government of india-ministry of railways research...

of 24 Effective from Jan. 2012 RDSO/PE/SPEC/AC/0081-2007 (Rev. 0) with Amendment No. 1

Prepared by SSE-8

Checked by Director/ PE & Metro

GOVERNMENT OF INDIA-MINISTRY OF RAILWAYS RESEARCH DESIGNS AND STANDARDS ORGANISATION

MINISTRY OF RAILWAYS

lR;eso t;rs

POWER SUPPLY AND EMU DIRECTORATE

SPECIFICATION

FOR

TEST DRIVE UNIT WITH REGENERATIVE FEATURES FOR 25 KW ALTERNATOR

& 4.5 KW ALTERNATOR WITH RRU/ERRU OF AIR CONDITIONED AND TRAIN LIGHTING COACHES OF INDIAN RAILWAYS

S No. Date of Revision/

Amendment

Revision/ Amendment

Page/Cl.No. Remarks

1 Jan 2012 Amdt.-1 - Scope of supply and specification in general streamlined, IP protection of Motor changed.

Approved by Executive Director / PS & EMU


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TEST DRIVE UNIT WITH REGENERATIVE FEATURES FOR 25 KW ALTERNATOR

& 4.5 KW ALTERNATOR WITH RRU/ERRU OF AIR CONDITIONED AND TRAIN LIGHTING COACHES OF INDIAN RAILWAYS

GENERAL 1.0 Objective & Scope (a) The test beds presently used by manufacturers of alternators and the Railways

in various shops are of eddy current drives or DC motor drives. The motors used in these types are more than 100 KW rating for testing 4.5kW and 25 KW alternators. The drive is highly inefficient and a lot of power is wasted in the form of heat and huge noise is produced during testing. The drive does not cater for testing of alternators at all speeds and at all loads without changing the drive pulley. This involves wastage of time and man power. These drives do not have the metering for testing alternators.

(b) This specification covers the testing of 4.5kW and 25 KW ‘V’ belt driven bogie mounted brushless alternators required for broad gauge SG AC coaches. Prescribed test shall be conducted on alternators with RRU/ERRU before commissioning or after overhaul.

(c) The objective of this specification is to improve the reliability of equipment i.e. alternator, RRU & ERRU & other associated equipments and on line performance. This test drive shall be used for conducting various tests to determine the working performance of AC alternators, RRU & ERRU.

(d) It is desirable that alternators are to be tested as per relevant RDSO specification without changing of pulleys and with less power of the drives.

(e) Alternators can be fully loaded from zero load to the full load as per requirements.

2.0 Definitions RDSO : Research Designs & Standards Organization. Tenderer : Firms/companies participating in the tender Supplier : The qualified tenderer for supply of the equipment. Railways : Indian Railway Administration. 3.0 Suppliers Responsibility 3.1 Scope of work:

i) Design, manufacture, supply, testing and commissioning of Control panel. This panel should be floor mounted with suitable IGBT / Thyristor based Variable voltage variable frequency (VVVF) drive for speed control of above said motor. This includes suitable arrangement for to read alternator speed, suitable motor starter and suitable protection switchgears and suitable arrangement for bi-directional operation of the


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Alternator. Suitable protection scheme which may be required for the successful and safe operation of the drive should be incorporated. The regenerative loading arrangement shall be incorporated so as to load the alternator form 0 to 193A step less and maximum loading shall be upto 230 A. All controlling equipment should be housed inside floor mounted desk type control panel for ease of operations. The Power supply cables from mains to control panel and from control panel to drive are also included in this work.

ii) Design, manufacture, supply testing and commissioning of suitable

mounting arrangements including construction of foundation etc for alternator under tested its variable speed drive testing equipment’s with suitable arrangement of V belt tension. This will consist of MS fabricated bed for fixing prime mover pulley V belt etc for driving alternator which shall be mounted on a MS frame (transom mounted) with suitable arrangement for adjusting belt tension. There should be a provision to hang & provide the tension to all the alternator viz 4.5 KW and 25KW. Only alternator with pulley will be supplied by the Railways and all other items such as mounting arrangement of alternator, fixing of motor and control panel etc shall be supplied and commissioned by the supplier.

This includes the provision of expanded metal enclosure 1250 mm in

height made out of hard drawn steel wire 25 mm mesh of weight not less than 7.5Kg per sq. meter of angle iron/flat iron frame including incidental work such as welding, provision of nuts and bolts, erection etc. around alternator testing bed for the safety of the staff.

iii) The design and general arrangements of all the equipment shall be got

approved before execution of the work.

This includes all civil works, mechanical involved in commissioning of the drive including repair of any part of the floor damaged during erection. Only alternator with pulley will be supplied by the Railways and all other equipment necessary for testing as mentioned in Para 4 of STR No. RDSO/PE/STR/AC/0019-2008 (Rev.-0) shall be provided by the contractor.

iv) Micro Controller / Microprocessor / DSP Controller

CONTROL PANEL (VVVF based) Design, manufacture, supply, testing and commissioning of control panel for testing of above alternator (VVVF based). The variable drive testing equipments shall be VVVF drive. The Output speed should be smoothly controllable (Step less) over a wide range so that it is possible to drive the alternator from 0 to 2500 RPM while supplying varying load from no-load to rated load. Accurate speed regulation under varying load condition should be possible.


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This panel should be floor mounted with suitable electronic control arrangement for speed control of the above said drive. This includes suitable arrangement for speed control and adjustment, speedometer to read alternator speed and drive speed, suitable motor starter and suitable protection switchgears and suitable arrangement for bi-directional operation of the Alternator. Suitable protection scheme which may be required for the successful and safe operation of the drive, should be Incorporated. All controlling equipments should be housed inside the floor mounted control panel for ease of operations. The following indications should be provided on the panel:- i) Indication for availability of supply in all 3 phases. ii) RPM meter to read drive speed. iii) Voltmeter along with selector switch to read the voltage in all 3

phases. iv) Ammeter along with selector switch to read current in all 3 phases.

CTs may be provided for metering purpose. v) Indications for Control ON and the drive speed can be varied only

when this indication is Available. vi) Indication for the direction of rotation of the drive. vii) Alternator output voltage AC for three phase viii) RRU/ERRU output voltage DC ix) RRU/ERRU output current DC x) Alternator field current xi) Alternator speed xii) Panel size – suitable to locations

3.1.1 Installation and commissioning of the complete testing drive shall be done by

firm including foundation work.

The supply of the detailed instructions for installation of equipment will be made by the firm. Supplier shall also depute his representative for ensuring correct installation of equipments in Depot/Workshop.

3.2 The supplier shall quote for spares which may be required for satisfactory

maintenance of unit for a period of 3 years after completion of warranty period. 3.3 The supplier shall be responsible for any damage to the equipment due to

defective design, material, workmanship upto a period of 24 months after commissioning or 36 months from date of supply which ever is earlier.

3.4 Maintenance activities of AC Testing drive during AMC


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A) Scope of AMC

i) The Preventive Maintenance contract/AMC shall be of comprehensive in nature where the breakdown maintenance as well as preventive maintenance of AC Testing Drive installed in pit line or workshop. The supplier shall ensure the satisfactory and trouble free service of AC Testing Drive. In addition to this, all the breakdown calls as and when necessitated by the user Railway at workshop or depot shall also be attended by the supplier/service engineer within the 12 hours from the time of complaint.

ii) No additional charges towards any type of replacement made in the

system will be paid by the Railways. B) Following activities shall be covered during preventive maintenance/AMC by the

supplier:- i) Cleaning of control panel with dry air ii) Cleaning the semiconductor devices, heat sink etc. with dry air. iii) Check that all connectors to PCB are tight and no insulation is damaged

on cables, boards and insulators etc. iv) Checking for normal routine performance test and test results duly signed

by Railway representative and Service Engineer shall be submitted to Head Quarter and RDSO.

v) Visual Checks for any type of ambiguity. vi) Cleaning of electronics cards and other electrical/electronic components. vii) Tightness checking of all relevant power connections and equipment

mounting, if required. viii) Setting/checking of device parameters as per drive requirements. ix) Functional checking with or without load as per site conditions, if required. x) Any other deficiencies or short falls observed in the system and work as

either noted by the Contractor or pointed out by the Railway. xi) Measure the insulation resistance of the system xii) Check the condition of cooling fan, replace it, if required. xiii) Check the value of the condensers in the system, if the value is observed

to be less then 80%, replace the condensers. 3.5 The supplier shall replace within 15 (fifteen) days, the faulty equipment during

the warranty period at his cost. The period of warranty will be extendable in case of recurring problems attributable to defective design, material or manufacturing.

3.6 The supplier shall be responsible for carrying out all the modifications at his cost

or any part of equipment during the period of warranty required for satisfactory operating of equipment.

3.7 Training:- The supplier shall arrange training for IR Personnel in maintenance

and trouble shooting of the system supplied. Training will be arranged free of cost at the place of installation. Suitable training material will be supplied to participants.


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3.8 The supplier shall supply the write-up and elaborate manual for maintenance

and trouble shooting. Two sets of manual will be supplied to the Consignee. 4.0 Railway’s Responsibility Railways will be responsible for the following:

• Electrical energy required for execution, testing and commissioning of equipment.

• Manpower required for testing. 5.0 Documentation 5.1 The tenderer shall submit the following:-

(a) System design, salient features and advantage of system. Functional description, Protection scheme.

(b) Man Machine Interface: Details of switches indications and fault diagnostic feature if any.

(c) Bill of material (BOM) –Data sheet for components/devices and other equipment proposed for use.

(d) Mechanical Interface diagram (out line general arrangement), assembly drawings of complete units mounting arrangement and weight.

(e) Details of technical support and training offered. (f) Supply experience. (g) Recommended list of spares with cost for 3 years maintenance after

warranty. (h) List of spare tools, jigs and fixtures needed for assembly, testing,

commissioning maintenance and repair. (i) Test protocol with procedure of testing.

5.2 The successful tender shall submit the following documents.

(a) Technical documentation explaining complete scheme, characteristic, diagnostics, protection and control.

(b) Detailed drawing of system/sub system with interface details in CAD format. (c) Vendor list of sub system (d) Operation and Maintenance Manual (e) Spares Catalogue.

6.0 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 item and any other factor not mentioned herein


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which may cause such a dispute. The entire responsibility to settle any such disputes/matters lies with the manufacturer/ supplier.

Details/design/documents given by them are not infringing any IPR and they are responsible in absolute and full measure instead of Railways for any such violation. Data, specifications 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.

7.0 Environmental conditions. 7.1 The equipment should function satisfactorily under the following environmental

conditions which are encountered where the equipment will be expected to work. (a) Maximum temperature - 55ºC (b) Minimum temperature - -5ºC 7.2 Humidity – upto 98% during rainy season 7.3 Altitude – upto 1200 m above mean sea level. 7.4 Rainfall – Very heavy in certain area, the equipment should be designed

suitably. 7.5 Environment – Extremely dusty and desert terrain in certain area. 7.6 Coastal Area – The equipment shall be designed to work in coastal area in

Humidity and salt laden and corrosive atmosphere. 8.0 TECHNICAL REQUIREMENTS 8.1 Induction motor of 75 kW (100 HP) to operate from 300 rpm to 2500 rpm, full

load from 800 rpm to 2500 rpm. The motor will be fitted with 250 mm diameter (PCD) 6 groove pulley. The entire speed range will be covered without changing the pulley.

8.1.1 Induction Motor

The each induction motor shall be of 75 kW (100 HP) at 960 rpm suitable to feed one 4.5kW and 25 kW alternator capable of alternator speed of 300 rpm to 2500 rpm and suitable for operation of electrical power supply 415 V±10%, 3 phase, 50 Hz ±2.5Hz AC energy efficient variable speed suitable for PWM voltage (VVVF) controlled upto 100 Hz, totally enclosed with protection level IP 55, induction motor with separately integrated cooling fan, with mechanical package including single pulley extended shaft 6 grooves 250 mm PCD, movement of motor with belt tensioning device 200 mm pulley shall be ensured, if provided beside the pit line. The motor mounting is to be horizontal foot mounting. The motor shall have ‘H’ class insulation.

Two induction motors (one for driving each alternator of AC coach) can be

mounted on the foundation inside pit line. If there is problem of water logging


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inside the pit, motors can be mounted beside the pit line and suitable drive has to be extended inside the pit to drive alternator.

The Induction motor should conform to the following technical particulars:

i) Capacity of Induction motor 75 kW (100 HP) with sufficient margin For load testing of alternators.. ii) Maximum speed Sufficient to run alternator from 0 to 2500 RPM attainable through VVVF drive. iii) Type of Motor Induction motor (Class H insulation)

iv) Speed range Suitable to meet the requirement for 300 RPM to 2500 RPM

v) Supply Voltage 415 V, 3-phase, 50 Hz. vi) IS 325 for 3 Phase Induction Motor vii) Make Siemens/ABB/Crompton

viii) Efficiency of motor at rated rpm not less than 85% ix) Power factor minimum 0.8 The Power supply cables to control panel and from control panel to motor are also included in this work. Note:--Following type of motors with suitable panel are recommended for

different applications. a) Workshop 75 kW (100 HP) b) TL & AC Depot 75 kW (100 HP) c) TL Depot 40 kW

8.1.2 Plummer blocks, pulley and shaft arrangements for pit line testing rig. 8.1.3 Alternator and motor mounting with belt tensioning device 8.1.4 Erection and commissioning of complete system 8.1.5 Facilities to start at no load, half load, full load and any other desired load

between no load to full load. 8.1.6 Earthing – Two suitable earthing terminals should be provided on control panel

and motor separately

8.2 TESTING BED The scope shall also include design, manufacture, supply testing and commissioning of suitable mounting arrangements including construction of foundation etc for transmission of power at variable speed from AC drive to alternators under test with suitable arrangement of V belt tension. This will consist of MS fabricated bed for fixing prime mover and suitable transmission


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arrangement from prime mover to alternator mounted on the coach at variable speeds & with suitable arrangement for adjusting belt tension. Only Coach with alternator will be supplied by the Railways and all other items such as mounting arrangement of transmission arrangement, fixing of variable speed drive and control panel etc shall be supplied and commissioned by the supplier. It also includes provision of expanded metal enclosure of appropriate height made out of hard drawn steel wire 25 mm mesh of weight not less than 7.5Kg per sq. meter of angle iron/flat iron frame including incidental work such as welding, provision of nuts and bolts, erection etc. around alternator testing bed for the safety of the staff. The design and general arrangements of all the equipment shall be got approved before execution of the work. This scope of work also includes all civil works, mechanical involved in commissioning of the drive including repair of any part of the floor damaged during erection. Only coach with alternator mounted underneath will be placed on PIT by the Railways and all other equipment necessary for testing shall be provided by the contractor. The following test is required to be carried out on the alternator in the AC shed. Operation and testing of the alternator for the adjustment of the Output voltage on full load, half load and no load at different speeds from 0 to 2500 RPM as per technical particulars of alternator.

8.3 Smart Energy Saver: There should be a provision of energy saver type of load on the Alternator / Regulator output. A minimum 80 % energy generated by the alternator with RRU/ERRU should be regenerative type and given back to the Test drive system for reutilization. Necessary panel for measurement inflow and outflow of power shall be provided.

8.4 Deleted 8.5 Deleted 8.6 Deleted

8.7 OVP test:- Over voltage protection shall be tested as per following test

programme. S. N

Load Speed of testing

Condition of RRU/ERRU

Status of relay

Remarks

1. O Amp DC 400, 800, 1500 2500 rpm

Control winding Zener intact (RRU /ERRU normal

Tripping/Not tripping

Transient/ Stabilized voltage to be recorded


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working) 2 10 Amp DC 800,1500

, 2500 rpm

(a)Opening of control winding (b) Opening of reference Zener for voltage

-do- -do-

3. 96.5 Amp DC -do- -do- -do- -do- 4. 193 Amp DC -do- -do- -do- -do- 5. Throwing off

193 Amp load to no load

-do- Control winding Zener intact (RRU/ ERRU normal working)

-do- -do-

6. Sudden loading from No load to full load

-do- -do- -do- -do

Note :-

1. During the testing of OVP, the status of relay (tripping / not tripping ) and DC output voltage shall be recorded under the above conditions.

2. OVP shall not trip under condition at item 1,5 & 6 . 3. Battery Circuit shall be kept out of circuit while testing OVP as per condition

mentioned at item no. 1,5 & 6. 4. OVP testing as mentioned at S.No.2,3 & 4 shall be done using battery bank

of adequate capacity and same shall be kept in perfect healthy condition. 5. In above conditions, relay should trip however, when voltage will not exceed

at the level of set voltage relay may not trip (This condition may occur when speed test is low i.e. MFO speed).

9.0 Deleted 9.1 Deleted 9.2 PC Instrumentation & Control:

There should be a set of control and test diagnostics hardware and necessary software complete with PC, Monitor, Data acquisition card and Printer mounted on a separate panel. The alternator test bench should be able to record and print the followings:

• Performance Characteristics with % Ripple Factor • Load Vs Output Voltage Characteristics • Alternator temperature at DE, NDE and frame ends during test w.r.t. time.


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Note:- No power wiring is allowed to be opened or disconnected from Coach wiring for Alternator test bed sensors.

Along with the above it should be possible to plot the real time graph in printable

format for followings: • Alternator Speed Vs Voltage characteristics. • Alternator current limiting characteristics with voltage and load at 1800

RPM. • Load Vs Speed characteristics.

AUTO MODE


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10.0 Tests

1. Visual Examination


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2. Insulation Resistance - 500V megger 3. Dielectric test - at 1.5 KV AC 4. Performance Test - shall meet the requirement of Cl 10.5 5. Reliability Test - At least 24 hrs 6. Full Load Test - The machine shall be capable to test the alternator at rated current 130 V and

alternator speed 800 rpm. 10.1 Visual Examination :

a) The object of visual examination is to check that equipment is free from defects and the equipment is as per approved drawing.

b) All the important dimensions will be measured and should be in permissible tolerance.

c) Bill of material will be submitted. d) The make, rating of equipments, sub assemblies will be checked as per

approved drawing. e) If a change is needed in make or rating of important equipments, sub

assemblies it should be intimated and should have the approval of RDSO. f) Check for general workmanship. g) Check terminals, switches, type no. etc. as per approved drawing. h) Check from supplier record that electronic component, PCB etc. have been

subjected to “Burn In” procedure and there is no failure of any component. In case there was a failure of any component check that the card has been again subjected to burn in.

i) The electronic cards/PCB should be wave soldered 10.2 Insulation Resistance The insulation resistance with 500V megger shall be measured & value of IR

should not be less than 20 MΩ. The minimum requirement at highly humid condition is to be ensured that its value should not be less than 10 MΩ.

10.3 Die-electric Test The equipment shall be applied 1.5 KV AC for 1 minute between shorted

connections and metallic supporting frame. There should not be any flash from any part during and after the test.

10.4 A. Technical particulars of 25 kW alternator for RRU/ERRU

• Type 25 kW • Rectifier output voltage 130 V • Rectifier output current 193 A • Cut in speed 400 rpm • Minimum speed for full output (MFO) 800 rpm • Maximum speed of alternator 2500 rpm • Insulation H Class • Cooling air velocity 6m/sec


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• Weight <525 kg • Ball bearing 7312BECBJ • Roller bearing NU 312 ECJ • Lubrication Grease • Stator winding resistance 0.045±0.01 ohm • Field winding 8.5± 1.5 ohm • Mounting Mounting on a bogie V belt

transom and suitable for working in a heavily dust Laden atmosphere.

• Combined efficiency of alternator with Not less than 80% at 130 V, 193 Rectifying regulating equipment. Amps at 1800 RPM

B. Technical particulars of 4.5 kW alternator for RRU/ERRU • Type 4.5 kW • Rectifier output voltage 120 V • Rectifier output current 37.5 A • Cut in speed 350 rpm • Minimum speed for full output (MFO) 600 rpm • Maximum speed of alternator 2500 rpm • Insulation F Class • Cooling air velocity 6m/sec • Weight <230 kg • Ball bearing 6309 BECJ • Roller bearing NU311ECJ • Lubrication Grease • Stator winding resistance 0.4±0.05 ohm • Field winding 4.5±0.5 ohm • Mounting Mounting on a bogie V belt

transom and suitable for working in a heavily dust Laden atmosphere.

• Combined efficiency of alternator with Not less than 80% at 120 V, 37.5 Rectifying regulating equipment. Amps at 1800 RPM One set testing facilities shall include the following :

• Control panel (VVVF based) • Induction motor 75 kW (100 HP). • Testing Bed. 2 Sets above equipments are required for testing of two alternators mounted underneath one AC coach. The alternators are to be run in both the directions during testing.

10.5 Performance Test

Following tests shall be carried out before commissioning or after repairing/maintenance on AC Alternator with RRU/ERRUs. The alternator out put


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voltage in conjunction with RRU/ERRU shall be within ±4% of voltage setting from base load to full load over the speed range of MFO to 2500 rpm. The alternator shall have the setting of 129V at 96.5 A at 1500 rpm & current limit shall be set Max.230A. i) No load test ii) Half load iii) Full load iv) Parallel operation test v) OVP test

10.5.1 No load test:- In this test, speed shall be varied covering the speed range of

800, 1500 & 2500 rpm. This test may be conducted at 10 A or only one compressor switched ON. And voltage current shall be recorded field current may also recorded to see the field current control, if required.

10.5.2 Half Load:- It shall be conducted at above mentioned speed in No Load Test keeping half load in circuit i.e. one RMPU, 50% light, fan load kept switched ON, and voltage & current shall be recorded.

10.5.3 Full load:- It shall be conducted at above mentioned speed as indicated in No

Load ,and voltage current shall be recorded keeping all Fan, Lights & both RMPUs on switched ON condition. Following shall be recorded manually. Apart from the recorded parameter manually, data shall be downloaded from ERRU through retrieval unit.

Clockwise Anti Clock wise Speed Output Voltage Field current Output Voltage Field current

800 1500 2500

Note: i) Above table shall be used for recording the parameters during

performance test at No Load, Half Load and Full Load tests while testing is conduced at workshop. However, performance in pit line field current may not be required.

ii) Performance test conducted as per RDSO spec. No.

RDSO/PE/SPEC/TL/0054-2003 (Rev.0) with Amendment 1& 2 for 4.5kW Alternator and spec. No. RDSO/PE/SPEC/TL/0056-2004 (Rev.0) with Amendment 1 for 25kW Alternator.

10.5.4 Parallel operation test:- This shall be conducted at base load (only one

compressor in ON condition), 50% & 100% of full load at 800 rpm, 1500 rpm & 2500 rpm , Voltage & current shall be recorded ,different of current between two alternator shall not be more than 30 A & 10 A with Alternator RRU & ERRU respectively. Speed Output voltage Total load Load current of Load current of


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Alternator 1 Alternator 2 800 1500 2500

Testing of Alternator before commissioning into the coaches as well as after

repairing at workshop, load bank and metering of load will not be required as at parameters will be measured from meters exiting into the coach and actual coach load will be present. Whereas after repairing at workshop, load bank as well as meters for alternator and load parameter measurements will be required.

Regenerative panel as a load bank to recover the power is required. For parallel

operation, there has to be one extra ammeter of range 0-1000 A DC range to measure total load current has to be upto 500 Amp. Regarding OVP test regenerative panel is not advisable because regenerative panel may trip during control open test, hence only trip setting of OVP can be verified for complete parameter of testing of OVP, resistive load bank is suitable.

10.6 Performance Characteristics:

Alternator

RPM DC Load on Alternator (Amps)

Alternator Field

Current (Amps)

RRU/ERRU O/P Voltage (Volts DC)

RRU/ERRU O/P Current (Amps DC)

% Ripple Factor in DC O/P Voltage

0% Load 25% Load 50% Load 75% Load

800

100% Load 0% Load 25% Load 50% Load 75% Load

1000


1500


2000

100% Load

10.7 Load Vs Output Voltage Characteristics:

Alternator RPM

DC Load on Alternator (Amps)

Alternator Field

Current (Amps)

RRU/ERRU O/P Voltage (Volts DC)

RRU/ERRU O/P Current (Amps DC)

% Ripple Factor in DC O/P Voltage


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0% Load 10% Load 20% Load 30% Load 40% Load 50% Load 60% Load 70% Load 80% Load 90% Load

100% Load 110% Load

1800

125% Load Note: The Graph between Output Voltage & Load at 1800 RPM should also be generated and printed automatically as shown bellow.

Alternator Load Vs Output Voltage Characteristics

90

95

100

105

110115

120

125

130

135

0 10 40 80 100 120 140 160 180 193 220 222 226

DC Load (Amps) *

DC

Vol

tage

(V)

*


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MAIN MENU AND SCREENS OF PC AUTOMATION

ALTERNATOR TEST PLAN NEW FILE HELP (F1) ABOUT OPERATIONS OPEN FILE SAVE FILE SAVE AS CLOSE

START STOP

DATE : 18/03/08

TIME: 15:10:00


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PERFORMANCE CHARACTERISTICS WITH % RIPPLR FACTOR

PLOT REAL TIME GRAPH FOR

PERFORMANCE CHARACTERISTICS

LOAD VS OUTPUT VOLTAGE CHARACTERISTICS TEST

CLICK APPROPRIATE BUTTON TO INITIATE TESTING


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ALTERN-ATOR RPM

DC LOAD ON ALTERNATOR

(Amps)

ALTERNATOR FIELD

CURRENT

(Amps)

RRU/ERRU OUTPUT

VOLTAGE

(Volts DC)

RRU/ERRU OUTPUT CURRENT

(Amps DC)

% RIPPLE FACTOR IN DC OUTPUT

VOLTAGE

0% LOAD

10% LOAD

20% LOAD

30% LOAD

40% LOAD

50% LOAD

60% LOAD

70% LOAD

80% LOAD

90% LOAD

100% LOAD

110% LOAD

1800

125% LOAD

LOAD VS OUTPUT VOLTAGE CHARACTERISTICS

PRINT


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ALTERNATOR RPM

DC LOAD ON ALTERNA-

TOR (Amps)

ALTERNA-TOR FIELD CURRENT

(Amps)

RRU/ERRU OUTPUT

VOLTAGE (Volts DC)

RRU/ERRU OUTPUT CURRENT

(Amps DC)

% RIPPLE FACTOR IN DC OUTPUT VOLTAGE

0% LOAD

25% LOAD 50% LOAD 75% LOAD

800

100% LOAD

0% LOAD


1500

100% LOAD

0% LOAD


2000

100% LOAD

PERFORMANCE CHARACTERISTIC WITH RIPPLE FACTOR

PRINT


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11.0 Reliability Test on AC test drive:

The equipment should be suitable to test the alternator continuously at full load condition for 24 Hrs.

AC Drive (single end extended shaft ) and test Panel for Workshop & Pit line Drive particulars:

SN Description Quantity Remarks 1 Motor 75kW (100 hp,

Voltage 415±10V, 3 phase, Variable speed 300 to 2500 rpm with 6 grooved pulley of dia 250 mm.

02 nos. For pit testing of AC coaches i.e Paralleling operation with separate AC drive so that complete redundancy and separate testing of alternator is ensured. It can be carried out both drives synchronized to run at same speed through a synchronization switch. For bench application i.e for testing of all types of alternators on bench i.e prior to mounting of alternator on under frame. Here the loading of the alternator will be through regenerative feed back where the output of the alternator can be fed back to mains and alternator can be tested at Various load conditions. This results in huge saving of the energy.

2. AC drive 75 kW (100 hp) 2 no. Test panel digital meter for workshop drive: DC Voltage meter range 0 to 200 V – 3½ digit One no. DC ammeter range 0 to 300 A - 3½ digit One no DC ammeter range 0 to 10 A – 3½ digit One no.

Motor input voltage 0-500 V AC -3½ digits One no. Alternator field current 0-20 A DC -3½ digits One no.

Alternator speed 0 – 2500 RPM Suitable watt-hour meter to measure input power from

mains One no. 0-50kW KW meter for each alternator output One no.


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Load Bank and Alternator suspension arrangement.

a) The load arrangement upto 230 A for each alternator along with the load switching panel should be available with Railways.

Along with the above the Provision of Alternator three phase On /Off and Field

On /Off through appropriate knife switches. b) Alternator Hanger arrangement with tensioning device and blower (to provide 6

m/s air flow towards alternator and Regulating Unit for cooling) and 6-groove pulley and belt architecture with prime mover / AC Motor to rotate the alternator from 800 RPM to 2500 RPM on full load (193 Amps). The motor may be required to be mounted beside the pit line and suitable drive has to be extended inside the pit to drive alternator. The following details shall also be considered necessary.

i) Plummer blocks, pulley and shaft arrangements for pit line testing rig. ii) Alternator and motor mounting with belt tensioning device iii) Erection and commissioning of complete system iv) Earthing – Two suitable earthing terminals should be provided on control

panel and motor separately.

Drive (Single End Extended Shaft) should be capable of taking full load 193 A and 130 V DC and rpm 800 to 2500 rpm of Alternator, AC drive and panel should have rpm meter to measure rpm.

No load (base load) test, half load and full load performance test at speed of

800, 1500 and 2500 rpm, shall be conducted, current limit may also be verified i.e. 230 A (max.) during testing at workshop.

• Single end Drive motor shall meet the requirement of IP 55. Suitable

arrangements shall be made to prevent ingress of water inside the motor during rains.

• Panel shall be mounted at plain surface near pit line or at other suitable place.

• One coach shall be tested, provided with 2 Alternator with RRU/ERRU (One in each side)

Each pit line & Workshop shall have two drives and separate control panel for controlling each drive.

12.0 APPROVAL BY USER RAILWAYS Prototype testing and approval of AC drive (complete setup) shall be done by the

user Railways after conducting the test on drive / panel with alternator and RRU/ERRU as per Clause 10.5 of this specification.

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government of india-ministry of railways research...

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