SCHEDULE OF TECHNICAL REQUIREMENTS FOR...

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GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

SCHEDULE OF TECHNICAL REQUIREMENTS FOR REPAIR / OVERHAUL / REHABILITATION OF

3-PHASE AC TRACTION MOTORS OF BROAD GAUGE DIESEL-ELECTRIC HHP LOCOMOTIVES

STR No. MP.STR.EM.01.02.14 (Rev.- 00) JUNE’ 2014

Issued by MOTIVE POWER DIRECTORATE

RESEARCH, DESIGNS AND STANDARDS ORGANISATION MANAK NAGAR, LUCKNOW- 226 011

STR for Repair / Overhaul / Rehabilitation of AC Traction Motors of BG DE HHP locomotives

STR No.MP.STR.EM.01.02.14 (Rev.‐00) June’2014 Page 1

1. Objective: This STR will serve as “Guidelines for repair / overhaul / rehabilitation of AC traction motors of BG diesel electric HHP locomotives” by eligible firms.

2. Description of Traction motor: 2.1 AC Traction motor used in the existing EMD locomotives is a four-pole three-phase

asynchronous induction motor. The original traction motors were supplied by M/s Siemens having model no: 1TB 2622 OTA02/OTB02 and 1TB2525OTA02/OTB02 & therefore, is OEM for these traction motors.

However, motors equivalent to these motors have been supplied by several other manufacturers also whose details are given in Clause 4.3 below.

2.2 Relevant Specification: The traction motors used on the EMD locomotives upto

4500 HP are procured as per RDSO specification no: MP.0.2400.52 (Rev.- 02) July’2013 or latest version.

3. Traction Control Equipment:

The functional details of the traction control equipment and system for locomotives up to 4500hp shall be governed by RDSO specification no. MP.0.2400.43 (Rev.- 05) May.’ 2013 or latest version.

4. General 4.1 The available details of the traction motor have been furnished in the above

mentioned specification. The vendor may study the design and application properly in order to understand the product and its end use.

4.2 It must be understood that IR may not have all the relevant design / manufacturing

details of the traction motor. 4.3 At present, following makes & models of 3-phase AC traction motors are in service

over IR for BG DE HHP locomotives or similar types of locomotives likely to be deployed in service:

Loco type where used

4000 HP (WDG 4) 4000HP (WDP4) 4500HP(WDG4B/WDP4B)Motor OEM Motor Model nos. M/s Siemens 1TB 2622-OTA-02 1TB 2525-OTB-02 1TB 2622 - OTA-02 &

1TB 2525 - OTA-02 M/s EMD A 2916-8 M/s Yongji YJ 157A However, the Vendor Directory in force may be referred to know the actual status of the vendors (Part – II & Part - I)

4.4 RDSO has modified the rotor over hang design of a particular make of traction motor to minimize the failures of rotor bars. In case, those types of motor which are already in service require repair to the rotor, the firm shall be able to modify the rotor as per the drawing attached (in case the rotor is not already modified) as per the tender condition. One sample drawing of the modified rotor is placed at Annexure-V.



4.5 The firm shall have established credentials for manufacture / repair / rehabilitation of AC traction Motors of equivalent capacity. The firm should have manufactured / repaired / rehabilitated at least 100 AC TMs of equivalent rating which have put up atleast average proven service of 02 years.

4.6 RDSO approved sources for the manufacture of the AC traction motors for HHP

diesel electric EMD loco, or their partly owned subsidiaries, recommended by them, would be automatically eligible for the repair / rehabilitation of the traction motors. OEM firms shall establish the repair facilities in India for undertaking repairs, either in their own name or as a subsidiary with a suitable Indian partner. OEMs may take major components like stator assembly and rotor assembly to their premises abroad till such time facilities are developed in India. However, dis-assembly, assembly & testing facilities must be available in the repair unit in India.

4.7 The firm shall be required to adhere to all the relevant specifications & drawings of

OEMs (to the extent available with RDSO) of the traction motor, RDSO specifications & STR, relevant IEC / NEMA / IEEEC Standards etc. Deviations, if required, shall be clearly brought out in the tender itself and applicable only after the approval of RDSO.

4.8 Spares listed in RDSO specifications shall be used from approved sources indicated

in RDSO Vendor Directory only. 4.9 Except repairs, manufacturing of mechanical components, all major repair /

manufacturing need to be carried “in-house”. Details of out-sourcing need to be mentioned alongwith QAP in the offer. These sublet vendors for the mechanical components shall be reputed firms having ISO certification & good quality systems. If required, RDSO may examine the facilities / quality systems of sublet vendors.

4.10 The activities out-sourced shall be clearly spelt out by the firm in the QAP. RDSO

would examine the extant of outsourcing and may permit for a particular period of time based on merit of the case.

4.11 The proposed repair / overhaul / rehabilitation activity shall not change the basic

design parameters of the traction motor and the motor must remain compatible with the locomotive traction control equipment / systems in use over IR and interchangeable with the existing traction motors.

5. Scope of work: 5.1 The scope of work is to carry out repair / overhaul / rehabilitation of AC traction

motors of EMD locomotives and service support back up for issues related to the supply of spares and any other contractual condition of contractual agreement and terms that are defined elsewhere in this document.

5.2 Generally, the scope of repair & rehabilitation shall be jointly decided between consignee & the contractor / firm carrying out the work at the time of work allotment. To identify the motors that are suitable for repairs / overhauling / rehabilitation, all motors shall be jointly inspected between the user railway and the firm at Railway premises and scope of repairs / overhauling / rehabilitation shall be jointly noted down.

However, the major activities involved in the scope of repair are as under:



De-assembly of the traction motor for examination of various component / sub- assemblies.

Thorough cleaning and checking of components. The condition of the components / sub-assemblies shall be established by measuring the crucial test parameters of component / assemblies.

Identification of the component / sub-assemblies requiring repair duly identifying the extent of repair.

Identification of the component / sub-assemblies requiring complete replacement.

5.3 Repair work to be carried out: The repair work of 3 phase traction motors consists of the following activities:

(A) Rewinding of stators: 1. Removing old winding from stator, 2. Cleaning of stator core 3. Checking of core for any damage. 4. Core loop loss test 5. Implementation of stator modifications if any 6. Manufacturing of stator coils 7. Placement of coils in stator core. 8. Placement of slot wedge 9. Brazing of joints 10. Bracing and final finish of overhangs 11. VPI of stator

(B) Repair of rotors: 1. Removing of rotor bars and resistance ring from rotor core. 2. Cleaning of rotor core 3. Core loss test 4. Checking of shaft dimensions 5. Modification of rotor core as per modified design, if unmodified e.g.

Replacement of any mechanical component e.g. end ring, stamping type resistance ring etc. as per design to be adopted.

6. Placement of rotor bars and resistance ring as per modified design to which rotor is to be repaired

7. Mechanized brazing of rotor bars and resistance ring 8. Swaging of rotor bars 9. Balancing of rotors.

(C) Replacement / Rehabilitation of mechanical components: 1. All mechanical assembly components e.g. stator chambers, end frames,

bearing assembly components etc. are not supposed to be repaired but replaced. The same are to be procured in Kit from RDSO approved sources only.

2. All assembly components to be used as per latest drawings / modification sheets.

5.4 The firm shall have to develop a standard work process sheet for all major repairs &

all actual repairs shall be conducted as per the plan. The detailed plan shall indicate work to be carried out at the ancillary unit and the main manufacturing unit of the firm. The firm shall have to submit details of work plan for repair of these motors.



The work plan shall include the following: Motor Sl. No.

Repair required (As per joint report)

Work process

Test protocol

Acceptance Criteria

6. Quality Assurance Plan (QAP): 6.1 The firm shall prepare a detailed Quality Assurance plan (QAP) followed by them for

repair / manufacture of traction motor at their existing plant as per RDSO’s format (as described in Para 5.1.8 of Guidelines for Vendor Approval MP-G-7.1-1 Ver.8.0 or latest) before approval is sought and submit the same as part of compliance of this STR.

The QAP shall be a comprehensive document covering the following aspects:

i) Details of Quality Control Organisation of the firm along with key personnel engaged in the QC function.

ii) Quality Assurance Process of incoming materials used for the subject items. iii) Process Flow Chart indicating process of manufacture for an individual product

or for a family of products if the process is same. iv) Quality Assurance System – Inspection & Testing Plan including the stage

inspection. v) Calibration scheme and status of calibration of equipments used in the quality

process.

6.1.1 Calibration of testing / measuring equipments or instruments:

1. Calibration of the testing / measuring equipments / instruments should be done at least once in a year unless stated otherwise.

2. Inspection staff conducting non-destructive testing shall be adequately trained and qualified by recognized agency and shall have adequate experience.

3. Staff conducting tests likes chemical Analysis and mechanical properties shall have adequate skill & components and shall have under gone sufficient training. Skill of such staff shall periodically be qualified by making them carry out tests in blind samples.

6.2 Process of Repair:

1. Complete Process Flow Chart covering all steps of process of repair for an individual product (or for a family of products if the process is same) shall be clearly enlisted as a part of QAP.

2. The following details of machines used for all the steps of machining operations should be included. a) Make and model of the machine b) Accuracy c) Details of machining operations

3. Details of Jigs and fixtures used during manufacture should be furnished along with the manufacturing process wherever used.

4. List of typical M&P required for repair / rehabilitation of traction motor is furnished in Annexure- I. The list is for general guidance only and actual manufacturing operations shall be submitted and got approved by the firm as a part of QAP.

5. The list of testing and measuring instruments are furnished in Annexure-II & III respectively for general guidance only. However the specific Testing & measuring instruments, gauges used by the firm will also form part of QAP, which shall be submitted and got approved.



7. Final Testing: 7.1 Motors involving only mechanical repairs viz. replacement of bearings, end fittings

etc. shall be subjected to routine test & field trials as per Para 8 of this STR. 7.2 Routine Testing:

All repaired / overhauled / rehabilitated motors shall mandatorily undergo routine testing as per IEC-60349 (Part 2) to ensure compatibility with the existing motors and the values obtained against the various parameters shall be as per the list given at Annexure – IV. The test reports shall be preserved for scrutiny of independent inspecting agency. The type test parameters / test values are not a part of this document and shall be obtained by the tenderer from RDSO/LKO who qualifies technically in the bid.

7.2 Type Testing: 7.2.1 The first overhauled / repaired / rehabilitated traction motor of each type / model

involving electrical repairs of each type viz. stator winding failure, rotor failure etc. shall be subjected to type testing separately as per IEC - 60349 (Part 2) or an approved test schedule to ensure matching of characteristics with the original motor. Thereafter, these motors shall be subjected to mixed field trials with existing motors as per plan given in Para 8 of this STR.

Type testing of the repaired / overhauled / rehabilitated motor shall be witnessed by

RDSO/IR personnel. 7.2.2 Type tested motors shall go under compatibility test on a locomotive to ensure the

compatibility with the existing traction motors and locomotive control system as per Para 8 of this STR. Rest of the motors shall undergo routine testing.

8. Field Trial Plan: Three motors shall be fitted with two nos. of AC-AC system each and shall be run for

three months. After successful trial, the firm shall be cleared for repair of balance lot. 9. Warranty: 9.1 All newly repaired / overhauled / rehabilitated traction motors shall remain under

warranty for a period of 24 months from the date of fitment or 36 months from date of supply.

9.2 Repeated failures of certain nature shall be classified as design / process defect of

the particular component repaired / rehabilitated and the firm shall have to address this problem at it’s own cost on all the motors irrespective of warranty status.



Annexure – I

LIST OF MACHINERIES / MANUFACTURING (M&P / T&P) FACILITIES

The following is the indicative list of machineries / facilities to be available with the firm or the sub-vendor as the case may be. The capacity of the machines shall be suitable for manufacturing / processing of assigned job. The firm shall indicate against each operation in the QAP, the capacity of the machine needed against the available machine capacity.

1) Brazing Plant- There shall be a state of art mechanised brazing plant for brazing

of copper rotor bars with short circuit ring (resistance ring). Induction brazing of copper bars with the ring is preferred.

2) Co-ordinate measuring machine (CMM) - Co-ordinate measuring machine of

suitable size (for measuring the dimensions of mechanical machined component which include stator frame, end shield etc.) shall be available. CMM shall have required accuracies / resolution in the order of microns to measure all the critical mechanical components.

3) VPI Plant - Automatic PLC control impregnations plant of adequate capacity for impregnating wound stators/ rotors with resin/ varnishes at specified vacuum, pressure and temperature condition shall exist.

The vacuum, pressure, temperature of the plant shall be computer controlled. Impregnations vessel shall be of suitable size to accommodate the wound rotor/ stator.

Pressure up to 7±0.5 bar. Minimum vacuum of 0.01 millibar shall be achieved. 4) Vacuum Oven-

There shall be a vacuum oven to dry out the wound stators & rotors to remove the moisture.

The size of the vacuum oven shall be suitable for wound stator/rotor assemblies. 5) Looping Machine- To produce coils of different size & dimensions be available. 6) Coil Spreading Machine- Hydraulic coil spreading machine of suitable capacity

exist for spreading of coil loops in the diamond shape with the specified dimension, shall exist.

7) Dynamic Balancing Machine-

Dynamic balancing machine of suitable capacity shall be available for Balancing (Dynamics) of rotors as per ISO 1940 or equivalent. Residual unbalance of 0.3gms.mm/Kg. shall be achievable.

8) Swaging Machine for swaging of rotor bars. 9) CNC wheel lathe & other machining facilities for machining of mechanical

components like rotor shaft, stator frame etc. 10) Hydraulic system for pinion Extraction, Mounting & Hydraulic jack of 50T. 11) Suitable material handling equipment for safe handles of component/assemblies. 12) Hydraulic Press machine > 350 T for pressing of cores of rotor/ stator. 13) Induction heater with temp control for bearing fitment. 14) Air compressor



15) Induction heater for stamping with temperature control. 16) Facilities for stamping of identification marking as per specification. 17) Annealing facility of leads. 18) Puller for mounting & dismounting of roller bearings. 19) Stands for stator & rotor winding. 20) Dust free air condition room for insulation of coils. 21) Air conditioned store for storage of insulating materials. 22) Varnish Spray Booth. 23) MIG/MAG welding plants 24) State of art jig & fixture designed / fabricated by professional agencies for various

assembly components.



Annexure - II LIST OF TESTING FACILITIES

1. Test Bed equipment for Type / Routine test of the motor:

Following is the mandatory list of facilities needed at the firm’s premises where repair / overhaul / rehabilitation are proposed to be conducted for conducting Type / Routine test as per IEC 60349-2 are furnished below: i) Three winding transformer & it’s associated auxiliary equipments / accessories ii) Off-circuit tap changer iii) Earthing bus-bars iv) No Load Test Bed with at least 2700V Motor Alternator set and Load Test Bed

alongwith Variable Voltage Variable Frequency (VVVF) facilities with measuring arrangement of Speed, Current, Voltage, Power Factor, Temperature, Slip including facilities of over speed test.

v) Control Desk from which the control of all the testing parameters can be controlled / monitored.

Generally, the test bed shall be as per RDSO IB no. MP.IB.EM.12.41.11 (Rev.-00) March’2011. In case, the firm intends to carry out type / routine testing with an alternative test bed / arrangement / facilities, prior approval of RDSO shall be required.

2. Physical & Chemical Test: The firm or it’s sub-vendor shall have following

machines duly calibrated from NABL accredited lab. In case of non-availability of these testing facilities, the tests shall be conducted from

any NABL accredited laboratory or any Government approved agency.

i) Universal Testing Machine of 40 ton capacity with graphical recording facilities for conducting tensile tests.

ii) Direct reading Hardness testing machine of capacity 95-500 BHN. iii) Impact testing machinery (Charpy V-notch) of 0-300 Joules capacity for

conducting impact test with facilities for notch cutting & undertaking this test at sub-zero temperature as per the specified standard.

iv) Shadowgraph facilities for assuring correct notch profile and dimension for impact test specimen.

v) Chemical Analyser (Spectrometer)

2.1 Inspection staff conducting non-destructive testing shall be adequately trained and qualified by recognised agency and shall have adequate experience.

2.2 Staff conducting tests likes chemical analysis & mechanical properties shall have adequate skill & competence and shall have undergone sufficient training. Skill of such staff shall periodically be qualified by making them carry out tests in blind samples.



Annexure - III

LIST OF MEASURING MACHINES / EQUIPMENTS & INSTRUMENTS / FACILITIES: The following is an indicative list of machine(s) / equipments / instruments / facilities to be available with the firm or the sub-vendor as the case may be. 1. For Dimensional measurement

The firm shall have a 3D-Coordinate Measuring machine (CMM) with appropriate fixed bed size to suit subject AC traction motor for complete dimensional measurement in single setting. In case the same is not available, the dimensional measurement shall be conducted from any outside recognised agency having CMM facility. Further, portable CMM machine shall not be acceptable.

2. For Mechanical parameters

i) Bore dial gauge ii) Bore micrometer iii) Hand thermometer iv) Infrared thermometer / Pyrometer v) Inside / Outside Micrometer vi) Manometer vii) Noise Level Meter viii) Pitot tube ix) Straight edge / Surface table of minimum 2 meter x 1.5 meter for marking. x) Temperature Scanner (Minimum 8-channel) xi) Tachometer with speed sensors xii) Ultrasonic thickness gauge xiii) Vibration measurement meter xiv) Vernier height gauge

2 For Electrical parameters

i) High Voltage Tester ii) Impedance Tester iii) Megger 500V & 1000V for IR measurement iv) Micro Ohmmeter v) Multimeter vi) Oscilloscope vii) Power Analyser viii) Polarisation Index Tester ix) Surge Comparison Tester x) Tan Delta tester xi) Tong tester for current measurement xii) Voltage & Current measuring instruments



Annexure – IV

TEST PARAMETERS & SPECIFIED VALUES

The specified values of the main test parameters to be tested during type testing are as under: S.No. Parameter Test condition Specified value 1 Resistance

measurement (ohms) U-V V-W W-U

0.22123 to 0.24451

2 Warming up of motor 1415V, 74.1A, 20Hz To run for 15 minutes. 3 No load test 20Hz, 1415V record

current and power input 66.7 to 81.5A

4 Locked rotor test 20Hz, 320A record voltage and power input

316.1 to 349.3

5 Vibration measurement

1000 rpm to 3300 rpm 1000 rpm - 2.8mm/s 2600 to 3300 rpm - 4.5mm/s

6 High voltage test -Stator

6.2 kV,50Hz for 1minute Shall withstand

7 Insulation Resistance measurement

1000V Megger >10M Ohm

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