SPECIFICATION FOR DEVELOPMENT OF 3 PHASE INVERTER BASED MOTOR DRIVEN OIL FREE COMPRESSOR FOR HHP TYPE DIESEL

ELECTRIC LOCOMOTIVES

SPECIFICATION NO. DLW/DESIGN/MISC-199, Nove !e"-#$13

1.

SCOPE: The specification covers the general technical and testing requirements of 3 Phase inverter based motor driven oil free compressor for use on HHP type Diesel Electric locomotives being manufactured by D !. This is a general technical specification and does not cover all the necessary provisions of a contract. STANDARDS: This specification refers to the follo#ing standards $pecification %o. &$ '('):"**) Description +ode of practice for testing of positive displacement type air compressor &$ 1*(31:1,,( -eaffirmed .easurement of air flo# of compressors 1,,, &$ '/"/:1,/* -eaffirmed 0lossary of terms relating to compressors "**1 1$ 1'/1 2Part &&3: 1,/' .ethod for simplified acceptance testing 21,4(3 for air compressors &$5: 4'/36"**1 2E3 +ompressed air for general use &E+: )13/361,,16*1 -ail#ay applications 7 $hoc8 and vibration test &E+: )1"4/ Electronic po#er converter mounted onboard rolling stoc8 &E+: )*'/1 $pecific rules concerning the electronic control part of converters &E+: )13/' +ommunication interface compatibility requirements &$5: 1"1/ Displacement compressors 7 9cceptance tests &E+: )**3(61 -otating Electrical .achines 7 -ating : Performance &$5: "1'1 9coustics 7 %oise test code for compressors 7 Engineering .ethod 0rade6"; %oise level

".

3.

F%NCTIONS:

3.1 The purpose of air compressor is to compress the available air ta8en at atmospheric pressure to the pre6determined gauge pressure i.e. 1*.* 8g<cm" and also to maintain the pressure of that compressed air bet#een 4.* : 1*.* 8g<cm" in the main reservoirs of locomotive; to be used for train bra8ing and au=iliary equipment operation.

(. &.1 &.#

DESIGN FEAT%RES: The air compressor shall be 1**> oil free and shall be suitable for installation in any orientation. The compressor should be positive displacement; reciprocating type; t#o stage; air6cooled type. 9 cooling fan #ith a suitable protective guard shall be provided for induced draft or forced cooling of the compressor. The compressor shall be motor driven having a 3 phase inverter based motor drive arrangement. The po#er input to the motor #ill be provided from the +ompanion alternator output. The notch6#ise voltage and frequency of companion alternator output #hich can be used for compressor drive input at different notches is as under: No'() CA o*'+*' Vo,' &dle 1 " 3 ( ' ) / 4 (* )* /4 114 13' 1') 1/' 1,, ")' F"e-*e.(/ "* 3* 3, ', )/.' /4 4/.' ,, 13".'

&.3

&.&

The compressor motor drive arrangement should be capable of operating at different modes i.e. at different input frequencies and voltage combinations for utili?ation of the spare po#er available from the +9 output at different notches. The @9D 2@ree 9ir Delivery3 at idle notch should not be less than 4** P. #ith ma=imum po#er consumption as , A! and at 4th notch the @9D should be more than (4** P. #ith ma=imum po#er consumption of (/ A!. To meet the @9D requirements a ma=imum of t#o motor driven oil free compressors can be utili?ed. &ntercooler and aftercooler arrangements shall be an integral part of the compressor assembly and shall be mounted #ithin the unit envelope. The heat e=changers should be capable of meeting the final air delivery temperature requirement of not e=ceeding "* o+ above ambient #hen #or8ing at a pressure of 1*.' Ag<cm".

&.0

&.1

PERFORMANCE PARAMETERS: $.%o. 1. ". 3. Parameters @9D at &dle engine -P. Performance values B 4** P.

@9D at rated 4th notch engine B (4** P. -P. %oise level C /) db 293; (.) mtrs

&.2

.a=imum space : The compressor envelope dimensions should not e=ceed 13'* mm2 3 = /** mm 2!3 = ''* mm 2H3 2 D1* mm3 2e=cluding inverter module<control bo= dimensions3 .a=imum #eight of the compressor unit 2including motor drive arrangement; heat e=changers 2intercooler<aftercooler3; mounting rac8 etc.3 should not e=ceed ('* Ags. 2for one compressor unit3 The compressor should be designed for under slung mounting provision. The mounting arrangement should include suitably designed 9nti6 Eibration .ounting 29E.3 pads to minimi?e vibration induced forces on the assembly for better reliability and performance of the unit. The equipment shall #ithstand satisfactorily the vibration and shoc8 normally encountered in service as per &E+ )13/3 +ategory61 +lass61. The manufacturer shall submit supporting documents in this regard. M%LTIPLE %NIT OPERATION: Train line signals conveyed through the "/6#ire Fumper cable 2D/( E D+ on6off e=cept po#er reduction pin and dynamic bra8e e=citation pin having * 7 /( E D+3 through #ires designated as : 1. $pare ". 9larm 1ell 3. GDH 0overnor $olenoid (. %egative Eoltage +ommon '. $pare ). .ain 9lternator @ield /. G+H 0overnor $olenoid 4. -everse ,. @or#ard 1*. !heel $lip &ndicator 11. $pare 1". G1H 0overnor $olenoid 13. +ontrol +ircuits : @uel Pump 1(. TE limit

&.3

&.9

&.1$

1'. 1). 1/. 14. 1,. "*. "1. "". "3. "(. "'. "). "/.

G9H 0overnor $olenoid Engine -un Dynamic 1ra8e +ontrol $pare $pare Dynamic 1ra8e !arning Dynamic 1ra8e &nterloc8 $pare .anual $and Dynamic 1ra8e E=citation A4" Co +"e55o" Co.'"o, $pare $pare

The 9ir +ompressor +ontrol signal #hich currently activates < de6activates .E++ as per the command given by ++ based on .- pressure values is available at pin "'. The purpose of carrying this command on train line is to enable use of air compressors on each unit to act as one to share the load and increase the capacity of the air system. D ! can use t#o compressor units on a HHP locomotive to meet the @9D requirement. +ompressor manufacturer #ill have to provide interface bo= 2intelligent control module3 #hich should have an interface #ith companion alternator output 2for estimating the spare po#er available3 and #ith ++ for .E++ signal for s#itching6on and s#itching6off of the compressor motor. The control unit should be capable of sequencing the operation of compressors #ith an aim to distribute the running of compressors evenly bet#een the t#o compressors. &n synchronous running mode 2in multiple consist operation3 the compressor run signal generated by leading loco and transmitted through train line to the trailing loco #ill be used to drive the compressor units on all the trailing locomotives. HHP locomotives have a computer controlled circuit for full compressor synchroni?ation #ith any other microprocessor controlled locomotive that are trainlined. !hen the .ain reservoir air pressure is belo# the lo#6 pressure limit 2called P 59D3; the ++ sends a signal out +H61(; D&563 #hich causes pic86up of the compressor synchroni?ation relay; +.P$I%. This provides a Gcompressor request to loadH signal 2+- 3 to the ++ 2+H614;D&5633 as #ell as trainline signal 2"'T3 to activate any trailing unit compressors. &n addition; +.P$I% provides the compressor synchroni?ation relay verification input signal 2+H 1";D&5633. 9fter a programmed period of time; the computer drops the output signal 2+H 1(;

D&5613; dropping out .E++. This causes the compressor to load; including #hen .E++ fails. %ote that #hen the locomotive is in trail; the input signal +- is activated via the "'T input and T @ 2Trainline @ilter .odule3. This singular input also tells the ++ that it is in trail and should load the compressor; providing that the .-PT setting on that particular trailing locomotive is belo# the lo# pressure limit. !hen coupled to locomotives not equipped #ith synchroni?ation; the ++$ 2+ompressor +ontrol $#itch3 #ill automatically start the compressor pumping #hen lo# main reservoir pressure is sensed. The signal from main reservoir pressure transducer 2.-PT3 #hich is read bet#een .ain -eservoir 1 and .ain -eservoir "; is sent to ++. &f the pressures of the main reservoirs are belo# ,.1( Ag<cm" 213* psi3 in leading loco and ,.(, Ag<cm" 213' psi3 in trailing loco; the ++ using the same circuit as compressor synchroni?ation; drops out the .E++ 2.agnet valve compressor control3 and activates the compressor. !hen the .pressure reads ,.4( Ag<cm" 21(* psi3 in leading loco and 1*.1, Ag<cm" 21(' psi3 in trailing loco; the ++ shuts off the output signal for the +.P$I% circuit; causing the +.P$I% relay to drop out. !ith the +.P$I% contacts open; the +- signal from "'T trainline and the D&5 input is removed. !hen ++ sees this combination of factors; .E++ is pic8ed up; allo#ing compressor to start loading. The vendor intending to supply this item should be a reputed compressor manufacturer #ho in turn can collaborate #ith motor and inverter manufacturers and also integration e=pert organi?ations for integrating the complete 3 phase inverter based motor drive arrangement for compressor and having an intelligent module < control unit for load sharing bet#een the compressors and s#itch6on < s#itching6off the consist based on po#er availability and functional mode < @9D requirements. 0.$$ SERVICE CONDITIONS: The compressor shall be capable of #or8ing satisfactorily under the service conditions indicated belo#: $.%o. 1 " 3 ( Parameters 9ltitude -elative Humidity Temperature 29mbient air3 9mbient conditions Description 9n altitude bet#een * and 1*** meters above mean sea level Jpto 1**> in rainy season 6' to '' o + The compressor shall be capable of operating efficiently inspite of dust; dirt;

mist; torrential rain; heavy sand or sno#; storms; presence of oil vapors and heat etc. to #hich the rolling stoc8 is normally e=posed in service. 1.$ D*'/ (/(,e: The compressors are subFected to run for an average of "" hours a day. The compressor must be able to give satisfactory performance at 1**> load of 1* bar Te5'4.6: The obFective of the tests is to ascertain the reliability; performance potential and quality requirement of complete compressor unit. The prototype tests shall constitute the follo#ing series of tests and measurements: 2i3. Dimensions 2ii3. +apacity measurement test 2iii3. Po#er consumption test 2iv3. Endurance test 2v3. High environmental temperature test 2vi3. Kuality of compressed air vii. !eight measurement. &n addition; the acceptance tests specified in various standards applicable for acceptance tests and performance reliability requirements mentioned under Para " of this specification #ill also be done #hile underta8ing type testing. Prototype testing shall be conducted Fointly by D ! and .otive Po#er Directorate of -D$5 and the firm shall provide all necessary assistance for inspection and testing of 36phase inverter based motor driven oil free compressor free of cost. Ho#ever; if any vendor is offering a proven compressor #hich has already passed the type testing and is already #or8ing in rail#ays 2 ocomotive application3 for similar @9D rating any#here in the #orld; D !<-D$5 reserves the right to #aive6off the type test for the offered compressor. Ho#ever; the inverter #ill have to be type tested as per the specified standards. F4e,7 '"48,5: 5n satisfactory completion of prototype tests; the compressor shall be subFected to field tests<trials for a period of 1" months. M8"94.6: The compressor shall have proper mar8ing on a nameplate for at least follo#ing information: 2i3 .anufacturerLs name 2ii3 Type : serial no. 2iii3 +apacity 2@9D3 in P. at rated -P. 2iv3 .onth : year of manufacture.

2.$

3.$ 9.$

1$.$ A((e55o"4e5: The compressor unit shall be fitted #ith the follo#ing accessories: 2i3 2ii3 2iii3 2iv3 2v3 Dry type air filter for suction and an indication to indicate the level of carboni?ation < bloc8age of filter element &ntercooler safety valve and drain coc8 9ftercooler; fitted #ith auto drain valve @le=ible pipe for use on delivery side; #hich shall be capable of #ithstanding the delivery of hot air temperature $uitable resilient mount of proven design

2vi3

$uitable safety sling to prevent the compressor from falling in case of failure < brea8age of the mounting arrangement

11.$ Ge.e"8, Co.74'4o.5 :o" I.5+e('4o. ; Te5'5: 11.1 9ll tests shall be conducted at .anufacturerLs premises. 9ny shortcoming or defect noticed during the type test shall be pointed out to the manufacturer by the D !<-D$5 or his representative to enable him to incorporate the necessary improvements before bul8 manufacture is commenced; #ithout affecting the guaranteed deliveries or guaranteed performance characteristics. 11." 9ny additional tests trials; if considered necessary by the D !<-D$5; shall also be arranged by the supplier free of cost. 11.3 The D !<-D$5 or their representative shall have access for stage inspection; to those portions of the manufacturerLs #or8s in #hich production is being carried out and #here the testing is ta8ing place. This also applies to the items procured from sub6suppliers. 11.( The D !<-D$5; at the time of inspection; shall have the po#er to as8 for additional information and<or tests he may consider necessary to satisfy him that proper materials and parts specified are actually used during the manufacture of the compressor. 11.' The manufacturer shall provide labour or appliances required by the D !<-D$5 Engineer; free of charge; for inspection and testing of the compressor and its components; as required. 11.) &f any part of the compressor unit requires alteration or any defect appear during the tests or trials; the supplier shall; #ithout any e=tra charge; ma8e such alterations or rectify the defects to the satisfaction of the D !<-D$5 engineer or their representative. 11./ 9ny modification or alteration to the components during the supply of the order shall be made only after the approval of the D !<-D$5 Engineer. The unit after such modifications < alterations shall be subFected to such tests as considered necessary by the D !<-D$5 Engineer. 11.4 Minc yello# passivation < 1lac8ening shall be done on all hard#areLs. 1#.$ SPARES:

9long #ith the quotation for supply of air compressor the tenderer shall also furnish a recommended list of spares for t#o years and quotations thereof. The tenderer shall also agree to hold the price of spares for a period of one year from the date of supply of the compressor. 13.$ INFORMATION TO BE F%RNISHED BY THE TENDERER< Data as per 9nne=ure & : && shall be furnished by the tenderer along #ith their K9P for this item. 1&.$ TOOL =IT: The price for tool 8it for the maintenance of the compressor shall be indicated separately; along#ith the tender. 10.$ MAINTENANCE MAN%ALS < The tenderer shall supply copies of e=haustive; fully illustrated manuals covering among other items; the follo#ing vital details; to the GEngineerH #ith the tender. 1. ". 3. (. '. ). Description and arrangement Technical data Dismantling and assembly instructions +ommissioning instructions Periodical inspection schedules Periodical maintenance instructions along #ith trouble shooting instructions /. Testing procedure for the equipment and other au=iliaries 4. !ear limits for vital components ,. Detailed parts catalogue #ith description of items. The parts shall be detailed by s8etches to facilitate ordering 1*. &nstructions for reclamation of #orn out components 11. ist of special tools #ith instruction for use. T#o copies of the maintenance manual shall be supplied #ith the quotation. 5ne copy of the manual shall be supplied #ith every 1* compressor sets or a part thereof. 11.$ TRAINING < The supplier shall provide facilities for free training of the rail#ay maintenance staff at their #or8s on aspects of maintenance; overhaul and testing of the compressor.

12.$ SPECIAL CONDITIONS< 1. 9t the time of approval of the prototype unit the manufacturer < supplier shall furnish the list of names and addresses of their $ub6supplier of the main items of the equipment and important ra# materials #hich they have used in the prototype unit and shall not ma8e any changes in the sources of supply #ithout prior approval of D !. ". 9fter successful completion of the type test the compressor shall be subFected to e=tended field trial for a minimum period of 1" months before according the prototype approval. 13.$ FINISH< The compressor motor set shall be suitably treated to remove rust and should be coated #ith antirust primer and finished #ith t#o coats of light grey or blac8 paint as per &$ ':1,,(. 19.$ SERVICE< 5verhauling period: 5verhauling period of the complete compressor and motor assembly along #ith the inverter drive arrangement should not be less than si= years. The units should #or8 satisfactorily in the filed #ithout failure < dismantling of any component. #$.$ >%ALIFYING CRITERIA< The tenderer shall meet the qualifying requirements listed belo# and submit the documents in support thereof; along #ith the proposal. The tenderer meeting any one of the follo#ing criteria shall qualify: a. Tenderer having a proven technology and minimum one year service e=perience of oil free compressor of similar @9D to &ndian -ail#ays for locomotive application or for other rail applications. b. Hundred or more of the offered compressor should have been in service any#here in #orld for rail applications for at least ' years. The supplier shall submit the details along #ith the reference list.

ANNE?%RE - 1 BROAD TECHNICAL FEAT%RES OF THE COMPRESSOR 1. Type; ma8e and model #. 0raph sho#ing free air delivery 2@9D3 against 4; , and 1*.' Ag<cm" at 1**> duty cycle and ma=imum rated speed 3. Displacement at rated r.p.m. &. Horse po#er consumption at rated capacity and speed against 4; , and 1*.' Ag<cm". 0. .a=imum permissible temperature at inlet and e=haust ports 1. !eight of the unit complete #ith accessories 2. Details of drive arrangements 3. Details of couplings 2if used3 including alignment data and method of chec8ing alignment 9. Details of mounting arrangement #ith overall dimensions 1$. 5verall space requirements; inclusive of all accessories for the compressor. 9ny additional space required for removal of valves in position; attending to air inlet filters etc. shall also be indicated. ayout dra#ings shall be supplied 11. ist of maFor #earing components and their e=pected life 1#. +omplete details of resilient mounts

ANNE?%RE-II GENERAL DATA OF COMPRESSORS 1. Type; ma8e and model ". Details of Technical collaboration; if any 3. 1asic design data +ylinder arrangement %o. of P cylinders %o. of HP cylinders P cylinder bore dia 7 mm HP cylinder bore dia 7 mm E=pected life of cylinder E=pected life of piston %o. of P piston rings %o. of HP piston rings E=pected life of piston rings Details of inlet : e=haust valves and their e=pected life $tro8e length 7 mm Piston speed 2ma=.3 Head clearance -atio of compression per stage 9ir temperature at P discharge and intercooler discharge and final delivery at rated capacity and 4;, and 1*.' Ag<cm" #ith inlet temperature range upto )*o+ Dimension; material specification; heat treatment and method of manufacture of: Piston; Piston -ings; Ealves; +ylinder Heads; +ran8 $haft; +onnecting rods : +ran8 pin

(. $tarting : running torque required for the compressor against a bac8 pressure of 1*.' Ag<cm" '. Type; details of suction air filter used in the compressor. &ndicate filtering efficiency and dust retentively. ). .aterials : specifications used for gas8ets /. ocation of rubber or synthetic sealing media; if used

4. Details of cooling fan; fan guard including mounting dra#ings

,. Details 2#ith overall dimensions3 of coupling used. The permissible limits of misalignments and guaranteed trouble free service life shall also be indicated 1*. Type; specifications; ma8e and average life of main and connecting rod bearings 11. Type; details and #or8ing of 2i3 &ntercooler safety valve 2ii3 9uto drain valve 1". Type; specification; ma8e and average life of resilient mount. .ounting and maintenance details of resilient mount.