STATEMENT OF TECHNICAL REQUIREMENTS
FOR
GT/ GTG STARTING RECTIFIER LOADING DEVICE
(RECTIFIER TESTING FACILITY)
EED 50­29
Jun 07
MATERIAL BRANCH
INTEGRATED HEADQUARTERS
MOD(NAVY)
‘D’ WING, SENA BHAWAN
NEW DELHI 110011
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RECORD OF AMENDMENTS
I. SL NO
AMENDMENT
I AUTHORITY
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II.
REVISION NOTE
No revision incorporated. III. HISTORICAL RECORD
This standard supersedes the following: ­ NIL. ii
DATE
SIGNATURE
CONTENTS
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Description
Introduction.
System Configuration
System Design
Rectifier Tests
Drive System
Duty Cycle
System Performance
Quality Assurance, Quality control and Inspection
EMI/EMC Specifications
Naval Specifications
Logistics Support
Drawings & Manuals
Trial Documents
Equipment Spares
Warranty
Technical Services
Training
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1.
Introduction . 1.1
The GT/GTG Starting Rectifiers are used on­board Indian Naval ships to control the speed of DC starter motor, which in turn provides the initial torque for starting the GTs. These rectifiers are to be tested and tuned prior to their installation on­board ships as new equipment or after major repair/overhaul. This testing shall be carried out using a dynamic loading device, which can cutoff the rectifiers at set output parameters of voltage and current. This loading facility shall be suitable for overall testing and tuning of GT /GTGs starting rectifiers without actually starting the GTs/GTGs. Further, the dynamic loading device will be trolley mounted. 2.
System Configuration . 2.1
The dynamic loading testing device should have a drive system, capable of regenerating the required output parameters of all types of GT/GTG starting rectifiers installed onboard Indian Naval ships and a suitable feedback system for automatically controlling the drive. The overall control should be from a Windows based Operator Workstation having features for monitoring and recording all parameters. 2.2
The input to the dynamic loading device should be connected to the output of the rectifier unit. The starting circuit of the rectifier should be integrated with the loading device. The switching ON of the rectifier should be from the Local Control panel. The rectifier should cut off automatically by the loading device after elapse of a set time according to the duty cycle.
3.
System Design .
3.1
The system should be modular in design and of contemporary digital technology. The cabinet should have a cover at the top and grids with holes for input and output cables, two bolts at the frame should be provided for grounding the loading device. Ringbolts are to be provided on top of the frame for transportation. All the loading device sub units should be easily movable as one integrated unit for carrying out tests at shop floor as well as on various Naval Platforms. The Loading facility should also be provided with adjustable output parameters so as to cater for testing GT/GTG rectifiers on­board various class of ships. The loading device should be capable to withstand specified output current and voltage limitation as per the duty cycle of the various GT/GTGs installed onboard the Naval platforms. The unit should be able to provide the maximum current as per the specifications and should be able to adjust the load automatically as per the output parameters of GT/GTG starting rectifiers. Further, the unit should cut off the rectifier as per the specifications. The max length of the cable (patt no 0561­5128338) between rectifier and the dynamic loading device will be 80 mts (02 parallel cables, NRM 1x240 mm2) 1
3.2
The dynamic loading device should be very compact and of minimum dimension so that it can be positioned nearest the GT/GTG rectifier onboard the ship. Depending on the proposed dimension (minimum) it should be possible to transport the device to the ship on a lister. If due to dimension being large this is not feasible, then it should be suitably mounted on a trolley. The device should have eye bolts for lifting. 3.3
The device should have an Ingress Protection IP55 4.
Rectifier Tests 4.1
The loading facility shall perform the following tests (not limited to) on the rectifiers as per the following technical specification:­
(a)
Duty Cycle Test
(b)
Current Clamp Test
(c)
Voltage Profile Test
4.2
Duty Cycle Test. There will a provision to generate the current demand (DC) to simulate the current requirement of the rectifier load. This shall be IGBT based and shall ensure the output of the drive to match the current demand of the rectifier on load. The control system shall be such that the set duty cycle requirement is always attained.
4.3
Current Clamp and Over Current Test. This test is used to check the operation of the current clamp of the rectifier under test. In this case the reference current demand to the current amplifier is fixed at a value higher than the maximum current setting of the rectifier under test. Once the current clamp is engaged the same shall be annunciated on the Operator Workstation. The exact load current is also recorded at the same instant. 4.4
Voltage Profile Test. The output voltage of the rectifier under test should be recorded on the Operator workstation and the same can be retrieved and analyzed at a later stage.
5.
Technical Specifications . The Test specifications of existing GT/GTG starting rectifiers and those of the various constituents of the proposed dynamic loading device is enumerated in the succeeding paragraphs. However, the specifications would be discussed and finalised during the technical discussions. 5.1
Drive System
Sl No
(i)
(ii)
(iii)
(iv)
PARAMETERS
Input Supply
Power Consumption at 1800 A & O/P Voltage 70V
Max. Output Current
Max. Output Voltage
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VALUES
380V±19V, 50Hz±1.5Hz, 3Ph
210KVA max
2000 A
70V
(v)
(vi)
(vii)
Output Power at Max. Current & 140 KW
Voltage
Output voltages limitation stages
User settable
Output Current maximum deviation ±7%
from given level %, not more
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Sl No
(viii)
(ix)
PARAMETERS
VALUES
Output Voltage stages established 10% to 3%
deviation from given level %
Control facility
The Operator workstation shall have facility for local control and monitoring of the system.
5.2
Drive. The Drive shall have protection features (but not limited to these) such as Instantaneous over current, Mains supply phase loss, Mains synchronization loss, DC bus over­voltage. The drive shall provide output to an oscilloscope to view desired parameter and shall use non­volatile trip alarm memory, and thus shall be able to preserve the last fault even after power recycle.
5.3 Test Controller. The test controller should be based on contemporary digital technology and be capable of Serial (RS 422/485) communication with the Operator workstation (OWS). It should have password protect features. The test controller should have capability of provision of alarm system for providing alarms for deviations in the current feedback waveform from the input current waveforms (not limited to). The test controller shall display all the parameters such as drive output feedback, Output voltage feedback, Current feedback between GT/GTG Rectifier under test & drive etc in LCD Display. The controller shall have self­
diagnosis feature & provide self­test alarms about problems within the drive controller, which may not relate to the motion control system. The controller shall also have self­diagnosis (BITE) features.
5.4
Operator Workstation. The operator workstation shall be totally based on COTS hardware to ensure continuous availability and modularity. The Operator Workstation shall be based on an industrial automation software solutions and open architecture in order that provide the user with process visualization, data acquisition, and supervisory control capability.
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5.4.1 Control & Monitoring Function. The Operator workstation shall support suitable amount of I/Os required for control & monitoring of the entire function. The number of I/Os selected shall be capable of catering to (not limited to) Controller enable/disable for both Rectifier under test and the drive, Current and voltage feedback, Status indication for the controller, Control triggering of the IGBTs, status of incoming and outgoing supply breakers, heat sink & Transformer temperature measurement, semiconductor fuse fail indications etc. Any other Input/Output points, which considered essential by the Supplier shall be included and their specifications with respect to the processors, communication capability of the display.
5.5
Specifications. The minimum specifications required for the Modules catering to the Input/Outputs for the controllers, digital IO modules, should be as follows:
5.5.1 Controller. 32 Bit, 40 MHz RISC Processor with built­in Real time clock & Battery back­up, 10/100 Base T Ethernet communication capability with the Display, RS 232 communication capability, input voltage – 24VDC, minimum 64KB minimum, LED indicators, over 20M Ohm insulation between power supply input terminal and protective ground
5.5.2 M
odules
. The specification for the digital I/O and Analog I/O modules are to be as per the minimum industrial norms. 5.6
Data Processing and Display.
5.6.1 The data processing and display on the Operator workstation shall be based on Windows Operating System and the software shall be advanced SCADA software. The salient features shall be as follows:­
5.6.2 Hardware Specifications (minimum). Industrial grade ruggedised for Naval applications, Operating display – Windows XP Pro/Windows 2000, housing – NEMA 4/4x (indoor use only), CPU – Intel Pentium 4 (3.0 GHz), hard disk – 80GB, DDR RAM – 1GB, FDD – 1.44MB, CD Writer 52X Type, Optical mouse, keyboard, LAN ­ 10 BaseT/ 100 BaseTx Ethernet port, Serial port – COM1 – Dedicated for RS 232 port, COM2 – RS 232/422/485 port, Parallel port – LPT1 SPP/EPP/ECP supported, USB port – 1 Nos, Expansion – 3 PCI slots, 2 ISA slots, 1 PICMG slot, VGA output – S­VGA (60 ft max). UL/CUL CE Approved Connectors ­ Serial Ports: D­Sub 9 pin (male); Parallel Port: D­Sub 25 pin (female
); Mouse Port: PS/2 Din connector; Keyboard PS/2 Din connector; Ethernet: RJ­
45; S­VGA: D­sub 15 (female), B Ports: standard USB connector
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5.6.3 Software. Windows 2000 based, COM Technology shall be utilized with Plug and Solve™ for easy integration of third­party applications, Full ActiveX control support to create interactive applications, Secure Containment to trap errant ActiveX controls to keep the Software Workspace running, VBA embedded as a powerful script authoring tool, Full OPC Client/Server support, SQL/ODBC API based which makes integration to relational databases simple, SQL Server 7.0 with Software
5.6.4
Protection Features & Alarms. The dynamic loading facility should have adequate protection features for all the power constituents. EED­Q­071(R2) would be the reference document. The alarms will be both visual and audio and will B LED based. 5.6.5 Data Collection and Management
(a)
Historical collection of data
(b)
Powerful Chart Object Trend Display Tool with many options and Chart Group Wizard
(c)
Capability to export data to relational databases for full reporting
5.6.6 The process shall be monitored and controlled by workstation computer with high­resolution monitor. The entire test shall be in such a manner that the operator can control the operation in an optimal and ergonomic manner without having to turn his eyes away from the display. All help information is available from menus and dialogue boxes on a dynamic and situation­oriented basis. The test data which are being monitored can be displayed in the form of hierarchically arranged displays with a constant selection structure or in a variable manner by means of the pan and zoom functions. Further displays, lists or dialogues can be displayed in additional windows, if required. A standard keyboard is available for alphanumerical entries. The workstation software shall provide various security levels for system monitoring and maintenance, the access to control or system maintenance functions shall be protected by password functions.
5.7
Duty Cycle
5.7.1 The dynamic loading device shall be provided with suitable stabilization circuit to maintain the output parameters at the preset values and ensures a continuous smooth rise in current during starting. The current and voltage curves are as per Fig 2 attached at the end of this document.
5.8
System Performance 5.8.1 Reliability. The system shall contain no ‘single point’ control, whose malfunctioning would result in complete failure of the system. The functional redundancy will be available in the shortest possible time through hardware 6
reconfiguration within shortest possible time. The design will cater for adequate fail­safe features. 5.8.2 Maintainability. The Operator workstation shall run online and off­line maintenance diagnostics. The Operator workstation, along with built­in test equipment (BITE) of individual units, shall be capable of selecting and localizing faults down to a single replaceable Module. The monitoring system shall also be designed to indicate corrective action either by a display or through a fault detection code, with amplifying notes used in conjunction with the maintenance manual. The manufacturer shall prepare and submit the following data on maintainability: ­
(a)
Maintainability programme.
(b)
Calibration Programme.
5.8.3 Modularity. The system shall be entirely modular and the applied modules shall be based on the COTS principle; extension of modules shall be very well possible.
5.9
G overning Environmental Conditions
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5.9.1 The is to be capable of operating in the following environmental conditions:­ 5.10
(a) Storage temperature 0 to 70 deg. C (b) Operating temperature 0 to 55 deg. C (c) Humidity 95% RH condensing at 35 deg. C
Technical Evaluation
5.10.1 The system and units would be required to undergo technical evaluation by ETMA (Mumbai)/MEPS (Naval Dockyard) and GTTT (MB)
5.11
Type Testing Requirements. 5.11 Truncated type testing, as per JS 55555, not leading to yellow banding of the equipment will be carried out by IN QA as tabulated below. These will be followed by actual on board performance trials. SER
(a)
(b)
(c)
(d)
TEST
High temperature
Damp heat
Driving rain
Tropical exposure
SEVERITY
Procedure ­5, Test condition­G
35 deg C, 95% RH for 16 hrs
Test condition­A
Test condition­A
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6.
(e)
(f)
(g)
Mould growth
Toppling
Bump
(h)
Roadability
On representative sample
As per test no 26
Peak acceleration­400m/s2
Pulse duration – 6ms
No of bumps ­1000+/­ 10
Procedure 2, Test condition­1
Quality Assurance, Quality Control and Inspection. 6.1
Inspection and acceptance tests will be jointly carried out by the representative of the Indian Navy and the manufacturer. A Quality Acceptance Procedure document containing the following details shall be provided to the Indian Navy:­
(a)
The details of Test Procedure and method of proving the performance of the system in factory.
(b)
Factory Acceptance Test (FAT) plan.
(c)
List of relevant hardware specifications, to which the testing/acceptance would conform to and the performance parameters required to be checked during the various acceptance phases. The manufacturer will undertake to make good, free of cost, any defects noticed during tests/trials/operations.
(d)
QAP be to prepared as per DQA(N) letter 66301/Policy/DQAN/Tech/011 dated 27 Jun 06, placed at Appendix A. 7.
EMI/EMC Specifications. 7.1
The test controller should confirm to Mil Standard/ commercial EMI/EMC standards Mil 461E. The system will be subjected to following Mil STD 461E EMI/EMC tests: ­
(a) CE 01 (b) CE 03
(c) RE 02
8.
Naval Specifications. 8.1
The system should be suitable for operating in saline environment, as it shall be erected in the Naval Dockyards. 9.
Logistic Support
9.1
Maintenance
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(a)
Monitoring & Diagnostics Tools. The controller shall have self­
diagnosis feature & provide self­test alarms about problems within the test controller, which may not relate to the control system.
(b)
Test Equipment. The Supplier shall provide details of the following test equipment that would be required:
9.2
Onboard Test Equipment. This should be adequate to meet the requirement of all repairs/ maintenance expected to be carried out by Naval Dockyard or Naval Ship repair yard.
10.
Drawings
10.1 Drawings are to be delivered in full size reproducible form and as CAD files on electronic media. The following information is to be included in the engineering drawings:­ (a) Dimensional outline, in metric units, of all major assemblies showing overall and principal dimensions in sufficient details to establish the limit of space in all directions required for installation, operation and maintenance. (b) A table of reference drawings to include drawing number of each major assembly. (c) A block diagram of all major assemblies showing interconnection between these assemblies.
(d) Location, type and dimension of cable entrance plates, connectors, etc. 11
(e) Any special instructions for installation, preservation, painting, etc. (f) Heat dissipation. Manuals
11.1 In addition to the general requirements covered by the data ordering document, the content and arrangement of the manuals shall be as follows:­ (a) Front matter (b) General (c) Installation Specifications (d) Operation 9
(e) Maintenance, repair and trouble shooting for levels up to second level maintenance. Component level maintenance procedures shall be offered as an option. (f) Parts identification (g) Test Data (h) Drawings reduced size (j) Appendix inserts on special components (k) Software Validation 12.
The technical manuals shall be provided in both hard copy form and on optical media (CD­ROM). Electronic documentation shall be compliant with the Computer Aided Logistics Support (CALS) standards. 13.
Weight and Dimensions. Details are to be intimated as part of the documentation.
14.
Trial Documents 14.1 The trial documents have to be prepared by the vendor and the same has to be approved by NHQ before its promulgation. The document will outline the type of tests, test procedures, and the validation criteria for evaluating the system. The trial documents are as follows (not limited to):­
15.
(a) Factory Acceptance Test Schedule.
(b)
Base (Dockyard) Acceptance Test Schedule.
Hardware Documentation 15.1 Hardware documentation in respect of hardware units like computers, interface units, data bus, I/O cards modules, control consoles, panels etc. specially designed by the firm must contain detailed information. The following documentation should be supplied by the firm:­
(a)
System Description. This document shall describe the system level concepts, inter connectivity, technical description of interfaces, communication protocols including block diagrams, test procedures using BITE and first level maintenance procedures. (b) Circuit Diagrams. Detailed circuit diagrams depicting implementation of various schemes along with signal description to be supplied. 10
(c)
Maintenance Manuals. Manuals containing hardware details of all repairable units to undertake fourth level maintenance should be provided.
(d)
Technical Specifications. This document shall be described the technical specifications of the hardware equipment used including details of I/O cards controllers etc. (e)
Installation Specification. This document shall include installation specifications and drawing of all hardware units.
(f)
Hardware User Manual. This document will contain all aspects pertaining to initial start up of the system, hardware configuration settings and system shut down procedures.
15.
Miscellaneous
15.1. Equipment Spares. 15.2 The manufacturer shall prepare the list of spares taking into account the Indian Navy’s maintenance philosophy and test equipment policy. Unit cost with Pattern numbers of each item is required to be specified. The Part Identification List should conform to the Integrated Logistic Management System (ILMS) format of the Indian Navy. The lead­time for the supply of items is also to be specified. An itemized list of spares, special tool and special test equipment, which will be supplied with the main equipment, is to be furnished along with the quotation for the main equipment. The following are the requirements of the Indian Navy so far as the spares are concerned:­ (a)
Provision of base spares based on one year’s requirement.
(b)
Scope, modalities and pricing for long term supply of spares during the life of the system and undertake to maintain the supply of same for at least a period of 12 years.
(c)
Provide working substitutes for those components becoming obsolete during the period of 12 years.
15.3 Annual Maintenance Contract. This option will be exercised by Indian Navy.
19.
Warranty.
19.1 The equipment with associated controls/instrumentation is to be guaranteed for stipulated performance for 18 month after commissioning. The equipment supplied shall be warranted from defects, manufacturer and performance for the said period and cover all the defects arising from malfunction through design faults, inappropriate material, bad production and non­conference to 11
specifications. Any expense because of repairs/supply of spares against guarantee defects is to be borne by the supplier.
20.
Life of the Equipment. The firm shall indicate the life of the equipment at its rated performance. 21.
System Performance Responsibility.
21.1 Supplier has to under take full responsibility for ensuring satisfactory performance of the system.
22.
Technical Services.
22.1 Installation Supervision. The representative of Supplier is to be positioned at the time of installation of the system. This is required for supervision of the installation process and to assist to resolve any technical holdups.
22.2 STW and Commissioning. The Supplier is responsible for Setting to Work, and commissioning of the system. 22.3. Training.
22.3.1 The Supplier is to provide on site training for Indian Naval personnel as follows.
(a)
Operators. Training for one day duration is to be imparted for minimum of 20 personnel on the operation and exploitation of the system.
(b)
Maintainers. Training for five days duration is to be imparted for minimum of 10 personnel on all levels of maintenance including PCB repair.
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