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GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

TECHNICAL SPECIFICATION FOR TRACTION ALTERNATORS USED IN BROAD GAUGE DIESEL ELECTRIC ALCO LOCOMOTIVES

SPECIFICATION NO. MP.0. 2402.19 (Rev. 01) February, 2016

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RESEARCH DESIGN & STANDARDS ORGANISATION MANAK NAGAR, LUCKNOW-226 011

RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01)

TECHNICAL SPECIFICATION FOR TRACTION ALTERNATORS USED IN BROAD GAUGE DIESEL ELECTRIC ALCO LOCOMOTIVES

1.0 FOREWORD

1.1 Diesel-electric locomotives with AC/DC transmission system use traction alternators to convert the mechanical power of engine into electrical form. This power, after rectification, is fed to DC traction motors with suitable controls as per traction requirement. Each locomotive is fitted with one traction alternator coupled directly with engine crankshaft.

1.2 This specification covers the design, manufacture, testing, supply and commissioning of Traction Alternators (having provision for top mounting of Rectifiers) alongwith Gear Case, Auxiliary Machines, PTU and associated equipment suitable for use in following type broad gauge diesel electric ALCO Locomotives having (i) 16 Cylinder ALCO 251-B type engines with gross engine output varying from 3100 HP up to 3300 HP. (ii) 6 Cylinder ALCO 251-D Diesel Engine with gross engine output of 1400HP OR 12 Cylinder ALCO 251-B Diesel Engine with gross engine output of 2300HP. which are manufactured at production units of Indian Railways such as DLW/Varanasi, DMW/Patiala , etc. Although the overall construction and features of alternators and its sub-assemblies used in the above Locomotives are similar, but they differ in rating, size and performance characteristics and thus they are not interchangeable/same. Firm shall clearly indicate in their proposal the loco for which it wishes to develop and manufacture Traction Alternator and its sub assemblies.

1.3 The proposed traction alternator shall be a 3-phase synchronous machine rated to supply full load current to all the traction motors. The drive for the traction alternator shall be obtained from ALCO type diesel engine by coupling its rotor rigidly with the engine crank shaft. Excitation current to the alternator shall be supplied from the DC exciter machine.

1.4 The alternator manufacturer shall be responsible for the commissioning of prototype traction alternator alongwith other offered equipment with ALCO engine on a locomotive at DLW/DMW in presence of representatives from RDSO/production unit.

1.5 No modification will be carried out in the existing engine/engine block for the purpose of mounting the proposed traction alternator. If any modification is required for successful mounting of the proposed traction alternator, it should be carried out in traction alternator only. Any changes in the mounting design should be approved by RDSO.

1.6 Proposed traction alternator should be interchangeable (electrically as well as mechanically) with the following type of traction alternator of BHEL make :  TA10102 CW/DW and TA10102EV (with modified openings provided for AC output terminals suitable for connection and mounting of Rectifier at Alternator top), which are working in service on existing 3100HP and 3300HP diesel-electric locomotives of Indian Railways with 16 Cylinder ALCO 251-B engines.  TA10106AZ and TA10106CY (with AC output terminals suitable for connection and mounting of Rectifier at Alternator top), which are working in service on existing Page 2 of 46

RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01)

1400HP Shunters having 6 Cylinder ALCO 251-D engines and as well as in 2300HP locomotives with 12 Cylinder ALCO 251-B engines.

The offered Alternator along with auxiliary generator, exciter, PTU, etc. shall also be designed such that they are fully compatible with other electrics used in existing AC/DC broad gauge diesel-electric locomotives with ALCO engines with minimum changes required, if any, in the existing electrics.

1.7 It is the sole responsibility of supplier to examine the compatibility issues of all the offered equipment with other equipment fitted on existing locomotives with ALCO engines. For this purpose the manufacturer may study the details of mounting arrangement of the engine. The traction alternator with attached auxiliary generator, exciter and PTU offered against this specification shall be designed so that it can be easily mounted on the locomotives with existing engines as well as the offered equipment shall be suitable for mounting of rectifier on its top.

2.0 SCOPE OF SUPPLY

The scope of supply includes suitable Traction Alternator (having provision for top mounting of rectifier) complete with Bull Gear, Pinion, Gear Case, Auxiliary Generator, Exciter and Power Take-off Unit (PTU - for traction motor blower) along with associated equipment/accessories that may be required for successful installation and operation and maintainability of following locomotive of Indian Railways:  3100/3300 HP Broad Gauge Diesel Electric Alco Locomotive  1400/2300 HP Broad Gauge Diesel Electric Alco Locomotive

Firm shall clearly indicate in their proposal the loco for which it wishes to develop and manufacture Traction Alternator and its sub assemblies.

3.0 GOVERNING SPECIFICATIONS

3.1 In preparation of this specification, assistance has been taken from latest standards IEC- 60349, IEC-34, IEEE-11 and IEC-60411. All the equipment offered shall generally conform to these specifications with a specific variation in that, on account of higher ambient temperatures observed in India, the temperature rise specified shall be suitably reduced.

3.2 In case any deviation is proposed from the relevant International Standards or from this specification, the standards followed in the design, manufacture, assembly and testing of these equipment shall be clearly indicated by the manufacturer. In the absence of any such indication, it shall be assumed that the offer complies fully with this specification.

3.3 Any deviation from this specification, incorporated by the manufacturer to improve the performance, durability, reliability and maintainability of the equipment or to reduce its cost significantly, may be favorably considered provided full particulars of the anticipated benefits along with technical data supported by drawings and calculations, are furnished by the manufacturer .

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RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01)

3.4 The manufacturer will furnish English version of all those standard specifications referred to in their offer but not called for in this specification.

4.0 CLIMATIC & ENVIRONMENTAL CONDITIONS

The alternator along with all the offered equipment shall be required to work continuously at full load under following atmospheric conditions:

Maximum temperature (Atmospheric) (i) 70 ºC (under sun). (ii) 50 ºC (in shade) (Temperature inside locomotive may reach 60 ºC.)

Minimum temperature -20 ºC. (Atmospheric) Humidity Up to 100% during rainy season

Altitude Max. 1200 meter above mean sea level

Reference site conditions (i) Ambient temp. 50 ºC (ii) Temp. inside engine compartment 60 ºC (iii) Altitude 160 m above sea level

Annual rainfall Between 1750 mm to 6250 mm. Very heavy in certain areas. The locomotive shall be designed to permit its running at 10 km/h in a flood water level of 10.2 cm above rail level.

Dust Extremely dusty and desert terrain in certain areas. The dust content in air may reach as high a value as 1.6 mg / m³. Atmospheric conditions in (a) Maximum PH value : 8.5 coastal areas in humidity (b) Sulphate : 7 mg / liter. salt laden and corrosive (c) Max. concentration of chlorine : 6 mg / liter atmosphere (d) Maximum conductivity : 130 micro siemens / CM.

4.1 The traction alternator and other offered equipment shall be suitable for rugged service normally experienced for rolling stock where locomotives are expected to run up to a maximum speed of 160 kmph in varying climatic conditions existing throughout India. The mounting arrangement of traction alternator and subassemblies shall be designed to withstand vibrations and shocks as specified in IEC-34.

5.0 BASIC DESIGN REQUIREMENTS AND SERVICE CONDITIONS

5.1 The stator of the traction alternator shall be provided with the three-phase AC armature Page 4 of 46

RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01) winding while the rotor shall consist of excitation field winding.

5.2 Traction alternator should be manufactured keeping in view its mounting suitability on existing ALCO engines without any modification required in the engine. The alternator offered shall be mounted directly on the diesel engine by bolting the stator on the engine block. The rotor shall be coupled rigidly with the engine crank shaft on the drive end and shall therefore be supported by the crank shaft bearing at this end. On the non-drive end an end shield shall be provided and the rotor shall be supported on a bearing. For mounting the traction alternator, RDSO drawing no. SK.DP.-3287 (applicable for 6 Cylinder ALCO 251-D engines and as well as 12 Cylinder ALCO 251-B engines) which provides relevant details of engine block and crank shaft flange shall be referred. In this arrangement the engine crank shaft supports approximately half the weight of the rotor while the other half is supported on the alternator bearing. The manufacturer shall submit the mounting details and drawings to RDSO/DLW before supply of the alternator.

5.3 The offered traction alternator shall be suitable for fitment within the envelope available for existing type traction alternators in Loco (3100/3300hp loco or 1400/2300hp). The weight of the traction alternator including auxiliary machines, PTU, bull gear, gearbox and pinions shall preferably not exceed 6400 Kg for 3100/3300hp locomotives and 5600 Kg for 1400/2300hp Locomotives.

5.4 In the existing system, gearbox is mounted on the slip ring end of the alternator to provide means of mounting the auxiliary generator, exciter and PTU. The alternator is provided with a bull gear on the rotor shaft and a gearbox such that the existing auxiliary machines and PTU can be mounted on the gearbox and driven by the existing gear and pinion drive. The proposed alternator shall have similar arrangement compatible with the existing.

5.5 In the existing locomotives, excitation to the rotor winding of traction alternator is supplied by the exciter mounted on the gear box and directly driven by the alternator through gear train. The exciter supplies a variable amount of excitation current to control the alternator output as per the predetermined settings. The exciter field itself is being fed with the DC output from existing electronic (E - type) or microprocessor based excitation control system of AC/DC diesel electric locomotives.

Microprocessor based control system used on existing locomotives is as per RDSO specification no. MP.0.24.00.26 (latest revision). Proposed alternator along with other equipment offered shall be compatible with both the existing E - type or microprocessor based excitation control systems designed as per this specification. The alternator manufacturer shall provide all the data required for interfacing with the existing microprocessor based control system. It is the responsibility of alternator manufacturer to demonstrate the compatibility of alternator with both the existing excitation control systems.

5.6 The traction alternator and rectifier shall be designed for high voltage and high current operation. The ratings of the traction alternator and auxiliary machines shall be adequate to meet the performance requirements as detailed in this specification. Traction alternator with the electrics offered shall equal or excel the tractive effort Vs speed performance characteristics of the existing locomotives. The manufacturer shall furnish the characteristic curves of the electrics offered to RDSO.

Page 5 of 46

RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01)

Typical data of various locomotives is given as below:

(a) FOR 3300 HP LOCOMOTIVES with Traction alternator type: TA10102EV

• Maximum starting current : 4200 Amps • Maximum voltage : 1100 V • Low voltage continuous ratings : 585 V, 3600 A, 2106 KW at 1050 RPM • High voltage continuous rating : 1075 V, 1938 A, 2083 KW at 1050 RPM

At site conditions and rated engine power, traction alternator rectified DC output V-I characteristics of existing 3300 HP locomotives are given at ANNEXURE – A. Tractive effort vs. speed curve of the loco is attached at ANNEXURE – B.

(b) FOR 3100 HP LOCOMOTIVES with Traction alternator type: TA10102DW

• Maximum starting current : 4400 Amps • Maximum voltage : 1130 V • Low voltage continuous ratings : 525 V, 3700 A, 1050 RPM • High voltage continuous rating : 1100 V, 1760 A at 1050 RPM

At site conditions and rated engine power, traction alternator rectified DC output V-I characteristics of existing 3100 HP locomotives are given at ANNEXURE – C. Tractive effort vs. speed curve of the loco is attached at ANNEXURE – D.

• Maximum starting current : 4400 Amps • Maximum voltage : 780 V • Low voltage continuous ratings: 413 V, 3400 A, 1404 KW at 1000 RPM • High voltage continuous ratings: 760 V, 1850 A, 1406 KW at 1000 RPM

At site conditions and rated engine power, traction alternator rectified DC output V-I characteristics of existing 2300 HP locomotives is given at ANNEXURE –E. Tractive effort vs. speed curve of the loco is attached at ANNEXURE – F

(d) FOR 1400HP LOCOMOTIVES with Traction Alternator type : TA 10106CY

• Maximum starting current : 3800 Amps • Maximum voltage : 780 V • Low voltage continuous ratings : 225V, 3660A, 823.5 KW, 1100RPM • High voltage continuous rating : 750V, 1125A, 843.75 KW, 1100RPM

At site conditions and rated engine power, traction alternator rectified DC output V-I characteristics of existing 1400 HP locomotives is given at ANNEXURE – G. Tractive effort vs. speed curve of the loco is attached at ANNEXURE – H.

5.7 The traction motors may be BHEL types TM4907, TM5002 or CGL type TM7362 / TM7362A, or equivalent GE make GE752.

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RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01)

Traction motor combinations of 2S-3P at starting and 6P at high-speed operation with field weakening (100% FF to 49%FF) are used. The traction alternator shall be suitable for these transitions.

With 18:65 gear ratio, performance characteristics of BHEL make traction motor TM4907 for 100% FF and 49% FF excitation are attached at ANNEXURE – I and ANNEXURE – J respectively. Similarly, with 18:65 gear ratio, performance characteristics of BHEL make traction motor TM5002 for 100% FF and 70% FF excitation is attached at ANNEXURE – K ANNEXURE – L respectively. Gear ratio of 18:74 is also used for freight locomotives.

5.8 The supplier shall furnish the alternator field current curve to obtain the desired alternator V-I characteristics as well as values of alternator rotor resistance and impedance at 25 ºC. It is necessary that the traction alternator offered should be so designed that the desired characteristics are obtained with the proposed exciter and existing electronic or microprocessor based excitation control system.

5.9 It shall be possible to get the existing characteristics of locomotives as detailed in Clause no. 5.6 by matching the traction alternator with control systems of these locomotives.

5.10 The alternator shall be designed such that its output when rectified by a three-phase bridge rectifier does not result in a ripple factor more than 5%.

5.11 The insulation scheme of the proposed traction alternator shall preferably be class-200 type. However, a minimum of class-H type insulation scheme may also be accepted. Auxiliary machines may, however, be designed for class ‘H’ insulation. The manufacturer shall provide maximum possible margin in temperature rise for prolonged life of the traction machines after taking into consideration the system of insulation adopted and environmental conditions prevailing on Indian Railways.

The Insulation scheme adopted for traction alternator of 3100/3300hp loco shall be as per RDSO drawing No. SKDP-3355 (latest revision) and SKDP-3619 (latest revision). Resins and varnish used for traction machines shall be confirming to RDSO document no. MPMI-153/92 (latest revision).

5.12 The alternator may be forced or self-ventilated type. The existing alternator in service are self ventilated type, having its own fan suitably designed to meet the cooling requirement of the equipment and sub assemblies such that it keeps the overall winding temperature well within the limit of specified insulation class. Even the cooling requirement of rectifiers mounted on the top of alternator is also met though same fan by suction method. In case, manufacturer offers forced cooling, required air flow with complete details of the blower motor with mounting arrangement and input power supply shall be furnished by the supplier.

5.13 The efficiency of the traction alternator at continuous rated current may be around 96 to 97%. The manufacturer shall clearly specify the efficiency of traction alternator, auxiliary generator, exciter, and also over-all efficiency of the electrical transmission system. The efficiency curves for the alternator (with and without rectifier) and over-all transmission system over the entire speed range shall be furnished.

Page 7 of 46

RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01)

5.14 The temperature of the cooling air at the inlet of the traction alternator shall be 60 ºC maximum with relative humidity varying up to 100% saturation.

5.15 The alternator and it’s mounting arrangement shall be of robust design suitable for traction duty and shall withstand satisfactorily vibrations and shocks normally observed in traction service as indicated below:

Maximum vertical acceleration - 1.0 g Maximum longitudinal acceleration - 3.0 g Maximum transverse acceleration - 0.5 g

5.16 The maximum service speed of the diesel engine with which these alternators shall be running is indicated in clause no. 5.6. However, the alternator offered should be mechanically and electrically capable of trouble free operation at these service speed.

5.17 The manufacturer should preferably offer a standard and well-proven alternator which is in current production. In this case, full particulars regarding the number of units in service, application area and present application ratings shall be submitted by the manufacturer.

5.18 AUXILIARY GENERATOR: Auxiliary Generator should be suitably designed to take care of cranking of the engine (along with Exciter Generator) and also to provide 72 VDC supply to other sub systems of the loco like batteries, control circuit, head lights, flasher lights, rectifier blower motor (if used) etc. The rating of Auxiliary Generator should be suitable to meet the above requirements with 10% margin for other future requirements.

Output of the Auxiliary Generator should be suitably regulated to 72 VDC ±1V by using voltage regulator. The existing voltage regulator shall be used to regulate the output of auxiliary generator. Type and rating of existing Auxiliary Generator used in Diesel Electric Locomotives are as follows: Locomotive 3100 HP and 3300HP 1400 HP and 2300HP Type AG 3101 AY-1 AG2702 AZ/AX Continuous DC Rating 75 Volts, 160 Amps, 75 Volts, 160 Amps, 950 900 to 2500 RPM to 2620 RPM Power 30 HP 30HP note: the above two machine type differs in constructional feature and are not interchangeable.

5.19 EXCITER GENERATOR: The exciter shall be used to excite the traction alternator field. The exciter shall be designed in such a way that existing E–type or microprocessor based excitation control system is able to control the load and speed of the engine with minimal changes required in the existing excitation control systems. Type and rating of existing Exciter Generator used in Diesel Electric Locomotives are as follows: Locomotive 3100 HP and 3300HP 1400 HP and 2300HP Type AG 3101 AY-1 AG2702 AZ/AX Continuous DC Rating 75 Volts, 160 Amps, 75 Volts, 160 Amps, 950 900 to 2500 RPM to 2620 RPM Power 30 HP 30HP note: the above two machine types differs in constructional feature and are not interchangeable. Page 8 of 46

RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01)

5.20 ENGINE CRANKING: Auxiliary generator along with exciter shall also be used for cranking the diesel engine initially for short time during which both the machines shall work as motors with input supply from 72 VDC loco battery. Hence, both the machines and shaft shall be designed suitably and robust enough to take care of cranking torque requirement. The cranking parameters of the 16 cylinder engine are as below:

(a) Initial cranking torque : 585 Kg-m (maximum) at the alternator shaft. (Firing torque may vary from 75 to 85 % of breakaway torque) (b) Firing speed : May vary from 60 to 90 rpm

It is the responsibility of the alternator manufacturer to design and demonstrate the cranking of the engine.

5.21 POWER RECTIFIER: To convert output of traction alternator from AC to DC, suitable three-phase power rectifier using silicon diodes is used in existing locomotives. Traction Alternator shall be suitable designed for mounting power rectifier on its top periphery and taking care of its cooling requirement through alternator. The three phase output terminals of Traction Alternator shall be suitable for making connection to rectifier input terminals. Design, dimension and rating of Power rectifier used in locomotives is confirming to RDSO specification No. MP.0.24.02.20. (latest revision).

5.22 POWER TAKE-OFF UNIT: Power Take-off Unit (PTU) shall be used for driving Front Traction Motor Blower (FTMB). For 3100 HP and 3300 HP locomotives, gear ratio for PTU / FTMB should be selected in such a way that at idle engine speed of 400 RPM, FTMB speed will th be 948 RPM and at 8 notch engine speed of 1050 RPM, FTMB speed will be 2490 RPM.

5.23 GEAR CASE: Details of existing gears used in 3100HP and 3300HP locomotives are given below:

Pressure angle = 20º Module =4.233mm Gear ratio= 2.372

Description Span size over teeth Centre Drg. No. distance 102 Teeth Bull 12 teeth 149.298/149.339 306.4 mm SKDP-3116 Gear for TA 43 Teeth Bull Gear 5 teeth 58.610/58.661 306.4 mm SKDP-3117 for AG 43 Teeth Bull Gear 5 teeth 58.610/58.661 306.4 mm SKDP-3117 for EG 43 Teeth Bull Gear 5 teeth 58.610/58.661 306.4 mm SKDP-3117 for PTU

Gears shall be confirming to RDSO specification No. MP.0.2800.16 (latest revision) and should match with RDSO drawings as mentioned above for 3100HP and 3300HP locomotives. The NYLON gear used shall be confirming to RDSO specification No. MP.0.2800.14 (latest revision) and drawing SKDP-2988 (latest revision).

Page 9 of 46

RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01)

6.0 GENERAL DESIGN FEATURES & MATERIALS

6.1 GENERAL

6.1.1 Easy access for inspection and maintenance requiring minimum attention shall be given special consideration in the design and layout of the traction alternator and other equipment.

6.1.2 The materials used as insulation for the components shall be non-combustible, non- hygroscopic and shall withstand the service conditions specified.

6.1.3 Standard metric hardware shall preferably be provided.

6.1.4 All nuts and screws shall be securely locked and shall not loosen in service due to excessive vibrations normally observed in DE locomotives.

6.1.5 All hardware components including nuts, bolts, washers and screws etc., shall be suitably protected against corrosion and rust.

6.1.6 All normal wearing and consumable items such as carbon brushes, bearing greases, etc. shall be selected to the similar grades/specifications as are already in use on the existing stocks on Indian Railways.

6.1.7 Clearances and creepage distances shall conform to the values given in table below. In case it may not be possible to comply with these values at some locations due to restriction of space etc., adequate insulation shall be provided at such locations. Use of protective coatings such as varnishes etc. shall not warrant reduced clearances and creepage distances. CLEARANCE AND CREEPAGE DISTANCES

Air clearance Creepage distance

Clean 15 40

Dirty 25 55

6.1.8 No contact pressure shall be transmitted through insulating materials and the gripping of the conductors shall normally take place between metal surfaces.

6.1.9 Suitable hooks/lugs for lifting the traction alternator, auxiliary generator, and exciter with crane shall be provided.

6.2 STATOR

6.2.1 The stator core shall be built up from low loss steel stampings (Typically, the laminated material should not have watt loss more than 2.5W/Kg for traction application). The clamping of the stamping between end rings and welding of end rings with stator ribs shall be done by using superior welding techniques such as to eliminate any danger of clamps / fingers giving way due to ventilation and damaging the coil insulation. The stator core shall be laminated with a suitable inorganic insulation between laminations.

Page 10 of 46

RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01)

6.2.2 Each slot formed by laminations and end plates shall accommodate identical armature sections of the AC winding.

6.2.3 The terminal with AC bus bars shall be mounted such that the connection to rectifier can be made easily. It shall however be ensured that at the stator frame cut-outs where the three terminals of the AC windings are brought out, the insulation of the bus bar is specially reinforced. Following shall be ensured:

a) The insulating material used for the terminal board shall be impervious to moisture. b) Suitable locking shall be provided with the fastener. c) The temperature rise of the terminal block shall not exceed 70 deg. C at continuous rated current. d) The terminal block shall not rotate when tightening / loosening the terminal screws.

6.2.4 Suitable anchoring arrangement shall be made for the cables such that stress is not transferred to the termination points in the terminal box.

6.2.5 Easily accessible field connections shall be ensured preferably by providing side mounted junction box.

6.3 ROTOR

6.3.1 The mounting arrangement of rotor poles on the rotor hub shall be designed such as to eliminate any danger of pole lifting even at 1.2 times the maximum alternator rotational speed. The rotor poles shall be of laminated steel, bolted in place for easy maintenance. The coil-to-coil and field to slip ring connections shall preferably be of brazed type.

6.3.2 The rotor field coil fitment in the salient pole piece shall be done such that the chances of the coil loosening on the pole are minimized. This shall be achieved by following a coil consolidation process such that the desired height of the coil is achieved with a high degree of tolerance.

6.3.3 The rotor slip ring assembly should be of stainless for corrosion resistance and firmly screwed to shaft assembly.

6.3.4 The rotor slip ring assembly would be dynamically balanced such that the residual unbalance is not more than 20 grams meter.

6.3.5 Suitable arrangement shall be provided for dynamic balancing of the complete rotor assembly by means of adjustable weights.

6.3.6 Tolerance on dimensions of the slip ring shall be as per IEC-60356 (1971).

6.3.7 The rotor and slip ring assembly shall be so mounted on the rotor shaft so as to facilitate re-shafting, during maintenance, without disturbing the rotor windings and slip ring connections.

6.3.8 The slip ring shall have a safe wearing depth to allow for a sufficient number of resurfacing operations. Page 11 of 46

RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01)

6.3.9 Connection of slip rings with rotor field coil shall be done preferably by using flexible cables.

6.4 INSULATION SYSTEM

6.4.1 The complete stator coils and connection assembly shall be vacuum-pressure impregnated with solvent-less resin. Rotor and stator coils should be provided with suitable moisture impervious sealing insulation. The Insulation scheme adopted for traction alternator of 3100/3300hp loco shall be as per RDSO drawing No. SKDP-3355 (latest revision) and SKDP-3619 (latest revision). Resins and varnish used for traction machines shall be confirming to RDSO document no. MPMI-153/92 (latest revision).

6.4.2 The coil insulation shall be pressure molded in such a manner that the exact coil contour related with the pole profile is achieved. The rotor coil surface mating with the pole shoe shall be provided with a smooth surface by special treatment during molding or otherwise to ensure proper heat transfer to the pole shoes.

6.4.3 The stator and the field coil shall be given an anti-tracking coat by spray application of a suitable furnishing varnish to obtain a smooth surface.

6.4.4 The maximum electric stress in the armature and field coils in service shall be well below the corona inception voltage.

6.4.5 The insulation system to be employed shall be particularly designed to withstand the adverse environmental conditions. The materials comprising this system and preferably the system itself shall have been proved to be of the highest reliability in traction application.

6.4.6 Having regard to the system of insulation adopted and the environmental conditions, the manufacturer shall provide maximum possible margins in temperature rise, for prolonged life of the traction alternators.

6.4.7 The temperature rise of traction alternator during type/routine tests shall be limited to TI – 80 deg C for both stator and rotor, it being clearly understood that no alternator exceeds this limits. The permissible temperature rise shall be 85 deg. C on slip ring. TI is the established Temperature Index for the alternator rotor and alternator stator insulation systems as determined by tests.

6.4.8 The requirements indicated in clause 6.4.7 are based on international standards. However, if the manufacturer has tested the traction machines as per ARR requirements or any other internationally recognized test scheme, the tests for determination of TI can be waived by RDSO on furnishing alternative test results by manufacturer, to the full satisfaction of RDSO.

6.4.9 The alternator shall be designed such that the “hot spot” temperature under any condition of loading in any winding (stator or field) does not exceed the average temperature of the winding (measured by resistance method) by more than 15 deg. C and remains at least 25ºC below the thermal endurance limit.

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RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01)

6.4.10 Alternatively, if the vendor offers an alternator with a proven insulation scheme for which the determination of Temperature Index (TI) has not been done, the temperature rise shall be limited to:

i) IEC-60349 limits minus 30ºC for stator windings ii) IEC-60349 limits minus 20ºC for field windings iii) 85ºC for slip ring.

The evaluation of the insulation system in this case shall be completed within a specific time frame decided mutually between the vendor and the RSDO. The temperature rise limit shall be limited to those given in clause 6.4.7 after determination of the temperature index.

6.4.11 Special protection shall be taken in strengthening the insulation, electrically and mechanically, at bends of the coils and edges of slot etc.

6.4.12 The overhang portion of the coil shall not only be reinforced at the coil noses and bends but the complete coil overhangs shall be additionally insulated.

6.5 END SHIELD & BEARINGS

6.5.1 Suitable end shield of robust construction shall be used. The bearing housing shall be provided in the end shield.

6.5.2 The rotor shall be mounted on anti-friction cylindrical roller bearings of standard make and dimensions. The bearings shall be of sealed type. Normally the overhauling of traction alternators is scheduled for 8 years. This should be taken care of in the design of alternator specially from the greasing point of view. Bearing shall be sourced from RDSO approved vendors for use in Alternators.

6.5.3 The bearings shall have the basic life rating L10, as calculated vide ISO 281 recommendation, of at least 2 million kms.

6.5.4 Provided that the static and dynamic loadings are well within the permissible limits, the roller bearings type with C4 radial clearances should be adopted for the alternator.

6.5.5 The bearings used should be of rivet-less cage type, roller guided, cylindrical cage pocket profile with drop roller feature and logarithmic profiled rollers.

6.5.6 Maximum permissible speed of the rotor shall not exceed the catalogue limiting speed of the bearing. The rolling elements and lubrication arrangement will be so designed that the working temperature of the bearings shall be well within the catalogued limits under worst operating conditions.

6.5.7 A built in safe guard in the design of bearing housings to prevent over greasing shall be preferred. Provision shall be made to prevent leakage of lubricating oil.

6.5.8 In existing Auxiliary Machines, use of bearing with rubber oil seal is preferred as it prevent leakage of lubricating oil in to machine. Page 13 of 46

RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01)

6.6 BRUSH GEAR

6.6.1 The brush box design shall be such that the brushes always ride in the center of the slip rings, this being achieved by easy adjustments provided for in the drawings.

6.6.2 The brush holder mounting stud shall be rigidly attached to the stator and provided with proper insulation to give the necessary protection against creepage to earth. The mounting of the brush holder on stud shall be such as to maintain it square against the slip ring in all conditions. Suitable provision for radial adjustment of the brush holder to correct for slip ring wear shall be provided.

6.6.3 Design of the brush holder springs shall be such that spring pressure remains fairly constant over the entire working length of the brushes.

6.6.4 Carbon blocks shall be confirming to RDSO Spec. No. MP.0.2400.60 (latest revision) and letter no. EL/2.2.70 dated 25-06-2014. Carbon Brushes for 3100/3300hp Traction Alternator shall be confirming to drawing no. SKDP-3818 (latest revision). Carbon Brushes and insulating pin for Auxiliary machines of 3100/3300hp locomotives shall be confirming to drawing no. SKDP-4097, SKDP-4098, SKDP-3543 (latest revision). It shall be possible to remove and put back the brushes easily during inspections. Separate spring rests will be included to hook the spring in released position for attending to the brushes.

6.6.5 Lightweight inspection covers shall be provided on the slip ring end for inspection/air- blowing/cleaning. The inspection covers shall preferably be of spring latch hinged or screwed type.

6.7 ALTERNATOR FAN

6.7.1 In case of self ventilated alternators, an alternator fan fixed on to the rotor by spigoting and bolting to the hub shall be provided. For forced ventilated alternator, all the relevant details of the blower motor with its mounting and input power supply shall be furnished by the supplier.

6.7.2 The fan shall be designed such that it can be gripped by a barring handle used for rotating the crankshaft manually for engine inspection. RDSO drawing SKDP-3287 (latest revision) shall be referred for Traction Alternator mounting arrangement on Loco with 251B Engine and 251D Engine.

6.7.3 The vendor shall establish by providing suitable data / curves that fan is designed for the correct air delivery with some margin without resulting in excessive power consumption. In case power rectifier is also cooled by this air, sufficient air delivery shall be established for both alternator and rectifier.

6.7.4 The alternator fan shall be dynamically balanced.

Page 14 of 46

RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01)

7.0 TORSIONAL VIBRATION ANALYSIS

7.1 After placement of order, the manufacturer shall furnish complete relevant data and dynamic system details pertaining to proposed traction alternator / auxiliary machines required for carrying out torsional vibration calculation. The manufacturer shall also furnish complete set of dimensional drawings required for calculation of mass elastic data i.e. mass moment of inertia, stiffness of different shafting, etc. Material specification and the permissible vibration stress values of different shaft sections of the proposed system shall also be indicated by the manufacturer. Dynamic system details of the diesel engine and other auxiliary attachments of existing locomotive will be supplied by RDSO to the manufacturer to assist them in deciding the dynamic system details by some approximate analysis. The details indicated here shall be submitted by the manufacturer to RDSO, well in advance of the actual manufacture, for scrutiny and approval.

7.2 Verification of the torsional matching of the equipment offered with the existing loco equipment shall be done by RDSO by carrying out detailed torsional vibration analysis.

7.3 The manufacturer shall be prepared to carry out modifications in the design of offered equipment, if considered necessary, from the torsional matching considerations.

8.0 SCHEDULE OF PARTICULARS, DRAWINGS & AS-MADE TRACINGS

8.1 The vendor shall furnish all relevant design data, curves, calculations, technical specifications, test results, relevant equipment drawings and descriptive write-up of all the offered equipment viz. traction alternator, auxiliary machines, gear train set, PTU etc. necessary for correct appreciation of the offer. The technical data and particulars of the Traction Alternator, Auxiliary Machines and subassemblies shall generally be in line with the proforma at ANNEXURE - M. As many of these data as would be relevant and applicable should be incorporated in the corresponding drawings themselves.

8.2 Complete manufacturing drawings will be supplied after acceptance of the vendor for the replaceable wearing out components such as rotor shafts, rotor poles, bearing housing, end fittings, brush holders, carbon brushes, rubber components etc. Complete details of manufacturing process & QA plan for Traction Alternator, Auxiliary Machines and subassemblies along with insulation schemes of stator & rotor shall also be submitted.

8.3 The successful vendor shall prepare and submit to complete working drawings in duplicate for scrutiny and approval by Indian Railways / RDSO, before taking up manufacture of the equipment.

8.4 Approval of the drawings would mean approval of general adaptability of design features to local conditions of service. Indian Railways will not be responsible for the correctness of the dimensions in the drawings, the material used, the adequacy of the designs for the satisfactory performance of the equipment, etc. for which the supplier will be wholly and completely responsible.

8.5 After all the drawings have been finalized including any modifications found necessary as a result of prototype testing and trials, five complete sets of 'as made' tracings as well as soft Page 15 of 46

RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01) copies shall be supplied to the Indian Railways & RDSO and shall include full dimensional drawings of all assemblies, sub-assemblies, component parts including proprietary fittings.

8.6 The drawings of the Traction Alternator, Auxiliary Machines and other equipment shall be fully detailed and self-explanatory. All important dimensions shall be figured. The drawings shall contain all essential data, material specifications, explanatory notes including limiting values in service etc.

8.7 All documents shall be in English. One additional copy of the drawings and other documents shall be supplied on soft copy indicating details of the hardware and software requirement suitable for latest release of Auto-Cad and IBM compatible PCs.

8.8 In case the vendor is unable to submit some particular data / calculations or drawings, the reason for not doing so shall be clearly stated.

9.0 SPARES & TOOLS

The vendor shall submit a list of spares required for the operation & maintenance of all the offered equipment including Traction Alternator, Auxiliary Machines, subassemblies and any other accessories as offered by them.

10.0 MAINTENANCE MANUALS

10.1 Maintenance manuals complete with necessary drawings and photographs for guidance in the installation, operation, trouble shooting and maintenance of all the offered equipment e.g. Traction Alternator, Auxiliary Machines and subassemblies etc. shall be supplied free of cost at the rate of one manual for every equipment.

10.2 Rewinding / Rehabilitation of the traction alternator and auxiliary machines shall be taken up by Indian Railway units whenever necessary after expiry of warranty. Complete technical information shall be provided by the vendor in the form of `Rewinding Manual' for satisfactory rewinding/rehabilitation of the machines.

10.3 A lubrication chart shall also be enclosed containing the manufacturer's recommendations on available standard lubricants, quantity and periodicity of lubricants, etc.

11.0 TESTING, COMMISSIONING & PROTOTYPE TRIALS

11.1 All the major equipment covered under scope of supply shall be subjected to type and routine tests at the manufacturer's premises in presence of RDSO and DLW officials at his own responsibility and cost before shipment / dispatch. The manufacturer shall provide all the facilities / instrumentation etc. for the tests.

11.2 The type test shall generally be conducted as per following list : a) Traction alternator : IEC – 60349 c) Auxiliary machines : IEC – 34.1 Page 16 of 46

RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01)

However, for each equipment, the vendor may also propose alternative test standards giving full details to justify the test standard. Type and routine test programme shall be drawn by the manufacturer in consultation with RDSO. If the vendor is not prepared to conduct any type test of particular equipment for any reason or any particular clause of IEC / IEEE or relevant specification, reason should be furnished to RDSO for consideration or else, it will be presumed that the vendor is willing to conduct all the type tests as per the specification. This will include all the optional tests also

11.3 The manufacturer shall formulate and submit an inspection and routine/acceptance test protocol for approval of RDSO before undertaking manufacture.

11.4 The manufacture shall demonstrate matching and integration of all the equipment under the scope of supply, as a complete system through simulated testing.

11.5 After tests, one prototype traction alternator complete with auxiliary machines and subassemblies will be first dispatched to examine it’s correct fitment on the existing locomotive and matching/alignment with the ALCO 251-B engine. Inter-changeability aspect of Auxiliary Machines with that of other make. The modifications, if required, will be checked up and carried out accordingly by the manufacturer at site.

11.6 The complete Traction Alternator Assembly shall be subject to Load box testing as per MP.MI-10 (latest revision) and verification of load characteristic curve.

11.7 This locomotive with prototype equipment will be subjected to extensive service trials for a period of at least twelve months or more as deemed necessary by the purchaser to prove the design, equipment performance, maintainability and reliability. All modifications found necessary based on these limited service trials to improve upon the equipment design and physical construction, and as mutually agreed, shall be incorporated in the prototype and also in series supplies of the equipment at the cost of the supplier and in the manner approved by the purchaser. The service trials shall generally cover the following:

a) Observations of the mechanical & electrical condition of the equipment including wear and tear. b) Temperature rise of the various parts of equipment. c) Overall reliability and maintainability aspects.

11.8 The detailed scheme of prototype trials to satisfy the above shall be indicated by the supplier and mutually finalized in consultation with the purchaser. Special instrumentation, if any, for correct appreciation of the various data will have to be arranged by the supplier.

12.0 EVIDENCE OF PERFORMANCE

Documentary evidence to the effect that the electrics offered by the vendor are proven and that same/similar electrics have been used by other Rail Roads for their Diesel Electric Locomotive application & have given trouble free/guaranteed performance, shall be furnished.

Page 17 of 46

RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01)

13.0 PACKING / MARKING

13.1 All the offered equipment including Traction Alternator, Auxiliary Machines and subassemblies shall be provided with suitable rating plates giving usual information including the following:

• Manufacturer's name • Type and serial number of equipment. • Date of manufacture. • Rated output KW/HP. • Rated voltage. • Rated current. • Rated speed (for machines only). • Insulation level (for machines only).

13.2 Rating plate shall be clearly visible when equipment are installed in position.

13.3 Identification numbers shall also be suitably stamped on non-interchangeable matched components to facilitate assembly and to prevent mixing up of the components.

13.4 All the equipment shall be suitably packed in wooden waterproof boxes to prevent damage during transit and handling.

14.0 WARRANTY

All the equipment shall be guaranteed for satisfactory performance for a period of three years from the date of commissioning. All aspects of workmanship and design shall be covered by this warranty. Only wearing parts, which require recurring replacements shall be excluded. A list of such parts shall be furnished by the supplier in the technical offer. The warranty shall include:

a) Replacement of defective components free of cost by the supplier. b) The supplier shall provide free of cost assistance in replacement of defective components / assembly at the site. c) Any specialized tools etc. not available with Indian Railways shall be supplied by the supplier.

15.0 TRAINING

Successful vendor shall also arrange free of cost training of IR personnel at the premises of manufacturer or of sub-contractors in the field of design appreciation, quality control, inspection and maintenance of the equipment supplied, for a period to be mutually decided upon. To and fro fare and living expenses shall, however, be borne by IR.

Page 18 of 46

RDSO SPECIFICATION NO. MP.0.2402.19 (REV. 01) ANNEXURE - A

TRACTION ALTERNATOR TA10102EV CHARACTERISTICS INPUT TO TRACTION : 2950 HP AT 1050 RPM

HV CONT. RATING : 1075V, 1938A, 2083KW, 1050RPM LV CONT. RATING : 585V, 3600A, 2106KW, 1050RPM

1200 1150 1100 1050

1000 Efficiency 100 950 900 90 850 800 750 700 650 600 550 500 450 DC TERMINAL DC TERMINAL VOLTS 400 350 300 250 DRAFT 200 150 100 50 0 0 1000 2000 3000 4000 5000 DC LOAD AMPS D K. Bhattacharya C K. Bhattacharya RDSO REF : APPD. (MP) BHEL CURVE No. Dir/EM/MP TME/401290

Page 19 of 46 RDSO SPECIFICATION NO. MP.0.2402.19 (REV. 01) ANNEXURE - B

RHP SPEED TE ADH PERFORMANCE0 0 40800OF WDM3D(3300 39000 HP) HP BG DE LOCOMOTIVE 2450 17.5INPUT 37800 TO TRACTION 35000 - 2950 HP AT 1050 RPM 2644.444 21 340001 - TA 33790.52 10102 EV Traction Alternator 2648.148 22 325006 - 33576.78 TM 4907 BZ Traction Motor 2668.519 27.5Wheel 26200 Dia.(Half Worn) - 1055 mm, Gear Ratio - 18:65 2492 35Motor 19224Combination - 2S-3P FF, 2S-3P 49%FF & 6P FF 2492 40Starting 16821 TE - 39000 Kg., Max. Speed - 120 Km/h 2492.037 50Cont. loco. 13457 speed - 25.4 Km/h, Cont. loco.TE - 26550g. 2492Transition 60 Speed 11214 : (i) 42 Km/h (Forward), 39.5 Km/h (Backward) 2492 70 9612 (ii) 65 Km/h(Forward), 62.5 Km/h (Backward) 2492.148 80 8411Adhesive weight of Loco: 118.2T 90 7476 2491.852 100 6728 110 6116 249240000 120 5607 38000 Adhesion : 33% 36000 34000 32000 30000 28000 26000 24000 22000 20000 18000 IVE EFFORT (Kg) EFFORT IVE

T 16000 14000 TRACTIVE 12000 DRAFT 10000 8000 6000 4000 2000 0 0 20406080100120 SPEED (Km/h) RDSO (MP) GDP - 1131(Rev 0.01)

Page 20 of 46 RDSO SPECIFICATION NO. MP.0.2402.19 (REV. 01)

ANNEXURE - C

0 1130 0 500 1120 10 1010TRACTION 1113 ALTERNATOR 16 TA10102 CW CHARACTERISTICS 1520 1106INPUT 28TO TRACTION : 2750 HP AT 1050 RPM 1760 1100HV CONT. 30 RATING 920 : 1100V, 1760A, 1936KW, 92 1050RPM 2000 972LV CONT. 35RATING 925: 525V, 3700A, 1942.5KW, 92.5 1050RPM 2500 782 44 930 93 3000 650 57 930 93 35001200 555 72 927.5 92.75 4000 485 85 920 92 1150 4200 460 93 44001100 100 100

1050

1000 Efficiency 950 100 900 90 850

800

750

700

650

600

550

500 DC TERMINAL DC TERMINAL VOLTS 450

400 350 DRAFT 300

250

200

150

100

0 0 1000 2000 3000 4000 5000

DC LOAD AMPS

Page 21 of 46 RDSO SPECIFICATION NO. MP.0.2402.19 (REV. 01) ANNEXURE - D

0 30450 43000 4300 PERFORMANCE OF 3100 HP WDM3A BG DE LOCOMOTIVE 6.4 29400 42600 4275 7.8 29300 425002750 HP INPUT TO TRACTION 4250 8.2 292001 - TA 42400 10102 CW TRACTION ALTERNATOR 4240 9.3 290006 42300 - TM 4906 AZ TRACTION MOTOR 4220 10 28900Wheel Dia.(Half 42200 Worn) - 1055 mm, Gear 4200 Ratio - 18:65 12.5 28700Motor 42000 Combination - 2S-3P FF & 3800 6P FF 17 28400Starting 35000 TE - 30450 Kg., Max. Speed 3343- 120 Km/h 21.9 28050Cont. loco. speed 31400 - 22.8 Km/h, Cont. loco.TE 2700 - 28050 Kg. 25.3 26000Transition 28000: Forward - 47.5 Km/h, Backward 2300 - 45 Km/h 30 22000 25000 1800 1800 40 16300 20000 3600 3600 47.5 13200 18000 2900 47.5 13200 35000 35000 2400 50.6 12400Adhesion 34000 2100 70 9100 27200 1500 40000 = 0.27 90 7100µ 23000 100 6200 21300 110 5800 20000Alternator Rectified Current/Speed 120 5500 19000 Alternator Current 2S-3P FF

30000 Alternator Current 6P

20000

e TE 6P FF g)/Rectifier Output Current/10(Amps) K

10000 DRAFT TE(2S-3P) FF

Tractive Effort (Kg)/R Effort Tractive Tractive Effort/Speed

0 0 20406080100120 D KB Speed (Km/h)

C HG Ref : RDSO GDP - 1034 APPD. JD/EM (MP)

Page 22 of 46 RDSO SPECIFICATION NO. MP.0.2402.19 (REV. 01) ANNEXURE - E

0 790 0 500 780 0 1000TRACTION 775 ALTERNATOR 7 TA10106AZ/BZ CHARACTERISTICS 1200 770FOR 8 2300 HP WDP1 Locomotive 1600 767 10Inut 945to traction : 2025 HP 92.5 1850HV 760 CONT. RATING 12 950: 760 V, 1850A,1406 93KW, 1000 RPM 2000LV 710 CONT. RATING 15 : 950 413 V, 3400A, 1404 93 KW, 1000 RPM 24001050 597 16 950 96 3000 480 20 950 96 36001000 395 25 945 100 4000 355 27 945 92 100 4200950 335 28 940 4400 30 30 900 90 90 850

800

750

700

650

600

550

500

450

400 DC TERMINAL VOLTS DC TERMINAL 350

300

250 200 DRAFT 150

100

0 0 500 1000 1500 2000 2500 3000 3500 4000 4500 DC LOAD AMPS D Sudhakar Kumar

C K. Bhattacharya

APPD V. Khare / Dir / EM

Page 23 of 46 RDSO SPECIFICATION NO. MP.0.2402.19 (REV. 01) ANNEXURE - F

0 20000 22000 4400 PERFORMANCE OF 2300 HP WDP1 BO - BO LOCOMOTIVE 6.4 18700 21750 4350 7.8 184002000 21650 HP(SITE) INPUT TO TRACTION 4330 8.2 183001 - TA 21600 10106 AZ TRACTION ALTERNATOR 4320 9.3 182004 21550 - TM 4906 AZ TRACTION MOTOR 4310 10 18050Wheel Dia.(Half 21500 Worn) - 1055 mm, Gear 4300 Ratio - 18:65 12.5 17800Motor 21400 Combination - 4P FF & 4P 428049% FF 17 17300Starting 21100 TE - 20000 Kg., Max. Speed 4220- 130 Km/h 20 17100Cont. loco. 21000 speed - 29 Km/h, Cont. loco.TE 4200 - 16400 Kg. 24.8 16740Transition 19500 : Forward - 50 Km/h, Backward 3900 - 48 Km/h 29 16400 18000 3420 40 12200 14900 2980 5025000 10000 12850 2570 3240 50 10000Adhesion 16200 16200 70 7000 13200 2640 = 0.25 90 5300µ 11100Alternator Current 2220 100 4700 103004P FF 2060 110 4200 9700 1980 12020000 3800 9200 1840 130 3600 8950 1790

Alternator Rectified Current/Speed

15000 Alternator Current 4P 49% FF

R 10000 g)/Rectifier Output Current/5(Amps) Output g)/Rectifier K TE 4P 49%FF TE 4PDRAFT FF 5000 Tractive Effort/Speed Tractive Effort (Kg)/ Effort Tractive

0 0 20 40 60 80 100 120 140 D KB Speed (Km/h)

C HG Ref : APPD. RDSO GDP - 1059 JD/EM (MP)

Page 24 of 46 RDSO SPECIFICATION NO. MP.0.2402.19 (REV. 01) ANNEXURE - G

0 780 0 TRACTION500 765 ALTERNATOR 12 TA10106CY CHARACTERISTICS 1000 755 25 WDS6 Locomotive 1125 750INPUT 27 TO TRACTION 935 : 1200 HP AT 1100 RPM 1500 580HV CONT. RATING 35 : 945 750V, 1125A, 843.75 92.5 KW, 1100RPM 2000 425LV CONT. 45RATING 948: 225V, 3660A, 823.5KW, 93 1100RPM 2500 335 55 940 93 100 30001000 280 68 925 92.75 3500 235 80 3660950 225 85 3800 87 87 900 92 90

850 Efficiency 800

750

700

650

600

550

500

450

400 DC TERMINALVOLTS 350

300

250 200 DRAFT 150

100

0 0 500 1000 1500 2000 2500 3000 3500 4000 4500 DC LOAD AMPS

Page 25 of 46 RDSO SPECIFICATION NO. MP.0.2402.19 (REV. 01) ANNEXURE - H

0 34000 8.2 31500 8.5PERFORMANCE 30300 CURVE OF WDS6 (1400 HP) 10.9 23580 20.7 12600 DIESEL ELECTRIC LOCOMOTIVE 30 8400 INPUT TO TRACTION:1201HP at 1100 RPM 40 6000 1 - TA 10106 CY Traction Alternator 50 4700 6 - TM 4907 BZ Traction Motor 60 3900Gear Ratio : 18:74, Wheel Dia.(Half Worn) : 1055 mm 70 3350Cont. Loco. Speed : 7.1 km/h, Cont. Loco.TE : 30,000 Kg. 80 2950Starting Tractive Effort : 34000 Kg., Max Speed : 70 Km/h 90 2600 Locomotive Weight - 126 T 100 2350

36000

Adhesion - 27% 32000

28000

24000

20000 f Effort (Kg) e 16000

Tractive E Tractive 12000 DRAFT

8000

4000

0 0 10203040506070 Speed (Km/h)

Page 26 of 46 RDSO SPECIFICATION NO. MP.0.2402.19 (REV. 01) ANNEXURE - I

0 40TRACTION MOTOR TM 120 4907BZ PERFORMANCE CHARACTERISTICS 100 70 70(TM PERFORMANCE 98 AT 325V 62 WITH 100% FF) 150 210 175CONT. 76.8 RATING 120: 1000A, 325V, 71 280KW, 430RPM 200 460 350ONE HR. 56 RATING 100 : 1060A, 78.9 305V, 278KW, 395RPM 92 300 805 700WHEEL DIA. : 1055 41.6 mm, 71.5GEAR RATIO 86 : 18/65, RPM : KPH 92.5 x 18.159 4007500 1295 1015 32 55 90 93 140 500 1820 1330 28 46.5 91 93 7000 130 600 2300 1645 26.5 42 90 92.75 7006500 2870 1960 25.5 39 89.5 92 120 800 3430 2380 24.5 37 89 6000 110 900 3955 2800 23.5 35.5 88.5 5500 1000 4550 3150 23Efficiency 34 88 100 11005000 5140 3710 22 32 87 90 1200 5705 4165 21 31.5 86 4500 1300 6335 4655 20.75 31 85 80 14004000 7105 5250 20.5 30.5 84.5 70 3500 60 3000 50 2500 40 2000 SPEED (Km/h) & (Km/h) SPEED EFF.(%) TRACTIVE EFFORT(Kgs.) 1500 30 1000 20 500 10 0 DRAFT 0 D 0 100 200 400 600 800 1000 1200 1400 MOTOR CURRENT (Amps.) REF : BHEL CURVE No. TME/401282 C RESISTANCE IN OHM AT115Deg.C RDSO GDP - 1126 APPD. Armature :- 0.0115, Series Field(FF) :- 0.0076 (MP) Interpole :- 0.0084, Arm. Ckt. :- 0.0254

Page 27 of 46 RDSO SPECIFICATION NO. MP.0.2402.19 (REV. 01) ANNEXURE - J

TRACTION MOTOR TM 4907BZ PERFORMANCE CHARACTERISTICS 0 (TM PERFORMANCE AT 325V WITH 49% FF) 40 CONT. RATING : 1000A, 325V, 280KW, 430RPM 100 70 ONE HR. RATING : 1060A, 305V, 278KW, 395RPM 150 220 120WHEEL 60 DIA. : 1055 mm, GEAR RATIO : 18/65, RPM : KPH x 18.159 200 410 96 70.9 6000 ( 130 300 700 72.4 80.4 4005500 1015 55.6 86 120 500 1330 46.5 88.5 6005000 1645 42 89 110 700 1960 39 88.5 100 8004500 2380 37 87 Efficiency 900 2800 35.5 86 90 4000 1000 3200 34 85.5 80 11003500 3710 32 85 1200 4165 31.5 84.75 70 13003000 4655 31 84 1400 5250 30.5 83 60 2500 50 2000 40 1500

TRACTIVE EFFORT(Kg.) 30 SPEED (Km?h) & (Km?h) EFF.(%) SPEED 1000 20 500 10 0 DRAFT 0 0 100 200 400 600 800 1000 1200 1400 D ARMATURE CURRENT (Amps.) REF : BHEL CURVE No. TME/401280 C RESISTANCE IN OHM AT115Deg.C Armature :- 0.0115, Series Field(FF):- 0.0076 RDSO GDP - 1127 APPD. Interpole :- 0.0084, Arm. Ckt. :- 0.0254 (MP)

Page 28 of 46 RDSO SPECIFICATION NO. MP.0.2402.19 (REV. 01) ANNEXURE - K

0 120 100 70TRACTION MOTOR TM 105 5002BY PERFORMANCE 62 CHARACTERISTICS 200 500 350(TM PERFORMANCE 61.4 100 AT 78.9 350V WITH 100% FF) 92 300 860 700CONT. 44.7 RATING 71.5 : 925A, 380V, 86 310KW, 530RPM 92.5 400 1300 1015ONE HR. 36 RATING 55 : 950A, 370V, 90 310KW, 511RPM 93 500 1850 1330WHEEL DIA. : 1055 31 mm, 46.5GEAR RATIO 91 : 18/65, RPM : KPH 93 x 18.159 6008000 2400 1645 28 42 90 92.75 140 700 3000 1960 27 39 89.5 92 7500 130 800 3600 2380 25 37 89 7000 900 4200 2800 24 35.5 88.5 120 10006500 4900 3150 23 34 88 110 11006000 5550 3710 22 32 87 1200 6150 4165 21.5 31.5 86 100 5500 Efficiency 1300 6850 4655 21 31 85 90 14005000 7550 5250 20 30.5 84.5 4500 80 4000 70 3500 60 3000 50 2500 40 2000 SPEED (Km/h) & (Km/h) SPEED EFF.(%)

TRACTIVE EFFORT(Kgs.) 30 1500 1000 20 500 10 0 DRAFT 0 D 0 200 400 600 800 1000 1200 1400 MOTOR CURRENT (Amps.) REF : BHEL CURVE No. TME/401293 C RESISTANCE IN OHM AT115Deg.C RDSO GDP - APPD. Armature :- 0.0151, Series Field(FF):- 0.0085 (MP) 0 Interpole :- 0.0065 Arm. Ckt. :- 0.0216 110 50 160 46

Page 29 of 46 RDSO SPECIFICATION NO. MP.0.2402.19 (REV. 01) ANNEXURE - L

200 250 90.8 73.4 300 550TRACTION 61 84 MOTOR TM 5002BY PERFORMANCE CHARACTERISTICS 400 1000 46.5 88 (TM PERFORMANCE AT 350V WITH 70% FF) 500 1550 38 89.7 CONT. RATING : 925A, 380V, 310KW, 530RPM 600 2050 35 90 ONE HR. RATING : 950A, 370V, 310KW, 511RPM 700 2550 32WHEEL 90 DIA. : 1055 mm, GEAR RATIO : 18/65, RPM : KPH x 18.159 800 3050 30 89.7 7000 170 900 3550 28 89.5 10006500 4100 27 89.2 160 1100 4600 26 89 150 6000 1200 5100 26 88.5 140 5500 1300 5600 25 88.4 130 1400 6300 24.5 88 5000 Efficiency 120 4500 110 4000 100 90 3500 80 3000 70 2500 60 2000 50

TRACTIVE EFFORT(Kg.) 40 1500 & (Km?h) EFF.(%) SPEED 30 1000 20 500 10 0 DRAFT 0 0 200 400 600 800 1000 1200 1400 D ARMATURE CURRENT (Amps.) REF : BHEL CURVE No. TME/401304 C RESISTANCE IN OHM AT115Deg.C Armature :- 0.0151, Series Field(FF):- 0.0085 RDSO GDP - APPD. Interpole :- 0.0065 Arm. Ckt. :- 0.0216 (MP)

Page 30 of 46 RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01)

ANNEXURE - M

TECHNICAL DATA OF TRACTION ALTERNATOR

The following data / description shall be supplied by the manufacturer:

1.Description of alternator :Make & Type

2.Classification :No. of poles, phases and phase connections. 3.Application :Class of loco./ loco HP

4.Excitation :Mode of excitation

5.Max. permissible speed :

6.Winding resistance and impedance at 50 Hz (at 25 deg. C and 115 deg. C)

a) Stator winding (phase to phase) : b) Rotor winding :

7. Ratings (DC Output)

a) LV One hour : LV Continuous :

b) HV One hour : HV Continuous :

c) Short circuit current (max.) :

8.Design Ratings

a) At max. Permissible RPM: Max. input to traction (KW) : Max voltage :

b) At 1050 RPM: Max. input to traction (KW) : Max voltage :

c) At 1100 RPM: Max. input to traction (KW) : Max voltage :

d) Max design rating (LV) : Max design rating (HV) :

e) Short circuit current : Page 31 of 46

RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01)

f) Max. permissible RPM :

9. Class and type of insulation: Stator winding : Rotor winding :

10. Insulation and securing details for stator winding connectors, coil to coil connectors and coil to slip ring connectors. :

11. Temperature rise limit. Stator winding : Rotor winding : Slip Ring :

12. Alternator power take off gear trains and gear case details : (if applicable )

13. Slip ring details. a) No. of slip rings : b) Dia. of slip ring (new) : c) Maximum permissible ovality :

14) Brush gear details. Number of brush arms : Number of brush holder / arm : Number of brush / brush holder : Brush size : Brush grade : Spring pressure on new brush : Minimum length (length at which brush becomes inoperative) : Clearance between brush and slip ring :

15) Stator details: Overall dimension : Core length : Weight : No. of slots : Slot size : Punching O.D. : Punching I.D. : Punching thickness :

Page 32 of 46

RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01)

Winding details: : (a) Conductors per slot : (b) Conductor size (bare) : (c) Conductor size (with insulation ) :

Flux density at continuous rating.

Core LV...... HV...... Air gap LV...... HV...... Core Volume...... cm³

Current density(amps/mm²) continuous...... for...... amps. 1 hour...... for...... amps.

Turns per coil...... Coil throw...... Length mean turn...... weight of copper...... Kg. Tooth volume...... cm³

16. Rotor details

Type of poles : No. of poles : Length of rotor : Pole strength : Rotor O.D. : Rotor I.D. : Air gap : • At pole center...... • At pole tip......

Pole securing arrangement......

Type of winding : Type of connections : Rotor pole run-out : Slip ring run-out : Distance between coupling flange and bearing abutment race......

Rotation......

17. Type and particulars of terminal box :

Page 33 of 46

RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01)

18. No. and type of bearing :

a. Diametrical slackness of free bearing when new : b. Fit between inner race and shaft : c. Fit between outer race and bearing housing : d. Minimum diametrical clearance when assembled in machine : e. Lubricant : f. Grease capacity : g. (initial filling) :

19. Magnetic circuit HV Rating LV Rating Const. One hr. Const. One hr. a) AT/pole of stator core b) AT/pole of stator teeth c) AT/pole of air gap d) AT/pole of rotor poles e) AT/pole of rotor run

20.Cooling :Type of cooling ( self / forced) CFM...... at 1000 RPM

21. Weight of alternator a) Stator : b) Rotor : c) Fan : d) Alternator without gear box and auxiliaries : e) Alternator complete with gear box and auxiliaries :

22. Mass moment of inertia : HP consumed by fan (at 1000 RPM) a) Without auxiliaries : b) With auxiliaries :

23. (a) Impedance at maximum RPM Direct Axis Quadrature Axis (i) Stator winding (ii) Rotor winding (iii) Damper winding (solid poles) (iv) Armature reaction (v) Synchronous (vi) Transient (vii) Sub-transient

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RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01)

(b) Time constant Open circuit Short circuit (i) Field winding (ii) Damper winding (solid poles) (iii) Armature S.C. time constant

Maximum short circuit fault current at:

(i) Alternator loaded on full RPM at top corner voltage: (ii) Alternator loaded on full RPM at constant rating:

24. Characteristic curves:

a) Constant HP curve b) Excitation current Vs load current c) Efficiency Vs. Load current d) OCC and SCC at rated speed e) Load saturation curve f) Natural load curves g) VI related curves h) Output waveform (AC non-rectified) at first notch and top notch PRM.

25. Drawings

a) Outline and assembly b) Longitudinal and cross section c) Stator assembly d) Stator star connection and bus bar arrangement e) Rotor assembly including mounting of poles and pole coils f) Rotor cross section g) Insulation details of stator and rotor h) Rotor coil to coil and coil to slip ring connections layout i) Rotor shaft j) Slip ring and brush gear k) End fitting / bearing housing l) Cooling fan drawing m) Gear case n) Stator core stampings

26. Bus bar and mounting arrangement (give details)

27. Material specifications Indicates material specification in the drawings specially for rotor shaft, rotor pole, steady state, stampings, slip ring, stator copper, rotor copper.

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RDSO SPECIFICATION NO. MP.0. 2402.19 (Rev. 01)

28. Calculations

a) Strength at pole bolts b) Moment of inertia c) Shaft strength d) Bearing- load carrying capacity and rating life at load e) Estimation of temp. rise at constant rating (LV & HV) at thermal time constant f) Estimation of leakage reactance, armature reaction synchronous impedance g) Magnetic circuit analysis and estimation of Ef & V1constant rating (LV & HV) h) Estimation of losses & efficiency at constant ratings (HV & LV)

29. Service experience

Year of manufacture : Loco types to which applied : No. of machines supplied : Mean time between failures : Periodicity of maintenance : Periodicity of overhaul : Expected service life :

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