‘RANSNEr t Request for Proposal RFP No,TE17-KLP-9DJ-1904 Annexure F TRANSNET ENGINEERING TECHNICAL SPECIFICATION for THE DEVELOPMENT AND SUPPLY OF VARIABLE SPEED DRIVES AND PERIPHERAL EQUIPMENT FOR AN AC TRACTION MOTOR TEST RIG Date of release 21 JANUARY 2016 DOC. No. PD_RD_NAT_SPEC_010 Revision 0 “The information contained herein isthe sole property of Transnet Engineering It may not be used, disclosed oF reproduced in part orn whole in any manner, except with the vrttan permission of and ina manner permitted by the propretorsTRANSNEF Cr Table of Contents ‘TABLE OF ABBREVIATIONS. 5 1, BACKGROUND AND INTRODUCTION 6 2. DOCUMENT SCOPE . 6 3, _ APPLICABLE STANDARDS.. 6 3.1, SABS Standards......se 6 3.2, IEC Standards 7 3.3. TEE Standards. sacri 7 4. RESPONSE TO TECHNICAL SPECIFICATION 7 4.1. General a7 4.2. Respondent's Technical Response. 7 4.3. Alternatives Offered. eves 4.4, Options Offered. 8 5. SCOPE OF SUPPLY 9 5.1. General. x) 5.2. Project Timelines. sanaacasaty oe) 6. DESIGN REVIEW AND TESTING REQUIREMENTS, 6.1. Conceptual Design Review.. 6.2, Detail Design Review... 6.3, Type Testing of VSD 6.4. __ Installation of VSDs & peripheral equipment 6.5. Site Commissioning of VSD & peripheral equipment... 7. DOCUMENTATION 7.1. Documentation Management. 7.2. Document Identification. 7.3. Spare Parts Catalogue. 7.4. Drawings and System/Component Documentation..... 8. SITE CONDITIONS. 8.1, General seven 8.2, Ambient Temperature, 8.3. Operating Temperature... Document Name: ‘The Development and Supply of Varlable Speed Drives and Peripheral DOC. No.: PD_RD_NAT_SPEC_010 Equipment for an AC Traction Motor Test Rig Classification: Restricted — RFP Specification Document Revision: - 0 Date: 21 January 2016 Page: Page 2of 29 _ |Ct 8.4. Altitudes. r a 16 8.5. Humidity..... i ei sageou16 9, RELIABILITY, AVAILABILITY AND MAINTENANCE 7 9.1. Useful Life. 7 v7 7 v7 7 7 18 19 19 20 20 sesseseseese 20 2 24 24 24 24 25 25 9.2, Obsolescence Management... 9.3. Availability 9.4, Reliabili 10, MAINTAINABILITY REQUIREMENTS.. 10.1. Maintenance Plan/Program... 10.2, Safety. 11. GENERAL SYSTEM LAYOUT. 11.1, General. 12. TESTING ARRANGEMENTS 12.1. General. 12.2. Back to Back Testing Arrangement.. 12.3. Routine Testing Arrangement... 13, TRACTION MOTOR CHARACTERISTICS AND TESTS. 13.1. Traction Motor Data..... 14, TECHNICAL SPECIFICATIONS FOR THE VARIABLE SPEED DRIVE.. 14.1, General. 14.2, Performance Requirements .. 143. Control. 14.4. Cooling 25 14.5. Noise Attenuation... 26 14.6. Cabling, sees senses sven arin 26 14.7. Protective Features. 26 27 7 7 Pay 7 14.8. Functional Description, 14.9. Temperature Range Specification 14.10. Maintenance Requirements .. 15. TRANSFORMER AND SINE FILTERS ... 15.1, General Document Name: ‘The Development and Supply of Variable Speed Drives and Peripheral DOG. No.: PD_RD_NAT_SPEC_010 Equipment for an AC Traction Motor Test Rig) Classification: Restricted ~ RFP Specification Document Revision: -0 Date: 24 January 2016 Page: Page 3 of 29Ct. 15.2. Input Power Transformer. 7 15.3. Sine Filters.. re 28 16.1. General. 28 29 DOCUMENT AUTHORITIES Document Name: ‘The Development and Supply of Variable Speed Drives and Peripheral Equipment for an AC Traction Motor Test Rig DOC. No.: PD_RD_NAT_SPEC_010 Classification: Restricted — RFP Spediicaton Document Revision: - 0 Date: 24 January 2016 Page: Page 4 of 28Table of Abbreviations [REY Aternaving current Original Equipment Manufacturer (SPE) spare Parts catalogue FFE trensnet engineering [THD Tot Harmonic Distortion [985 voriatie Speed Drive Documant Namo: ‘The Development and Supply of Variable Speed Drives and Peripheral DOC. No.: PD_RD_NAT_SPEC_010 Equipment for an AC Traction Motor Test Rig ‘Classification: Restricted ~ RFP Specification Document Revision: -0 Date: 21 January 2016 Page: Page Sof 29‘TRANSNEF C 1. BACKGROUND AND INTRODUCTION During the course of 2015, Transnet Engineering (TE) has embarked on a project to build a test rig/bench for AC Traction Motors. This Technical Specification for the Variable Speed Drive (VSD) requirements refers to the power supply and control package that is required for driving the Traction Motors under test. This document is written to specify the major components of the Variable Speed Drive and peripheral equipment, including input and output characteristics of voltage and current required for performing the routine and type tests on the Traction Motors. This document provides an understanding of the AC Traction Motor Test Rig system as a whole and Interfaces thereof that are planned between the different system components. 2. DOCUMENT SCOPE 2.1. This Technical Specification employs one (1) medium to communicate its intentions: 2.1.1 ‘This Technical Specification document 2.2. For clarity, when used in this document the entities listed below shall have the following ‘meanings: 2.2.1. Respondent the person tendering along with others for the supply of the Goods/Services required under this RFP. 2.2.2 Suecesstil Bidder - the person who after submitting its RFP, has successfully passed evaluation and has been awarded the business, thereafter referred to as the Supplier. 3, APPLICABLE STANDARDS Unless stated otherwise, all requirements/regulations set forth In the following Technical Specification are applicable to the RFP which should thus be read in conjunction with this document. The assumption will be that the Respondent agrees and adheres to every clause within this Specification, Unless specified otherwise within the Respondent's response to the RFP, ‘The Respondent must provide a list of standards that they have adhered to other than those that are ‘mentioned in this specification document. 3.1, SABS Standards SANS 10111 (Latest): Engineering drawing. SANS 10142-1 (Latest): The wiring of premises Part 1: Low-voltage installations SANS 10142-2 (Latest): The wiring of premises Part 2: Medium-voltage installations above 1 KV ac, not exceeding 22 kV a.c, and up to and including 3 MVA installed capacity Document Name: “The Development and Supply of Variable Speed Drives and Peripheral DOG. No. Equipment for an AC Traction Motor Test Rig Classification: Restricted ~ RFP Specification Document D_RD_NAT_SPEC_010 Date: 21 January 2016 Page: Page 6 of 29v 3.2, IEC Standards TEC 60349 (Latest): Electrical traction — Rotating electrical machines for rail and road vehicles «Part 2: Electronic converter-fed alternating current motors TEC 60076 (Latest): Power Transformers IEC 60617 (Latest): Graphical Symbols for Diagrams: TEC 61287 (Latest): Rallway applications - Power converters installed on board roling stock - Part 1, 2 3.3, IEEE Standards IEEE 519 (Latest): IEEE Recommended Practice and Requirements for Harmonic Control in Electric Power Systems 4, RESPONSE TO TECHNICAL SPECIFICATION 4.1. General ‘The Respondent must adhere to all the requirements included in this document. Failure to adhere to these requirements may result in the disqualification of the Respondent's submission, subject to the decision of the adjudication panel. ‘Transnet reserves the right to disqualify any Respondent should its submission not adhere to all the requirements specified in this document, 4.2. Respondent's Technical Response 4.2.1 _ Respondents shall provide a clause-by-clause response to this Technical Specification. Failure to comply with this requirement may result in the disqualification of a Respondent. 4.2.2 _ RFP responses should therefore contain a clause-by-clause response for each clause in this document, containing at least one of the following answers: (Noted and Agreed: Response used when responding to informational causes, Full Compliance: When the current solution complies already. Future Compliance: To state that the solution does not exist currently, but will be offered as part of their offer. Respondents to state the development time needed to attain compliance. (0 Partial Compliance: To state that the current solution only provides partial compliance to the clause. In such a case, Respondents to specify discrepancy, the reasons for partial compliance, the possibilty of attaining full compliance plus cost and development time needed to attain compliance, (Non Compliance: To state that the clause is not met currently and not an option atall Document Name: “The Development and Supply of Variable Speed Drives and Peripheral OC. No.: PD_RD_NAT_SPEC_010 Equipment for an AC Traction Motor Test Rig) Classification: Restricted — RFP Specification Document Revision: - 0 Date: 24 January 2016 Page: Page 7 of 28v 4.2.3 Respondent must supply an outline proposal of the design, or datasheets along with corresponding test results if an existing module is quoted. 4.24 Respondents shall provide drawings, diagrams and additional iterature to dearly describe the operation of the proposed system and highlight any noteworthy features. 4.2.5 Respondents must provide calculations and any assumptions made must be stated Gearly. 426 ‘Where applicable, Respondent must indicate specifications whereto the units are and will be tested. 43, Alternatives Offered 4.3.1 In addition to offers which in the first instance comply with the requirements set forth in this Specification, Respondents may also offer, as alternatives, variations of detail that they consider might be advantageous and acceptable to TE. 4.3.2 The respondent may also offer additions to the scope, either being requested or of their own accord. The final decision on the additions rests upon TE. 43.3 This will include existing approved units that are already used in motor testing applications, and it is accepted that these units will not have the same additional functionalities as the new designed offers. In all instances where alternatives are ‘offered for consideration, the following information shall be furnished: The same amount and extent of information, comments and data applicable to the original component offered. The detailed reasons for offering the alternative(s). (The detailed implications in terms of price, reliability, maintenance considerations, local stock holding, performance, etc. in comparison with the basic offer. A Respondent need not submit a fully compliant offer should they truly feel that they have a better solution but TE's engineers may reject the offer out of hand if the information supplied does not meet a cursory approval. 4.4, Options Offered 441 Certain items may be requested through option, in such cases the supplier Is to provide a quote to TE. The decision to include the option in the scope of supply is solely TE's. Document Name: ‘The Development and Supply of Variable Speed Drives and Peripheral Equipment for an AC Traction Motor Test Rig DOC. No.: PD_RD_NAT_SPEC_010 ‘Classification: Restricted - RFP Spectication Document Revision: -0 Date: 24 January 2016 Page: Page 6 of 29v . SCOPE OF SUPPLY 5.1. General 5.1.1 This Technical Specification is in respect of The Development and Supply of Variable Speed Drive Units for an AC Traction Motor Test Rig. 5.1.2 The Respondent is required to indicate related information regarding the production pricing and volumes capability of their manufacturing facilities. 5.1.3 It should be dearly understood that this RFP is for the production of two Variable ‘Speed Drives and accompanying peripheral equipment only, 5.2. Project Timelines 5.2.1 The high level timeline for the AC Traction Motor Test Rig Development Project is as follows: Table 1: High Level Timeline forthe Test Rig Project Phase Period From To Concept Design ‘3 months | 01 February 2016 | 30 April 2016 Detail Design. ‘Smonths | 01 May 2016 31 July 2016 Delivery 7 months [01 August 2016 | 28 February 2017 Installation 2months | O01 March 2017 | 31 March 2017 ‘Commissioning imonth | 01 April 2017 30 April 2017 5.2.2 The required timeline for the delivery of the Variable Speed Drives and the peripheral equipment is 28 February 2017. 5.2.3 Expected Project completion date for the build of the AC Traction Motor Test Rig is end of April 2017. 5.2.4 Should the respondent not be able to meet the above dates, the respondent shall state reasons for not meeting TE's expectations as well as including actual dates which the respondent will be able to deliver at the earliest together with the activities (and accommodating dates) on which the build and delivery of the goods are dependent. 5.2.5 The respondent is made aware that failure to reach the stated delivery dates in 5.2.1 above may result in disqualification of its Bid, since time will be of the essence. Document Name: ‘The Development and Supply of Variable Speed Drives and Peripheral DOC. No.: PD_RD_NAT_SPEC_010 Equipment for an AC Traction Motor Test Rig) Classification: Restriced — RFP Speaifeation Document 0 Page 9 of 29 Date: 24 January 2016aRANSNEr r 6. DESIGN REVIEW AND TESTING REQUIREMENTS 6.1, Conceptual Design Review Within 30 days after the RFP has been awarded, the successful bidder should provide the following to Transnet Engineering's experts in a formal presentation: A complete system overview, introducing the various building blocks, their functionality, possible location within the space available in the container, their interface with one-another, the motors and the remote control system. D _Provide specific details on the main concepts, components and technologies that. will be utilised. Provide the project schedule. 2 _Discuss the test plan for all the tests to be conducted during commissioning. During this meeting, Transnet Engineering will then review these concepts and will provide feedback on the approval or objection against any concept being presented. The successful bidder may only proceed to the detail design stage once Transnet Engineering accepts the ‘concepts in principal (approval in principle). 6.2, Detail Design Review 6.2.1 The design review shall be held at Building 21 at the CSIR, Meiring Naude Road, Pretoria and shall be scheduled duly between the parties. 6.2.2 During this stage, the successful bidder must implement the changes requested/agreed during the Conceptual Design Review within the scheduled/agreed timeframe. 62.3 On the agreed date, the successful bidder must present: 1 The updated conceptual designs that incorporate the modifications agreed during the conceptual design review meeting. 1D —_Detalled mechanical drawings, circuit diagrams and software functional diagrams, Installation, testing and calibration procedures. 6.2.4 Transnet Engineering's experts will review the data provided and scrutinise the designy/installation for any possible weaknesses, irregularities or non-conformance to standard-practices with regards to its reliability, operability, maintainability, availabilty and safety. 6.2.5 If needed, Transnet Engineering could request investigative tests to be conducted on certain components/parts of the system when the experts are not convinced that the technology offered will be able to perform according to desired/agreed specification. 6.2.6 The successful bidder may only proceed with the manufacturing of the units once Transnet Engineering accepts the detail designs in principal. Any parts, rmanufactured/procured prior to this approval will be to the risk of the contractor and ‘Transnet Engineering will not be held accountable for any rework costs Involved. Document Name ‘The Development and Supply of Variable Speed Drives and Peripheral DOC. No.: PD_RD_NAT SPEC 010 Equipment for an AC Traction Motor Test Rig Classification: Restricted - RFP Specification Docurnent Revision: -0 Date: 24 January 2016 Page: Page 10 of 296.3, Type Testing of VSD All type tests must be carried out at the manufacturer's site and expense, The tests must be witnessed by Transnet Engineering personnel. Prior notice of 30 days shall be given to Transnet Engineering personnel for witnessing tests to be conducted in South Africa. At least 60 days’ notice shall be given to Transnet Engineering for witnessing tests that are to be conducted outside of South Aftica, Prior notification of Transnet Engineering is vital for its booking arrangements for the employees, Transnet Engineering will pay for all the travel expenses, local or international, ofits employees who will witness the type tests. 6.3.1, 6.3.2, 63.3. 63.4, 6335. 63.6, 63.7. oooocagod Unless stated otherwise, testing to be in accordance to the relevant standards as agreed by Transnet Engineering as well as specifications set forth in section 3. Respondents to ‘supply details on any other international specifications used for testing purposes. Except when using Transnet Test Facities, the Test Faclty used for type testing must issue a test certificate and the prospective vendor shall submit a copy to Transnet Engineering for evaluation and record keeping. All type tests data must be made available to Transnet Engineering. In the event of a design change occurring, Transnet Engineering holds the right to request the vendor to repeat some/all type tests if the possibilty exists that the design change has an unknown/significant impact on the outcome of initial test results. If the system, or part of it, Is almost identical to one tested previously, the manufacturer may supply a certificate of previous tests which shall cover at least the tests given in this specification. In such cases, Transnet Engineering will study the test Conditions and respective results of each test and may waiver the need to conduct the tests) For the purpose of testing the drive system shall Include input transformer, switchgears, converter, motor and fiters. Transnet Engineering will only allow the installation of the equipment once their experts are convinced that the system(s) will operate in their normal as well as abnormal operating conditions. So based on the discretion of Transnet Engineering, one/all of the following tests, not limited, should be conducted before the units may be installed: Visual Inspection, Insulation Test, Power Factor, Functional Test, Efficiency Test, ‘Temperature Rise Test, ‘Torque pulsations, Line side Current and Voltage distortion, c. Document Name: ‘The Development and Supply of Variable Speed Drives and Peripheral DOC. No.: PD_RD_NAT_SPEC_010 Equipment for an AC Traction Motor Test Rig Classification: Restrcied - RFP Specification Document Revision: -0 Date: 21 January 2016 Page: Page 11 of 29 =|ooaqooa 63.8 o oooo0cagg00 TRANSNET Dynamic performance test, Audible noise test, Cooling system test, Fault condition and protection scheme validation, Overcurrent, and Overvoltage. It is a mandatory requirement that test certificates shall be submitted in duplicate within 14 days after the completion of the tests in respect of all tests performed and shall contain the following: The ratings, insulation class, applicable standards to which the equipment is manufactured and tested, the date of tests and equipment serial number. All test bed data, ‘measurements taken during the course of the day. Where applicable, the flow of cooling air to the machine/equipment. Reference temperature and other applicable environmental conditions. ‘A dear description of all abbreviations used. Where applicable, oscillograms, recordings, cooling curves, etc. lear line diagrams of test circuits. Ful details of all calcuations. ‘Any further information, details, curves, etc., that will facilitate checking and evaluation of test certificate. 6.4, Installation of VSDs & peripheral equipment 64.1. 6.4.2, 6.4.3, ‘The installation area for the drive system is outdoors with the drive outputs going indoors into a test bed area, where motors will be connected with cables onto a connection box. Itis the responsibilty of the successful bidder to install the drive system. Transnet Safety and Risk officers will conduct a visual inspection to ensure that the Installation conforms to regulatory practices. The CSIR faclity management team will also conduct inspection to evaluate conformity of the installation to their practices. 6.5. Site Commissioning of VSD & peripheral equipment 65.1. 65.2. ‘Transnet Engineering will integrate the full test rig but the successful bidder will do the installation of all equipment forming part of the scope of this document. It is the responsibility of the successful bidder to commission the drive system. It is Important to Include the costs for commissioning in the proposal. Document Name: Equipment for an AC Traction Motor Test Rig Classific Dat January 2016 The Development and Suppl of Variable Speed Drives and Pergheral | DOC. No: PD_RO_NAT SPEC. 010 Rested RFP Spectcalon Docu = Page at 2965.3. 65.4, t ‘The successful bidder shall ensure that the commissioning will be performed by certified service techniclans/engineers. ‘The commissioning shall be considered complete when the entire system is working propery, all issues have been resolved and Transnet Engineering has approved. 7. DOCUMENTATION 7.1, Documentation Management Aa. a a a ‘The respondent shall have a suitable document management system in place to ensure the following Control and distribution of documentation relevant to and required by Transnet Engineering, Updated and approved documentation is forwarded to Transnet Engineering timeously. Documentation is in the format/s acceptable to Transnet Engineering. 7.2. Document Identification 72.1, ooaa 7.2.2. ndDooaooo 7.23. Allitems of equipment whose identification is to be controlled must be identified by: {A description of the item, including the item type, A part number, A serial number where traceability is a requirement, Relevant documentation identifying the item and required to support the item - such as specifications, drawings, maintenance detail, operational requirements etc. ‘All documentation is to be identified by: ‘A document reference number, A revision number, Atitle, ‘The person(s) that updated it, ‘An issue date, and ‘The equipment the document is applicable to. In the case of drawings, a reference (where it is applicable) shall be made to the following: Next higher assembly drawing, Lower sub assembly drawings, documents and diagrams. Document Nam “The Development and Supply of Variable Speed Drives and Peripheral DOG. No.: PD_RD_NAT_SPEC_010 Equipment for an AC Traction Motor Test Rig) Classification: Reslvcied - RFP Specifcalion Document Revision: -0 Date: 24 January 2016 Pag Page 13 of 287.24, — ‘Changes to documents or equipment must be identified by means of a "Change Number” against which all information identifying the “change” must be linked. 7.3. Spare Parts Catalogue 73.1. 73.2. 733. It is mandatory that the successful bidder allocates their own part numbers to 3rd party ‘equipment. The contractor shall then supply the original OEM parts numbers along with their own allocated parts numbers within the Spare Part Catalogue (SPC). It is mandatory that identical equipment from the same supplier used on different locations/applications shall have the same part number within the SPC. It is essential that the level of information within the SPC should be broken down to the same level as in the approved maintenance philosophy. 7.4, Drawings and System/Component Documentation 74d 742. 7.43. 74.4, 745. 746. 747. ooo0000 Document Name: ‘The Development and Supply of Variable Speed Drives and Peripheral DOC. No.: PD_RD_NAT_SPEC_010 Equipment for an AC Traction Motor Test Rig Transnet must be able to manage and maintain drawings throughout the system's lifecycle, Drawings are supplied in a format compatible with current Transnet CAD systems in place: Microstation: Used by Transnet for both Mechanical and Electrical drawings (files can be supplied in .dgn or .dwg file formats) PTC Creo: Used by Transnet for mechanical drawings, CAD modelling and finite element analysis. (.ast, drw, .prt, stp, and xt files) Drawings must conform in general principle to specification SANS 10111, and relevant specifications as referred to therein, Drawing symbols used on electrical circuit diagrams must conform to IEC 617. Drawings for submission and approval purposes must be submitted in pf format (raised from the CAD source file). This will allow easy access to Transnet personnel to raise their relevant comments during the approval process. ‘An index is to accompany submissions and is to depict: Filename Drawing number Drawing title Version Status Approval date (once approved) Once ail drawings are approved and finalised, itis essential that the contractor provide: a complete set of native CAD files in the format as requested in 7.4.2 as well as an updated index as described above. Classific jon: Restricted - RFP Specficaton Document Revision: -0 Date: 21 January 2016 Page: Page 14 of 29T- 7.4.8, It is mandatory that the drawing must contain, as a minimum, the following information 1D Name of Manufacturer a Drawing number (Manufacturer's number, and in the case where there is a TE number to be reflected as well, D__ Drawing title - the title must clearly identify the item drawn (e.g, not just “plate” but rather “plate, support assembly, ...) to enable the user to identify where the Item is used Scale Date of drawing Approval signature Revision Higher assembly (where applicable) Material or parts list, where relevant oooooog Relevant Contract no 7.4.9. Tt is mandatory that the following drawings are provided: Complete index of as-made drawings Electrical circuit diagrams Equipment layouts (system Interface drawings (2 _Equipment/Component drawings (D—Wiring diagrams (entire Test Rig) a a equipment. ‘Table of wires which include all relevant cable/wire detail/make-up Drawings relevant to the Maintenance / Overhaul of the VSDs and peripheral 7.4.10. Ttis desirable that Piping and Electrical circuit diagrams Are to have a complete index that includes all component designators, a component description, relevant sheet and zone where item/system to be found. D__ Are to be zoned across the top of the page starting at Zone 100 Document Name: ‘The Development and Supply of Variable Speed Drives and Peripheral Equipment for an AC Traction Motor Test Rig DOG. No.: PD_RD_NAT_SPEC_010 Classification: Resifcled - RFP Spactication Document Revision: -0 Date: 21 January 2016 Page: Page 15 of 29,C . SITE CONDITIONS 8.1. General 8.1.1. The location of the Test Rig is at Building 21, Council for Scientific and Industrial Research (CSIR), 1 Meiring Naude Road, Pretoria. 8.1.2. The equipment to be quoted on shall be capable to operate and maintain the required performance under the following environmental conditions. 8.2. Ambient Temperature 8.2.1, The maximum external air temperature that the Test Rig will be exposed to due to environmental conditions is 45 °C. 8.2.2. The minimum external air temperature that the Test Rig will be exposed to due to environmental conditions is -5°C. 8.2.3, Tt isa mandatory requirement that no de-rating of any equipment shall occur when the ‘Test Rig operates within the minimum and maximum ambient temperature ranges listed above. Further, deration curves of the system (e.g. kW vs °C) must be provided, 8.3. Operating Temperature 8.3.1, The design shall take into account temperature rises within the panels to ensure that tthe components do not exceed their specified temperature ratings, or shorten the usable design life of the equipment. 8.3.2, The design shall not raise its internal panel or ambient temperature of any equipment within the container of VSDs above 60°C. 8.4, Altitudes 8.4.1. The operation site of the Test Rig has an altitude of about 1350 m above sea level. 8.4.2, It is a mandatory requirement that no de-rating of the VSD equipment should occur at the abovementioned altitude, 8.4.3. If altitude does cause deration, the system will have to be resized to provide desired Power on site, 8.5, Humidity 85.1, The Test Rig will operate continuously in an atmosphere with: 1 Anannual relative humidity of less than 60%, 1 Athirty consecutive day relative humidity of 70%. Document Nar ‘The Development and Supply of Variable Speed Drives and Peripheral DOC. No.: PD_RD_NAT_SPEC_010 Equipment for an AC Traction Motor Test Rig Classification: Restricted - RFP Specification Document Revision: -0 Date: 21 January 2016 Page: Page 16 of 23wT |. RELIABILITY, AVAILABILITY AND MAINTENANCE 9.1, Useful Life 9.1.1. It is anticpated that the traction motor test rig will have a lifespan of 25 years. 9.1.2. The VSDs and its components shall therefore be designed to ensure a lifespan of 25, years with due maintenance. 9.1.3. If applicable, the respondent should provide a list of any components that (might) have a limited lifespan. The mean time between failures (MTBF) of these components shall bbe supplied and provided by the supplier in the list form. 9.2. Obsolescence Management 9.2.1. Itis a mandatory requirement that obsolescence management is guaranteed fo lifespan of the traction motor test rig. This implies that the successful bidder must provide 100% compatible (form/fit/function) spare parts forthe entire lifespan. Respondents to provide a detailed obsolescence strategy at the Ume of tendering, Failure to do so could result in disqualification 9.2.2. Respondents shall state how they intend maintaining the software of the VSDs for this period of time 9.3, Availability 9.3.1, The lead time for any production module (or the repairing thereof) should not exceed 3 months and the respondent should provide a list of items/components that exceeds this requirement at the time of tendering. 9.3.2. Respondents are to supply a spares list (and costing thereof) and ensure adequate supply in order to maintain test rig availabilty of greater than 90%. 9.4, Reliability 9.4.1. To increase the reliability of the drive system, the quantity of power electronic components shall be kept low as possible without compromising performance. 9.4.2, All cables shall be properly fastened and neatly arranged 10, MAINTAINABILITY REQUIREMENTS 10.1, Maintenance Plan/Program 10.1.1. The respondent shall ensure that the spare parts and maintenance support services for the VSDs and offered equipment is available for 15 years from date of supply. 10.1.2. The respondent shall have their maintenance and spare supply in South Africa in order to ensure quick maintenance service and response. 10.1.3. The respondent shall indicate the source for supply of maintenance service and spares in South Africa. Document Name: “The Development and Supply of Variable Speed Drives and Peripheral DOG. No.: PD_RD_NAT_SPEC_010 Equipment for an AC Traction Motor Test Rig Classification: Restricted - RFP Specification Document Revision: -0 Date: 21 January 2016 Page: Page 17 of 2910.2. 10.1.4, 10.1.5. — ‘The respondent shall provide documents detailing routine and full maintenance of the VSDs and sub components. No special tools shall be required to perform routine maintenance, Safety 10.2.1. 10.2.2 10.2.3. a 10.24, 10.25. 10.26. 10.2.7. All safety requirements for operating, testing, maintaining or storage ofthe sub systems are to be stipulated and documented by the successful bidder. These requirements must comply with the Occupational Health and Safety Act and Regulations, Act 85 of 1993, No components and materials, which could pose a health risk to operators and maintenance staff or a fire risk, will be permitted. High voltage cabinet shall be provided with the safety interlock so that the cabinet cannot be opened unless the following safety conditions are met: Upstream breaker is opened, Safety grounding switch is closed, and ‘The DC link capacitor is discharged to voltage less than 50 V. ‘The respondent shall provide a detailed operational procedure and datasheet of the safety interlock system. “The VSDs shall have a visible indicator system for signaling when itis safe and when it is not safe to open the panels. ‘The power circult shall be separate from the control circuit. Cables used inside and outside the VSD cubicles shall be made from halogen free insulation material Document Name: “The Development and Supply of Variable Speed Drives and Peripheral Equipment for an AC Traction Motor Test Rig DOC. No: PD_RD_NAT_SPEC_010 Classification: Restricted — RFP Specification Document Revision: -0 Date: 21 January 2016 [Page: Page 18 of 290 14. GENERAL SYSTEM LAYOUT id. General 11.1.1, The general layout of the traction motor test rig is described in Figure 1. Inside a @ container Figure 1: Layout ofthe Test Rig 11.1.2, The layout depicted on Figure 1 is that of a back-to-back test configuration that will be used to perform the type test on the traction motor. 11.1.3, The Variable Speed Drives (VSDs) must be able to supply appropriate amount of power (energy) into one motor and recover energy from the other motor that is acting as a load in the back to back test configuration. 11.1.4. The equipment that forms part of the scope of supply for the purposes of this decument in the above image, Figure 1, is as follows: (Two 4-quadrant VSDs both capable of motoring and regenerative braking 1D Cabling from the VSDs to the connection box (including the connection box) (_DC-Link connection between the two VSDs Input Power Converter Document Name: ‘The Development and Supply of Variable Speed Drives and Peripheral DOC. No.: PD_RD_NAT_SPEC_010 Equipment for an AC Traction Motor Test Rig Classification: Restricted ~ RFP Specification Document Revision: - 0 Date: 21 January 2016 Page 19 of 29T- Input Power Transformer Input Switchgear (Cabling from the transformer to input converter Cabling from CSIR's 11 kV supply to transformer Housing panels with contactors, switches, and volt and amp meters. Preferably as an electronic LED/LCD for equipment display. Container (with complete integration of equipment into the container) Motor load (Optional Supply) 1 Sine fiter with bypass contactors Digging of trenches D__Installation and commissioning 12. TESTING ARRANGEMENTS 12.1. General 12.1.1. The traction motor test rig will be employed for two types of test; namely (Type Test using the back to back testing arrangement and Routine Test 12.1.2, The principle ofthe two tests are briefly explained below. 12.2, Back to Back Testing Arrangement 12.2.1, The back to back testing arrangement showing the electrical power flow on the test rig ‘when testing one of the motors is shown on Figure 2. The principle of operation is that the motor under test will be driven by one VSD, the motor will in turn be driving the ‘other motor acting as the load. The second motor or motor load will generate power into the system permitted by the regenerative VSD. Document Name: “The Development and Supply of Variable Speed Drives and Peripheral DOG. No.: PD_RD_NAT_SPEC_010 Equipment for an AC Traction Motor Test Rig Classification: Restricted - RFP Specticaton Document Revision: -0 Date: 21 January 2016 Page: Page 20 of 29Scope of ‘Supply we Contzctos +1000 kVA esoKW YT Sine Finer ‘Figure 2: Power Flow on the Test Rig when testing one motor. 12.2.2, The incoming power into the test rig will be for supplying losses into the system when the energy is recovered from the second motor, in this diagram, 434 kVA. 12.2.3, The parameters that will be tested on the motor are as defined on the IEC 60349-2 standard. The summary of test items to be covered when performing type testing are shown in Table 2. Document Name: ‘The Development and Supply of Variable Speed Drives and Peripheral Equipment for an AC Traction Motor Test Rig) DOC. No.: PD_RD_NAT_SPEC_010 Classification: Restricted - RFP Specification Document Revision: -0 Date: 24 January 2016 Page: Page 21 of 29,Table 2: Summary of the Type Test FETS oO | SyReTTONOTS] Ternperstre Hee F 7 Shor time Geral tat 5 | Characteristics x x arerapaed 5 : Dielectric Vibration x / x — z 5 12.2.4, For the temperature rise test, the test motor will be loaded with the motor load, applying the full load conditions on the respective locomotives where traction motors are utilized in service. The test is conducted until steady temperatures are reached. 12.25. Upon completion of the temperature rise test, the short-time thermal testis started by ‘overloading the test motor at specific temperatures dependent on the thermal class of insulation system of the motor. 12.2.6, ‘The characteristics test will be done to demonstrate the specified characteristics of the motor by measuring the electrical input to the motor and the mechanical output. 12.2.7, The over-speed test will be carried out by running the motor for 2 minutes at 1.2 times the maximum working speed of the tested motor. 12.2.8, The measurements for the vibration tests will be taken at a number of speeds covering the whole working range of the tested motor. 12.2.9, The noise tests will be conducted at the maximum working speed of the tested motor in both directions of rotation. The drives must therefore be capable of both forward and reverse power. 12.3, Routine Testing Arrangement 12.3.1, The routine test procedure requires the VSD to have the capability to supply the rated voltage of the motor for performing the no-load test. 123. ‘The VSD must be able to supply the rated current for performing the locked rotor test ‘on the motor. 12.3.3, Other parameters that will be tested for the routine test are as defined in the IEC 60349- 2 standard. 12.3.4, The routine test summary as defined on the IEC 60349-2 standard is shown in Table 3. Document Nam ‘The Development and Supply of Variable Speed Drives and Peripheral DOG. No.: PD_RD_NAT_SPEC_010 Equipment for an AC Traction Motor Test Rig Classification: Restricted — RFP Specification Document Revision: - 0 Date: 21 January 2016 Page: Page 22 of 29