ISpecification for Oil Cooling Unit with Casing for

Transformer/Converter of Three Phase Locomotives

Specification No. RDSO/2016/EL/SPEC/OI23, Rev. '0'Issued on 05/10/2016

Approved byEDSE(Co-ord)

ELECTRICAL DIRECTORATERESEARCH, DESIGNS & STANDARD ORGANISATION

MANAK NAGAR, LUCKNOW - 226 011

S. N. Date of Revision Page No. Revision Reasons for Revision

1. - All 0 First Issue.

2.

3.

~EDSEl &AM

Clause Number Item Page no

1.0 Scope 42.0 Terminology, Symbols and Units. 43.0 Reference Standards 44.0 Technical Particulars 45.0 Service Conditions. 56.0 Design and General Construction 67.0 Special construction features 68.0 Finish 79.0 Inter-Changeability 710.0 Marking plate 711.0 Maintenance Instructions 712.0 Drawings 713.0 Data 714.0 Tests 7-1015.0 Field Trial 1016.0 List of Drawings 10

Technical particulars of oil cooling unit. Annexure-I 11&12Standard procedure for calculation of fan delivery 13-15,

parameters Annexure-IIData Sheet of Oil Cooling Unit 16Annexure-III

Motor for Oil cooling Unit Annexure-IV . 18Oil Cooling Unit for transformer/converter 19Annexure-V

Annexure- VI 20Annexure- VII 21Annexure- VIII 22Annexure- IX 23

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SPECIFICATION AND TEST SCHEDULE FOR OIL COOLING UNIT FORTRANSFORMER/CONVERTER

1.0 Scope1.1 This specification covers the performance requirements and tests of Oil Cooling

Unit(OCU) with Centrifugal Design Impellers for transformer/converter fitted in 25 KVAC/50 Hz 3 phase drive electric locomotives.

1.2 Oil Cooling Unit includes following.Blower casingMounting BaseBlower including 3 -phase Induction motor

1.3 Each locomotive is equipped with 3 auxiliary converters each rated at 100 KVA. Theseconverters directly gets supply from a common auxiliary winding of 1000 V (correspondsto 25 KV catenary voltage) from the main transformer. The three phase output voltage ofthe auxiliary convertor 1&2 feeds variable voltage and variable frequency to the OilCooler Unit in 3 steps (17 Hz, 33Hz, and 50 Hz) by the control electronics which getssignal from the temperature sensors in Oil Cooling Unit circuit.

1.4 All OEMs who were approved for centrifugal design OCU as per CLW specification no.CLW/ES/3/0647 Alt. E will remain approved with this specification also with samestatus.

1.5 All the provisions contained in RDSO's ISO procedure laid down in DocumentNo.QO-D-7.1-11 dated 19.07.2016(titled "Vendor-Changes in approved status")andsubsequent versions/amendments thereof, shall be binding and applicable on thesuccessful vendor/vendors in the contracts floated by Railways to maintain quality ofproducts supplied to Railways.

2.0 Terminology, Symbols and Units.For the purpose of this specification, the definitions given in IS: 4894 and shall apply.

3.0 Reference StandardsIn preparing this specification assistance has been taken from the followingspecifications.IS: 4894 - Specification for centrifugal fans.IS: 12075 - Measurement and Evaluation of Vibration of Rotating Electrical Machines.ISO-1940 - Specification for dynamic balancing.IEC 61373 - Shock & Vibration test.

4.0 Technical ParticularsThe technical particulars of Oil Cooling Unit is given under Annexure-I.

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5.1 The equipment and mounting arrangement shall be of robust design for traction duty andshall withstand satisfactorily the vibration and shocks normally encountered in service asindicated below:a) Maximum vertical acceleration 1.0g

c) Maximum transverse acceleration 1.0g5.1.1 The vibrations are of sine wave form and the frequency 'f' vibration is between 1 Hz and

50Hz. The amplitude 'A' expressed in millimeters is given as a function of f, by theequations:A= 25/ffor values off from 1 Hz to 10 HzA= 250/-f for values of f exceeding 10Hz upto 50Hz.

5.1.2 In the direction corresponding to the longitudinal movement of the vehicle, theequipment is subjected for 2 min to 50 Hz vibration of such a nature that the maximumacceleration is equal to 3g (amplitude 'A'=O.3mm).

5.1.3 The level of harmonics in three phase electric locomotives is of the order of 50% each forvoltage & current.

5.1.4 Climatic and Environmental conditions

~ Atmospheric Maximum temperature of metallic surface under the Sun: 750etemperature d' h d 550ean In s a e: .

Minimum temperature: - lOoe (Also snow fall in certain areasduring winter season).100% saturation during rainy season.

i) Ambient temperature: 500e .ii) Humidity: 100%.iii) Altitude: 1776 m above mean sea level.Very heavy in certain areas.Extremely dusty and desert terrain in certain areas. The dustconcentration in air may reach a high value of 1.6 mg/m3. Inmany iron ore and coal mine areas, the dust concentration is veryhigh affecting the filter and air ventilation system.Humid and salt laden atmosphere with maximum pH value of 8.5,Sulphate of 7 mg per liter, maximum concentration of chlorine 6mg per liters and maximum conductivity of 130 I.l Siemens / em.High wind speed in certain areas, with wind pressure reaching150 kglm2

.

~ Humidity~ Reference site

conditions

~ Rain fall~ Atmospheric

conditions

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6. t Drive and couplingThe fan impeller shall be directly mounted on the motor shaft. A Steel!Aluminium boss ofcircular shape should be cast/rolled and fixed with bolting /welding/brazing to Aluminumimpeller (centrifugal design). The drive may be by a key of adequate strength with theimpeller locked in position shall be further locked against, unscrewing in service bylocking plates. Alternatively a tapered shaft without a key but with locking arrangement bybolt and locking plate may be used.

6.2 Direction of rotationAn arrow indicating the direction of rotation shall be permanently marked on the blowercasmg.

6.3 BalancingThe rotor and the blower impeller shall be dynamically balanced individually, in qualitygrade G 2.5 of ISO-1940.

6.4 Vibration:The peak to peak value shall not exceed 25 microns on motor body, foot and bearing ofmotor and 40 microns at blower casing.

6.5 Lifting arrangementsSuitable lifting arrangement for the blower fan and the motor separately and for thecomplete unit shall be provided.

7.0 Special construction features7.1 Special manufacturing processes: As the blowers operate for long periods at high speeds;

the impeller blade should be designed with a higher margin of safety as compared tonormal industrial designs and stress calculation for the same shall be furnished.

7.2 CasingCasing should be of heavy duty industrial design and shall be of mild steel with minimumthickness of 3>millimeter or Aluminium alloy of 5 millimeter thickness. It should notdeform during lifting. It should be of single side intake having mixed flow form with axialintake direction and radial discharge direction with centrifugal impeller flow fan. Alloutside welds of the housing should be welded continuously. Casing shall be designed asper existing arrangement of centrifugal fans provided on 25 KV ac-electric locos typeWAP-S & 7/WAG-9.The inlet cone may be manufactured by spinning/fabrication/welding process. It shall notbe hammered to give the cone shape. Inlet cone shall be die formed.

7.3 The mounting arrangement of the blower on the casing shall be properly secured so as toavoid loosening during the vibrations countered in service.

7.4 Centrifugal Impeller can be Fabricated /Casted. The dimension stipulated in the drawingplaced at Annexure -IX is for reference.Impeller diameter shall not be more than 710 mm.

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8.0 FinishThe fan motor, blades and the casing shall be suitably treated to remove rust and should becoated with an anti-rust primer and finished with two coats of RAL 7030 stone grey silkpaint. All hardwares shall be cadmium plated.

9.0 Inter-ChangeabilityThe Motor, Impeller and Casing shall be interchangeable with other make so that theperformance of the Oil Cooling Unit is kept within the limits of the standard.

10.0 Marking plateEach Oil Cooling Unit shall have a suitable name plate having the following informationengraved/punched on it:i) Manufacturer's name, Type and Serial Number.ii) Air Deliveryiii) Total Head at 20°C.iv) Rated Speed.v) Make of the Motorvi) 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 fetched on

Steel/Aluminium boss.

11.0 Maintenance InstructionsThe manufacturer shall supply detailed Maintenance Instructions as desired by thepurchaser.

12.0 DrawingsThe drawings (to be asked by the purchaser) giving the overall dimensions of the OilCooling Unit shall be supplied with the tender.

13.0 DataThe particulars of the Oil Cooling Unit set shall be furnished in the data sheet atAnnexure -III.

14.1 GeneralTests are classified as Type and Routine tests.

14.2 Type & Routine tests on MotorThe Type & Routine tests on prototype motor shall be conducted as per RDSaspecification no. E-10/3/09(Motor) with latest amendments.

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Tests on Oil Cooling UnitThe following are the different tests on the complete Oil Cooling Unit with Casing.a) Type Testsi) Air Delivery Test.ii) Starting Time Test.iii) Starting Duty Test.iv) Endurance Test.v) Vibration level Test in line with IEC 61373.vi) Weighment.vii) Checking of bearing by shock pulse meter.viii) Checking of dimensions, workmanship, clearances of impeller fixing and locking

arrangement.ix) Starting Current, Running Current, Starting Time with full load at

- 373V,33Hz- 415V, 50Hz to be recorded.

x) The balancing of rotor with impeller shall be done and to be witnessed byinspecting officials. The balancing shall conform to grade 2.5 of ISO-1940.

xi) Visual Inspection for workmanship and Dye Penetrant Test (DPT) on impellerwelding.

xii) Noise measurement at a distance of one meter from the equipment in all direction.b) Routine Testsi) Checking of obligatory dimensions and clearances of impeller fixing and locking

arrangement.ii) Starting time testiii) Vibration level test.iv) Condition of bearing by shock pulse meter.v) Visual inspection for workmanship and DPT on impeller welding.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 measurementadopted shall comply with Indian Standard specifications for centrifugal flowfans.

14.3.1 Details of Type Tests14.3.1.1 Air delivery test

Test shall be carried out with the supply to the driving motor maintained at 415(± 10%)at 50Hz. However it is desirable to conduct the tests at 33 Hz also with supply from theVVVF drive. Adequate number of observations shall be made on both sides of theoperating point to plot the characteristic curve. Measure the following quantities.

i) Line voltageii) Line current

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iii) Power inputiv) Speedv) Total pressure.vi) Ambient temperature.

The manometer pressure readings shall be taken at 4 points at least to arrive at a meanvalue as per IS 4894.Calculate the blower output at standard conditions Wt. =1.2 kg/m3.The standardprocedures to be followed for calculation of fan delivery parameters is given underAnnexure-II.

14.3.1.2 Starting time testWith a test installation similar to that adopted for the air delivery test, start the blowersuccessively at 415V and 373V. Measure oscillographically or by any other accuratemethod, the starting time of the motor for Oil Cooling blower Unit from zero speed tothe full speed. Record starting current, running current, starting time with full load at373V, 33Hz and 415V, 50Hz.

14.3.1.3 Starting duty testThe Oil Cooling Unit shall be subjected to repeat "start and stop" cycle for 1000 timesat a supply voltage of 415V. The 'ON' and 'OFF' period shall be 1minute in each case.If the unit takes more than 1 minute to stop fully, the next start shall commenceimmediately after the unit has stopped. At the end of the test, the efficacy of impellerlocking device shall be checked; the impeller shall then be dismantled and various partslike key, key way and the fit of the impeller on the shaft shall be examined for wear andany abnormal condition.

14.3.1.4Endurance testThis test shall be conducted for a period of 48 hours with rated output and head with415 V supply at the motor terminals. After the test, the blower and the motor shall bedismantled and examined for wear and tear of the parts and conditions of bearings etc.

14.3.1.5Vibration level test.For the measurement of vibration intensity, electronic vibration measurementequipment having a frequency range of 5 to 2000 CPS shall be employed. Vibrationmeasurement shall be made at motor body, foot and bearing of motor and blowercasmg.Limits of vibration intensity: The peak to peak value shall not exceed 25 microns onmotor body, foot and bearing of motor and 40 microns at blower casing.

14.3.1.6Condition of bearing by shock pulse meterCondition of bearing shall be checked at rated voltage and frequency. The deflectionshall be within green zone of the instrument.

14.3.1.7 Testing of material and welding strength.(i) Suitable size of test piece of material used for manufacturing of impeller shall be

prepared for testing .

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(ii) Two sets of test piece shall be welded & be kept ready for checking the weldingstrength.

Note: The test for welding strength shall preferably be done at firms premises.However, same may be tested at Government Accredited Laboratory if facilityis not available.

14.3.2 Details of Routine TestsSame as item no: 14.3 b) and its procedure given in type test 14.3.1

15.0 Field TrialOil Cooling Unit with Casing shall be subjected to extensive field trials for a period ofat least 12 months after fitment on locomotives. During field trials; performance ofthe OCU with casing shall be observed & recorded.

16.0 List of DrawingsThe drawings are for guidance. However, the dimensions are to be followed so as toensure interchangeability of motor, impeller and casing with other makes.

SN Existing Drawing No.as Revised Drawing Title Page no.per CLW Specification number as perno: CLW/ES/3/0647 ALT E RDSO ,

Ispecification I

I CLW/ES/3/SK -2/064 7 RDS0/2016/ SK-l/ Motor(200L) for oil Cooling ANNEXURE-IV 1,ELiSPEC/O 123 Unit for

transformer/converterII CLW/ES/3/SK -3/064 7 RDSO/20 16/ SK-21 Oil Cooling Unit for ANNEXURE-V

ALTB ELI SPEC/O 123 transformer/converter(for guidance only)

iii CLW/ES/3/SK -4/0647 RDS0/2016/ SK-31 Oil Cooling Unit for ANNEXURE·VI

ALTB ELiSPEC/O 123. transformer/converteriv CLW/ES/3/SK-5/0647 RDSO/20161 SK-4/ Bracket for casing(W AG-9) ANNEXURE-VII '

- ELiSPECIO 123.-

v CLW/ES/3/SK -6/0647 RDSO/2016/ SK-5/ Support for bracket, self ANNEXURE-VIPi

ELiSPECIO 123. gripping rubber gasket,looming bar & MS channel.

VI CLW/ES/3/SK -1/0647 RDSO/2016/ SK-61 Impeller for Oil Cooling ANNEXURE-IXELI SPECIO123 Unit for

transformer/converter ii

Note:a) All rubber items and hardwares shall be procured from CLW approved sources.b) OEMs shall submit the Bill of material (BOM) and shall get approved by RDSO.

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(i) Type Aluminum Impeller of centrifugal design

(ii) Fan Duty Point at rated speed 802m3/s at 1781 Pascaland 20°C

(iii) Rated speed 2920 rpm(iv) Driving motor 30kW Squirrel cage Induction Motor(v) Details of Pressure drops

- Cooler section ,air 800Paside

- Inlet/Outlet 930Paducts/filters

- Reserve 51Pa- Total fan Pressure 1781Pa

(i) Type 3 Phase, 30kW, 2 Pole Squirrel Cage, Totallyenclosed surface cooled as per RDSOspecification No.E-10/3/09(Motor) with latestamendments.

(ii) Frame Size & Mounting 200L foot mounted as per IS 1231Arrangement

(iii) Motor Rating:(a) Nominal Mechanical Power 30kW

(b) Rated -Speed 2920 rpm

(c) Rated Voltage 415 ±10%V,3 Phase

(d) Rated Current 50Amp

(e) Starting Current 320Amp or less

(f) Class of Protection IP 54

(g) Type of Enclosure TESC

(h) Duty cycle S1 continuous(i) Wave form Quasi-square waveG) Cos 0 Not less than 0.84(k) Efficiency Not less than 88%(1) Bearing Size DE & NDE 6312-open type

Make: From RDSO approved sources ofrelevant size

(m)Insulation H class VPI (corona resistant copper windingwire of RDSO approved make should be used)

(n)Harmonics in Voltage 50%(0) Harmonics in current 50%(p)dv/dt Less than 1OOOV/micro second

Note: - Other parameters· & performance requirement of motor will remain same asmentioned in RDSO specification No. E-l 0/3/09 (Motor) with latestamendments.

3. Starting performance: The blowers shall accelerate from stop to the full speed withinsix seconds over the entire range of supply voltage i.e.415± 10%.

Characteristic

Volume flow

Tolerance

-5%

5. The centrifugal flow fans covered by this specification are capable of working againstpressure.

ANNEXURE-IISTANADARD PROCEDURES FOR CALCULATION OF FAN DELIVERY

PARAMETERS1. Test set up for air delivery shall be as per IS 4894.2. Make a sketch of testing duct and record various dimensions of test set up arrangement.3. Air delivery test shall be carried out at 373V, 4l5V and 457V, all at 50Hz, 3 phase power

supply to driving motor.4. Starting from full open position to full close ,adequate number of measurements on either

side of duty point shall be recorded as per procedure given in IS 4894 so that sufficientdata point becomes available for drawing a smooth fan characteristic curve. In any case,at least 2 readings on either side of duty point and one reading near duty point must betaken. The suitable no: of charges of mesh with difference holes simulating to 25% ,50%& 75 % closing shall be available in line with IS 4894.

Observed values starting from full open tofull close position

Observations Full open Full closePressure at section AA(Paa) in mmWGPressure at section BB (Pbb) III

mmWGTest speed in rpmCurrent(Amp)Voltage(Volts)Power FactorMotor Input(kW)Frequency of supplyAmbient temperature near sectionBB(t) in degree Celsius

5. For each of, above observations, the values of air flow, fan total pressure, fan staticpressure; fan efficiency and overall combined unit efficiency shall be calculated and shallbe converted at rated speed and temperature.

6. From the values of air flow and fan total pressure at rated speed and temperature, Fancharacteristics curve along with system resistance curve shall be drawn. The curves forfan efficiency and static pressure versus flow shall be drawn on same graph. Theintersection of fan characteristics curve and system resistance curve shall be taken asoperating point of the fan. The operating point should fall on right side of the specifiedfan duty point.

7. Three set of observations, calculations sheets and curves for 373 V, 415 V and 457 Voltsshall be furnished.

8. Calculation sheet along with formulas to be used for determining fan characteristic curve& efficiency is as under.

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Duty Point at 20uC as per spec.Rated Q(mJ/s)Rated FTP at 20uC(Pa)Rated RPMFan DiameterTest Duct diameter in meter, DTest Duct Area( sq m)Fan Outlet area(sq m)Barometric Pressure(mmlIg)'B'Coefficient of discharge, CdCd2

Motor efficiency (%)

Observations Observations fromfull open to fullclose

Paa(mmWG)Pbb-Ps(mm WG) ,Ps:- absolute pressure of theambient atmosphere.Test Speed(rpm)Motor Input(k W)Amb Temp(t) near sectionBB °c,Calculations FormulaeDensity of air at section BB, 1.2 X (B+0.737Ps) X (273+20)Wt(kg/m3) 760 (273+t)

-

Inlet Volume, Qv(m3/hr) 12500XCdXD2X--J(Paa/Wt)

Outlet Velocity (Vo ),m/hr Qv/Outlet Area

Velocity Pressure atoutlet,Vpot = Tpot Wt X (Vo/16000i

(mmWG)

Velocity Pressure at fan PaaX Cd 2inlet (mm WG), VpiTotal Pressure at fan

Pbb+ Vpiinlet(mm WG), TpiFan Total Pressure at temp t Tpot - Tpi

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(mmWG),FTPtMotor Output (Mo), kW

(Motor input x Efficiency)x 100

Conversion to Rated Speed and Temperature

Volume at rated speed inQvX

Test Speedm3/hr,Q1

Rated speedVolume at rated speed in QIm3/s,Q2 3600Outlet Velocity(V 0) at QIrated speed, m/hr Outlet AreaVelocity Pressure atOutlet at rated speed and 1.2 X(Vo /16000) 2

temp, Vpo2

FTP at rated RPM and GRatedrpm] X1.2

temp FTPX Test rpm Wt

Fan Static Pressure atFTP-Vporated rpm and temp

Shaft Power(kW) at rated MO{ Ratedrpm J X 1.2speed & temp Test rpm -Wt

Air power in kW at rated 2.723 X QI X FTP X lO-bspeed & temp

Air PowerFan efficiency (%) X 100

Shaft PowerOverall efficiency of the Air Powercombined unit X 100(OCB+Motor)(%) Motor input

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A2 Air delivered in cubic meter per minute and total head in mm WG corrected to 20°C and760 mm barometric pressure at rated voltage

A3 Design dataa) Impeller diameter.b) Type of impeller blades.c) Number of blades.d) Method of fixing of the blades.e) Clearance between inlet cone and impeller (maximum 6mm and minimum 1.5mm)f) Maximum shaft speed of the impeller.g) Motor shaft and impeller bore diameter (maximum and minimum).h) Method of fixing of impeller on motor shaft and locking arrangement.i) GD2 value of the impeller (indicated the maximum variation in manufacture).J) Stress calculation for impeller and casing.

Note: GD2 value of the impeller will be made use for calculating the startingperformance of the blower with regard to the specified electric motor. As such thevalue 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.

A5 Torque necessary for the blower when working against constant rated head anddelivering the rated output.

A.6 The supplier shall enclose the following characteristic curves at 20°C and 55°C.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.7 Vibration level in microns.A.8 Furnish the welding strength calculation for the joint between impeller and back plate and

cone.

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A.10 Necessary dimensioned drawings of the blowers and its all components showing theconstructional and material specification as per IS or any other relevant internationalstandard for assembly details shall be submitted.

1 Application2 Type3 Rated voltage4 Number of phases(Star/Delta)5 Frequency6 Speed7 Continuous rating(HP /kW)8 Rated current

a)At rated voltage (415V)b)At lowest voltage(3 73V)

9 Slip at full load in percentage at-a) Rated voltage (415V)b)Lowest voltage(3 73V)

10 Class of insulation11 Type of enclosure12 Method of ventilation13 Type of protection14 Frame size15 Overall dimension16 Type & make of bearing17 Size of bearing and their estimated L 10 life18 Weight of the motor

- Weight of rotor19 Rotor construction20 GD2 value of the rotor(indicate the maximum variation)21 Starting current and torque in kgm

a) at 373 Vb)at457Vc) at 415 V

22 Any deviation from the specification indicating reasons thereof may please beexplained.

23 Corona resistant winding wire used as per amendment no 3

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