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Spec. No. RDSO/2012/EL/SPEC/0112, Rev.

GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

Main Transformer of 6500KVA with Steel tank for 3-Phase drive locomotives Type WAG-9

Specification No. RDSO/2012/EL/SPEC/0112, Rev.

2012

Approved by
Sr EDSE

Signature

ELECTRICAL DIRECTORATE
RESEARCH DESIGNS & STANDARD ORGANISATION
MANAK NAGAR, LUCKNOW- 226011

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Spec. No. RDSO/2012/EL/SPEC/0112, Rev.

Status of Revision

S.N.

Date of Revision

Page No.

Revision

Reasons for
Revision

1.

All

First Issue

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Spec. No. RDSO/2012/EL/SPEC/0112, Rev.

Index

Clause Description
No.
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
11.0
12.0
13.0
14.0
15.0
16.0
17.0

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Page Nos.

Abbreviations
FOREWORD
Scope
Climate & Environment Conditions
Standards
Description
Technical Data
Tank
Reliability Requirements
Tests
Quality Assurance Plan
Bill of Material
Documentation
Scope of Supply
Documents to be supplied by Bidder
Technical Documents to be supplied by Contractor
Declaration for Infringement of IPR by Vendors
Note
Technical data to be supplied with the offer(Annexure-A)

4
5
5
5-6
6
7-8
9-13
14
14
15-22
23
23
23-24
24-25
25
25
25
25
26-32

Additional data to be submitted by the Contractor(Annexure-B)

33-36

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Abbreviations

The following abbreviations are used in this specification:

Abbreviations Full Name

CLW

Chittaranjan Locomotive Works.

OEM

Original Equipment Manufacturer.

RDSO

Research Design and Standards Organisation.

Bidder

Shall mean firm or company participating in the tender to manufacture

of the item.

Contractor

Shall mean firm or company with whom the order to manufacture the
item has been placed.

Supplier

The successful tenderer for supply of the equipment.

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1.0

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Spec. No. RDSO/2012/EL/SPEC/0112, Rev.

Foreword

This specification covers broad features, requirement and testing of the main transformer
for 3-phase drive locomotive type WAG-9 for working with IGBT based power converters
having switching frequency 450 Hz. This locomotive is presently being manufactured by
CLW with LOT 6500 KVA capacity transformers as per their original design provided
with GTO based power converters. As on electric locomotives GTOs are getting
obsolete, IGBT based traction converters are now being provided in phased manner.
Finally, all the new locomotives are expected to be provided with IGBT based Converters
in future
The main transformer type LOT 6500 for WAG 9 locomotive compatible to work with
IGBT based converters is to be manufactured with steel tank having identical outlines
drawing to that of LOT 6500 KVA transformer. The technical parameters of
Auxiliary(BUR) winding and filter winding are almost identical with existing design of LOT
6500/7500 KVA transformer.
2.0

Scope
The scope of this specification is to design, develop, manufacture and supply traction
transformer type LOT 6500 KVA with One HV winding, Four traction windings, One filter
winding, One Auxiliary winding for used on WAG 9 locomotives with the same
dimensional envelop and mounting arrangement to that of the existing LOT 6500
transformer. The new transformer shall be designed using the latest world-wide
technology to work in conjunction with IGBT based power converters.

3.0

Climate & Environment Conditions

Atmospheric
temperature

Metallic surface temperature under Sun: 75o C max. and in

shade: 55o C max.
Minimum temperature: - 10 C (Also snow fall in certain
areas during winter season)

Humidity

Reference
conditions

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100% saturation during rainy season.

site i) Ambient Temp.: 50o C
ii) Humidity: 100%
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iii) Altitude: 1776 m above mean sea level.

Rain fall

Very heavy in certain areas. The locomotive shall be

designed to permit its running at 10 kmph in flood water
level of 102 mm above rail level.

Atmosphere
Extremely dusty and desert terrain in certain areas. The
during
hot dust concentration in air may reach a high value of 1.6
weather
mg/m3. In many iron ore and coalmine areas, the dust
concentration is very high affecting the filter and air
ventilation system.

4.0

Coastal area

Locomotive and equipment shall be designed to work in

coastal areas in humid and salt laden atmosphere with
maximum pH value of 8.5, sulphate of 7 mg per litre, max.
concentration of chlorine 6 mg per liters and maximum
conductivity of 130 micro siemens /cm

Vibration

The equipment sub-system and their mounting

arrangement will be designed to withstand vibrations and
shocks encountered in service as per IEC : 61373 unless
otherwise prescribed.

Electromagnetic
Pollution

High degree of electromagnetic pollution is anticipated in

locomotive machine room, where the equipment will be
mounted. Necessary precaution should be taken in this
regard.

Wind speed

High wind speed in certain areas, with wind pressure

reaching 150 kg/m2

Standards

The following specifications shall generally be followed for manufacture and testing of the
transformer:-

IEC-60310

- Rules for traction transformers and reactors

IEC-60076

- Recommendations for power transformers

IEC-60077

- Rules for Electrical Traction Devices

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Spec. No. RDSO/2012/EL/SPEC/0112, Rev.

IEC-61373

- Vibration & shock

IEC-60038

- Standard voltages

IEC-60296

- Transformer Oil

IEC-60529

- Degree of protection provided by enclosures.(IP-code)

IEC-60085

-Thermal evaluation and designation

IEC-60850

- Supply voltages of traction systems

EN-10025-2

- Non alloy structural steels

5.0

Description

5.1

Each loco requires one transformer for feeding supply to traction converters/ traction
motors, to auxiliary converter for supplying to auxiliary machines and to supply Hotel load
of train. This transformer will consist of Primary winding, 04 Traction windings, Auxiliary
winding (BUR). In addition, it has a FILTER winding which is connected on locomotive to
passive filter.

5.2

The transformer tank also contains 02 series resonant chokes (one for each converter) &
03 Auxiliary Converter double chokes (one for each of the 03 auxiliary converters).

5.3

The transformer has also provision of 01 additional reactors for Auxiliary(BUR) winding.
This reactor is provided to ensure the impedance of auxiliary winding similar to their
existing rating (in LOT 6500 KVA transformer with Aluminium tank) and shall be
connected internally in series with the winding and therefore, bushing terminals for this
reactor is not required on the tank cover. However, the provision of these 01 additional
reactor in the transformer is provisional and their actual requirement will be decided
based on testing results of the prototype unit.

5.4

Transformer is forced oil cooled and external cooling of the oil is designed with two
independent oil circuits with cooling units of capacity 120 KW each located within the
machine room of locomotives. However, the cooling units / circuit component do not form
part of transformer supply.

5.5

L.V. and H.V. bushings mounted on the top shall be in line with the existing bushing
mounted on the LOT 6500 KVA transformer.

5.6

The transformer main tank and its two conservators shall be made of standard steel. The
proposed outlines of the LOT 6500 KVA transformer shall have identical interfaces as
described in HSTN 003359(original outlines of LOT 6500 KVA transformer). The

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transformer is under slung mounting and therefore, the steel tank should has a provision
of 04 nos. safety chain for its fixation with under frame.
5.7

The mounting arrangement drawing of LOT 6500 KVA transformer with steel tank shall
be submitted to CLW for approval before undertaking manufacturing and prototype
testing.

5.8

Design document is required to be approved by RDSO before going for manufacturing of

the LOT 6500 KVA transformer.

5.9

Technical data to be furnished by the tenderer with the offer is given in Annexure-A.

5.10

Additional technical data to be furnished by the successful tenderer is given in

Annexure-B.

5.11

The special features of the transformer are

Transformer is mounted under slung on under frame

Transformer is designed for feeding IGBT based Power and Auxiliary converter load. The
transformer is designed to work with 450 Hz inverters switching frequency.

Approx. 30% impedance between primary & traction windings.




Very high magnetic de-couplings between traction windings

Use of continuous transposed conductor for windings

Transformer and conservator tank of Standard Steel S 355J2N(EN 10025-2)/equivalent

IS

Rapid action coupling between transformer and conservators in oil circuit

5.12

Additional apparatus of the transformer

Overflow valve (In case of over pressure, the tank must not be damaged and overflowing
oil shall be drained off the transformer cover)

Oil drain tap, oil level screw

Temperature sensor

Slide of oil intake and drainage

Transformer tank fastening

Two conservator tanks including

Air dehumidifier including valve

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-Oil level gauge

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-Connection to the transformer including rapid action coupling

-Oil filler tap
-Oil drainage screw

Earthing

5.13

General arrangement drawing of the transformer shall be in line with CLW Drawing
No.CLW/ES/3/SK-1/0456 for LOT 6500 KVA transformer for WAG9 locomotive.

6.0

TECHNICAL DATA

6.1

Catenary Voltage:
-

Nominal

25 KV

Maximum

30 KV

Minimum

17.5 KV

50 Hz 6%

6.2

Frequency(Hz)

6.3

Ratings for WAP 5/WAP 7 Locomotives Transformer

WINDING

POWER (KVA)

VOLTAGE (V)

CURRENT (A)

HV

1 x 6130*

25000

245

TRACTION

4 x 1450

4 x 1420

4 x 1021

BUR

1 x 334

1 x 1000

1 x 334

FILTER

1 x 400

1 x 1150

1 x 348

* The filter power is only reactive. HV only feeds the losses of the filter winding and
therefore, the HV current is defined on the 6130 KVA base.

6.4

Percentage Impedance:
HV to Traction winding 1, 2, 3 or 4

: 30 % Tolerance as per IEC:60310

(at 1450 KVA)

HV to Auxiliary winding

: 10 % Tolerance as per IEC:60310

(at 334 KVA)

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HV to Filter winding

:4%
(at 400 KVA)

6.5

Series resonant choke type 2 SOD 240

i) Inductance per choke

2 x 0.551 mH (15%)
Linear to I peak = 1391A

Thermal current ITh

2 x 984Aeff

100 Hz

ii)

iii) Resonant frequency

iv) Voltage stress between

a. terminals
max. :
b. to earth
max. :
v) Separate voltage withstand capability :
vi) Losses(KW)
6.6

482 VAC
3471 V
10 KV

: 12.5 KW + IEC Tol.

Auxiliary converter choke type 6 GOD 120

(i) Inductance per BUR-choke :
0A

30 mH

120A

30 mH

155A

26 mH

190A

20 mH

(ii)Tolerances

-0%, +free

(iii) Frequency

100 Hz

(iv)Current

(v)Ripple
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rated :

155 A

max. :

190 A

nom. :

38.6%

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(vi)Voltage to earth

Spec. No. RDSO/2012/EL/SPEC/0112, Rev.

max. :

50.2%

rated :

1153 V

max. :

2000 V

(vii)Separate voltage withstand

capability

viii)Losses(KW)

6.7

10 KV
: 12 KW + IEC Tol.

Auxiliary converter choke type 6 GOD 22 (Provisional)

i. Quantity

ii. Inductance per choke

2 x 0.3 mH (15%)

iii. Thermal current Irms

2 x 330 A

iv. I max

2 x 700 A(Peak)

v. Frequency(Hz)

50 Hz

vi. Resistance(RDC) at 85 C

2 x 3.9 mohm 10 %

vii. Total Losses

1.5 KW 15 %

viii. Electrical connection

In series with Auxiliary

(BUR) winding internally

Compatibility as per
Auxiliary(BUR) winding

ix

6.8

Voltage Class

No load magnetization current (A)

at 25 KV

6.9

: 0.7%(approx.)

Transformer losses at 25 KV
i) No load loss

- 4 KW + IEC Tol.

ii) Load losses, harmonic losses, reactor losses and stray losses 192 KW
iii) Total transformer losses shall be approx. 196 KW.
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6.10

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Transformer overall efficiency

At 25 KV

6.11

6.12

Spec. No. RDSO/2012/EL/SPEC/0112, Rev.

: 97 %(approx.)

Permissible and designed temperature rise

(i) Oil (C)

: 45 C [ IEC 60310-20 C]

(ii)Winding (C)

: 55 C [IEC 60310-20 C]

Type of Cooling and cooling medium

OFAF. Inhibited mineral Transformer Oil as per IEC: 60296

6.13

Class of Insulation
(i) on conductors

: Enamel of class H and nomex insulation of class H

(ii)Cooling medium : Class A( Mineral inhibited insulation oil as per IEC:60296)

6.14 Dielectric levels

Primary
(i) Induced voltage withstand (KV)

60

(ii) Separate source withstand (KV)

10

(iii) Impulse voltage withstand (KVp)

150

6.15

Traction

Aux.

Filter

10

Transformer Rating Plate

Each transformer shall be provided with a rating plate showing at least the items
indicated below, unless otherwise agreed between user and manufacturer:







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Manufacturers name
Manufacturers serial number
Date of manufacturing
Connection diagram
Principal tappings
Rated power and voltage of each winding
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6.16

Spec. No. RDSO/2012/EL/SPEC/0112, Rev.

Rated frequency
Cooling medium and type
Volume of cooling medium
Identification of cooling method
Total mass.

Inductor Rating Plate

Each inductor shall be provided with a rating plate showing at least the items
indicated below, unless otherwise agreed between user and manufacturer:










Manufacturers name
Manufacturers serial number
Type of inductor
Rated current(r.m.s. value, or mean direct current for smoothing inductors)
Value of inductance(at one or more specified reference current values)
Rated frequency
Cooling medium and type
Identification of cooling method
Total mass.

7 Tank
Transformer main tank and its two conservator tanks will be of Standard Steel
S 355J2N(EN 10025-2)/or its equivalent IS. Outline of the tank will be identical to
HSTN003359(original outline drawing of LOT 6500 KVA transformer)
7.13 Total Weight
Weight of the transformer shall be - 9000 3% kg
7.14

Mounting Dimensions
External dimension(overall) including cooling unit shall be according to HSTN003359.
Length-2866 mm
Width 1970 mm
Height 1339 mm
7.3

FEM Analysis of Tank

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FEM analysis of tank shall be conducted considering the vibration and shock
requirement mentioned in the IEC:61373. Tank shall be structurally stable for
mounting in under frame of 25 KV AC 3-ph drive electric locomotives.

8.0

Reliability Requirements

8.1

Life time/Operational Time

8.2

Daily

Approx. 16 hours(at approx. 330 days/year)

Yearly

5280 hours

Within 40 years

211200 hours

Reliability
Under operational conditions as per clause 8.1 above, MTBF of 11 x 106
expected.

9.0

Tests

9.1

Transformer Including Filter Winding

hours

is

The Type and Routine Tests shall be carried out on the transformer as per Table-1 below
which also stipulates the category of the tests and the clause to which the reference is to
be made. Tests on the chokes which can not be disassociated from the transformer shall
be carried out together with the latter.
TABLE-1
Test Description

Clause or Sub Clause

Type

Routine

Preliminary checks

9.1.1

9.1.1

Measurement of winding resistance

9.1.2

9.1.2

Measurement of voltage ratios

9.1.3

9.1.3

Measurement of no-load primary current and losses

9.1.4

9.1.4

Measurement of impedance voltages

9.1.5

9.1.5

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Measurement of load losses

9.1.6

9.1.6

Determination of total losses

9.1.7

9.1.7

Temperature Rise

9.1.8

Measurement of Insulation Resistance of windings 9.1.9

- before and after the HV test

9.1.9

Dielectric :
-

full wave impulse voltage withstand

9.1.10

induced voltage withstand

9.1.11

9.1.11

separate source voltage withstand

9.1.12

9.1.12

Short-circuit test

9.1.13

Measurement of Frequency Response Analysis

9.1.14

9.1.14

Measurement of Transformer noise

9.1.15

Pressure and Leakage test on Tank

9.1.16

9.1.16

Measurement of weight

9.1.17

9.1.17

9.1.1 Preliminary Checks (IEC 60310- Clause 10.2.3)

Visual inspection and identification of the circuit diagram, terminal meetings, polarities &
particulars on the rating plate shall be carried out.

9.1.2 Measurement of Winding Resistance (IEC 60310- Clause 10.2.4)

Resistance of each winding shall be measured with direct current at ambient temperature
and the values thus obtained corrected to 85 deg.C.

9.1.3 Measurement of Voltage Ratio (IEC 60310- Clause 10.2.5)

Voltage ratio shall be measured between primary winding and all secondary windings
individually. Voltage ratio shall also be measured between primary winding & Bur
winding, Filter winding & Hotel load winding .
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The measured values shall be with-in 0.5% of the design values.

9.1.4 Measurement of No load primary current & losses (IEC 60310 -Clause 10.2.6)

No load primary current and losses shall be measured with 50 Hz sinusoidal voltage
applied to high voltage winding. However, this measurement can also be carried out by
energising Bur winding. No load current and losses for the primary winding shall be
measured at 17.5 KV 27.5 KV in steps of 2.5 KV.
The measured no load losses at 25 KV shall not exceed 4 KW + IEC 60310 Tol..

9.1.5 Measurement of Impedance Voltage (IEC 60310- Clause 10.2.7)

Impedance voltage between each pair of the windings shall be measured at rated
frequency using approximately sinusoidal voltage supply.
The short circuit impedance between primary winding and each of the traction
windings shall be with-in 15% of the design value.
9.1.6 Measurement of Load Losses (IEC 60310- Clause 10.2.8)
Load losses between HV winding and traction windings, filter, Bur winding and Hotel load
winding (for WAP-5/WAP-7 locomotives transformer) shall be measured and corrected to
85 deg.C. The corrected losses shall not exceed the limit specified at clause No. 6.10.

9.1.7 Determination of total losses of transformer (IEC 60310 -Clause 10.2.9)

The total losses of the transformer at reference temperature of 85 deg. C shall be

computed as under:-

(a)
(b)
(c)
(d)
(e)
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Load losses of HV to all Traction windings

Load losses of HV to Filter winding
Load losses of HV to BUR winding
No load losses
Harmonic losses
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Since all the windings are very high magnetic de-coupled, the total transformer losses will
be the sum of (a), (b), (c), (d) & (e) above.

The total transformer losses shall not exceed 240 KW.

9.1.8 Temperature rise test (IEC60310- Clause 10.2.10)
This test on the transformer shall be carried out by short circuit method to determine
temperature rise of oil, average temperature of air at the blower entrance, average
temperature of air at cooler exit, average temperature of oil at transformer exit, average
temperature of oil at cooler exit and winding temperatures including windings of the two
reactor units.
DGA & BDV of Oil must be performed before and after the temperature rise test.
For temperature rise test, thermocouples shall be provided at locations as under:
Top oil pocket - One
Air entrance on top of the blower Two, one on each blower
Air exit under the cooler Two, one on each cooler
Oil exit from the transformer Two, one on each exit
Oil containers Three, located at about 3 m from the transformer

9.1.8.1 Oil Temperature Rise

For this test, with the auxiliary winding and filter winding left open circuited, the primary
winding shall be short circuited and all traction windings connected in series and
energized such as to feed losses in the transformer determined in clause 9.1.7 above
and reactor losses measured in Clause 9.2.3. These losses fed in the transformer shall
be maintained till oil temperature stabilizes. The oil temperature measured and
temperature rise calculated.
The temperature rise of oil shall not exceed 45 deg.C.

9.1.8.2

Winding Temperature Rise

HV Winding

For this test, the primary winding shall be short circuited and supply given to four series
connected traction windings so as to feed 245 Amps. in HV winding for a duration of 60
min. At the end of 60 min., blowers shall be switched off and hot resistance of the HV
winding measured.
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Traction Winding

For this test, with blowers on, series connected traction winding shall be short circuited
and supply given to HV winding to feed 1021 Amps. in traction winding for a duration of
60 min. The blowers shall be switched off and hot resistance of the traction winding
measured.

BUR Winding

For this test, with blowers switched off, the Bur winding shall be short circuited and
supply applied to HV winding with 334 Amps. in Bur winding for a duration of 60 minute
at the end of which hot resistance of the winding shall be measured.

Filter Winding

For this test with blowers switched off, the filter winding shall be short circuited and
supply given to HV winding with 348 Amps. in the filter winding for a duration of 60
minutes at the end of which hot resistance of the filter winding shall be measured.

Series Resonant Choke Windings

For this test, with blowers switched off, 1144 Amps. at 50 Hz shall be given to the two
series connected reactor windings for a duration of 60 min. at the end of which hot
resistance of the reactor windings shall be measured.

Aux. Converter Choke Windings

For this test, with blowers switched off, 127.4 Amps. at 50 Hz shall be given to the six
series connected reactor windings for a duration of 60 min. and the end of which hot
resistance of the reactor windings shall be measured.
From the measured hot resistance of the windings, the temperature rise of the different
windings of the transformer & reactors shall be determined.

The temperature rise of windings shall not exceed 55 deg.C.

9.1.9 Measurement of IR value (IEC 60310 -Clause -)
Measurement of IR value of individual windings to Tank and Earth and between windings
shall be carried out at room temperature. The values obtained after 60 seconds shall be
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corrected to 30 deg. C. For HV winding 5kV and all other windings 1kV megger shall be
used. These measurements shall be taken before and after HV test.
9.1.10

Impulse voltage withstand test (IEC 60310- 10.2.11.3)

The HV winding shall be subjected to impulse voltage test of 150 KVp, 1.2/50 micro
second wave.
The winding shall withstand the test voltage.

9.1.11

Induced Voltage Withstand Test (IEC 60310- Clause 10.2.11.1

All traction and filter windings shall be connected to tank and earth. Test voltage will be
applied to Auxiliary(Bur) winding in order to induce 60 KV voltage in HV winding.
Frequency of the applied voltage shall be more than 100 Hz and accordingly duration of
the test may be decided.
The winding shall withstand the test voltage.

9.1.12

Separate source voltage withstand test (IEC 60310-Clause 10.2.11.2 )

Single phase 50 Hz, separate source voltage of amplitude as given below shall be
applied for 1 minute between each winding to be tested and all other windings connected
together to tank and earth:-

(i)

primary winding and all other windings to earth

10 KV

(ii)

Traction winding to all other windings and earth

10 KV

(iii)

Filter winding to all other windings and earth

5 KV

(iv)

Auxiliary winding to all other windings and earth

5 KV

The windings shall with stand the test voltage.

9.1.13

Short-Circuit test (IEC 60310 -Clause 10.2.12)

Short Circuit test shall be carried out as per IEC:60310. The test
voltage shall be 27.5
KV and all the secondary traction windings are to be subjected to short circuit test.
Variation in % impedance before & after the short-circuit test shall
not
differ
more than 1%. After the test, the transformer to be removed from the tank and no
observable deformation, movement or slackening of any winding, insulation over
clamping devices should be revealed.

9.1.14 Measurement of Frequency Response Analysis

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Frequency response analysis of the transformer winding under different configurations

shall be measured and recorded for future reference.
9.1.15

Measurement of Transformer noise

Noise of transformer and associate equipments in different operating conditions will be
measured in accordance with ISO3744.

9.1.16

Pressure & Leakage Test on Tank (IEC 310 -Clause -)

The transformer tank shall also be tested with a water/ oil pressure of 0.6 Bar for a
period of 12 Hours to detect any leakage.
There shall not be any leakage during or at the end of the test.

9.1.17

Measurement of weight (IEC 310 -Clause -)

The weight of the Transformer filled with oil and provided with its accessories shall be
measured.
The measured weight shall be approx. 9000 3% kg

9.2

Series Resonant Choke, Auxiliary Converter Choke and other additional reactors
The Type and Routine Tests shall be carried out as per Table-2 below which also
stipulates the category of the tests and the clause to which the reference is to be made :TABLE-2
TESTS

Type

Routine

Preliminary checks

9.2.1

9.2.1

Measurement of winding resistance

9.2.2

9.2.2

Measurement of losses

9.2.3

Measurement of inductance

9.2.4

9.2.4

Temperature Rise

9.2.5

Separate source voltage withstand

9.2.6

9.2.6

Measurement of IR of windings

9.2.7

9.2.7

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Spec. No. RDSO/2012/EL/SPEC/0112, Rev.

9.2.1 Preliminary Check (IEC 60310- Clause 10.3.3)

A check shall be made on the terminal marking, the polarities and the particulars on the
rating plates of both the reactors.
9.2.2 Measurement of Winding Resistance (IEC 310- Clause 10.3.4)
The resistance of each choke coil shall be measured with a dc current at ambient
temperature. The measured values shall be corrected to 85 deg.C.
9.2.3 Measurement of Losses (IEC 310- Clause 10.3.5)
The losses of each choke coil shall be measured at rated current and ambient
temperature and corrected to 85 deg.C.
The total losses of the two series resonant chokes shall not exceed 12.5 KW +
15%.
The total losses of the three auxiliary converter chokes shall not exceed 12.0 KW +
15%.
9.2.4 Measurement of Inductance (IEC 60310 - Clause 10.3.6)
The series resonant choke coils shall be fed at rated current of 984.0 amps at 50 Hz and
impedance / inductance measured.
The inductance of the coils measured at the rated current shall be within 15% of
the designed value of 0.551 mH.
The inductance of the aux. converter chokes shall be measured at the rated current of
155 Amps. for each coil. Inductance curve shall also be drawn as a function of current
over the entire operating range from 17 Amps. to 190 Amps. rms.
The inductance of the each coil at the rated current shall not be less than 30 mH.
9.2.5 Temperature Rise Test (IEC 60310 - Clause 10.3.7)
Temperature rise test shall be conducted as per Clause 9.1.8 above.
9.2.6 Separate Source Voltage Withstand Test (IEC 310 Clause 10.3.8.2)
50 Hz AC voltage shall be applied for 01 minute between the winding and earth and
between windings. The test voltage shall be 2.25 U + 2000 volts, where U is the rated
voltage of the windings.
The winding shall withstand the test voltage
9.2.7 Measurement of IR of windings
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Spec. No. RDSO/2012/EL/SPEC/0112, Rev.

This test shall be conducted as per Clause 9.1.8 above.

10.0

Quality Assurance Plan

Quality Assurance Plan as per the requisite format of RDSO/CLW is required to be
submitted for approval.

11.0

Bill of Material (BoM)

Bill of Material (BOM) as per the requisite format of RDSO is required to be submitted for
approval.

12.0

Documentation
12.1

Contents

12.1.1 Drawings, Tracing and Description

All drawings and description which are necessary for design, assembly and
commissioning of the Transformer. A part list / composition list of each drawing has to
be given. Within the individual Lists all parts of the corresponding drawing have to
mentioned, including consumable items. A family tree has to be given, including all
drawings, arts lists and other relevant documents which are part of the
documentation. Also a complete list of all documents and a complete list of all
components (Bill of Material).
12.1.2 Manual
The manual includes all necessary information for correct operation, maintenance,
faultfinding and repair of the transformer. Including spare parts catalogue and
instruction for assembly, dismantling and replacement of the individual components.

12.1.3 Language
All documents, including reference documents, shall be in English.
12.2

Structure

12.2.2 Drawing, Tracing and Descriptions

The documentation shall be structured by the following order:
1. Family Tree
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Spec. No. RDSO/2012/EL/SPEC/0112, Rev.

2. List of drawings (sorted by Indent-NO.)

3. Bill of materials (sorted by Indent-NO.)
4. Drawings, etc. (sorted by subassembly components, corresponding to the family
tree).
All documents have to be given in proper folders. Loosen documents Will be not be
accepted.
12.2.3 Manual
An overview of function and work order has to be given. The chapters of the Manual
must belong to the individual sub-assembly components. All drawings and
documents, which are used as reference documents, have to be given as annexure to
the manual.
12.2.4 Standards / Units
Only IEC Standards or internationally recognized standards shall be accepted. Only
SI Units will be accepted.
12.2.5 Drawings, Tracing and descriptions
4 Sets of hard copies and one set of softcopy of complete design document,
Drawings, BoM, etc.
12.2.6 Manuals
4 sets of copies
13.0

Scope of Supply
Qty / Loco

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Transformer

: 1 No.

Series Resonant choke

: 2 Nos.

D.C. Link circuit choke aux. converter

: 6 Nos.

High Voltage bushing mounted on Transformer

: 1 Set

RTD PT 100 mounted on Transformer

: 1 No.

Conservator tank with Breather

: 2 Nos.

Hose with nipple (3EHP431215R0001)

: 2 Nos.

Connecting Hose complete with nipple (3EHP431217R0001)

: 1 No.

Connecting Hose complete with nipple (3EHP431253R0001)

: 2 Nos.

Quick Couplings as per drawing no.-CLW/ES/3/SK-4/0456 Alt.F

( set consists of one male and one Female )

: 6 Nos.

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Spec. No. RDSO/2012/EL/SPEC/0112, Rev.

Elbow Union as per drawing no.-CLW/ES/3/SK-5/0315 Alt.H

: 2 Nos.

Transformer Oil- As per IEC:60296

The Transformer and conservator tank should be completely filled with Oil. Onebarrel (209 liters) to be separately provided for filling in oil pipes and other
accessories.
Set of Transformer fixing bolts and plates as per Spec no.
CLW/ES/3/SK-1/0315 Alt.H

: 1 Set

Scope of supply of this transformer should be in line with drawing no.CLW/ES/3/SK-1/0456 Alt.F to CLW/ES/3/SK-5/0456 Alt.F which is for LOT 6500
KVA transformer.
Additional auxiliary reactor for Auxiliary winding(provisional)

: 2 No.

14. 0 Documents to be supplied by bidder:

The tender shall integrate the following along with the quotation.
i)

Clause wise comments on the specification and Test Program.

ii)

Detailed drawings.

iii)

Past experience with supporting papers (if Any)

iv)

Quality Assurance Program

v)

Machinery & Plant for Such Job.

vi) Technical data as per Annexure-A

15.0 Technical documents to be supplied by Contractor:
The following documents shall be supplied by the supplier as a part of the contract.
i)
ii)

Type Test reports

Routine Test reports along with each set

iii)

Maintenance manual

iv)

Design data calculation and drawings of transformer submitted by that

supplier to CLW and RDSO during design approval.

v) Technical data is to be submitted as per Annexure-B.

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16.0

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Spec. No. RDSO/2012/EL/SPEC/0112, Rev.

Declaration for Infringement of IPR by Vendors:

The Supplier shall submit a signed undertaking to IR in the following format as part of
Design Concept and while entering the contract:
Indian Railways shall not be responsible for infringement of patent rights arising due to
similarity in design, manufacturing process, use of similar components in the design
and development of hotel load converter and any other factor not mentioned herein
which may cause such a dispute. The entire responsibility to settle any such
disputes/matters lies with the Supplier.

17.0 Note
1. Standard fasteners of M/s TVS, M/s un-brako and Spring washers of M/s Forbes make
only to be used.
2. Firm should provide Min/Max Oil level scale in Conservator tanks.
3. For other references, if any, RDSO or CLW may be approached.

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Spec. No. RDSO/2012/EL/SPEC/0112, Rev.

Annexure-A

TECTNICAL DATA TO BE SUPPLIED WITH THE OFFER

TRANSFORMER

1.

Make

2.

Type

3.

Standard

4.

Primary Voltage (kV)

i)
ii)
iii)

5.

Nominal
Maximum
Minimum

Continuous rating at 22.5 kV

Winding

Primary

Traction

Auxiliary

(secondary)

No. of windings

No load voltage (V)

Current (A)

Capacity (kVA)

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6.

Percentage impedance voltage

7.

Percentage impedance voltage of

8.

No load magnetization current

i)
ii)
9.

11.

at 22.5 kV (A)
at 27.5 kV (A)

Flux density in the core

i)
ii)
10.

Auxilliary winding (%)

Hotel load winding (%)
Filter winding(%)

at 22.5 kV (Wb/m)
at 27.5 kV (Wb/m)

Current density at rated current

i) Primary

(A/mm)

ii) Traction (Secondary)

(A/mm)

iii) Auxiliary

(A/mm)

iv) Filter

(A/mm)

Transformer losses

At 22.5kV

At 27.5kV

Core (kW)
Copper (kW)
Total (kW)

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12.

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Spec. No. RDSO/2012/EL/SPEC/0112, Rev.

Transformer overall efficiency

i) at 22.5 kV

(%)

ii) at 27.5 kV (%)

13.

Permissible and designed temperature rise separately

(i) Oil ( C )
(ii) Winding

( C )

(By resistance method)

14.

Type of cooling and cooling medium

15.

Class of insulation
a) On conductors
b) Cooling medium
16.

(i)

Material of insulation on the conductor

(ii)

Material of the cooling medium

(iii)

Thermal and electrical characteristics of conductor insulation.

(iv)

17.

Thermal and electrical characteristics of cooling medium.

Dielectric levels
(a)

Primary

Traction

Auxiliary

Induced voltage
withstand (kV)

(b)

Separate source
voltage withstand (kV)

(c)

Impulse voltage

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withstand (Kvp)
18.

Construction
i) Type of core

: Core type/Shell type

ii) Type of winding

: Concentric coils/sandwich coils

iii) type of winding

construction (single coil or more coils in series/parallel)
-

Primary
Secondary
Auxiliary
Filter
Weight of transformer and oil

19.

i)
ii)
20.

Without cooling equipment

'with cooling equipment

Overall dimensions of the transformer

i)

Without cooling equipment

ii)
21.

Oil
i)
ii)

22.

With cooling equipment (Attach drawings)

Weight
Volume

Data on additional equipment

i)

oil circulating pump

a) Motor

- Make
- Type
- Rating
- Insulation class
- Weight

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b) Pump

Spec. No. RDSO/2012/EL/SPEC/0112, Rev.

- Make
- Type
- Speed
- Quantity & head
- Weight

ii)

Fluid circulating blower

a) Motor

- Make
- Type
- Rating (kW)
- Voltage (V)
- Current (A)
- Speed (RPM)
- Insulation class
- Weight

b) Pump

- Make
- Type
- Speed (RPM) (Max)
- Air Quantity (m3/hr) & head (mm WG)
- Weight (kg)

iii)

Radiator

- Make
- Type
- Rating (kW)

iv)
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- Type
- Make
- Ratio
- Burden (VA)
- Accuracy class
- Insulation class

v)

Overload relay

- Type
- Make
- Ratio
- Burden
- Accuracy class
- Setting value

vi)

Oil flow relay

- Type
- Make
- Range
- Setting

vii)

Oil temperature indicator

- Type
- Make
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- Range
- Setting
viii)

Silicagel
- Type
- Make

23. The following drawings/curves/calculations shall be submitted by the tenderer along with
the offer :
Outline and general arrangement drawing of the transformer,

24. The contractor shall also furnish detailed drawings showing core arrangement, winding/coil
arrangement, insulation arrangement, cross sectional drawings, rating plate etc. for
transformer.

25. Overload Vs. duration curve of the transformer with sample calculations for the same.

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Spec. No. RDSO/2012/EL/SPEC/0112, Rev.

ANNEXURE-B

ADDITIONAL DATA TO BE SUBMITTED BY THE CONTRACTOR

TECHNICAL DATA OF MAIN TRANSFORMER

1.

Rating:
1.1

Primary

Volts

Amps.

kVA

1.2

Traction (Secondary)

Volts

Amps.

kVA

1.3

Auxiliary

Volts

Amps.

kVA

1.4
1.5
1.6

Filter
Magnetising current(%)
Core losses:
- 22.5 kV
- 27.5 kV
Primary

Traction

_______

(Secondary)
_______

Auxiliary

_______

1.7 Copper losses

1.8 Total losses
1.9 Resistance (%)
1.10
Reactance (%)
1.11
Current density
2. Winding details Primary
______

Traction
______

Auxiliary
______

Filter
______

2.1 Total No. of turns

2.2 No. of windings
2.3 No. of coils
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2.4 Sections per coil

2.5 Turns per coil
2.6 Turns per layer
2.7 No. of layers
2.8 Size of conductor
2.9 Total sectional area
2.10 No. of parallel conductors.
2.11 Mean length of
winding (mm)
2.12 Weight of copper wire(kg)
2.13 Coil dia (inner)
2.14 Coil dia (outer)
2.15 Depth of winding (radial)
2.16 Height of section
2.17 Conductor insulation
2.18 Winding method
2.19 Inter connection of sections
2.20 Inter connection of coils
2.21 Clearance between HV&LV

3.

Magnetic Circuit Details

Primary
______

Traction
______

Auxiliary
______

3.1 Grade (silicon sheet steel)

3.2 Thickness (mm)

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______

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3.3 Space Factor (%)

3.4 Core constructional

arrangement (2 or 3 limb)

3.5 Sectional area

- Gross ( cm)
- Nett

( cm)

3.6 Flux density at :

- 22.5 kV (wb/m)
- 27.5 kV (wb/m)
3.7 Volt/turn at :
- 22.5 Kv
- 25.5 kV
3.8 Mean core length (mm)
3.9 Dimensions of
windows (mm)
3.10 Outer dimensions
4.

Ancillary Data
4.1

Operating pressure
of explosion vent

4.2

HV and LV bushing
Specification

4.3

Weight (kg)
i)
ii)
iii)
iv)

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Core and coils

Tank and fittings
Fluid (lit.)
Cooler and pump
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v) Fluid
vi) Total weight of
Transformer block
5.

Calculations

5.1

Temperature rise calculations for

rated load and overloads.

5.2

Reactance calculations for different

windings for arriving at designed value.

5.3

Calculations for thermal and mechanical

effects under 3 second short circuit.

5.4

Calculations for arriving at the regulation

characteristics of the transformer alongwith
the regulation curve (dc voltage vs dc current)

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