draft specification for motor driven oil free compressor 1

8/13/2019 Draft Specification for Motor Driven Oil Free Compressor 1

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SPECIFICATION FOR

DEVELOPMENT OF 3 PHASE INVERTER BASED MOTORDRIVEN OIL FREE COMPRESSOR

FOR HHP TYPE DIESEL ELECTRIC LOCOMOTIVES

SPECIFICATION NO. DLW/DE SIGN/MISC-199, November-2013
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1. SCOPE: The specification covers the general technical and testingrequirements of 3 Phase inverter based motor driven oil free compressor

for use on HHP type Diesel Electric locomotives being manufactured byDLW. This is a general technical specification and does not cover all thenecessary provisions of a contract.

2. STANDARDS:This specification refers to the following standards

Specification No. Description

IS 5456:2006 Code of practice for testing of positivedisplacement type air compressor

IS 10431:1994 Reaffirmed

1999

Measurement of air flow of compressors

IS 5727:1970 Reaffirmed2001

Glossary of terms relating to compressors

BS 1571 (Part II): 1975(1984)

Method for simplified acceptance testingfor air compressors

ISO: 8573-2001 (E) Compressed air for general useIEC: 61373-1991-01 Railway applications Shock and

vibration testIEC: 61287 Electronic power converter mounted

onboard rolling stock

IEC: 60571 Specific rules concerning the electronic

control part of convertersIEC: 61375 Communication interface compatibility

requirements

ISO: 1217 Displacement compressors Acceptancetests

IEC: 60034-1 Rotating Electrical Machines Rating &Performance

ISO: 2151 Acoustics Noise test code forcompressors Engineering MethodGrade-2, Noise level

3. FUNCTIONS:

3.1 The purpose of air compressor is to compress the available air taken atatmospheric pressure to the pre-determined gauge pressure i.e. 10.0kg/cm

2and also to maintain the pressure of that compressed air between

8.0 & 10.0 kg/cm2in the main reservoirs of locomotive, to be used for trainbraking and auxiliary equipment operation.


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4.6 PERFORMANCE PARAMETERS:

S.No. Parameters Performance values

1. FAD at Idle engine RPM > 800 LPM

2. FAD at rated 8th notch engine

RPM> 4800 LPM

3. Noise level < 76 db (A), 4.6 mtrs

4.7 Maximum space : The compressor envelope dimensions should notexceed 1350 mm(L) x 700 mm (W) x 550 mm (H) ( +10 mm) (excludinginverter module/control box dimensions)

4.8 Maximum weight of the compressor unit (including motor drivearrangement, heat exchangers (intercooler/aftercooler), mounting rack

etc.) should not exceed 450 Kgs. (for one compressor unit)

4.9 The compressor should be designed for under slung mounting provision.The mounting arrangement should include suitably designed Anti-Vibration Mounting (AVM) pads to minimize vibration induced forces onthe assembly for better reliability and performance of the unit. Theequipment shall withstand satisfactorily the vibration and shock normallyencountered in service as per IEC 61373 Category-1 Class-B. Themanufacturer shall submit supporting documents in this regard.

4.10 MULTIPLE UNIT OPERATION:

Train line signals conveyed through the 27-wire jumper cable (+74 V DCon-off except power reduction pin and dynamic brake excitation pin having0 74 V DC) through wires designated as :

1. Spare2. Alarm Bell3. D Governor Solenoid4. Negative Voltage Common5. Spare6. Main Alternator Field

7. C Governor Solenoid8. Reverse9. Forward10. Wheel Slip Indicator11. Spare12. B Governor Solenoid13. Control Circuits & Fuel Pump14. TE limit
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15. A Governor Solenoid16. Engine Run17. Dynamic Brake Control18. Spare19. Spare

20. Dynamic Brake Warning21. Dynamic Brake Interlock22. Spare23. Manual Sand24. Dynamic Brake Excitation25. Air Compressor Control26. Spare27. Spare

The Air Compressor Control signal which currently activates / de-activatesMVCC as per the command given by LCC based on MR pressure values

is available at pin 25. The purpose of carrying this command on train lineis to enable use of air compressors on each unit to act as one to share theload and increase the capacity of the air system.

DLW can use two compressor units on a HHP locomotive to meet the FADrequirement.

Compressor manufacturer will have to provide interface box (intelligentcontrol module) which should have an interface with companion alternatoroutput (for estimating the spare power available) and with LCC for MVCCsignal for switching-on and switching-off of the compressor motor. Thecontrol unit should be capable of sequencing the operation ofcompressors with an aim to distribute the running of compressors evenlybetween the two compressors.

In synchronous running mode (in multiple consist operation) thecompressor run signal generated by leading loco and transmitted throughtrain line to the trailing loco will be used to drive the compressor units onall the trailing locomotives.

HHP locomotives have a computer controlled circuit for full compressorsynchronization with any other microprocessor controlled locomotive thatare trainlined. When the Main reservoir air pressure is below the low-pressure limit (called P LOAD), the LCC sends a signal out CH-14, DIO-3which causes pick-up of the compressor synchronization relay, CMPSYN.This provides a compressor request to load signal (CRL) to the LCC(CH-18,DIO-3) as well as trainline signal (25T) to activate any trailing unitcompressors. In addition, CMPSYN provides the compressorsynchronization relay verification input signal (CH 12,DIO-3). After aprogrammed period of time, the computer drops the output signal (CH 14,


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mist, torrential rain, heavy sand or snow,storms, presence of oil vapors and heatetc. to which the rolling stock is normallyexposed in service.

6.0 Duty cycle: The compressors are subjected to run for an average of 22hours a day. The compressor must be able to give satisfactory performanceat 100% load of 10 bar

7.0 Testing: The objective of the tests is to ascertain the reliability,performance potential and quality requirement of complete compressor unit.The prototype tests shall constitute the following series of tests andmeasurements: (i). Dimensions (ii). Capacity measurement test (iii). Powerconsumption test (iv). Endurance test (v). High environmental temperaturetest (vi). Quality of compressed air vii. Weight measurement. In addition, theacceptance tests specified in various standards applicable for acceptance

tests and performance reliability requirements mentioned under Para 2 ofthis specification will also be done while undertaking type testing. Prototypetesting shall be conducted jointly by DLW and Motive Power Directorate ofRDSO and the firm shall provide all necessary assistance for inspection andtesting of 3-phase inverter based motor driven oil free compressor free ofcost. However, if any vendor is offering a proven compressor which hasalready passed the type testing and is already working in railways(Locomotive application) for similar FAD rating anywhere in the world,DLW/RDSO reserves the right to waive-off the type test for the offeredcompressor. However, the inverter will have to be type tested as per thespecified standards.

8.0 Field trials: On satisfactory completion of prototype tests, the compressorshall be subjected to field tests/trials for a period of 12 months.

9.0 Marking: The compressor shall have proper marking on a nameplate for atleast following information: (i) Manufacturer s name (ii) Type & serial no. (iii)Capacity (FAD) in LPM at rated RPM (iv) Month & year of manufacture.

10.0 Accessories: The compressor unit shall be fitted with the followingaccessories:

(i) Dry type air filter for suction and an indication to indicate the level ofcarbonization / blockage of filter element

(ii) Intercooler safety valve and drain cock(iii) Aftercooler, fitted with auto drain valve(iv) Flexible pipe for use on delivery side, which shall be capable of

withstanding the delivery of hot air temperature(v) Suitable resilient mount of proven design
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(vi) Suitable safety sling to prevent the compressor from falling in case offailure / breakage of the mounting arrangement

11.0 General Conditions for Inspection & Tests:

11.1 All tests shall be conducted at Manufacturer s premises. Anyshortcoming or defect noticed during the type test shall be pointed out to themanufacturer by the DLW/RDSO or his representative to enable him toincorporate the necessary improvements before bulk manufacture iscommenced, without affecting the guaranteed deliveries or guaranteedperformance characteristics.

11.2 Any additional tests trials, if considered necessary by the DLW/RDSO,shall also be arranged by the supplier free of cost.

11.3 The DLW/RDSO or their representative shall have access for stageinspection, to those portions of the manufacturer s works in which productionis being carried out and where the testing is taking place. This also appliesto the items procured from sub-suppliers.

11.4 The DLW/RDSO, at the time of inspection, shall have the power to askfor additional information and/or tests he may consider necessary to satisfyhim that proper materials and parts specified are actually used during themanufacture of the compressor.

11.5 The manufacturer shall provide labour or appliances required by theDLW/RDSO Engineer, free of charge, for inspection and testing of thecompressor and its components, as required.

11.6 If any part of the compressor unit requires alteration or any defectappear during the tests or trials, the supplier shall, without any extra charge,make such alterations or rectify the defects to the satisfaction of theDLW/RDSO engineer or their representative.

11.7 Any modification or alteration to the components during the supply ofthe order shall be made only after the approval of the DLW/RDSO Engineer.The unit after such modifications / alterations shall be subjected to suchtests as considered necessary by the DLW/RDSO Engineer.

11.8 Zinc yellow passivation / Blackening shall be done on all hardware s.

12.0 SPARES:


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Along with the quotation forsupply of air compressor the tenderer shall alsofurnish a recommended listof spares for two years and quotations thereof.The tenderer shall also agree to hold the price of spares for a period of oneyear from the date of supply of the compressor.

13.0 INFORMATION TO BE FURNISHED BY THE TENDERER:

Data as per Annexure I & II shall be furnished by the tenderer along withtheir QAP for this item.

14.0 TOOL KIT:

The price for tool kit for the maintenance of the compressor shall beindicated separately, alongwith the tender.

15.0 MAINTENANCE MANUALS :

The tenderer shall supply copies of exhaustive, fully illustrated manualscovering among other items, the following vital details, to the Engineer withthe tender.

1. Description and arrangement2. Technical data3. Dismantling and assembly instructions4. Commissioning instructions5. Periodical inspection schedules6. Periodical maintenance instructions along with trouble shooting

instructions7. Testing procedure for the equipment and other auxiliaries8. Wear limits for vital components9. Detailed parts catalogue with description of items. The parts shall be

detailed by sketches to facilitate ordering10. Instructions for reclamation of worn out components11. List of special tools with instruction for use.

Two copies of the maintenance manual shall be supplied with the quotation.One copy of the manual shall be supplied with every 10 compressor sets ora part thereof.

16.0 TRAINING :

The supplier shall provide facilities for free training of the railwaymaintenance staff at their works on aspects of maintenance, overhaul andtesting of the compressor.


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17.0 SPECIAL CONDITIONS:

1. At the time of approval of the prototype unit the manufacturer / suppliershall furnish the list of names and addresses of their Sub-supplier of themain items of the equipment and important raw materials which they

have used in the prototype unit and shall not make any changes in thesources of supply without prior approval of DLW.

2. After successful completion of the type test the compressor shall besubjected to extended field trial for a minimum period of 12 monthsbefore according the prototype approval.

18.0 FINISH:

The compressor motor set shall be suitably treated to remove rust andshould be coated with antirust primer and finished with two coats of light

grey or black paint as per IS 5:1994.

19.0 SERVICE:

Overhauling period: Overhauling period of the complete compressor andmotor assembly along with the inverter drive arrangement should not be lessthan six years. The units should work satisfactorily in the filed without failure/ dismantling of any component.

20.0 QUALIFYING CRITERIA: The tenderer shall meet the qualifyingrequirements listed below and submit the documents in support thereof,along with the proposal.

The tenderer meeting any one of the following criteria shall qualify:

a. Tenderer having a proven technology and minimum one year serviceexperience of oil free compressor of similar FAD to Indian Railways forlocomotive application or for other rail applications.

b. Hundred or more of the offered compressor should have been inservice anywhere in world for rail applications for at least 5 years. Thesupplier shall submit the details along with the reference list.


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ANNEXURE - 1

BROAD TECHNICAL FEATURES OF THE COMPRESSOR

1. Type, make and model2. Graph showing free air delivery (FAD) against 8, 9 and 10.5 Kg/cm2 at

100% duty cycle and maximum rated speed3. Displacement at rated r.p.m.4. Horse power consumption at rated capacity and speed against 8, 9 and

10.5 Kg/cm2.5. Maximum permissible temperature at inlet and exhaust ports6. Weight of the unit complete with accessories7. Details of drive arrangements

8. Details of couplings (if used) including alignment data and method ofchecking alignment9. Details of mounting arrangement with overall dimensions10.Overall space requirements, inclusive of all accessories for the

compressor. Any additional space required for removal of valves inposition, attending to air inlet filters etc. shall also be indicated. Layoutdrawings shall be supplied

11.List of major wearing components and their expected life12.Complete details of resilient mounts


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ANNEXURE-II

GENERAL DATA OF COMPRESSORS

1. Type, make and model2. Details of Technical collaboration, if any3. Basic design data

Cylinder arrangement

No. of LP cylinders

No. of HP cylinders

LP cylinder bore dia mm

HP cylinder bore dia mm

Expected life of cylinder

Expected life of piston No. of LP piston rings

No. of HP piston rings

Expected life of piston rings

Details of inlet & exhaust valves and their expected life

Stroke length mm

Piston speed (max.)

Head clearance

Ratio of compression per stage

Air temperature at LP discharge and intercooler discharge and finaldelivery at rated capacity and 8,9 and 10.5 Kg/cm2 with inlettemperature range upto 60oC

Dimension, material specification, heat treatment and method ofmanufacture of: Piston, Piston Rings, Valves, Cylinder Heads, CrankShaft, Connecting rods & Crank pin

4. Starting & running torque required for the compressor against a backpressure of 10.5 Kg/cm2

5. Type, details of suction air filter used in the compressor. Indicate filteringefficiency and dust retentively.

6. Materials & specifications used for gaskets

7. Location of rubber or synthetic sealing media, if used

8. Details of cooling fan, fan guard including mounting drawings


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9. Details (with overall dimensions) of coupling used. The permissible limitsof misalignments and guaranteed trouble free service life shall also beindicated

10. Type, specifications, make and average life of main and connecting rod

bearings

11. Type, details and working of (i) Intercooler safety valve (ii) Auto drainvalve

12. Type, specification, make and average life of resilient mount. Mountingand maintenance details of resilient mount.

draft specification for motor driven oil free compressor 1

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