DRAFT SPEC For OCB UNIT 09 05 16
DRAFT SPEC For OCB UNIT 09 05 16
DRAFT SPEC For OCB UNIT 09 05 16
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lR;eso t;rs
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
Issued on XX/XX/2016
Approved by Signature
EDSE(Co-ord)
ELECTRICAL DIRECTORATE
RESEARCH, DESIGNS & STANDARD ORGANISATION
MANAK NAGAR, LUCKNOW – 226 011
Status of Revision
2.
3.
INDEX
Sr No Item Page no
Page nos. will be put
1 Scope after finalization of
specification.
3 Reference Standards
4 Technical Particulars
5 Service Conditions.
8 Finish
9 Inter-Changeability
10 Marking plate
11 Maintenance Instructions
12 Drawings
13 Data
14 Tests
15 Field Trial
16 List of Drawings
1.0 Scope
1.1 This specification covers the performance requirements and tests of Oil Cooling Unit(OCU)
with Centrifugal Design Impellers for transformer/converter fitted in 25 KV AC/50 Hz 3
phase drive electric locomotives.
1.2 Oil cooling unit includes following.
- Blower casing
- Mounting Base
- Blower including 3 –phase asynchronous motor
1.3 Each locomotive is equipped with 3 auxiliary converters each rated at 100 KVA. These
converters directly gets supply from a common auxiliary winding of 1000 V (corresponds to
25 KV catenary voltage) from the main transformer. The three phase output voltage of the
auxiliary convertor 1&2 feeds variable voltage and variable frequency to the oil cooler unit in
3 steps (17 HZ, 33HZ, and 50 HZ) by the control electronics which gets signal from the
temperature sensors in oil cooling unit circuit.
1.4 The vendors who were approved as per CLW specification no. CLW/ES/3/0647 Alt. E will
remain approved as per this specification also till the currency of their approval.
2.0 Terminology, symbols and units.
For the purpose of this specification, the definitions given in IS: 4894 and shall apply.
3.0 Reference Standards
In preparing this specification assistance has been taken from the following specifications.
IS: 4894 - Specification for centrifugal fans.
IS: 4729 - Measurement And Evaluation Of Vibration Of Rotating Electrical Machines
ISO-1940 - Specification for dynamic balancing.
IEC 61373 -Shock Vibration level test
4.0 Technical Particulars
The technical particulars of oil cooling unit is given under Annexure-I.
5.0 Service Conditions.
5.1 The equipment and mounting arrangement shall be of robust design for traction duty and shall
withstand satisfactorily the vibration and shocks normally encountered in service as indicated
below:
5.1.3 The level of harmonics in three phase electric locomotives is of the order of 50% each for
voltage & current.
5.1.4 Climatic and environmental conditions
Atmospheric : Maximum temperature of metallic surface under the Sun:
temperature 75oC and in shade: 55oC
Minimum temperature: - 10oC ( Also snow fall in certain
areas during winter season)
Humidity : 100% saturation during rainy season
Reference site : i) Ambient temperature: 50oC .
conditions ii) Humidity: 100%
iii) Altitude: 1776 m above mean sea level
Rain fall : Very heavy in certain areas.
Atmospheric : Extremely dusty and desert terrain in certain areas. The dust
conditions concentration in air may reach a high value of 1.6 mg/m3. In
many iron ore and coal mine areas, the dust concentration is
very high affecting the filter and air ventilation system
Coastal area : humid and salt laden atmosphere with maximum pH value
of 8.5, Sulphate of 7 mg per liter, maximum concentration
of chlorine 6 mg per liters and maximum conductivity of
130 micro Siemens / cm
Wind speed : High wind speed in certain areas, with wind pressure
reaching 150 kg/m2
6.0 Design and general construction
6.1 Drive and coupling
The fan impeller shall be directly mounted on the motor shaft. A steel/Aluminium boss of
circular shape should be cast/rolled and fixed with welding/brazing to Aluminum impeller
(centrifugal design). The drive may be by a key of adequate strength with the impeller locked
in position shall be further locked against, unscrewing in service by locking plates.
Alternatively a tapered shaft without a key but with locking arrangement by bolt and locking
plate may be used.
6.2 Direction of rotation
An arrow indication the direction of rotation shall be permanently marked on the blower
casing.
6.3 Balancing
The rotor and the blower impeller shall be dynamically balanced individually, in quality grade
G 2.5 of ISO-1940.
6.4 Vibration: The vibration level when blower is coupled with motor shall not exceed 25 micron
(peak to peak) on motor bearing and 40 micron (peak to Peak) on the blower casing.
6.5 Lifting arrangements
Suitable lifting arrangement for the blower fan and the motor separately and for the complete
unit shall be provided.
Casing should be of heavy duty industrial design and shall be of mild steel with minimum
thickness of 5 millimeter or Aluminium alloy of suitable thickness. It should not deform during
lifting. It should be of single side intake having Mixed flow form with axial intake direction
and radial discharge direction with centrifugal impeller flow fan. The inlet cone (if required)
shall be manufactured by spinning .The inlet cone shall not be manufacture by welding ,it shall
not be hammered to give the cone shape. Inlet cone shall be die formed. Welding shall be
avoided on shroud portion of impeller. All outside welds of the housing should be welded
continuously, The welding shall be done by the qualified welder; casing shall be designed as
per existing arrangement of centrifugal fans provided on 25 KV ac electric locos type WAP-5
& 7 /WAG-9.
7.3 The mounting arrangement of the blower on the casing shall be properly secured so as to avoid
loosening during the vibrations countered in service.
7.4 Centrifugal Impeller can be fabricated /casted. The dimension in the drawing placed as
Annexure –IX is for reference, diameter of impeller shall not be more than 710 mm.
8. Finish
The fan motor, the blades and the casing shall be suitably treated to remove rust and should be
coated with an anti rust primer and finished with two coats of battle ship grey synthetic paint.
All hardware’s shall be zinc plated.
9. Inter-Changeability
The motor, impeller and casing shall be interchangeable with other make such that the
performance of the oil cooling unit is kept within the limits of the standard.
10. Marking plate
Each Oil cooling unit shall have a suitable name plate having the following information
engraved/punching on it:
i) Manufacturer’s name, type and serial number.
ii) Air delivery
iii) Total head at 200C.
iv) Rated speed.
v) Make of the motor
vi) Power consumption in ‘KW’.
vii) Impeller diameter.
viii) Weight of the unit.
ix) Manufacturing date and year.
x) Impeller serial number , manufacturing date & year to be punched /etched on
steel /Aluminium boss
14. Tests
14.1 General
Testes are classified as type and routine tests.
14.2 Type & Routine tests on Motor
The type & Routine tests on prototype Motor shall be conducted as per RDSO specification
no. E-10/3/09(Motor) with Amendment no.1, 2, 3, 4, & 5.
14.3 Tests on Oil Cooling Unit
The following are the different tests on the complete Oil Cooling Unit with casing.
a) Type Tests
i) Air delivery test.
ii) Starting time test.
iii) Starting duty test.
iv) Endurance test.
v) Shock Vibration level test in line with IEC 61373.
vi) Weighment
vii) Checking of bearing by shock pulse meter.
viii) Checking of dimensions, workmanship, clearance of impeller fixing and locking
arrangement.
ix) Starting current , running current ,starting time at full load at
- 373V, 33Hz
- 415V, 50Hz to be recorded.
x) The balancing of rotor with impeller shall be done and to be witness by inspection
officials. The balancing shall conform to grade 2.5of ISO-1940.
xi) DPT on impeller welding shall be witness by Inspecting officials.
xii) Noise measurement at a distance of one meter from the equipment in all direction.
b) Routine Tests
i) Checking of obligatory dimensions and clearance of impeller fixing and locking
arrangement.
ii) Starting time test
iii) Vibration level test
iv) Condition of bearing by shock pulse meter.
v) Visual check workmanship and DPT on impeller welding to be done which shall
include checkup of welding, painting, workmanship etc.
vi) Noise measurement at a distance of one meter from the equipment in all direction.
Unless otherwise specified in the contract the test and the method of measurement adopted
shall comply within Indian standards specifications for centrifugal flow fans.
ANNEXURE-I
3. Starting performance: The blowers shall accelerate from stop to the full speed within 6
seconds over the entire range of supply voltage i.e.415±10%.
5. The centrifugal flow fans covered by this specification are capable of working against
pressure.
ANNEXURE-II
Coefficient of discharge, Cd
Cd2
Motor efficiency (%)
Volume at rated Q1
speed in m3/s,Q2 3600
Outlet Velocity(VO) Q1
at rated speed, m/hr Outlet Area
Velocity Pressure at 1.2 X(VO/16000)2
Outlet at rated speed
and temp, Vpo
Record details of equipment’s used and their calibration due date .Calculation is to be carried out from
observed values as per above formula .
ANNEXURE-III
Data sheet for Oil cooling unit
1. Blower
A.2 Air delivered in cubic meter per minute and total head in mm WG corrected to 200C and 760
mm barometric pressure at rated voltage
Note: - GD2 value of the impeller will be made use for calculating the starting performance of
the blower with regard to the specified electric motor. As such the value to be
furnished should take into account the inertia, the friction and the resistive torque of
the impeller while it is being started.
A.4 The manufacture shall furnish the speed- torque characteristic of the blower. This is required
for matching the motor and the impeller.
A.5 Torque necessary for the blower when working against constant rated head and delivering
the rated output.
A.6 The supplier shall enclose the following characteristic curves at 200C and 550C.
a) Total and Static head vs. air delivery.
b) Total and Static efficiency vs. air delivery.
c) Air horse power vs. air delivery.
d) Power absorbed vs. air delivery.
e) Speed vs. Air quantity in m3/sec.
A.8 Furnish the welding strength calculation for the joint between impeller and back plate and
cone.
A.9 Calculation for locking strength calculation for impeller locking arrangement and key
strength.
A.10 Necessary dimensioned drawings of the blowers and its all components showing the
constructional and material specification as per IS or any other relevant international standard
for assembly details shall be submitted.
1 Application
2 Type
3 Rated voltage
4 Number of phases(Star/Delta)
5 Frequency
6 Speed
7 Continuous rating(HP/kW)
8 Rated current
a)At rated voltage (415V)
b)At lowest voltage(373V)
9 Slip at full load in percentage at-
a) Rated voltage (415V)
b)Lowest voltage(373V)
10 Class of insulation
11 Type of enclosure
12 Method of ventilation
13 Type of protection
14 Frame size
15 Overall dimension
16 Type & make of bearing
17 Size of bearing and their estimated L10 life
18 Weight of the motor
- Weight of rotor
19 Rotor construction
20 GD2 value of the rotor(indicate the maximum variation)
21 Starting current and torque in kgm
a)at 373 V
b)at 457 V
c)at 415 V
22 Any deviation from the specification indicating reasons thereof may please be explained.
23 Corona resistant winding wire used as per amendment no 3
Annexure-IV
Annexure-V
Annexure-VI
Annexure-VII
Annexure-VIII
Annexure-IX