source and work as Battery operated locomotive by drawing power from Battery set in non-electrified yards / station area.

1.2 Tangible benefits of Dual Mode Shunting locomotives:- The features of Dual Mode Shunting Loco (DMSL) may be summarized as follows:

1.2.1 Improved operational flexibility in last mile operation in goods yards, sidings and in shunting operation which are non-electrified.

1.2.2 Dependency on diesel locos will not be there. Further, the populations of diesel locos are decreasing as the same are being phased out for various reasons.

1.2.3Free of Air & Noise Pollution which is prime concern in station area

1.3 The purpose of the specification is to provide the technical specification of the integration of Li-Ion Battery or any other suitable battery set in existing WDS6 platform/ any other suitable loco car body.

1.4 The Contractor should get himself acquainted with the technical parameters of the present WDS6 platform/any other suitable loco car bodyto be used in Dual Mode Shunting Locomotive (DMSL) to understand the necessary modification that needs to be done so that it will operate in Electric and Battery Mode. Contractor may collect necessary and required data, Specification & Drawings of existing WDS6 or any other suitable loco car body from Indian Railways.

1.5 The existing IRAB brake control system shall be used . The contactor should get into the

technical details and collect the necessary information from RDSO/CLW before submitting their proposal. Supplier should take necessary approval of modification during design stage.

1.6 IR shall prefer to use the existing bogie of the same platform of WDS6 or any other suitable loco

car body. The Contractor may study the existing design of bogie after collecting necessary design documents from Railway and may confirm the same in their offer.

1.7 The suitable traction chain i.e transformer, Power converters, Traction motors, shall be designed and should match the technical requirements mentioned in this specification. The contractor should submit their design to RDSO/CLW during the design approval stage. Other

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minor electrical panels, cab equipment shall be provided by the supplier after finalizing the design in consultation with RDSO/CLW.

1.8 The environmental and service conditions, performance requirements and technical

requirements are specified in these Specifications and Standards. 1.9 The design and manufacture of the equipments shall be based on the requirements set out in

these Specifications and Standards and in accordance with Good Industry Practice. 1.10 The Contractor shall demonstrate, to the satisfaction of the IR, that the sub-systems proposed

to be used in the Locomotives are based on proven technology and design. For the avoidance of doubt, the IR may require the Contractor to conduct such tests and trials as may be necessary to establish the reliability and efficiency of such technology and designs in accordance with the Good Industry Practice.

1.11 Due consideration shall be given at design stage to ambient conditions of dust, moisture, high

temperature and vibrations prevalent in India, as specified chapter 3 in these Specifications and Standards.

1.12 References to various standards 1.12.1 The standards applicable and relevant to the complete Locomotive and to the various sub-

systems and systems shall be: i. IEC publications; ii. EN ; iii. UIC; iv. AAR; v. IEEE; vi. BS; vii. IS; viii. TSI ix. Any other standards referred to in these Specifications and Standards.

In the event of any contradiction in the aforesaid standards, the following standards shall have priority in the order listed:

i. Standards mentioned in Specifications and Standards set forth herein; ii. EN /IEC/UIC/AAR; and iii. IS. For avoidance of any doubt, in case of any conflict between the requirements of these standards, the stipulations of these Specification and Standards shall have precedence.

1.12.2 The design of the upgraded equipment, system and sub-systems there of shall comply with the following standards

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SN Standards Title

1 IEC 61133 Electric traction - rolling stock - test methods forelectric and thermal /electric rolling stock oncompletion of construction and before entry into service

2 IEC 61287 Electronic equipment used on rail vehicles

3 IEC 60571 Specific rules concerning the electronic control part of converters.

4 IEC 60349 -2 Electronic converter fed alternating currentmotors

5 IEC 61377-7 Railway application - rolling stock - Part 1: combined testing of inverter fed alternative current motors and their control system

6 IEC 60505 Guide for the evaluation and identification of

insulation systems of electrical equipment

7 IEC 60034-18 Rotating electrical machines: Functional

evaluation of insulation systems

8 EN 50121-3-2/

IEC 62236-3-2

Railway applications – electromagnetic compatibility - Part 3-2: Rolling stock –Apparatus

9 EN 50121-2/

IEC 62236-2

Railway applications – electromagnetic compatibility - Part 2: emission of the whole railway system to the outside world

10 EN 50238 Railway applications - compatibility betweenrolling stock and train detection system

11 IEC 60310 Transformer and chokes

12 IEC 60296 Transformer oil

13 IEC 60077-4 High voltage AC circuit breaker

14 IEC 60494 pt.-I Rules for pantograph of electric rolling stock

15 IS3231,

IEC60337, 60947 Relays, Contractors and switches

16 IEC 60228, IS 10810 Cables

17 IEC 60099-4,

IS 3070 pt. III Lightning arrestor

18 IEC 61373 Railway applications - rolling stock equipment -shock and vibration test

19 IEC 61131 Programming languages for PLC

20 IEC 60077 Railway applications - electric equipment forrolling stock

21 IEC 60571 Electronic equipment used on rail vehicles

22 IEC 61287-1 Power converter installed on board rolling stock- Part 1:Characteristics and test methods

23 IEC 61287-2 Power converter installed on board rolling stock-Part 2: Additional technical information

24 IEC 61991 Railway application - rolling stock protectiveprovisions against electrical hazards

25 IEC 60034 Auxiliary machines

26 IEC 60871 Power factor correction

27 IEC 60068 Control cubicle

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28 IEC 60623 Batteries

29 IEC 60529 Degree of protection provided by enclosures

30 EN 50343 Rules for installation of cabling

31 M-211 AAR approved couplers and coupler yokes

32 IRS R-34 Wheels

33 IRS R-43 Axle

34 EN15085 Railway applications, welding of railway vehiclesand components.

35 RDSO's specification No.02-

ABR-02 Air brakes

36 IR Schedule OfDimension forBroad Gauge,revision

2004 Schedule of Dimension for broad gauge

37 IEC 61709 Reliability of electronic component

38 RDSO's technicalcircular no.ELRS/TC/0071(rev.'0')

Metallised carbon strip for pantograph

1.12.3 The latest version of the aforesaid standards, which have been published at least 60 (sixty) days before the last date of tender submission shall be considered applicable.

1.12.4 Alternative Standards

The requirements listed in these Specifications and Standards are the minimum. The Contractor may adopt alternative internationally recognized codes, standards and specifications if it can demonstrate to the Government that such alternative is superior or more pertinent to the Locomotive than the standards specified in these Specifications and Standards. The Contractor shall seek the prior approval of the Government for any alternate standards proposed to be used.

1.13 Quality of Materials, Manufacturing Processes and Workmanship 1.13.1Materials (including surface coatings, metals, insulators, adhesives, fluids, grease etc.)used in

the manufacturing of the additional equipment required for DMSL shall not give rise to health hazards for crew and staff. The materials shall also be suitable for standard repair operations such as those currently used by the Government (e.g. welding, cutting etc.) without the need for staff to be protected by other than standard means. Materials used for additional equipments required for DMSL shall be appropriate for achieving the Design Life of the Locomotive.

1.13.2Materials shall be suitable for disposal without any special precautions. 1.13.3 Reliability, Availability, Maintainability and Safety (RAMS) 1.13.4 The Contractor shall design the equipment required for DMSL to ensure Guaranteed

Reliability, Availability and high degree of Safety in order to provide a dependable service. The optimization of the system with respect to Reliability, Availability, Maintainability and Safety shall form an integral element of these Specifications and Standards.

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1.13.5 The plan for Reliability, Availability, Maintainability and Safety shall conform to EN 50126/ IEC 62278. Reliability of electronic components shall conform to IEC 61709.

1.13.6 The Contractor shall develop RAMS targets both for the complete system and for the major sub-systems such as transformer, traction converter, auxiliary converter, electronics, traction motor, Transmission and Suspension System, Battery, high voltage equipments, blowers and other auxiliary machines, such that it will provide a high level of dependability.

1.13.7 There shall be an efficient means of operation of the Locomotive after all failures in accordance with Good Industry Practice.

1.13.8 Components critical for safety shall fall into safe operating mode in case of malfunctioning. The system safety plan shall identify and list safety critical components and this list shall be updated periodically.

1.13.9 TheContractor shall establish and operate a detailed Reliability, Availability, maintainability and Safety (RAMS) Assessment system in support of the design, manufacture and subsequent testing, commissioning, operation and maintenance of the Locomotives.

1.13.10 Safety Assessment shall be carried out and shall include the following principles:

(i) Degraded modes and emergency operations shall be considered as well as normal operations;

(ii) Safety risk assessment shall utilize more than one methodology to assess risks; and (iii) Safety risk assessment shall include the consideration of dependent failures, in

particular the traction power, braking and control systems. 1.14 Infringement of patent rights:

Indian Railway shall not be responsible for infringement of patent rights arising due to similarity in design, manufacturing process, components used in design, development and manufacturing of inverter and any other factor, which may be cause of such dispute. The responsibility to settle any issue lies with the manufacturer.

1.15 Documentation

Following documents shall be submitted by the Supplier along with the offerfor evaluation:

1.15.1 Schematic Circuit; - Functional description; - System design concept; - Communication protocol and software structure description along with

compatibility with the locomotive control system; - Cooling System design; - Mechanical interface diagram and compliance to existing mechanics; - Clause by clause compliance of this specification; - Credentials with details of supply made of similar items; - Data sheets for devices and other equipment proposed along with detailed

description of supply proposed; - Thermal calculation of power devices; - Salient features and advantages of the offered system;

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- Details of technical support and training offered, the training shall cover on assembly, testing, commissioning, operation, maintenance and repair to IR personnel and training shall also cover in software parameter settings, fault diagnostic and analysis;

- Recommended list of spares for 3-year maintenance after warranty along with full drawing/design and details of OEM;

- List of special tools, jigs and fixtures needed for assembly, testing, commissioning, maintenance and repair along with full technical specifications and probable suppliers;

- Logistics proposed for warranty support within India;

- Declaration for long-term support by the supplier; and

- IRIS/ISO 9001 certification

1.15.2 The Supplier shall submit the design details, including but not limited to the following, to CLW before commencing manufacturing. Only on getting the approval from IR in writing should the production begin.

- Technical documentation explaining the complete scheme, characteristics,

diagnostics, protection and control etc.; - Detailed drawings of each system/sub-system with interface details; - Design calculations for selection of devices, cooling systems and various

subsystems, establishing the adequacy of the components selected; - Complete BOM / technical specification of components with source of supply; - Cooling system design description, data and cooling fluid data; - Mechanical drawings, mounting arrangement, weight, details of mounting

accessories; - Procedure for parameter alteration, software downloading, diagnostic

uploading, analysis etc.; - Schedule maintenance activities with periodicity; - Maintenance, trouble shooting and repair manual in soft form & hard copy; - Guaranteed values of efficiency of devices/subassemblies and assemblies; - Calculation to withstand short circuit current under fault conditions; - Details of short time rating of the converter; - Expected efficiency with respect to vehicle load/speed along with calculations; - Calculation and simulation results of system behavior, including interference to

the S&T circuits; - All calculations evaluated on the basis of software simulations shall be

supported by sample calculations; and shall details of tools and plants with design/drawings and supplies.

Approval of design means approval of general design features. Notwithstanding the approval, the Supplier shall wholly and completely be responsible for the performance of the complete equipment.

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1.16 Supplier’s responsibility

The supplier’s shall supply the materials as per the scope of work mentioned in this specification. Other minor items and its scope of supply shall be decided during design approval stage which would have meager financial implication. The responsibility shall be extended to the following:

a. The supplier shall design, evaluate, examine, and validate all the equipment in the scope

of supply of the tender. The ultimate responsibility of the performance of this equipment vis-a-vis performance of the Dual Mode Shunting locomotive shall lie with the supplier only.

b. The supplier shall supply detailed instructions for proper installation and commissioning

of the equipments in the scope of this specification on the DMSL. For this purpose, the supplier shall also depute their representative during installation and commissioning of the equipments, supplied against the specification.

c. The supplier shall arrange to carry out detailed test & performance proving, jointly with

CLW. d. The supplier shall also quote for special tools, testing jigs, and instruments, which may

be required for troubleshooting and maintenance of the equipment supplied. The design shall be developed as per requirement given in the specification.

e. The supplier shall also quote for Annual Maintenance Contract (AMC) for equipments

supplied against this specification.

f. The supplier shall supply suitable software for off-line analysis of diagnostic data downloaded from the converter and control electronics.

g. Contractor shall perform necessary simulation and analysis including FEM analysis and

load analysis, running dynamics etc. in simulation mode on modified equipments to be supplied against the specification. Test results should be within acceptable limits in light of enhanced rating of equipments on existing locomotive. The test results with observations, if any, shall be submitted with the design document.

h. Integration& testing/validation of additional equipments with the locomotive shall be

underContractor’s scope of work. Contractor shall also associate themselves during the field trial of first locomotive.

i. Contractor should submit all the design details covering modified items, their

mounting & integration details, wiring diagram etc. in hard and soft copy to IR.

j. Contractor shall submit all the Characteristics curves specified in the specification such as Power, Torque, current, power factor, stator & rotor frequency, voltage etc. with respect to speed(rpm).

k. Contractor shall submit the traction motor parameters which is suitable for

respective bogie of WDS6/ or any other suitable loco car body and can be fitted in the

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respective bogie. Supplier should take necessary approval of modification during design stage.

l. Traction motor drawings shall be submitted.

m. Performance Curves: The preliminary throttle-wise "Tractive Vs Speed" & 'Braking

Effort Vs Speed' at standard as well as site conditions shall be submitted along with the offer. In addition, the manufacturer shall submit "Draw Bar Pull Vs Speed" and "DC link voltage/current Vs Speed" characteristic curves at standard as well as site conditions.

n. Efficiency: The Contractors shall indicate efficiency for the different additional/modified

components/equipments/systems supplied by them against the specification. 1.17Railway’s responsibility

The commissioning of the locomotive shall be done at any Railway premises maybe at CLW or at Dahod Workshop. The Railway’s responsibility shall be extended to the following:

a. The fixing arrangement and location of equipments shall be submitted by supplier during

design approval stage and approval for the same shall be provided by railway.

b. The railway will support for proper installation of the equipments required for dual mode shunting locomotive. For this purpose, railways will provide skilled as well as unskilled artisan staff in addition to the deputed representatives of the supplier during installation and commissioning of the dual mode shunting locomotive.

After getting the requisite information from the supplier regarding the equipment/sub-

assemblies, the mounting and necessary cable layout and piping for different equipment which is under the scope of supply against the specification shall be carried out by the IR.

Railway will provide proper space to carry out detailed test and validation jointly with

the supplier.

However, the supplier shall ensure close liaison for the commissioning of the equipment supplied against this specification.

The basic dimension of locomotive shall remain the same and the supplier should design

the equipment layout accordingly within the existing framework. However, the fixing arrangement and relocation of existing equipment (if required) shall be submitted during design approval stage and approval for the same shall be obtained.

The mounting and necessary cable layout for different equipment which are under the scope of supply against the present specification shall be carried out by the purchaser as per the design details given by the supplier.

All skilled as well as unskilled artisan staff shall be provided by the purchaser Manufacturing facility to be provided by Railways: After getting the requisite

information from the supplier regarding the equipment/sub-assemblies to be modified, CLW shall start equipment mounting including cabling in supervision of the supplier.

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However, CLW shall arrange the following (as per advice of supplier) for successful commissioning of the new equipment on the locomotive:

Updated jigs and fixtures as per advice of supplier.

Assembly and testing tools.

1.18 Scope of Work/Supplies:In general, the differentiation of scope of work of supplier & purchaser shall be done on the following lines as given below:-

SN Item description Responsibility

of Design and validation

Responsibility of Manufacturing or

Procurement

1.0 Super Structure

1.1 Under Frame IR IR

1.2 Car body IR IR

1.3 Cab with Driver desk and cab equipments

Firm Firm

1.4 Driver Display unit with Annunciation panel

Firm Firm

2.0 Bogie, suspension and Under-gear Arrangement

2.1 Bogie Complete Firm Firm

2.2 Bogie suspension, axle and gear drive arrangement.

Firm Firm

2.3 Wheel set IR IR

2.4 Transmission system including Traction bar/link

Firm Firm

3.0 Traction Chain

3.1 Roof equipments IR IR

3.2 Traction Motorand cooling arrangement

Firm Firm

4.0 Transformer Firm Firm

4.1 Cooling arrangement for transformer

Firm Firm

4.2 LT panel Firm Firm

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*1 no. Per 5 no. of DMSL or part thereof **1 no. Per 5 no. of DMSL or part thereof

4.3 HT panel Firm Firm

4.4 Power and Auxiliary converter

Firm Firm

4.5 Battery Firm Firm

4.6 Battery management system

Firm Firm

5.0 Pneumatic equipment

5.1 Compressed air supply system

IR IR

5.2 Complete brake system including piping and brake rigging

IR IR

6.0 Cabling IR IR

7.0 Pump for filling of coolant in the converter and transformer *

Firm Firm

8.0 Coolant Firm Firm

9.0 Special tools and jigs for maintenance and commissioning **

Firm Firm

10.0 Auxiliary machines,blowers,ducts and filters

Firm Firm

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CHAPTER 2- OPERTAING AND ENVIRONMENTAL CONDITIONS 2.1 CLIMATIC & ENVIRONMENTAL CONDITION

The Climatic and environmental conditions prevailing in India in area off operations are the following

2.1.1 Atmospheric Temperature: Maximum touch temperature of metallic surface inside stabled Locomotive under sun during summer : 75˚C (degree Celsius) Maximum touch temperature of metallic surface inside stabled Locomotive under shade : 55˚C (degree Celsius) Maximum temperature near electronic cards inside stabled Locomotive standing under direct sunlight during summer : 70˚C (degree Celsius) Maximum temperature near electronic cards in working condition of Locomotive during summer : 65˚C (degree Celsius) Minimum atmospheric temperature : -10˚C (degree Celsius) The equipment shall be able to start up at the maximum specified temperature inside the locomotive without any pre-cooling requirement.

2.1.2 Humidity: Up to 100% during rainy season. 2.1.3 Altitude: Up to 1776 m above mean sea level. 2.1.4 Rainfall: Very heavy in certain areas. 2.1.5 Atmospheric condition: Extremely dusty and desert terrain in certain areas. The dust

concentration in air may reach a high value of 1.6 mg/m3. In many iron ore and coalmine areas, the dust concentration is very high affecting the filter and air ventilation system.

2.1.6 Coastal area: The equipment shall be designed to work in coastal area in humidity and salt laden and corrosive atmosphere. The maximum values of the condition shall be as follows:

a) Maximum pH value : 8.5 b) Sulphate : 7 mg per L. c) Max. Concentration of chlorine : 6 mg per L. d) Maximum conductivity : 130 micro Siemens/cm

2.1.7 Vibration: The equipment shall be designed to withstand the vibrations and shock encountered in service satisfactorily as specified in IEC 61287 and 60571 publication for the electronic equipments used on Rail Vehicle and relevant IECs as applicable to other equipment.

2.1.8 Electromagnetic Pollution: High degree of electromagnetic pollution is anticipated in locomotive machine room/HT & LT compartment, where the equipment shall be mounted. Necessary precaution shall be taken in this regard. The system shall be interference free from the communication system between the Guard-Driver-Control and Public address system. The system should be tested as per IEC 61000 for Electro Magnetic Compatibility.

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2.1.9 Wind speed: High wind speed in certain areas, reaching 150 kg/m2. 2.1.10 Solar radiation: The locomotive shall be exposed to solar radiation and the design of the

integrated converter shall take this into consideration. A minimum value of 1kW/m2 shall be applied during summers.

2.2 EMC 2.2.1 The additional equipments of DMSL shall comply with the EN50121/IEC62236 series of railway

electromagnetic compatibility standards and EN50238. 2.2.2 The supplier shall prepare, implement and maintain and EMC management plan in accordance

with the standards referenced in clause 2.2.1 of this specifications and standards.

2.3 Train and Locomotive Resistance Data 2.3.1 Train and Locomotive Resistance Data: The train resistance and locomotive resistance data as

followed by IR is as follows: 2.3.2 General: It is important to note that this data pertains to the existing system and for the

existing generation of locomotives and rolling stock for speeds up to 120 kmph. 2.3.3 Train resistance (of BOXN wagon excluding locomotive)

(i) Mean starting resistance on level tangent track (including acceleration reserve):

4.0 kg/tonne

(ii) Mean running resistance on level tangent track (excluding locomotive up to 120 kmph):

Rƒ=0.6438797 + 0.01047218 V + 0.00007323 V2 (kg/tone) "Rƒ” = the resistance in kg per metric tonne of freight train “V” = The speed in kmph

(iii) Grade resistance

= 1/G x 1000 (in kg/tonne), where G is gradient (e.g. G=200 in case of 1 in 200 gradient)

(iv) Curvature resistance

= 0.4 x curvature in degree (in kg/tonne)

2.3.4 Loco resistance as followed by IR is (i) Starting resistance on level tangent track:

6 kg/tonne

(ii) Running resistance on level tangent track:

RL = 0.647+ 13.17/W + 0.00933 V + 0.057V2 /WN [kg/Tonne] "RL" = Resistance in kg/Tonne of locomotive N = Number of axles W = Axle load of the loco in tonne V = speed in kmph

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CHAPTER 3- TECHNICAL SPECIFICATION

3.0 Car body:The car body of DMSL may be selected from the existing loco car body/WDS6.The option is left open for designer.Firm should submit the details during the design document submission.The mechanical design of DMSL will generally remain same as that of platform being used for this project WDS6 or any other suitable loco car bodywith bare minimum changes. The general arrangement and equipment layout of the DMSL shall be jointly worked out by RDSO, CLW and the firm (supplying the Battery mode equipments).

3.1 General layout:The general layout of the DMSL shall be decided jointly the supplier and IR.This

will depend upon the locomotive car body being selected.However some of the features are tabulated below.

There may be single/dual driving cab in the locomotive depending on the existing loco car body.

This cab should consist of equipments which will measure and control item like display meter, pneumatic gauge, driver display unit, external socket, wiper, blower unit, cab fan, brake system controller, fire extinguisher, cab heater, driver seats and switches for light, traction, vigilance, sanding, master controller, reverser, change over switch from OHE to battery mode(automatic change over should be present from OHE to battery mode), charging switch for battery and any other equipment required for operation and maintenance of Dual Mode Shunting locomotive.

There should be single pantograph located on the cab which will supply electrical energy from OHE to locomotive.In case of dual cab design it may be provided on anycab.

An annunciation panel is provided in the cab to inform crew the status of working of DMSL in Battery mode or in 25kV AC mode.

The layout of the HTpanel, LT panel, Pneumatic system, brake system, cab, compressors, auxiliary machines,ducts, blowers and additional equipments etc.shall be decided during design evaluation stage as this will vary from one car body to another.

3.2 Battery 3.2.1Type of battery:Li-ion or any suitable battery meeting the performance requirement can be

used. The battery should have adequatecapacity to meet the functional requirement of the locomotives mentioned in the specification. The type of the battery should be decided with due consideration of its size and weight.

3.2.2 The voltage of the battery,series and parallelcombination of thecells isleft open for the designer .the contractor should ensure the proper integration of the battery with power converters.

3.2.3The responsibility for safe operation of battery shall lie with the supplier. Suitable batterymanagement system may be adopted.

3.2.4 Battery capacity of the battery should be capable to start/haul the train as mentioned in the clause no. 3.3 for 90 to 100minutes on battery mode.

3.3 Haulage capacity: The power rating of the locomotive should be such that it should be capable of hauling /start load of 1500T at a speed up to 30kmph in both OHE and Battery mode.

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Thereshould be an option to couple maximum three DMSL in multi-units to start/haul higher loads.The maximum speedof light engine movement on OHE mode should be 60kmph.

3.4 Traction Motor:The traction motor meeting the requirement of this project shall be supplied

by the firm. The performance,testing,evaluation,validation shall lie in the scope of supplier. The supplier shall submit the design document during design approval stage.The mechanical dimension of the motor shall be designed in such a way it can be fitted in the bogie of the car body being selected. The cooling arrangement of traction motor for entire range of speed shall be designed and ensured by the contractors.

3.5 Bogie: The selection of the bogie depends upon the car body. The existing bogie of the car body being selected shall be used with bare minimum changes to accommodate the new traction motor and drive gear. The responsibility of modification in the bogie forfitment of the drive gear, traction motor and its performance, validation,evaluation and safe operation in the DMSL shall completely lie with the supplier.

3.6 Drive gear: The drive gear with axle shall be supplied by firm; wheel set shall be supplied by the railways.The gear ratio shall be decided by the firm as per the technical parameters duly meeting the speed and hauling requirement as mentioned in the clause no. 3.3.

3.7 Brake system: The existing Air Brake system IRAB shall be retained and used for the locomotive with WDS6 or any other suitable loco car body. The necessary details/design shall be obtained from RDSO or CLW. For this purpose the compressor units of the three phase electric locomotive can be used, the details of which are in Annexure-V. Supplier should take necessary approval of modification during design stage.

3.8 Pneumatic system: There should be two compressors for air supply of the brake system, the location of the brake system either on machine room or under frame shall be decided as per the car body being selected. The supplier shall submit the mechanical and electrical connection during design approval stage.

3.9 Trickle charging of the battery: In case of drainage of the battery in un-electrified section it is necessary to provide alternate method of charging of the battery so the locomotive can be moved from un-electrified section to electrified section .A DG set of suitable capacity along with necessary equipment may also be provided to trickle charge the battery set of DMSL of loco in un-electrified area. The number of DG set, its rating and weight and location shall be decided during the design approval stage.

3.10 Other parameters:

Axle load should be within permissible limits of Indian Railways.

Weight balancing of Shunting locomotives with addition of Battery set & their accessories.

The firm should ensure that the centre of gravity will remain same as that of locomotive being selected for design of DMSL.

The FEA analysis should be submitted by the firm for the critical components like bogie,drive gear, mounting arrangement, if there any changes from the existing one.

A design objective during the development of the DMSL will be to keep the interface identical in both Electric & Battery Mode for crew.

Changeover from electric mode to battery mode (manual and automatic both) & vice-versa may be accomplished following due safety precautions.

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3.11 Traction related details

3.11.1The nominal overhead voltage is 25kV AC 50Hz, single phase. The supply voltage is fed to

thetraction transformer through a Vacuum Circuit Breaker (VCB). The transformer output is to be connected to the power converter. The overhead traction supply is subjected to variations as under:

Nominal Voltage -25kVac Maximum Voltage -27.5kVac Minimum Voltage -19kVac OccasionalMaximum Voltage -31kVac Occasional Minimum Voltage -16.5kVac Supply Frequency -50Hz±3%

The occasional maximum and occasional minimum voltage may persist for 30 minutes.

3.11.2 Power converter:

Traction Converter: The supplier shall design and supply the traction converter.The performance, testing, evaluation, validation shall lie in the scope of supplier. The supplier shall submit the design document during design approval stage. o Regeneration: Regeneration is not effective at lower speed and light load, hence in this

project the regenerationoption may be left out.

Auxiliary Converter: The firm should design and supply the Auxiliary Converter. The rating of the Auxiliary Converter shall be decided by the contractor as per the auxiliary load requirement of DMSL. However there should be 100% redundancy for meeting auxiliary loads. Other Auxiliary machines, blowers, ducts for the requirement of DMSL shall be supplied by the firm.

3.11.3 The system and equipments shall be of proven latest technology specially adopted for

application to meet the performance requirements under environmental conditions specified in this Chapter 2. Adequate margin shall be built in the design, particularly to take care of condition of high ambient temperatures, dusty condition, high humidity prevailing in India.

3.11.4 In design and construction, reliability and maintainability shall be of paramount

consideration. Supplier shall submit reliability calculations indicating MTBF for different devices, cards and sub-assemblies. Adequate margin shall be provided to take into account ambient conditions prevailing in India. The components shall be sourced from reputed firms.

3.11.5 High efficiency of equipment shall be important consideration, next only to high reliability.

The components and technology used shall ensure very high efficiency of the converter. Supplier shall furnish the expected efficiency with respect to vehicle load/speed with necessary calculations.

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3.11.6 The design calculations of worst case temperature rise of equipment shall be made. A safety margin of at least 10°C shall be kept with respect to maximum permissible junction temperature of power devices declared by the manufacturer.

3.11.7 Dimension: Should be within the limit of MMD. Th shall be collected from RDSO. 3.11.8 Further; the additional equipments including battery set will be located in such a way so

that the DMSL remains balanced weight wise &centre of gravity (CG) remains as before addition of battery mode equipments.

3.11.9 Interference: The harmonic currents injected in the overhead supply system (as also the track return current) can introduce voltage harmonics on power supply and can interfere with signal and telecom circuits. The following interference current in the input current shall not be exceeded at any point in the operating envelope of the locomotive:

SN Interference Current Limit

1. Psophometric current 10.0 A

2. DC component 4.7 A

3. Second Harmonic component (100 Hz) 8.5 A

4. 1400 Hz up to 5000 Hz 400 mA

5. >5000 Hz up to 32000 Hz 270 mA

6. 39500 Hz up to 43500 Hz 270mA

3.11.10 The Supplier shall undertake FFT (Fast Fourier Transformation) analysis of the total

current from 1000Hz to 5000Hz and 5kHz to 50kHz separately to find out the frequencies

which produce the highest currents within each bandwidth. In the frequency bands

>32000Hz to <39500Hz and >43500Hz to 50000Hz the frequencies at which the current

values exceed 270mA shall be identified. EN 50238 includes interference current limits

for trackcircuits and axle counters. Where these overall interference current limits are

more onerous than those stated above these limits shall be applied. 3.11.11 The Supplier shall submit the simulated values of these interference currents during

design evaluation stage.

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CHAPTER-4 Annexure - I

Schematic Circuit Diagram of Power and Auxiliary Circuit

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Annexure - II

Important data for design Parameter of WDS6

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Annexure-III SALIENT INFORMATION ABOUT WDS6

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Annexure-IV Details of existing compressors of Three Phase Electric Locomotive (Specification No.

CLW/ES/03/0100)

Sl.No. Compressor 1 No. Of compressors per loco 2 2 Cylinder alignment Vertical

3 Drive AC Electric, motor totally enclosed, surface cooled

4 Mounting Resilient at three points 5 Displacement 2330 lit/min 6 Free air delivery 1745lit/min (no deviation allowed) 7 Delivery Pressure 10 bar/10.2kg/cm2 (no deviation allowed)

8 Compressor speed 730 rpm/980 rpm

9 Weight of the complete unit with motor 600kg approx.

Sl.No. Motor 1 Power Consumption 15kW/20.4hp 2 Voltage 3x415V±10% 3 Frequency 50Hz 4 Motor speed 756 rpm/1000rpm 5 Class of protection IP 55/ Terminal box IP 65 6 Rating Continuous S1 7 Insulation Class Mica insulation H class 8 Cooling Separate ventilation 8m3/min 9 Current 34.5A

10 Frame size 200L 11 Motor terminal connection MB screw 3 no.

12 Slip 2.75% at rated voltage and 6% at min. Voltage

13 Bearing single row deep groove ball bearing 6312 5KP/FAG imported origin

14 Vibrations 15microns max.

15 Winding temperature rise Max 85°C above ambient temperature 65°C

16 Permissible temperature rise of bearing Max 30°C above ambient temperature

17 Power factor 0.67 and above 18 Starting current (IS) 151A

19 IS/IN (Ratio of starting current to nominal current 438%

20 Starting torque 221Nm 21 Nominal torque 196Nm 22 Weight of motor apprx. 236kg 23 Cooling Direct 24 Efficiency Greater than88%

indian railways chittaranjan locomotive...

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