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GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

SPECIFICATION FOR SUPPLY, INSTALLATION AND COMMISSIONING OF

R&D TEST BED FACILITY FOR DUAL FUEL (CNG, DIESEL) KTA 50L DEMU ENGINE ON

TURNKEY BASIS

RDSO Technical Specification No. TS/ED/2011/58 October 2014

ENGINE DEVELOPMENT DIRECTORATE Research Designs and Standards Organisation

Manak Nagar, Lucknow– 226 011, India

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1. Introduction

The document contains details for the work of Supply, Installation and Commissioning of R&D test bed facility for dual fuel (CNG, Diesel) KTA 50L DEMU engine on turnkey basis.

2. Objective

The purpose of this project is to set up the R&D test facilities for dual fuel (CNG, Diesel) 16-cylinder KTA 50L (and similar) DEMU engine on turnkey basis.

3. Scope

3.1 RDSO’s scope of supply:

Supply of one 16 cylinder KTA 50L DEMU engine.

Supply of fuel injection system suitable for direct injection, duel fuel controller (DFC) along with ECU’s.

3.2 RDSO’s scope of work: Clear site for installation of test bed and utilities.

Diesel and CNG supply arrangement for Test Bed operation. All engine accessories except those given in clause 3.3 will be provided by RDSO.

3.3 Tenderer’s scope of supply Sl.No. Details of Equipment Qty. Reqd.

1. Engine Automated Test bed Control System Operating and Control Desk, Software Package with User License, Hardware Package (including Test System Computer Hardware and Peripherals), Signal Conditioning Modules (along with the necessary Wall Mounted Housings) for Digital I/O, Analog In and Counter Channels etc.

1 Set

2. Hydraulic Dynamometer including coupling in between engine and dynamometer (Drg. of engine flywheel at Annexure 10).

1 set

3. Engine Dynamometer Control Unit 1 Set

4. Dynamometer Calibration System 1 Set

5. Data Post Processing Software Module with User License 1 Set

6. High Speed Data Acquisition System (Hardware, Software and sensors with signal conditioner for measurement system) and interfacing with Test bed Control System

1 Set

7. Temperature calibrator for low and high temperature 2 Nos.

8. Hardware and Software Package for interfacing Test bed Control System with the existing ‘PIERBURG’ Exhaust Analysis System AMA 4000 and ‘AVL’ Smart Sampler SPC 472 Particulate Measurement System

1 Set

9. Fuel (Diesel) Consumption Measuring Equipment with provision of measuring the main and return fuel simultaneously.

1 No.

10. Air Consumption Measurement Meter 2 nos. required as per

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page 15 (one per turbocharger)

11. CNG Consumption Measuring Equipment 1 No.

12. On-Line Humidity Measuring Equipment 1 No.

13. Temperature Sensors with signal conditioning modules and Cable Extension

As per list

14. Set of Connectors for connecting above temperature Sensors As required

15. Pressure Transducers with signal conditioning modules and connecting cables/pipes

As per list

16. Speed Sensors with signal conditioning modules and Cable Extension

Totally 4 required (two turbochargers, 1 dyno, 1 engine)

17. Barometric Pressure Transducer (Digital) 1 No.

18. Flow meters for water flow and Lube oil flow measurements 4 no. required (3 for water as per page 15 and 1 for lube oil).

19. Vibration and Noise measurement System 1Set

20. Knock measurement System 1Set

21. Air Starting Motor 02 nos.

22. Fuel pump (This fuel pump is required with rating 1500 kg/hr with provision of fuel regulation arrangement for diesel supply.)

1 No.

23. Fire fighting System 1 Set

24. Filters (Diesel, air, water, lube oil) As per req.

25. Complete Electrical distribution and lighting system As per req.

26. Furniture Annexure-8

27. 2 ton. Capacity each Split Type Air Conditioners 04 nos.

28. PID type Temperature Controllers As per req.

29. Water circulation system including cooling tower, pumps, piping, water softener and storage tank etc.

As detailed above.

30. Charge Air Cooler and accessories as detailed above 1 set

31. Coolant condition system and accessories as detailed above 1 set

32. Storage As detailed in item No.4.1

33. UPS 2 KVA 1 set

34. Engine Mounting Fixture 1 no

35. 2 ton mounting type jib crane 1 no

36. Fixture for checking dynamometer and engine alignment 1 set

37. Centrifugal blower for fresh air & room exhaust 1 set

38. Acoustic door, vision panel and tiles etc. As per Requirement

39. Compressed air piping As per Requirement

40. Fuel (Diesel & CNG) piping As per Requirement

41. Water piping As per Requirement

42. Training As per schedule

43. Installation and Commissioning 1 Unit

44. Walky talky 02 sets i.e. 04 units

45. Multi stage safety arrangement (alarms for fire, smoke and leakage detection)

As per requirement.

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3.4 Tenderer’s scope of work The Tenderer shall perform the following main tasks:

Development of detailed layout drawings of complete test bed including all sub systems. These drawings shall be approved by ED Dte authorised representative.

Execution of the following works after approval of layout drawings

Test cell control room furnishing with control systems and other equipments

Complete engine room construction along with engine and dynamometer foundation work

Instrumentation work including installation and commissioning of all control equipments, dynamometer with its controller and laying of cables.

Ventilation system

Charge air intake and engine exhaust system: It is not a part of ENGINE; it will be done by the tenderer.

Electrical power distribution and Lighting system

Acoustic treatment in Engine room

Compressed air piping, fuel piping and water piping

Fire, smoke and gas leakage detection system

Water circulation system

Fuel Piping from Diesel tank to Engine Input

Required CNG piping from Cascade system to Engine.

Vibration isolation of the engine test beds by using suitable engine isolators between engine and test bed plate and between engine test bed plate and test bed floor and adjoining areas.

A common grounding scheme should be implemented for the engine test bed facility design

The nature of work includes turnkey execution including complete civil, mechanical, instrumentation and electrical work pertaining to setting up of test bed with latest infrastructure being used for R&D test beds worldwide.

4. Details of various works to be executed by Tenderer

4.1 Test cell control room furnishing with control systems and other equipments

The room required for test cell is already available. Its furnishing shall require the following features:

(i) Provision of separate distribution Panels for UPS and AC mains to power pumps, motors and other equipment’s/systems

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(ii) Supply of Furniture in Test bed control Room as per Annexure 8.

(iii) Supply of four nos. 2 T capacity split air conditioners. Make Hitachi/Voltas/Bluestar/Samsung.

(iv) Provision for separate concealed electrical and signal cables channels

(v) Storage Godrej or equivalent make Items: 1.) Storage unit for keeping Manuals and calibration certificates etc.- Godrej model

No. VSDU7/VSDU8 or equivalent with 1833 mm height- 1 No. 2.) Personal Lockers of height 1830 mm with 3 or more lockers-1 No.

(vi) Control room to be provided with UPS of 2 KVA capacity and with minimum 30 minutes backup for all testing equipments.

4.2 Complete engine room construction along with engine and

dynamometer foundation work

The layout drawing indicating the construction of proposed engine room including foundation drawing for engine and dynamometer is enclosed as Annexure 1. Engine room shall be constructed as per drawing at Annexure 1. Size of various civil structures will be as follows (in mm):

I. Test Cell 1 No. Overall size (Internal)

12000 X 5600 X 6000 ( Approx.)

II. Control Room 10000 X 4000X 6000 H False ceiling at 3500 Height

III. Engine & Dynamometer Foundation 7000 X 1600 X 1500 Deep

IV. Trenches 750 X 750 X 5600 Long 500 X500 X 8000 Long 2 Nos.

V. Trench Covers Trench covers to above mentioned Trenches. Each cover should not weigh more than 20 Kg

VI. Fits & Finishes

a) Test cell walls Concrete grade will be M 25. This grade should be able to absorb vibrations generated in walls during engine operation. For reference the IS code 456 issued in year 2000 will be followed.

b) Test Cell Floor RCC industrial floor with smooth finish

c) Test Cell Slab Smooth concrete finish with water proofing.

d) Finish Painting Finish painting in Synthetic enamel (Mat finish) all over except test cell walls & ceiling.

e) Blower Room 5500 X 4500 X 3500 Approx. having wall thickness 150 mm

f) Platform for CNG Cascade 2000 X 2500 X300 H (Made of bricks).

g) Weather shed for CNG Cascade 3500 mm Height, ISMB 200 I Beam with 3T Chain Pulley Block for loading & unloading of Cascade

Other requirement for civil work:

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a. Existing stair case for approach to test cell roof needs to be demolished and to be reconstructed in new location.

b. Safety railing of 1000 mm to be provided all around on the test cell slab

c. Floor painting is to be done in the control room floor.

d. All doors & Vision panel are in Acoustic system and also under the civil scope of work. The safety measures should not be compromised.

e. 1:100 slope to be provided to the bottom face of the trench for flow of waste water.

f. 9500 X 2500 mm cut out (made of concrete grade M 20) to be provided in the test cell slab for loading and unloading of the engine to the test bed from top.

g. In order to have an effective ventilation system and sound proofing in the engine room, the slidable/movable pads (with suitable lifting arrangement) shall have to be provided for sealing of the engine room during test bed operations.

h. Over all wall thickness except for Blower room shall be not less than 230 mm. Site plan showing Test Cell, Water tank, Cooling Tower etc. is given in Annexure 1.

i. Engine mounting Fixture Engine mounting fixture having T slotted rails. Fixture to be grouted in the test cell floor such that after mounting the engine on the fixture Crank shaft axis and Dynamometer axis shall be collinear. Along with the fixture 2 sets of Engine mounting brackets suitable for Cummins KTA 50 Engine with anti vibration mounts to be included in the scope of supply.

j. 2T Wall Mounting Jib Crane with

Electric Hoist with following specifications to be provided

Type of system

Wall Mounted Type. With Floor operated Pendent

I. Class / Duty II / Indoor

II. Safe Working Load 2 Tonne

III. Arm Radius 4 M Approx.

IV. Height of Lift. 4 M Approx.

V. Hoist Details

1. Type Electric Wire rope Hoist

2. No of Falls 4

3. Speed 2.5 M/ Minute +/- 10%

4. Hoisting Duel with Creep Feed Soft Start & Soft Stop

5. Motor Flame Proof

6. Brake AC Electromagnetic Type

7. Wire Rope Make Usha martin or Equivalent.

8. Hook Forged with Latch

5. Instrumentation work including installation and commissioning of all control equipments and dynamometer

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The Instrumentation work includes supply, installation and commissioning of the following: 5.1 Automated Engine Test Cell Control System for the engine performance/ development,

research and testing of medium speed, turbocharged 16-cylinder dual fuel CNG/ Diesel engine used in DEMU services.

5.2 Various measurement sensors. 5.3 Hydraulic Dynamometer of 3000 HP capacity for Engine loading including dynamometer

calibration system. 5.4 Adequate PID type temperature controllers to be mounted on the engine cooling water

system heat exchangers with remote control in control room.

5.1 Automated Engine Test Bed Control System (AETBCS) The AETBCS should be able to acquire, process, save, display graphically and textually, and control the engine parameters on-line during the engine test. The loading parameters for dynamometer should be programmable, as well as, manually alterable on-line with a response time of less than 0.1 ms minimum. Data throughput rate of signal conditioning module should be at least 60 kHz or better. Formula calculation frequency and limit monitoring should be at least 100 Hz. The system should itself detect the direction/sense of rotation. The system should be programmable for scheduling multiple tests without manual interference.

Real time data acquisition frequency shall be selectable starting with at least 200 Hz per channel. The basic hardware of the AETBCS shall be based on latest processor technology and shall support latest standards of Standard Industrial Interfaces, for example, RS 232, RS 422, RS 485, USB, IEEE, CAN, Profibus, Ethernet, LAN, Blue Tooth, Wi-Fi etc. Suitable and universally accepted protocols will be accepted. The AETBCS shall be suitable to operate in temperature range of 0 deg C to 55 deg C in engine room and 0 deg C to 35 deg C in control cabin. The system should be able to filter noise signals. The system should have the ability of setting upper and lower limit values for all primary data inputs and programmable taking necessary corrective action on the test engine if any value goes beyond the set range/limits. Sensors used should be suitable and rugged enough for deployment in tough industrial conditions with high levels of accuracy. Data acquisition system should be interference protected. Data channels of similar type should be interchangeable. The data acquisition/capture frequency and ranges should be programmable for all channels. The assignment of channel(s) should be software configurable. System should have on board calibration facility corrections starting with simulated electrical value for all feasible channel(s). The system should collect, correct, and convert the necessary signals for storage and display in user selected units (for example S.I.) and in user entered numbers of entire reading sets. Alarms and Indicators Suitable visible indicators should be provided in data acquisition channels, power points, safety alarms, etc. These should be coupled with suitable sound alarms where necessary. On screen values which are beyond their normal range should become highlighted and flashing/blinking, along with necessary corrective action being taken, if so programmed. Absolutely vital parameters of the engine should be alterable only by a pre-defined user (such as the system

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administrator).The complete system should be vibration protected; electrically isolated, adequate lightening protected, and properly earthed. Associated Software Package(s): The software has to be provided in executable formats. All necessary design, revisions, alterations, and usage documentation has to accompany the software(s) provided. It should preferably be compliable and compatible for operation on latest windows operating system .The following are the desired features of the software. a) Multilevel security system for Administrator, Supervisor, and Operator with defined

roles. b) Ability to control the test engine manually, semi-automatically or automatically. c) Ability to edit/set/reset engine parameter ranges and values with a complete default set

readily available. d) Ability to view previous data points while running a test. e) Ability to program test sequences. f) User defined norm names. g) Interactive and user friendly test programmability. h) Extensive and expandable help library. i) Ability to store multiple points of observation during tests in user selected units. j) Multi-level safety monitoring system/tools for operator, unit under test and control

system in all operating conditions. k) Suitable calculation for computed values and their display with possibility to enhance

these in future. l) User interface programmability through user defined look-up tables etc. m) The software should be compatible to multiple standards/interfaces preferably compliant

with open standards. n) A test library with a collection of pre-compiled test programs/sequences with ability for

adding more test programs or parameters by the user. o) Capability to online monitor the mix of diesel and gas being injected. p) Capable of being interfaced with ECU’s for the natural gas and diesel systems.

Standard tests schedules should be available in a test library with capability for user built test sequences to be preserved, intelligent measuring device management and unmanned operation (remote operation) should be available. The software should be capable of integration with fuel oil consumption measurement system, CNG consumption measurement system, particulate and gaseous emission measurement system and safe monitoring and control. Tenderer should provide required documents/set of manuals in hard and soft copies explaining the interfaces to the HOST (PC). HOST system is not required. Operator's Desk: Essential features of operator's desk should include: a) Operating panel with ergonomic displays and control b) Display of all values on terminal with user configurability. The display should include

throttle or actuator position for diesel and gas, load/torque, speed. c) Control of the entire test bed should be possible from the operator desk. d) The test and control system should be capable of maintaining its own test and operation

diary, including entries for its maintenance on the operator desk, hours run since inception and since last maintenance schedule should be readily displayed, with reset facilities.

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e) Capability for engine start (with two step series button control, one from the test bed and other from the test cabin/control room, with audio and visual (red-light) indicators with at least 10 seconds gap before start button can be activated), adequate number of emergency stop buttons placed at several places around the test bed, measurement, control switches/knobs for engine ‘Stop’, ‘Measurement’, separate activation switches for diesel flow, gas flow, engine start, ‘Ignition on/off (CNG and Diesel)’.

f) Selection of operating mode such as Idle, Speed/Throttle Angle, Torque/Throttle Angle, Speed/Torque, and Torque/Speed.

Monitoring: There shall be provision in the Test bed Control System for monitoring the following activities:

i. Interface to communicate with System Computer

ii. Control via System Computer

iii. Selecting Control Modes

iv. Selecting Demand Value

v. Acknowledging Alarm and Errors

vi. Bump less transfer from one Mode to another Mode

vii. Limit monitoring for 32 Channels input Signals with definable reaction such as Warning/Switch Off and limit monitoring for Engine parameters viz. Water Temperature, Oil Temperature, Oil Pressure, Temperature of CNG, Pressure of CNG and Leakage of CNG etc. (details available in engine monitoring)

viii. Watch Dog or similar module such as Monitoring of System Signal, Shutdown/Failure of devices, and Function Test on Power Up.

Broad Hardware configuration with latest Windows operating system

The ‘Engine Automated Test bed Control System’ shall consist of Operating system with Real Time capability for synchronized execution of time critical functions in combination with MS Windows to provide user interface functionality. Genuine High End Chip based Mother Board and Processor with latest Windows Operating System Industrial Personal Computer (PC) with the following configuration:

i. Latest highest version suitable processor

ii. 4GB RAM or more (expandable), 4 MB(expandable) Full Speed Cache Memory

iii. Three 27" LED Colour Monitors with highest version suitable Graphic Accelerator Card (with one set spare)

iv. Cordless latest version suitable Key Board and Optical Mouse Kit (with one set spare)

v. 2 Nos. of 140 GB or more, 10,000 rpm or better, SCSI/SAS Ultra Wide Hard Disk

vi. DVD Rewriter (External on USB Port)

vii. Minimum 8-USB (2-USB Ports on front side for easy access), 2-Serial and minimum 2-Ethernet Cards. All standard ports e.g. LAN, IEEE and Serial etc.

The ‘Engine Automated Test bed Control System’ should have Interface/Control for the following features:

Parameter Type Control to be provided

Fuel Pump Starter for Diesel Electro-Mechanical Relay Relay Contact and Switch

Fuel Pump Stop for Diesel NO/NC Contact Relay Contact and Switch

Fuel Pump Starter for CNG Spark Less Electro-Mechanical Relay

Relay Contact and Switch

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Fuel Pump Stop for CNG Spark Less NO/NC Contact Relay Contact and Switch

Air Starting Motor Ingersoll-Rand recommended Air starter model No. SS825GC03R31

24 Volt DC,16 bar air pressure Operated Solenoid

24 V DC Supply and Relay Contact

The relay contact rating will be as per standard current load rating of electrical/electronic system. The relay contact rating of fuel pump motor will be decided on the basis of the rating of fuel pump motor.

Control and Monitoring Automated test cell Control System will be required to control the Dynamometer coupled to the engine under testing by regulating Dual Fuel supply to the Engine by controlling ECUs of the diesel and the CNG fuel systems as per Load and Speed of the Engine. The 'closed loop' control shall be provided to ensure that both preset Speed and preset Torque have been achieved. The system shall be able to control Digital Amplifier of Dynamometer, Torque Signal and Speed Signal.

The Dynamometer conditions should be fully monitored with definable responses i.e. Idle, Speed/Throttle Angle, Torque/Throttle Angle, Speed/Torque, and Torque/Speed. The Controller should be capable of monitoring conditions of load actuator, water loading valves with definable delay time and response tolerance within ±0.1% FS.

The Controller should have an ergonomically designed LCD Operating Panel, Incremental Encoders and Function Buttons, show demand and actual values, parameter settings, operating menus as well as alarm and warning messages.

The Real Time Digital Dynamometer Controller running at 500 Hz or better shall be capable to operate in the following modes and ensure bump less transfer of control modes: Idle, N/A (Speed/Rack Angle), T/A (Torque/ Rack Angle), N/T (Speed/Torque), T/N (Torque/Speed), N/x (Speed/x), T/x (Torque/x) – where x is free variable (e.g. Manifold Absolute Pressure, Oil Pressure, Fuel Consumption, etc.).Both Automatic and Manual controls should be possible. Swapping of Modes should be possible without disturbance.

During Manual Operation Mode, it should be possible to set the prescribed Torque, Speed and Time Schedules through Keyboard of System PC. During Automatic Operation Mode, the parameters, which are already stored in memory by a suitable Engine Monitor and Control Testing Software, should be executed one after another in any prescribed sequence.

Software incorporated should also have the capability to implement Integrated Proportional Control of Engine Speed, Imposed Torque and Fuel Rack position (Diesel and CNG), provide pre-programmed Set-point demand values for the Dynamometer and Fuel Injection Control Actuator with common Interface.

These demand values may be in suitable form to suit the requirements given below:

Incremental stepping for mapping characteristics keeping Torque or Fuel Rack position constant while Speed increases in increments to desired Set-point.

Defined steps for Speed and Torque or Fuel Rack position.

Ramp functions for Torque, Speed or Fuel Rack position.

Continuous curve to simulate actual Speed and Torque relationship.

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Demand values may be defined as actual values or percentage values.

Timers for determining duration of demand conditions, time of Fuel Consumption Measurement Cycle and time of data printout.

Possibility to define Alarm Levels according to the different Engine demand conditions i.e. it must be possible to define limits values for each Test Step.

Test to be resumed at the point at which Test Cycle was interrupted.

To synchronise the Data Acquisition (Data sampling) with Engine Speed, or on receipt of Pulse from the Electromagnetic Pick up.

To carry out simple averaging of sample points, for giving mean level of the Signal.

Display Management It shall be possible to display the Measured/Calculated Data selectively in multi-page/multi screen format with appropriate headers that may be defined by the Operator. Data on the Control Monitor shall be updated after every measurement. There shall be provision for short-term storage of Test Data, so that in the event of an Emergency Shutdown, the Operator may recall the Data measured prior to and at the time of the Shutdown. It shall be possible to recall data at the rate of up to 20 seconds (or less) intervals up to 10 min prior to the (emergency) shutdown for 32 selectable/monitored channels. The alarms for Engine Speed, Torque, Fuel Rack Position, Dynamometer Water Outlet Temperature, Dynamometer Water Inlet Pressure, Engine Jacket Water Temperature, Lube Oil Pressure, Exhaust Gas Temperature, Exhaust Gas Turbo Inlet Pressure, Fuel Pressure in Header, Crankcase Vacuum Pressure, Water Temperature of after Cooler Outlet, CNG inlet Pressure and temperature and Turbo Bearing Oil Pressure Channels are to be monitored. There shall be a provision of compiler for compilation of Formula in the Formula Table for Real time and Data Clock, Calculated Channels like HP, BMEP, BSFC, Torque etc. as well as to give input to Engine Map Calculations routines for Automatic Plotting of Power Curves, Specific Fuel Consumption Curves, etc. The Compiler shall perform the following basic functions:

Basic Arithmetical operations

Exponent to base e.

Logarithms

Min, Max., and Average Value

Parenthesis

Arithmetic Function

Trigonometric functions

Logical Operations

Comparisons

Boolean

Graphic software for post processing and documentation of engine data

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Graphical Calculation Software with user friendly menus, GUI and with requirement of minimal Programming knowledge at Operator level shall be provided for detailed post processing, presentation and documentation of engine data e.g. for creation of graphs, tables and protocols and also for data export and archiving. Software shall be capable for combining and evaluating different type of Data Measured on the Test Bed, Stored Result Files and Data from other sources such as High Speed Data Acquisition System, Mass Emission Measurement System and Particulate Measurement System, which are already available with Engine Development Directorate. This Software Package shall have the following features:

Data Management - Reading Data from:

Support of Standard File Formats

Export of Data to MS EXCEL, MS WORD, and in ASCII format etc. Data Presentation:

Graphics: Standard y-t diagram vs. time, Log Point, Crank Angle, Cycle, Frequency, X-Y Graphics, Bar Chart, Histogram, Scatter Plot, Scatter Band, Box Plots etc. Automatic Legend Generation and Graph Annotation for all kinds of Graphics, Header and Text definition, Combination of Graphics and Tables, Intelligent Data Comparison Logic etc.

Graphic Manipulation: Zoom, Free definition of Scales, Range and other latest features etc.

Reports: Freely Definable Forms and Listings Advanced Report Generation with Text, Insertion of Bit Maps, Templates for Reports, Multi Page Plotting and Listing.

Calculation Features: Formula Compiler: Arithmetic, Trigonometric, Boolean functions, Integral, Differentiation, FFT, Digital Filtering, Polynomial Regression, Structures with Loops and Conditions, Macros for Nesting and complex functions, X and Y Transformation via Macros etc.

Engine Map Calculation: Regular/Irregular Distributed Points, Peak Filter, Clipping of Map at Full Load Curve, Replacing Calculated Full Load Curve with Measured Full Load Curve, Automatic or Manual insertion of Isolines, Overlaying Engine Maps etc.

Combustion Analysis: Peak firing pressure, fuel line pressure, IMEP, injection timing, nozzle lift, valve lift, Knock Analysis, Heat Release, PV Diagram etc.

Note: It is the work of ECU (RDSO supplied) to control duel fuel injections completely. Only there should be provision in control system to get interfaced with this ECU.

Engine Test Surveillance:

Automatic Engine Testing requires close Monitoring of Engine conditions to either alter or implement Emergency Shutdown in the event of abnormal conditions. Some Engine parameters may vary widely between Idle and Full Load running hence these limits have to be set to allow for this variation. The Engine Test Surveillance shall be available on at least 32 Channels. All Alarm Channels as explained above shall be Programmable to set limit levels, high or low. Alarm limits shall be stored in the files. These files shall be accessible from the ‘Engine Automated Test Cabin Control System’.

An Alarm Annunciation Unit with necessary sensing devices shall be provided to protect the dual fuel engine and dynamometer from damages against following:

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(i) ENGINE

Fault Action by Supervisory System

Low Lube Oil Pressure : Engine Shutdown and Audio Alarm

High Cooling Water Temperature

Above 90 deg C : Audio Alarm

Above 95 deg C : Engine returns to Idle. Engine RPM and Load is dropped to Idle set point.

(ii) DYNAMOMETER

Fault Action by Supervisory System

Low Dynamometer Water Pressure

: Audio Alarm and Shutdown

High Cooling Water Outlet Temperature

: Visual Indication and Audio Alarm

Low Lube Oil Supply Pressure to Dynamometer Bearing

: Audio Alarm and Shutdown

High Bearing temperature : Audio and visual Alarm

In all these cases, Visual indication of Fault should be displayed on Operator’s Panel. Engine Shutdown should be achieved by cutting off Fuel to the Diesel Engine and unloading the Dynamometer. The response time of the two actions should be such as to avoid Over-Speeding of Diesel Engine. Necessary provision for implementing Engine Shutdown depending upon Signals from allied sources should be incorporated.

Engine starting interlock system The ‘Engine Automated Test bed Control System’ should ensure that the Engine starting sequence has been completed before Engine may be cranked or started in order to protect the Engine from damage. The Engine should not start unless:

Fuel Line Pressure after Booster Pump should be above minimum limit of 3 bar

Minimum Air Reservoir Pressure for Engine Starting is 13.0 bar. The engine starting will be done by an air Starting motor.

Engine Monitoring An Engine Monitoring System incorporating Alarm Annunciation Unit and Engine Shutdown facility to protect Dual Fuel (Diesel/CNG) Engine and Dynamometer against damages should be incorporated into the ‘Engine Automated Test bed Control System’. It should have the following features:

I. Minimum 32- Channel Monitoring Capacity

II. Output for both Audible and Visible Alarm III. Programmable Engine Emergency Stop and parameter limits. IV. Possibility to set Pre-Low and Low or Pre- High and High limits for each Channel i.e.

Audio and Visual Alarm at first limit (Pre) and Engine Shut-Down at second limit (Low/High).Engine should come at idle before Shut-Down (except emergency shutdown).

V. Facilities to `Shut-Down' the Engine [programmable for each Channel]

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VI. Provision regarding Engine Monitoring shall be made for the following Parameters:

Engine RPM (Pre- High and High limits)

Engine Lube Oil Pressure (Pre-Low and Low)

Smoke and Fire in Test-Cabin (Shut-Down)

Smoke and Fire in Engine Room (Shut-Down)

Diesel Engine Cooling Water Pressure (Pre-Low and Low)

Dynamometer Water Inlet Pressure (Low limit)

Dynamometer Water Outlet Temperature (High limit)

Fuel Oil Pressure (Low limit)

CNG Pressure(Low limit, High limit)

CNG Leakage (Shutdown)

Dynamometer Overload (Pre- High, and High limits)

Exhaust Gas Inlet Temperature (High Limit)

After Cooler Water Outlet Temperature (High Limit)

Necessary Transducers, Limit Switches, Electronic Control Circuits etc. for Engine Monitoring System should be part of supply.

Wall mounted junction boxes for housing signal conditioning modules The ‘Wall Mounting type junction box’ housing shall have: (i) Suitable mounting inside engine test bed wall and away from exhaust manifold of the

engine for the protection from excessive temperature.

(ii) Standard Interface Cabling from this housing to connect the ‘Engine Automated Test and Control System’.

(iii) Necessary Amplifiers and Proper Cooling arrangement for accommodation of Signal Conditioning Modules of Temperature, Pressure Sensors etc.

(iv) Auto engage pneumatic adopters to withstand 0-30 bars pressure with proper housing support mounted on the housing itself.

5.2 Various Measurement sensors:

I. Speeds/rpm. II. Temperatures.

III. Pressures. IV. Flows/Mass Flows. V. Ambient conditions.

VI. Vibration and Noise VII. Knocking.

VIII. High speed data acquisition system. IX. Emissions

The required measurements and their frequency of measurement are separately detailed in Annexure-3 to Annexure-7. 5.2.1 Speed Measurement (Engine and Turbo):

Speed measurement equipment/sensor will be required to measure speed of the following:

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S.No. Point of measurement Maximum (in rpm)

Measuring Range (in rpm)

Minimum Accuracy

1. Engine 2000 0 to 3000 ±3 rpm

2. Dynamometer 3000 0 to 3000 ±3 rpm

3. Turbocharger 79000 0 to 100000 ±100 rpm

Measurement of speed of engine and dynamometer is part of engine testing. The Tenderer will specify the type and make of the sensors. 5.2.2 Temperature Measurement System:

The temperature measurement systems should be provided with temperature sensors, compensating cable extensions, connectors (convenient to use, fit, remove, and replace) and standard interfaces with signal conditioning modules.

The tolerance for temperature sensors shall be as per JIS C 1602, JIS C 1604 class A / EN 60751(for Pt-100) Accuracy in deg C: ± 0.15 + 0.002 * temperature for PT 100 Accuracy in deg C: ±1.5 °C or ± 0.004 * temperature for K type Thermocouple An exhaustive list of required readings and ranges in temperature is given in Annexure-3 to Annexure 5. Note: The scope also includes mounting of temperature sensors with suitable adaptors on engine at various locations as instructed by RDSO. Temperature Calibrator / Oven (02 Nos): shall also be in the scope of supply. Temperature Calibrator/Oven should be capable to calibrate any Temperature Sensors upto 1200 deg C (Accuracy ± 0.01 % or better). High stability Dry Block Calibrator for the calibration of temperature sensors (0 to 1200 deg C) This equipment will be used for calibration of temperature sensors. Technical Specification for high temperature calibrator: (1 No.) Minimum Temperature 300 deg C

Maximum Temperature 1200 deg C

Heating Time 45 Minutes or less

Cooling Time 2 Hrs or less

Accuracy 2 deg C

Stability ± 0.5 deg C

Insert Diameter 27 mm or more

Insert Depth 140 mm or more

Number of sensors to be held 02 or more

PC Interfacing

Automatic Calibration Software

Tool for Insertion Tube for holding sensors

Heat resisting arrangement to check heat loss in the sensor insertion area

Technical Specification for low temperature calibrator: (1 No.) Minimum Temperature 0 deg C

Maximum Temperature 700 deg C

Heating Time 45 Minutes or less

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5.2.3 Pressure Measurement System:

The pressure measurement system(s) should be provided with pressure sensors, cable, connectors (convenient to use, fit, remove, and replace, with push fit adopter for connecting pipes) and standard interfaces with signal conditioning modules. Measurement of pressures at various locations will be in the ranges as given in Annexure 6 and Annexure 7 with accuracy of at least ± 0.15% FSO. Note:

1. The scope also includes mounting of pressure sensors with suitable adaptors and pipes etc. on engine at various locations as instructed by RDSO.

2. In cabling work all Cables/channels should be numbered at both ends and their circuit diagrams with clearly showing numbering connection are to be provided by the tenderer.

3. In all wirings, suitable leak proof industrial/electrical coupler should be used. 5.2.4 Flow Measurements: Flow measurement system supplied should be of integral type having highly refined digital signal processing electronics, so that accurate and stable mass flow measurement is achieved. Automated test bed for dual fuel CNG engine should have suitable flow measurement system for Fuels(CNG and Diesel), lubricating oil, engine cooling water and air. The accuracy of flow measurements should be less than 1% .The details are as follows:

Fuel (Diesel): Mass flow rates measurement device should be based on Coriolis principle.

Measuring Range 0 to 1500 kg/hr

Temperature range 0 to 80 deg C.

Location At the output of filter or as specified by RDSO.

Fuel pump motor capacity 45 litre/min minimum

Fuel (CNG): The device should be based on Coriolis principle.

Measuring Range 0 to 750kg/hr minimum

Temperature range 0 to 125 deg C

Location at the output of gas filter or specified by RDSO

Cooling Time 2 Hrs or less

Accuracy 0.1 deg C

Stability ± 0.1 deg C or better

Insert Diameter 27 mm or more

Insert Depth 140mm or more

Number of sensors to be held 02 or more

PC Interfacing

Automatic calibration Software

Tool for insertion tube for holding sensors

Heat resisting arrangement to check heat loss in the sensor insertion area

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Lubricating oil: The device should be based on Coriolis principle.1 inch diameter pipe for fitment of the flow meter will be used.

Measuring Range 0 to 800 litre/hour

Temperature range 0 deg C to120 deg C

Location at the output of lube oil pump or specified by RDSO

Engine cooling water: The device should be based on Coriolis principle.

Measuring Range 0 to 50 Litre/sec

Temperature range 0 deg C to100 deg C

Location At inlet and outlet of the heat exchanger. (The flow meter shall be fitted between the heat exchanger and the engine for both inlet and outlet to maintain the minimum required straight length of 3D and 6D.)

Air Flow: The device should be based on hot film Anemometer or better principle. At present ABB make sensiflow air mass flow measurement system is being used at our existing test beds.

Measuring Range 0 to 5 kg/sec i.e. 18000kg/hr

Temperature range 0 to 55 deg C

Location At the intake of both the Turbo chargers separately. (The Air flow meter will be fitted between the Air filter and turbo inlet for both the turbochargers to maintain the minimum required straight length of 3D and 6D.)

02 nos of Air Consumption Measurement Meter (one per turbocharger) is mentioned in ANNXURE 3: Broad Details of System Deliverables (item 10).

5.2.5 Atmospheric/Ambient conditions measurement system

Test cell should have provision for measurement of barometric pressure and relative humidity. The features of barometric pressure and relative humidity measuring equipment are as follows:

Barometric Pressure: Measurement equipment should be capable for online ambient pressure measurement in the test bed with the following features:

Measuring Range 800 to 1100 mbar

Accuracy at least 0.5 mbar

Temperature Range 0 to 55 deg C

Temperature compensation and linearization shall be included in the sensor itself. Complete electrical connection and communication to the control stand is to be provided.

Humidity Measuring Equipment: On-line relative humidity measurement should be provided with following features:

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Power Supply: 20 - 28 V DC Parameters at nominal temperature of 20 deg C

Measuring Range 0-100% RH

Accuracy at least 2% RH (0-90% RH)

at least 3% RH (90-100% RH)

Nominal Temperature + 20 deg C

Output Signal 4- 20 mA

Parameters at ambient temperature

Measuring Range -40 to +60 deg C (Range is to be decided based upon the location)

Accuracy at least 0.2 deg C

Output Signal 4- 20 mA

Note: The scope also includes mounting of above sensors with suitable adaptors, pipes etc. at locations as instructed by RDSO. 5.2.6 Vibration and Noise Measurement System:

Vibration and Noise measurement system having 16 channels to be provided as follows:

S.No. Location of sensor Range Quantity

1 Measurement of engine speed 0-2000 rpm 1no.

2 Measurement of engine vibration 0 - 4 g 8 nos.

3 Measurement of Turbocharger vibration

0 - 4 g 3 nos.

4 Measurement of Dynamometer vibration

0-2 g 3 nos.

5 Measurement of engine noise 0-150 db 1 nos

Portable Vibration and Noise measurement system shall be interfaced with the control system. The number of channels should be expandable.

Note: The scope also includes mounting arrangement of sensors of above system with suitable adaptors at locations as instructed by RDSO.

5.2.7 Knock Measurement System:

Knock Measurement System with sensors should be provided and fitted/mounted on all 16 cylinders of engine. Non cooling type piezoquartz based sensors, integrated with suitable software are to be used for the measurement of Knock.

Technical Specification of Knock Sensor

Measuring Range 0 – 250 Bar/3625 PSI

Over Load 300 Bar / 4350 PSI

Sensitivity nominal 19 pC/ Bar ( 131 pC/PSI)

Linearity < ± 0.20 % FSO

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Sensitivity < 0.003 Bar/g without cooling water

Insulation Resistance > 1013 Ohm

Capacitance 10 pF

Acceleration < 0.013 BAR/g , with cooling water

Natural Frequency 69 KHz.

Temperature Co-Efficient of sensitivity 0.003 % / deg C from 20 deg C to 80 deg C

Accessories required with knock measurement system Cable, Coupling, Cable Mounting Tool, Gasket, Dummy and Necessary Adaptors will be in the scope of supply. Software Software to recognise the knock pulses and analysis of the signals for the diagnosis of their proper ignition will be part of supply. Electronics Suitable amplifiers for acquisition and interfacing with High Speed Data Acquisition System and PC will be the Scope of Supply. Note: The scope also includes machining in engine components, mounting arrangement of knock sensors with suitable adaptors on engine at locations as instructed by RDSO

5.2.8 High Speed Data Acquisition System

The tenderer has to supply, install and commission complete high speed data acquisition system interfaced with main control system of test bed. High speed data acquisition system includes complete hardware and software for measurement of peak firing pressure, fuel line pressure, IMEP, injection timing, nozzle lift, valve lift, Knock Analysis, Heat Release, PV Diagram etc.

Hardware Requirements:

1. Suitable optical angle encoder with Amplifier, fitting arrangement and cables. 2. Suitable Piezo resistive sensors cooling/Non-cooling type, with cables, adopters and

charge amplifiers for the measurement of peak cylinder pressure of up to 250 bar in maximum four nos. cylinders at temperature up to 1200 deg C.

3. Suitable LVDT (Linear variable differential transformer) based, positioning sensors, amplifier, adopters and cables for the measurement of valve and needle lift in two of the cylinder of the engine.

4. Suitable sensors, amplifier, adopters and cables to measure Fuel Line in four nos HP tube for pressure up to 2500 bar.

5. The whole unit integrated with all the signal conditioning amplifier racks will be mounted on a portable trolley with heavy duty self-locking wheels fitted underneath.

6. The Unit should have individual UPS unit (Minimum 2 KVA with half (1/2) an hour back up).

Software Requirements:

1. Suitable software for interfacing and transportation of the data acquired by the High Speed Data Acquisition system with the automated test cell control system.

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2. Suitable Software for Data Acquisition and Display of Entire Data in the monitor of Automated Test Facility and simultaneously on a 21” LED monitor of the High Speed Data Acquisition system. Note: The 03 monitors of 27” are required to display maximum major parameters (01 monitor in spare) while 21” monitor is required to display High speed parameters.

3. Suitable software for Post Processing and analysis.

5.2.9 Interfacing with existing emission equipments:

The test bed controller offered should be interfaced with the existing emission measurement system. The Test bed Controller should be able to start and stop the measurement of Emissions from the Control desk and should be able to acquire measured emissions data so that an integrated performance, emissions and combustion data file can be generated by the Test bed Controller. Emission measurement equipment will include the gaseous emissions measurement system, PM gravimetric measurement system, smoke measurement system, FTIR based spectrometer (Fourier Transformation Infra-Red Spectroscope) and EEPS (Exhaust Emission Particulate Sizer).The requisite information will be given by RDSO on request.

All the interfaces should be part of the Test cabin controller and should be based on open architecture with plug ‘n’ play feature.CAN- bus interface is preferred in between ECU and Automated Engine Test Bed Control System (AETBCS).

The protocols are as below: 1. Indi master HSDA- RS232 2. Mass emission measurement system-AMA 4000, SPC 472- AK protocol. The supplied systems by tenderer should be compatible with M/s Pierburg make AMA and SPC472, AVL Graz make Indi master 670, M/s Horiba make FTIR and M/s TSI make EEPS.

5.3 Technical specification of hydraulic dynamometer for Engine Loading:

Type Hydraulic

Max. Performance 3000 HP

Max. Speed 5500 RPM

Max. Torque 15000 Nm.

Max. Balance Indication 50 kN.

Measuring Range of Speed Indication 0-6000 RPM

Moment of Inertia Less than or equal to 5.0 kgm2

Measuring Accuracy RPM +/- 1 but not less than 0.025% of rated. Torque Accuracy class 0.2 (related to full scale), that means hysteresis < +/- 0.2, linearity < +/-0.2.

Load cell High accuracy strain gauge load cell for torque measurement. Preferably HBM Germany make.

Water Filter Heavy duty water filter with easy removal type Stainless steel basket. Filtration level 250 microns

Regulation of the Brake Digital control

Max. Water Outlet temperature Dyno outlet temperature shall be 65 deg C

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max. and the Temperature difference between outlet and Inlet temperature. Should not be more than 20 deg C.

Lubrication Forced air lubrication of dyno bearings

Indication for the rotation of the Dynamometer Should be clearly engraved on the Dynamometer

Dynamometer Control cables Not less than 30 meter in length

Coupling Dynamometer and engine Drawing of engine end coupling is available at Annexure - 10

5.3.1. The Dynamometer controller system supplied with the system should be compatible with

the automated test bed control Hardware and Software systems. 5.3.2. Tenderer has to provide conventional calibration kit consisting Arms, pan and set of

standard weights. In addition to this High Torque calibration kit with transfer standard load cell with display, Screw jack, with turning bar and high torque calibration torque arm assembly which eliminates handling of bulky weights.

5.3.3. Suitable coupling arrangement between engine and dynamometer shall be supplied by the

tenderer. Propeller shaft guard with heavy duty fabricated structure to arrest any flying object from drive shaft assembly will be provided by tenderer. The guard shall protect drive shaft coupling also. Guard shall be

Easy for installation

Completely covers drive shaft & Coupling.

Hinged with lock pins on both sides.

Hydraulic lifter to support Shaft & Coupling Capacity 500 kg.

5.3.4. Fixture for checking Dynamometer and Engine alignment: Mechanical type fixture with dial mounting arrangement to check the alignment. Fixture shall be user friendly.

5.3.5. Pressure Regulating & Flow control valve: Dynamometer shall be supplied with these valves which will ensure constant water pressure and flow of Dynamometer supply water.

5.3.6. Propeller Shaft & Coupling

Propeller Shaft

Torque. 15,000 Nm + min. 10 % Overload.

Balancing. Dynamically balanced.

Axial movement 100mm min. Coupling

Torsionally resilient coupling to isolate high amplitude Torsional vibrations

Mounting one end on the flywheel & other end on Propeller shaft flange. Flywheel drawing is as per Annexure 10.

5.3.7. Adapter Plate 1 Set.

Adapter plate for fitment of propeller shaft on Dyno and Coupling on Engine flywheel

5.3.8. Typical Duty cycle & operating points at various notches of DEMU engine is given at Annexure – 9.

6. Ventilation system:

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It has two components: A) Fresh Air Supply B) Room Exhaust (Hot Air Removal)

A) Fresh Air Supply Supply air through Blowers to have evaporative cooling system Air Flow To be worked out by the tenderer based on heat load of 300 kW

Suction Velocity 1.5 m/sec

Air supply velocity 15 m/sec in main duct. Less than10 m/sec in Test cell supply duct

Duct work Made out of 22 SWG GI sheet Ducting shall be well supported

Thermal insulation Min 40 mm Mineral wool of fire retarded thermocole.

Cladding 24 SWG Al cladding for insulation or Nitrile Rubber foam 25 mm thick.

Supply Grill Decorative with louvers for setting direction of flow.

Dampers manually operated dampers in Test Cell supply duct for flow control

Fire damper in main duct

Blower Room To be built in masonry.

Blower Features Type DIDW Limit Load Type

Blower Casing 2 mm CRCA Sheet steel

Impeller 2mm MS Sheet with backward Curve

Bearing SKF DRSA

Belt Fenner

Motor ABB/ BB / KEC

Finishing Epoxy paint (Interior & Exterior)

Filter pressure drop 6 to 7 mm of water column

Cooling Media Cross corrugated cellulose paper pad treated with antirot , rigidifying and wetting resin

Pressure drop in cooling media

9 mm of Water Column

Water pump KBL / Mono block

Duct Work 22 SWG GI

Duct Flanges MS Angle

Supply grills Extruded aluminium

Construction Details of Blowers The recommended Centrifugal Blower is of Double Inlet Double Width (DIDW) Limit Load type suitable for Belt Drive. The Blower is of standard MS construction and has smooth interior. It has backward curved multi-bladed impeller in heavy gauge sheet steel construction. This Blower is ideal for Ventilation System that handles very large volume of air at less speed and pressure. The maximum load of blower is specified and cannot be over-worked. Blower shall be painted with two coats of Epoxy Primer both on the interior & exterior and finished with Epoxy paint on the exterior. Drive Motor shall be of reputed Make like ABB / BB / KEC or equivalent of TEFC SC Induction type suitable to work off 415 V, 3 Phase, 50 Hz., AC Supply with Class ‘B/F’ Insulation and IP-44/55 Protection. The Intake Filters shall be of Panel type with HDPE media having filtration efficiency of 90% down to 15 - 20 microns. The Filters are of Dry type with several layers of media crimped to form deep folds ensuring maximum filtration area vis-à-vis face area of the filter unit resulting in

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low differential pressure, high dust retention capacity and high flow rate. These filters shall be washable type. The Air Intake Louvre shall be of galvanized iron (GI) with necessary provision for grouting. to prevent the rainwater entry into the filtration area / plant (blower) room besides avoiding birds, dry leaves, reptiles, rodents, air-borne objects, etc., which may cause damage to the filters. The Evaporative Cooling Unit shall consist of three main parts – the Outer Casing of Stainless Steel with Water Tank of Masonry construction Cellulose Pads and GI / CPVC Pipes & Fittings. Cooling media shall consist of corrugated sheets of especially self supported wettable strong cellulose material impregnated with decay-resisting chemicals. Canvas below to be provided at outlet of the blower to absorb vibrations. Blower to be mounted on Anti Vibration mounts.

B) Room Exhaust (Hot Air Removal) Hot Air from the test cell shall be extracted through by centrifugal blower from the test cell. Hot Air from the test cell will be let out in the atmosphere via ducting. The capacity of this Blower shall be such that it will work in harmony with the fresh air supply blower. Blower shall be DIDW limit load type with backward curve and housed in totally enclosed sheet metal canopy.

7. Charge air and engine exhaust system:

Charge Air for the Engine will be drawn from the test cell through air filters (Air filters will be RDSO supplied). Filter shall be mounted on portable stand. Air filter shall be connected to the engine by suitable flexible hose. Inter Cooler conditioning (CAC) Inter cooler conditioning system, to be provided, shall be suitable for following specifications a) Air Flow 3000 Lit / sec b) Inlet temperature 180 deg C c) Outlet temperature 90 deg C (Max) d) Raw water inlet temperature 65 deg C Engine exhaust system Engine exhaust main header Diameter. 400 mm

Flexible SS below to connect to turbo charger out let 2 Nos

Exhaust gas volume 3.57 kg/sec

Thermal Insulation 50 mm ceramic felt

Cladding 24 SWG Aluminium sheet

Height of Stack In line with Existing Test Beds exhaust Stack Heights (2.63 m above Exhaust outlet)

Expansion below 400 Dia SS below for thermal expansion

Suitable residential silencer is to be provided in the exhaust outlet. Provision of Rain hood is to be provided in the outlet.

In addition to this SS Flexible bellow to be provided for thermal expansion. Suitable supports to be provided from the side wall. Supporting structure with monkey ladder is to be provided outside the test cell to support Exhaust pipe, Residential silencer and rain Hood. Sampling port is to be provided for taking exhaust gas samples for checking purpose.

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Exhaust pipe within the test cell shall be thermally insulated by 50 mm thick ceramic pad. For protection, thermal insulation 24 SWG Al cladding to be provided. Exhaust pipe outside the test cell shall be painted heat resistant paint which can withstand up to 600 deg C. Motorised Exhaust Back Pressure control valve made of Stainless steel and with fast response electronic actuator to be provided. Monitoring signal for the control loop shall be provided for integration with data acquisition system. General arrangement is shown in annexure 13.

8. Electrical distribution system and lighting

The single line diagram indicating general arrangement for flow of power supply from main distribution panel to individual equipment is enclosed as Annexure 2. Power supply to individual equipment shall be given through isolator. System shall be consisting of i) Main Distribution Panel. Main MCB rating shall be according to total connected load. ii) APFC Panel shall be provided and coupled to main distribution panel so as to achieve Power factor close to 1. ii) Feeder Panels for power supply to various load centres. iii) From Feeder Panel power supply shall be given to individual equipment through isolator. iv) All cables shall be laid through cable trays. v) Minimum 3 Earth pits to be provided The following are the required alternative makes of major electrical items to be used for electrical system. S N Item Description Make

1. Air Circuit Breaker Schnider / L&T / Siemens

2. MCB Schnider / MDS

3. MCCB Schnider / MDS

4. Switches ( SFU ) Schnider / Siemens

5. Push Buttons TECKNIK / Siemens

6. Lamps LED Type TECKNIK / Siemens

7. Ammeter AE / Rishabh

8. Volt Meter AE / Rishabh

9. ASS KAYCEE / Salzer

10. VSS KAYCEE / Salzer

11. Lugs DOWELL / BRACO

12. Light Fittings WIPRO / PHILIPS

13. Cables POLYCAB / FINOLEX

Tenderer shall provide over all dimensions of Main Distribution panels & Feeder panels. All panels shall be made in CRCA sheet having IP 55 protection and finished by powder coating. Adequate illumination shall be provided in control room and Test Cell. Light Fittings shall be Flame proof in Test Cells. Light intensity in the Test cell shall be 350 LUX Control Room shall be provided with decorative recessed mounting type fittings. Light intensity in control room shall be 250 to 300 LUX. Light intensity shall be measured at 1500mm from the floor level .All fittings shall be energy efficient. Emergency lighting arrangement shall be provided in Test Cell as well as in control room in case of Power failure. Battery backup for the same shall be for not less than 1 hour. Dry cell type batteries shall be used in the system.

9. Acoustic treatment in Engine room

General arrangement is shown at annexure 12.

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Maximum noise produced by Engine 115 to 125 dB

Reduction in noise level 40 dB

The above noise level is to be measured outside the test cell at 1500mm distance with test cells operating at full load, all doors closed and with no background noise within the Corridor.

Acoustic Tiles are to be provided on all sides of the walls including ceiling.The following are the specifications of the acoustic tiles:

Over all dimensions of tiles 600 X 600 OR 600 X 1200(mm)

Acoustic Insulation 50 mm Preformed mineral wool slab

Density Not less than 96 GSM

Material Of Construction (MOC)

22 SWG GI sheet with perforation Thickness 1mm

Finish Powder coated on both sides

Utility channels 42 X 42 X 2.5 mm thick separator on all 5 sides of the cells

Acoustic Door & Vision Panel Schedule

Sr No Description Clear Opening

1 Double leaf Door 75 mm Thick 3000W x 3500H

2 Single Leaf Door 75 mm Thick 900W X 2100 H

3 Vision Panel 100 mm Thick 3000W X 1500H

4 Power operated sliding Door 9500L X 2500W

Safety norms should not be ignored while setting up of acoustic door & vision panel. Acoustic Door specification

Material CRCA Sheet

Viewing Window 550 X 400 mm fully sealed with inert gas

Kick Plate SS Plate on both sides to the doors.

Door Frame 100 X 100 mm square Tube

Heavy duty Lift off hinges made in Stainless Steel for long life. Operation shall be smooth so that the hinge will operate as door closer.

Finish Powder coated.

Door Lock

Heavy duty

Panic Release Mechanism

To be provided from Inside for quick exit In case of emergency

Vision Panel Specifications

The viewing panels on doors & Vision panel between control Room and test cell shall be fully sealed with inert gas or vacuum, multi-glazed units constructed from toughened shatterproof glass incorporated within a 50mm wide extruded aluminium frame suitable for flush mounting on the external wall. The acoustic properties of the glazed unit shall be similar to or better than that of the composite wall.

10. Compressed air piping, fuel piping and water piping

Compressed air piping

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Tenderer has to lay only separate high pressure (approx 17 bar) pipe line required for starting the engine and same pipe will work for cleaning the engine or engine parts using air regulator from available air reservoirs Air starting Motors (2 nos.) similar to Ingersoll Rand Make and MODEL NO. SS825GC03R31 will be under tenderer scope of supply and commissioning. The piping will be of following specifications:

For General purpose MS B class

For Air starters MS Seamless tube Schedule 80

All pipe fittings shall be hydraulic.

Fuel piping

A. Diesel

Piping arrangement from available day tank to engine room shall be done by tenderer as per detailed layout drawing. Piping & Fittings shall be completely leak proof and of MS Class B with hydraulic fittings.

B. CNG

Storage Construction of platform with shed to be provided for CNG Cascade of least 16 cylinders

Piping SS seamless schedule 80 piping leak proof system including hoses and connectors suitable for CNG from Cascade to Engine room as per detailed layout drawing.

Water piping

Complete water piping system to be laid from the proposed cooling system ( with existing heat exchangers ) to the engine room for cooling of dynamometer and engine water and back to the proposed hot water tank as per detailed layout drawing.

11. Fire and smoke detection system :

System shall operate on double Knock arrangement to confirm fire. System shall consist of following items. As far as possible Honeywell make components shall be provided.

SN PLACE ITEM DESCRIPTION QUANTITY

1.

In Test Cell Flame detectors 2 nos.

Heat detectors 2 nos

CO sensors 2 nos.

HC sensors 2 nos.

Gas release nozzles As reqd.

2 Control Room Smoke detectors 2 nos.

Hooter and flasher 1 set

3 Outside test cell Fire alarm panel Co2 gas bank Hooter and flasher

1 No 1 set 1 set

Gas monitor control system to be available in test control room. System shall consist of addressable fire alarm panel with battery backup and minimum 3 Auxiliary signals for remote operation and indication to Main fire alarm panel of the complete premises.

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In addition, Conventional fire Extinguishers 3 nos. (Soda Acid Type ) to be provided in the test cell and 2 nos in Control Room for attending fire.

12. Water Circulation system

General arrangement is shown in Annexure 14. System shall consist of

I. Centrifugal Pump (One Operating & one Stand by) for supply of water to test cell from Cold sump

II. Centrifugal Pump (One Operating & one Stand by) for supply of water to Cooling Tower from Hot sump.

III. COOLING TOWER

IV. Piping in GI Class B

V. Valves, Bends, Flanges etc.

VI. Pipe support material

VII. Cut ring gaskets, fasteners etc.

Presently 4 Test Cells are in operation. Proposed cooling Tower shall be suitable for all existing test cells as well as proposed test cell. Therefore, integration of existing test cells piping with common Cooling Tower and underground Tank shall be considered in the scope of supply.

Specifications

1. Centrifugal Pumps having following features

High Efficiency

Preferably Mono Block type

Stainless steel Shaft

Gun metal impeller

Mechanical Seal.

2. Cooling Tower

Flow Rate 1000 Cubic Meter per hour

Inlet Temperature.

65 deg C Max

Outlet Temperature. 35 deg C.

MOC Fiber glass & with basin

Type Power Saver

Total Loss of water

Less than 2.5 %

Type of Fills ABS

Fan Blades

AL Die cast.

Fasteners

Stainless Steel.

3. Flanges. As per Table E of British standard no. 10 of 1962.

4. Fasteners Cadmium Plated & Zinc passivated.

Along with this water softener, Storage tank for soft water and make up water supply to Underground tank by gravity to be included in the scope of supply.

Engine Coolant Conditioning

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Coolant conditioning, to be provided, shall have following feature

Engine coolant temperature accuracy It will be dependent on the temperature sensor accuracy however It can be maximum ± 1 deg C.

Engine Coolant Water + Additive

Special feature Blow down and Refill arrangement.

Coolant inlet temperature 95 deg C Max.

Coolant outlet temperature 80 deg C Max.

Raw water inlet temperature 40 deg C Max.

System shall be suitable for integration with Data Acquisition system and operate as per the set demand

For General arrangement drawing for makeup water system see Annexure 15.

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Annexure- 1 LAYOUT OF TESTBED

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Annexure- 2 ELECTRICAL DISTRIBUTION SYSTEM

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Annexure-3

Low Temperature Channels

S.No. Norm Name

Description Range (deg C)

Expected pressure range (bar)

1. T_OIL Temperature oil 0-250 1-10

2. TAMB Temp. Air Ambient 0-250 1

3. TAI Temp. Air Intake 0-250 -0.3 to +0.3

4. TAIM Temp. Air Inlet Manifold 0-250 -0.3 to+0.3

5. TAAC_L Temp. Air After Cooler _L 0-250 1-10

6. TAAC_R Temp. Air After Cooler _R 0-250 1-10

7. TWCI Temp. Water Cooler In 0-250 1-10

8. TWCO Temp. Water Cooler Out 0-250 1-10

9. TWOCI_R Temp. Water -Oil Cooler In 0-250 1-10

10. TWOCO_L Temp. Water -Oil Cooler Outlet 0-250 1-10

11. TOS Temp. Lube oil Sump 0-250 -1 to +1

12. TWACO_L Temp. Water Air Cooler Out_L 0-250 1-10

13. TWACO_R Temp. Water Air Cooler Out_R 0-250 1-10

14. TWACI Temp. Water After Cooler In 0-250 1-10

15. TDPI Temp. diesel Pump In 0-100 1-20

16. TDPO Temp. diesel Pump Out 0-100 1-20

17. TDHLE Temp. diesel Header Left End 0-100 1-20

18. TDHRE Temp. diesel Header Right End 0-100 1-20

19. TDRPL Temp. diesel Return Path Left 0-250 1-20

20. TDCR Temp Diesel common Rail 0-250 2000

21. TDRPR Temp. Diesel Return Path Right 0-250 1-20

22. TWDI Temp. Water Dyno Inlet 0-250 1-10

23. TWDO Temp. Water Dyno Outlet 0-250 1-10

24. TOIN Temp. Lube Oil Inlet to Engine 0-250 1-20

25. TWI Cooling Water Temp. /In 0-250 1-10

26. TWO Cooling Water Temp. /Out 0-250 1-10

27. TWHEIP Temp. Water HE In Plate Type 0-250 1-10

28. TWHEOP Temp. Water Plate Type HE Out 0-250 1-10

29. TWHEIS Temp. Water HE In Shell Type 0-250 1-10

30. TWHEOS Temp. Water HE Out Shell Type 0-250 1-10

31. TACTLI Temp. Air Comp. (Turbo Left) In 0-100 1-10

32. TACTLO Temp. Air Comp. (Turbo Left) Out 0-250 1-10

33. TOTLI Temp. Lube oil (Turbo Left) In 0-250 1-20

34. TOTLO Temp. Lube oil (Turbo Left) Out 0-250 1-20

35. TWTLI Temp. Cool Water (Turbo After cooler Left) In 0-250 1-10

36. TWTLO Temp. Cool Air/Water (Turbo Left) Out 0-250 1-10

37. TACTRI Temp. Air Comp. (Turbo Right) In 0-100 1-10

38. TACTRO Temp. Air Comp. (Turbo Right) Out 0-250 1-10

39. TOTRI Temp. Lube oil (Turbo Right) In 0-250 1-20

40. TOTRO Temp. Lube oil (Turbo Right) Out 0-250 1-20

41. TWTRI Temp. Cool Air/Water (Turbo Right) In 0-250 1-10

42. TWTRO Temp. Cool Air/Water (Turbo Right) Out 0-250 1-10

43. TBFB Diesel Temp. before fuel balance 0 - 100 1-20

44. TAFB Diesel Temp. after fuel balance 0 - 100 1-20

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Annexure-4 Gas Temperature Channels

S.No. Norm Name

Description Range (deg C)

Expected pressure range (bar)

1. TSG Temp. Storage gas -200 to 100 1-350

2. TST_1 Temp. gas train 1 -200 to 100 1-350

3. TST_2 Temp. gas train 2 -200 to 100 1-350

4. TST_3 Temp. gas train 3 -200 to 100 1-350

5. TST_4 Temp. gas train 4 -200 to 100 1-350

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Annexure-5 High Temperature Channels

S.No. Norm Name Description Range (deg C)

Expected pressure range (bar)

1. TGCHL_1 Temp. Exhaust Air Cyl L 1 0-1200 1-250

2. TGCHL_2 Temp. Exhaust Air Cyl L 2 0-1200 1-250

3. TGCHL_3 Temp. Exhaust Air Cyl L 3 0-1200 1-250

4. TGCHL_4 Temp. Exhaust Air Cyl L 4 0-1200 1-250

5. TGCHL_5 Temp. Exhaust Air Cyl L 5 0-1200 1-250

6. TGCHL_6 Temp. Exhaust Air Cyl L 6 0-1200 1-250

7. TGCHL_7 Temp. Exhaust Air Cyl L 7 0-1200 1-250

8. TGCHL_8 Temp. Exhaust Air Cyl L 8 0-1200 1-250

9. TGCHR_1 Temp. Exhaust Air Cyl R 1 0-1200 1-250

10. TGCHR_2 Temp. Exhaust Air Cyl R 2 0-1200 1-250

11. TGCHR_3 Temp. Exhaust Air Cyl R 3 0-1200 1-250

12. TGCHR_4 Temp. Exhaust Air Cyl R 4 0-1200 1-250

13. TGCHR_5 Temp. Exhaust Air Cyl R 5 0-1200 1-250

14. TGCHR_6 Temp. Exhaust Air Cyl R 6 0-1200 1-250

15. TGCHR_7 Temp. Exhaust Air Cyl R 7 0-1200 1-250

16. TGCHR_8 Temp. Exhaust Air Cyl R 8 0-1200 1-250

17. TETLI Temp. Exh. (Turbo Left) In 0-1200 1-10

18. TETLO Temp. Exh. (Turbo Left) Out 0-1200 1-10

19. TETRI Temp. Exh. (Turbo Right) In 0-1200 1-10

20. TETRO Temp. Exh. (Turbo Right) Out 0-1200 1-10

21. TEC Temp. Exhaust Chimney 0-1200 1-10

Expected pressure range will be upto 10 bar. The temperature should be measurable at a frequency scalable upto 200 HZ or better. Total required Temperature channels = 80 Spare temperature channels = at least 32

Page 34 of 56

Annexure-6 Low Speed Pressure Channels:

(Low speed pressure channels (scalable upto 200Hz) List of Pressure Channels is as below:

S.No. Norm Name Description Unit Range Expected Temp range ( deg C)

1. POIL Pressure Oil bar 0-20 0-80

2. PDYWI Pressure Dyno Water Inlet bar 0-10 0-80

3. PAIM Pressure Air Inlet Manifold bar 0-10 0-80

4. PACI Pressure Compressed Air Intake mbar -300 to +300

0-80

5. PACO Pressure Compressed Air Outlet bar 0-10 0-80

6. PFUELDL Pressure Diesel Fuel low pressure bar 0-20 0-80

7. PFUELDH Pressure Diesel Fuel high pressure bar 0-2500 0-250

8. PFUELDCR Pressure Diesel Fuel Common Rail

bar 0-2500 0-250

9. PCNG Pressure CNG before diffuser bar 0-450 -200 to 100

10. PCNGBFUEL Pressure CNG before fuel conditioner

bar 0-450 -200 to 100

11. PCNGAFUEL

Pressure CNG after fuel conditioner

bar 0-450 -200 to +100

12. 7 POIN Pressure Lube Oil Inlet bar 0-20 0 –80

13. 8 POTB Pressure Oil Turbo Bearing bar 0-20 0 –80

14. 9 PWO Pressure Water Outlet bar 0-10 0 –80

15. 10 PODYB Pressure Oil Dynamometer

Bearing bar 0-10 0 –80

16. 11 PCCV Pressure Crank Case Vacuum mbar -300 to

+300 0 –80

17. 12 PDWLC Pressure Drop water In AC1 mbar 0 to 350 0 –80

18. 13 PDFIL Pressure Drop in Oil Filter mbar 0 to 1000 0 –80

19. 14 PATLI Pressure Air Turbo Left In bar 0-10 0 –80

20. 15 PETLI Pressure Exhaust Turbo Left In bar 0-10 0–600

21. 16 PATRI Pressure Air Turbo Right In bar 0-10 0 –80

22. 17 PETRI Pressure Exhaust Turbo Right In bar 0-10 0–600

23. 18 PATLO Pressure Air Turbo Left Out bar 0-10 0 –80

24. 19 PETLO Pressure Exhaust Turbo Left Out bar 0-10 0–600

25. 20 PATRO Pressure Air Turbo Right Out bar 0-10 0 –80

26. 21 PETRO Pressure Exhaust Turbo Right

Out bar 0-10 0–600

27. 2PASM Pressure Air Starting Motor bar 0-20 0 –80

Page 35 of 56

2

28. 23 PIM Pressure Air Manifold mbar -300

to+300 0 –80

29. 24 PDACL Pressure Drop Air After Cooler

Left mbar 0 to 350 0 –80

30. 25 PDACR Pressure Drop Air After Cooler

Right mbar 0 to 350 0 –80

31. 26 PDCOOL Pressure Drop in Lube Oil Cooler mbar 0 to350 0 –80

32. 27 PGTO Pressure Gas Turbo Left Out bar 0-10 0 –80

33. 28 PGTO Pressure Gas Turbo Right Out bar 0-10 0 –80

34. 29 PAMB Pressure Ambient mbar 800 to

1200 0 –80

Low speed pressure channels (scalable upto 200Hz) Total required Pressure channels (200Hz) = 50 Spare pressure channels (200Hz) = at least 20

Page 36 of 56

Annexure-7 High Speed Pressure Channels (1 MHz):

Expected temperature range (deg C) for SN 1 to SN 4 is 0-120 deg C but for SN 9 to SN 12 the expected Temp range (deg C) is 0 -1000 deg C.

S.N Norm name Description Pressure Range Expected Temp range

(deg C)

1. PICYL1 Pressure injection HSD Cyl L 1 0 to 2000 bar 0-120

2. PICYL8 Pressure injection HSD Cyl L 8 0 to 2000 bar 0-120

3. PICYR1 Pressure injection HSD Cyl R 1 0 to 2000 bar 0-120

4. PICYR8 Pressure injection HSD Cyl R 8 0 to 2000 bar 0-120

5. PIGCY_L1 Pressure injection Gas Cyl L 1 0 to 450 bar 0-100

6. PIGCY_L8 Pressure injection Gas Cyl L 8 0 to 450 bar 0-100

7. PIGCY_R1 Pressure injection Gas Cyl R 1 0 to 450 bar 0-100

8. PIGCY_R8 Pressure injection Gas Cyl R 8 0 to 450 bar 0-100

9. PFCY_L1 Pressure firing Cyl L 1 0 to 2250 psi 0-1000

10. PFCY_L8 Pressure firing Cyl L 8 0 to 2250 psi 0-1000

11. PFCY_R1 Pressure firing Cyl R 1 0 to 2250 psi 0-1000

12. PFCY_R8 Pressure firing Cyl R 8 0 to 2250 psi 0-1000

The High Speed Pressure should be measurable at a frequency of at least 1 MHz Total required pressure channels (1MHz) = 12 Spare pressure channels (1MHz) = at least 8 (4 nos. of pressure range 0-2500 bar, 2nos. of 0-450 bar and 2nos. of 0-300 bar)

Page 37 of 56

Annexure-8

LIST OF FURNITURE REQUIRED

S.No. Description Quantity 1. Chairs for main operators, Godrej

model no PES PCH-7002 or superior 3 Nos.

2. Chairs for data analysts/technicians, Godrej model no PES PCH-7003 or superior

10 Nos

3. Tables, Godrej WT series or superior 2 Nos 4. Computer table, Godrej Stylo series or

superior 2 Nos.

5. Couch set, Godrej Aristocrat series or better

2 sets

6. Centre table, Godrej Aristocrat series or better

2 Nos.

Page 38 of 56

Annexure -9

TYPICAL INDIAN RAILWAY OPERATING DUTY CYCLE FOR PASSENGER OPERATION

NOTCH PASSENGER SERVICE

Idle 49%

1st 6%

2nd 7%

3rd 5%

4th 4%

5th 7%

6th 5%

7th 5%

8th 12%

OPERATING POINTS ON LOAD BOX AT VARIOUS ENGINE NOTCHES

Notch

Position

Speed

(RPM)

LOAD

(kW)

8 1800 923

7 1650 760

6 1497 645

5 1390 505

4 1285 376

3 1220 243

2 1010 144

1 716 63

Page 39 of 56

Annexure-10 DRAWING OF ENGINE END COUPLING

Page 40 of 56

Annexure – 11

Sample Engine Data Sheet

Diesel Engine General Data:

SN DESCRIPTION

1. Make & type Cummins KTA 50L

2. Rated output under UIC and site conditions

1436 RPM

3. Rated Engine Speed 1800 RPM

4. Number and arrangement of cylinders 16 Cylinders, V – arrangement

5. Cylinder bore 159 mm (6.25 inch)

6. Compression ratio at a) Rated output b) Idle

13.8:1

7. Mean Piston Speed Mean piston speed is 9.5m/sec. (1875 ft/s)

8. BMEP at rated output 1441 kPa (209 psi)

9. Normal no load idling speed 700 rpm

10. Low idling speed, (if provided) 700 rpm

11. Fuel Injection Timings -0.126 inch@-0.2032 inch pistons travel

12. Peak Firing Pressure 2000 PSI

13. Heat Balance at rated Output Heat equivalent to power 41% Heat rejection to coolant 23.5% Heat rejection to exhaust 33.5% Heat rejection to ambient 2%

14. Pressure Vs. Crank Angle Diagram Available for 1500 HP.

15. Specific Fuel Consumption at various throttle positions with tolerance band under UIC and site conditions – Lower Calorific Value of the Fuel used in arriving at SFC figure

1800 RPM – 0.339 Lb/BHP-Hr. 1700 RPM – 0.339 Lb/BHP-Hr. 1600 RPM – 0.340 Lb/BHP-Hr. 1500 RPM – 0.345 Lb/BHP-Hr. 1400 RPM – 0.348 Lb/BHP-Hr. Lower Calorific Value of Fuel – 10300 BTU/min.

16. Lube Oil Consumption at rated output as percentage of Fuel Oil Consumption

0.3% of Fuel Consumption

17. Deration Calculations for site condition 4% per 300 m above 2200 m altitude

18. Number of Engines in Traction Application

150

19. Weight of Engine excluding Oil and Water

4858 Kg (10700 Lb)

20. Weight of Water contained in the Engine 153 Kg (337 Lb)

21. Weight of Oil contained in the Engine 159 Kg (328 Lb)

Page 41 of 56

22. Temperature of Exhaust Gases at Turbo Inlet at Rated Output UIC and site conditions

1350 0F (max)

23. Method of Starting the Engine Air Starter Motor

24. Estimated Period between Major Overhaul

22000 to 25000 hours of Engine operation with recommended operation and maintenance practices.

25. Periodicity of Overhauling the following critical items:

- Turbocharger

- Air and Exhaust Valve

- Connecting Rod Bearings

- Fuel Injection Pump

- Fuel Injectors

Based on performance of Engine and condition of various components.

26. Special Design Features of Engine highlighting the measure which have been taken to achieve:

- Lower Specific Fuel

Consumption

- Lower Lube Oil Consumption

- Reduced Thermal and Mechanical

Loading of critical components

- High reliability

- Maximum availability

1. PTG – AUTO – AFC Fuel Pump

2. STC (Stepped Timing Control) Injectors

with 2 STC Oil Control Valves. Variable

Injection Timing.

3. 2 Breathers on each Bank

4. Pulse Tuned Exhaust Manifold

5. Valve Rotators for both Intake and

Exhaust Valves reduce Wear of Valve seat.

Page 42 of 56

Fuel Injection System

SN Description

1. Type Cummins PT system

2. Diameter of pump plunger Not applicable as Cummins PT system is a low pressure system

3. Number and diameter of holes in nozzle Number of Hoses = 10 Diameter of holes = 0.0085 Inches (0.2159 mm)

4. Spray cone angle 100 +/- 10

5. Whether fuel injection timings are fixed or variable with engine speed / load

Fuel Injection timing is variable with engine speed and load. This is achieved with STC (Step timing control) Injectors.

6. Single / Double walled high pressure pipe

High pressure pipes are not required for P T system as pressure in fuel lines from fuel pump to injectors is low (around 115 psi in this case)

7. Details of injection pump, injector and nozzle

Cummins P T Fuel Pump – PTG-AUTO-AFC type. Injector – Unit Injectors with S T C configuration along with nozzle

Turbocharger

Air flow will be 5kg/sec. (max.) at rated output, This comes to 18000 Kg/h.

Sl. No. Description

1. Number of turbochargers used per engine

2 Nos.

2. Make and model Make – Holset Model – HS5A – 3075R /M51P4

3. Single / Double stage Single Stage

4. Exhaust gas / mechanically driven Exhaust Gas Driven

5. Air flow at rated output 27.21 Kg/Hr (198 Lb / min)

6. Pressure ratio of compression 1 : 3.78

7. Temperature of charge air after compressor

Max 250

8. Speed of turbocharger at rated output 62750 RPM

9. Type of bearings Free floating Bush Bearings

10. Details of lubrication Forced lubrication from Engine Lube Oil Pump

11. Whether pre and post lubrication provided

No pre-lubrication or post lubrication is provided

12. Turbine, compressor and mechanical efficiency

Turbine = 82%, Compressor = 73%

Mechanical = 97%

Page 43 of 56

Charge Air Cooler

Sl. No. Description

1. Type Water to Air – Tube and Fin Type

2. Separate / engine water circuit Engine Water Circuit

3. Temperature of charge air after charge air cooler

192.5 deg C

4. Details of mounting indicating whether cooler can be removed without removing turbocharger

Charge Air Cooler is mounted on Cylinder Head. It can be removed without removing the Turbocharger

Exhaust System

Sl. No. Description

1. Type of exhaust system – (Constant pressure / pulse type / multi-pulse / converter)

Pulse Type

2. Method of cooling No external forced cooling

3. Number of exhaust gas entry segments

16

4. Exhaust gas pressure at rated output 32.5 Inch Hg

5. Whether the exhaust manifold is shrouded / insulated

No

Piston and Rings

Sl. No. Description

1. Material specification Piston – Cummins Material Specification CM 50059

2. One piece or two piece piston One piece piston

3. Method of cooling Lubricating Oil sprayed through Piston Cooling Nozzles

4. Shape of bowl in piston crown Mexican Hat design

5. Number and configuration of piston rings

4 Piston Rings (Compression Rings) – 1 Top Compression Ring, 2 Intermediate Compression Rings, 1 Oil Ring with “I” Type channel

Page 44 of 56

Valves

Sl. No. Description

1. Material specification Cummins Material Specification – CMS 31012

2. Single / Composite type Composite

3. Details of valve seat insert Tribology

4. Method of fitting and holding valve seat inserts

Press fit and Stacking

5. Whether valve rotators used Yes

6. Method of adjustment of tappet clearance

Injector and Valve adjusting using 3375004 Dial Indicator Kit. Refer Operation and Maintenance Manual page No. 7-8

7. Angle of valve and seat Exhaust Valve – 300 +/- 15’ Intake Valve – 170

Cylinder Head

Sl. No. Description

1. Material Specification Cummins Material Specification – CMS41050

2. Coolant flow distribution

Cylinder Block

Sl. No. Description

1. Whether cast or fabricated Cast

2. Is the mounting rigid or on resilient pads Rigid

Crankshaft

Sl. No. Description

1. Type of bearings, bearing loads, method used to calculate bearing loads

Bi – metal Shell Bearings Bearings Loads

2. Particulars of vibration damper and its characteristics

Viscous Vibration Damper

Cylinder Liner

Sl. No. Description

1. Method of manufacture Centrifugally cast

2. Type of finish – Chrome plated / porous honey chrome etc.

Lubricated liners with Criss-cross pattern

3. Dry / Wet liners Wet liners

4. Water sealing arrangement between liner and cylinder block

Neoprene Rubber Seals

Page 45 of 56

Connecting Rod and bearings

Sl. No. Description

1. Design features – side by side. Fork and blade or articulated

Side by Side

Cooling Water System

Sl. No. Description

1. No. of water pumps and its characteristics viz. Delivery Vs. Flow resistance

Number of Water Pumps – 1

2. Is the cooling system pressurized? If so, upto what pressure?

Cooling system is pressurised upto 7 PSI by Pressure Regulator on Radiator

3. Max. Permitted cooling water temperature at inlet outlet of circuit

203 0F (95 deg C) Maximum at Outlet 160 0F (70 deg C) Minimum at Inlet

4. Normal cooling water temperature at full load under UIC and site conditions

70 deg C to 85 deg C

5. Radiator construction and dimensional details

4 Radiators mounted sideways.

6. Radiator fan drive arrangement 4 nos. Side mounded Radiators with 2 nos. of roof mounted fans driven by hydraulic motors

Lube Oil System

Sl. No. Description

1. Lube oil pressure at full and idle speed 345 – 483 kPa (50 – 70 PSI) at rated speed

2. Max. Temperature at hottest point 250 0F (120 deg C)

3. Details of filters used in the lube oil circuit

5 Nos. of replaceable paper element cartridge type filters with 40 micron filtration capability

4. Efficiency of filtration and periodicity of attention

40 Micron. Every 300 hours

Page 46 of 56

Fuel System

Sl. No. Description

1. Schematic fuel oil circuit Fuel Lift Pump is not required

2. Details of fuel oil lift pump and its drive Fuel Lift Pump is not required

3. Details of filters used in fuel oil circuit Dual Fuel Filter with replaceable paper element cartridge with 10 micron filtration capability

4. Periodicity of attention 300 Engine operation hours

Intake Air System

Sl. No.

Description

1. Type of primary and secondary stage filters and their efficiency

Primary filter paper Micron capability and secondary filter – paper – paper micron capability and 9

2. Pressure drop permitted at the operating point for new and dirty filters

New Filters – 15 Inches (Max) Dirty Filters – 25 Inches (Max)

3. Periodicity of attention Every day

Page 47 of 56

Annexure – 12 ACOUSTIC TREATMENT TO WALLS

Page 48 of 56

Annexure – 13

ENGINE EXHAUST DISPOSAL SCHEMATIC

Page 49 of 56

Annexure – 14 WATER CIRCULATION SCHEMATIC

Page 50 of 56

Annexure – 15 MAKE UP WATER SCHEMATIC

Page 51 of 56

GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

SPECIAL COMMERCIAL CONDITIONS FOR SUPPLY, INSTALLATION AND COMMISSIONING OF

R&D TEST BED FACILITY FOR DUAL FUEL (CNG, DIESEL) KTA 50L DEMU ENGINE ON

TURNKEY BASIS

RDSO Technical Specification No. TS/ED/2011/58 October 2014

ENGINE DEVELOPMENT DIRECTORATE Research Designs and Standards Organisation

Manak Nagar, Lucknow– 226 011, India

Page 52 of 56

1. On Site Installation, Commissioning and Training:

The complete responsibility for installation and commissioning (including prove out tests) of R&D test bed facility is of the tenderer. The commissioning shall be completed within 6 months from the date of receipt of all material at RDSO. The tenderer has to provide all necessary Operation &Maintenance manuals with detailed circuit diagrams (3 nos. hard copies and 01 no. soft copy) including certificates of calibration (traceable to National/International standards) along with the equipments. Commissioning engineers shall also provide training to ED Dte. Staff for operation, calibration and maintenance of complete system with required documents during installation and commissioning works.

2. Warranty

Two years warranty to be provided from the date of commissioning of the system. The defective parts has to be replaced free of cost within 21 days for the stock item and within 3 months for non stock items from the date of rejection at their own expense. The contractor shall bear all cost of such replacement including freight, insurance, customs duty etc. if any, on such replacing and replaced stores but without being entitled to any extra payment on that or any other account from RDSO. The warranty period shall be further extended by the breakdown period during the warranty period.

3. Other terms and conditions 3.1. The Tenderer must indicate in its offer the Facilities/Equipment(s) to be provided by RDSO

for Installation and Commissioning of the System .

3.2. The Tenderer shall be responsible for unloading, unpacking, shifting and positioning the Equipment(s) at the Installation Site.

3.3. The Equipment/system shall be sturdy and reliable in operation and incorporate components that can withstand the hostile environmental conditions of Diesel Engines such as Dust, Water, Fuel/Lubricating Oil, Extreme Temperatures and Humidity as per Indian Weather and Electrostatic Interferences. The Electromagnetic compatibility of the Equipment shall be of such level so as to minimize errors.

3.4. The System operation shall be unaffected by vibration and shock under the normal operating conditions of Engine Test bed.

3.5. The Tenderer shall confirm that he will extend all the maintenance support for the full period

of expected life of the equipment supplied.

4. Annual maintenance contract

1. AMC to be quoted for each of five years after expiry of 24 months warranty period. The

AMC charges for each year shall be firm.

Page 53 of 56

2. The AMC offer should include all costs of personnel and spares etc. Unit Personnel charges

as well as unit cost of spares should be specifically mentioned in the AMC offer. It shall also

include all cost of preventive visit (frequency as suggested by manufacturer) and maximum

two nos. breakdown visit per year. No cost of consumables required for day to day operation

and daily maintenance checks to be included in the offer.

3. Maximum downtime allowed is 18 days per year. Maximum response time should not be more

than 48 hours from the time of intimation by email.

4. Penalty in case of downtime of more than 18 days will be Rs 2000 per day .Penalty in case of

response time of more than 48 hrs will be Rs. 1000/ per 24 hour delay or part thereof.

5. AMC charges will be payable only in Indian Rupees. For a Foreign Tenderer, the AMC charges

will be paid to his authorized Indian representative only. The AMC charges would be added to

the FOR destination price quoted for equipment for the purpose of the comparative

evaluation of the offer.

6. Tenderers are required to give the current cost of spares required for maintenance of machine

after AMC period and the current service charges for each items of work of repair of

equipment beyond the AMC Period. These charges will not be included in the price of

equipment for the purpose of comparative evaluation of offers.

7. Tenderers, who are OEM, must give undertaking for supply of spare parts for a period of

expected life of the machine/equipment. Other Tenderers must submit undertaking from

OEM for supply of spare parts for a period of expected life of the machine/equipment.

5. Inspection

Pre-acceptance/Inspection of the systems and control equipment will be carried out by the 2 nos authorized representatives of RDSO at the manufacturing premises of the tenderer prior to dispatch of the equipment.

Page 54 of 56

GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

QUALIFYING CREDENTIALS FOR SUPPLY, INSTALLATION AND COMMISSIONING OF

R&D TEST BED FACILITY FOR DUAL FUEL (CNG, DIESEL) KTA 50L DEMU ENGINE ON TURNKEY BASIS

RDSO Technical Specification No. TS/ED/2011/58

October 2014

ENGINE DEVELOPMENT DIRECTORATE Research Designs and Standards Organisation

Manak Nagar, Lucknow– 226 011, India

Page 55 of 56

1. QUALIFYING CREDENTIALS OF TENDERERS

1. The tenderer should be in line of design, development and setting up of similar test beds for at least past five years ending 31st March of the previous financial year.. The tenderer itself must possess this qualification. Representation on behalf of a reputed manufacturer or designer/consultant will not be sufficient Documents must be attached to prove that the tenderer has at least 5 (Five) years experience of design and setting up test bed facilities in various Organizations of National/International repute.

2. The firm should have completed at least one project involving design, development and setting up of similar test beds. The details of the projects which have been successfully completed by the tenderer should be furnished.

3. The tenderer should preferably have requisite software and hardware to meet the requirements of the project. Tenderer may tie-up with suitable vendor(s) for meeting the software and hardware requirements. Capability and resources assessment of the sub-vendor, if any, engaged by the tenderer shall however be the responsibility of the tenderer.

4. The tenderer should have qualified and experienced personnel. The tenderer should submit qualification and experience profile of each such personnel along with the offer. The tenderer is required to furnish an undertaking to have the personnel on their roll during the execution, till completion of the project. Tenderer may tie-up with suitable vendor(s) for augmentation of personnel requirements. Capability and resources assessment of the sub-vendor, if any, engaged by the tenderer shall however be the responsibility of the tenderer.

5. Average Annual financial turnover during the last 3 years, ending 31st March of the previous financial year, should be at least Rs. Eight Crore or equivalent in any other currency. The tenderer should submit following documents in support of the above clause:-

Balance sheet for last three years

Profit and loss accounts statement for last three years

6. The Tenderer should clearly spell out the facilities available with him for providing adequate After-Sales Service in India during Warranty period. The Tenderer should also indicate the Service Organization(s) in India and the availability of infrastructure, qualified trained staff and spares for maintenance etc.

Page 56 of 56

2. DISQUALIFICATION

Indian Railways would like to caution that the respondents shall be ineligible to bid for or participate for development of the project in any one of following cases:-

1. In regard to matters relating to the security and integrity of the country, any

charge sheet by any agency of the government or conviction by a court of law for an offence committed by the company or any sister concern of the company would result in disqualification. The decision in regard to the relationship between the sister concerns would be taken by Indian Railways, based on the relevant facts and after examining whether the two concerns are substantially controlled by the same person/persons.

2. In regard to matters other than security and integrity of the country, any conviction by a court of law or indictment/adverse order by a regulatory authority against the company or against any sister concern which relates to a grave offence, or would constitute disqualification. Grave offence is defined to be of such a nature that it outrages the moral sense of the community. The decision in regard to the nature of the offence would be taken on case to case basis after considering the facts of the case and relevant legal principals by Indian Railways.

3. In regard to matters of International Trade, any conviction by an International Agency like U.N or any other Government besides the Government of India, against the company or against any sister concern which relates to grave offence, or would constitute disqualification.