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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

SCHEDULE OF TECHNICAL REQUIREMENTS (STR)

for

MANUFACTURING AND TESTING

Of

7775 KVA, 7475KVA (7500 LOT) and 6531KVA (6500LOT) Transformers

for

3-Phase Electric Locomotives

as per

Specification Nos. (a) CLW/ES/3/0660/AIt. A or latest

(b) CLW/ES/3/0315/AIt. J or latest
(c) CLW/ES/3/0456/AIt. G or latest

Issued by:

Centre for Design & Development

Chittaranjan Locomotive Works
Ch itta ra nj an

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Details of Revisions

SN Date of Revision Page No. Revision Reason for Revision

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/ CONTENTS

SN Description - Page No.

1. Scope 4
2. Quality System 4
3. Assistance to be provided by IR 4
4. Responsibilities of the Contractor 4
5. Test and Trials - 5
6. Raw Material - 5
7. Process of Manufacturing _____ 6
8. Quality assurance Process-Inspection and Testing Plan 6
9. Annexure-I (List of Manufacturing Facilities) 7-8
10. Annexure-II (Testing Facilities) 9
11. 4nnexure-Ill (List of Measuring Instrument)- 10

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1.0 Scope
1.1 The Schedule of Technical Requirements (hereafter called STR) specifies the requirements to be
met by vendor (hereafter called Contractor) who intend to manufacture, test and supply 7775 KVA,
7475KVA (7500 LOT) and 6531KVA (6500LOT) Transformers for 3-Phase Locomotives. This STR should
be read in conjunction with the technical specification Nos. CLW/ES/3/0660, CLW/ES/3/0315 and
CLW/ES/3/0456 with latest alteration. -
1.2 The Contractor should satisfy themselves having complied with the requirements of relevant
specification and this STR.

2.0 Quality System

2.1 The Contractor should have valid ISO 9001:2008 certification covering the manufacturing and testing
of the subject item.
2.2 The Contractor should possess a clearly laid down Quality Assurance Plan for the product covering the
following aspects:-

a) Organisation Chart, clearly indicating the quality control set-up.

b) Qualification of key personnel and the officials deployed in quality control cell.
c) Process Flow Chart indicating process of manufacture for an individual product orfora
family of products, if the process is same.
d) Quality Assurance System - Inspection and Testing Plan to cover:
Incoming material
• Process control
• Product control
• System control
• Testing facility
e) Stage inspection detailing inspection procedure, inspection parameters, method of
/
testing test procedure including sample sizes for destructive and non-destructive
testing etc.
f) Calibration Scheme and status of calibration of test equipment.
2.3 The Contractor should ensure that proper record of complaints received from users (Railways) is
&
being maintained corrective action is taken.
t
3.0 Assistance to be provided by IR
3.1 IR will give relevant specification, Design/Drawings etc.
3.2 IR,..to the extent possible, will assist the Contractor during testing of components, sub-assemblies and
the equipment by way of deputing suitable Railway personnel to witness such tests.
3.3 IR will assist the Contractor in timely completion of prototype testing and field trials of the equipment
developed.

4.0 [Responsibilities of the Contractor

4.1 The Contractor, shall be responsible for complete development of the above 3-phase Loco
Transformer based on the technical documents passed on to him by IR. The design shall be developed
based on the requirements given in the relevant specifications for the 3-phase Loco Equipment and
sound, proven and reliable engineering practices. The Contractor will maintain close contact with IR

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for this purpose.

4.2 A time bound programme shall be made for the development of prototype.
4.3 The Contractor shall be responsible for converting drawings into a version suitable for use in his
factory. Nevertheless, before implementation of such converted drawings for manufacture, the
Contractor shall obtain approval from IR. Approval of IR means the approval of general design
features. Notwithstanding approval from IR, the Contractor will be wholly and completely responsible
for the satisfactory performance of the equipment developed.
4.4 Representatives of IR shall be free to visit the works of the Contractor or his Vendors during the stage
of development and later during manufacture to assess / check the manufacturing processes, quality
assurance etc. The Contractor shall ensure that Railway representatives are given access to all
information during their visits.
4.5 The training of IR Personnel at the Contractor's design offices and works to the extent necessary for
understanding the maintenance and operation of the Equipments will be arranged by the Contractor
free of cost.

5.0 Tests and Trials

5.1 The equipment shall be tested in accordance with the relevant IEC, IS, IRS, BS etc., as stated in the
specification to the satisfaction of IR. The Contractor shall arrange to conduct all such tests at his own
responsibility and cost.
5.2 IR, at their discretion, will witness some or all of the tests as stated in above Clause. The Contractor
1 shallprovide all reasonable facilities to the Inspecting -Officer for- testing/ inspection at any stage.
5.3 The developed equipment will also be evaluated during operation under actual load conditions. These
will be termed 'Field Trials'. Apart from checking on repeatability of the operational performance
under actual working conditions of a locomotive, these trials will also be used to assess the
maintainability, accessibility, reliability and such other aspects, which have been mentioned in the
relevant specifications.
5.4 During the period of prototype tests / trials, if any problems are experienced or feedback information
is obtained, which warrants a re-check on the design / manufacture / quality of the equipment and
components, action shall be taken as may be necessary by the Contractor to carry out the required
investigations and to incorporate the improvements considered most appropriate to attain
compliance with the relevant specification without any extra costs to IR. Such improvements shall be
carried out on all units of the equipment developed and will be evaluated for their validity for a
further period of time as decided by IR in each case. Modifications mutually agreed to comply with
the specifications will be incorporated by the Contractor at his own cost in all the prototype units as
well as in all new units manufactured thereafter.
6.0 RAW_MATERIAL
6.1 The Contractor shall ensure that the purchased product/raw material conforms to the specified
requirements and is procured from RDSO/CLW approved sources if available or from reputed
suppliers on the basis of well-prepared technical specification. Such technical specification shall be
4 made available to the conSumer/CLWa5 and when for. . - ..........

6.2 Keeping in view to achieve objective of quality-oriented' material, a quality team of engineers shall be
4nploYed for preparation of the specification of raw material. ...

6.3 1 Proper test procedures shall be evolved and carried out on all the raw materials purchased by the
Contractor. Such test results, documentary proof of purchase and test certificate of each component
shall be maintained and produced to the consurner/CLW/inspectiflg official as and when called for.
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A record of each sub-supplier clearly showing the quantity purchased and rejected as well as cases of
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late delivery, if any shall be kept.

7.0 PROCESS OF MANUFACTURING

7.1 Complete Process Flow Chart covering all steps of process of manufacturing for an individual product
shall be clearly enlisted as a part of QAP.
7.2 Details of Jigs and fixtures used during manufacturing should be furnished along with the
manufacturing process wherever used.
7.3 List of typical M & P required for manufacturing of transformers used in Railway system Application
by lR is indicated in Annexure I. The actual manufacturing operations shall be submitted and got
approved by the Contractor as part of QAP. -

8.0 QUALITY ASSURANCE PROCESS- INSPECTION AND TESTING PLAN

8.1 Complete inspection and testing Chart covering all steps of process of manufacture for an individual
product including final inspection should be clearly enlisted as a part of QAP.
8.2 The following details of measuring instruments/equipments/jigs/fixtures used for all the steps of
measurement operations should be included:
• Make and model of the measuring equipment & procurement/commissioning
• Accuracy
• Quantity to be measured and acceptable value range.
8.3 Stage inspection detailing inspection procedure, inspection parameters, and method of testing/test
procedure including sample sizes for destructive and nondestructive testing. Record of test results of
stage inspection should be available and furnished.
8.4 The typical list of Testing and Measuring instruments required for manufacture for this transformer
are indicated in Annexure-11 & Ill respectively. However the specific Testing & measuring instruments,
gauges used by the Contractor will also form part of QAP, which shall be submitted and got approved
by the Contractor.

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LIST OF MANUFACTURING FACILITIES

The following basic machinery and plant for manufacturing of Traction Transformers for 3-Phase
Locomotives shall be available with the Contractor. The rating of these machines should be adequate
enough to perform the desired function satisfactorily and also sufficient numbers of these machines
should be available to ensure smooth operation:

1.0 Basic Workshop Equipment

1.1 Machines for cutting and stacking of transformer laminations.

1.2 Machines for slitting transformer sheets to smaller width.
1.3 Sheet bending machine.
1.4 Punching machiiies.
1.5 Lathe machiries(Center distance 350 mm) -
1.6 Drilling machines (Radial drilling machine for drilling maximum 50 mm diaj.
1.7 Pipe bending machines.
1.8 Hydraulic press 50 tonnes or 100 tonnes. -

1.9 Overhead cranes of 25 tonnes

Fork lifters.
1.11 Welding Plants-preferably of CO2 type 400 Amps MIG welding machine.
p1.12 Vacuum tank Vacuum devices for work in a temperature of 120C.
Complete equipments for drying, filling with oil and other operations necessary in the installation of
transformers. -
1.14 Oil filtration plants of suitable capacity.
1.15 Compressor room.
1_
1.16 Shearing machine
1.17 Gas cutting machine
1.18 Shot blasting plant
1.19 j Paint booth with Drying Arrangement.
1.20 Power saw
1.21 Bed plate (3.5mx3.5m)
1.22 Test set-upfor no load loss measurement.
1.23 Test set-up for load loss measurement with minimum 50% loss feedingcapacity. 0

NOTE:
(i) If contractor is outsourcing the laminations in required shape & size, then the associated M&Ps
are not required at Contractors premises. It is, however to be ensured that firm from which these
materials are procured have the desired M&P items.
(ii) Contractor shall have dust proof & controlled environment for winding and assembly shop. -

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2.0 Winding and Assembly shop

21 Winding machine up to winding dia. of 2 meters.

2.2 Vertical winding machine.
2.3 Tension equipments for winding conductors.
2.4 Conductor's paper wrapping machine (not required if insulated conductors are procured).
2.5 Spring loaded fixture for seasoning of coils.
2.6 Suitable size oven for drying the core coil assembly up to 150 °C.
2.7 Separate oven for drying the coil.
2.8 Clamping fixtures for the winding.
2.9 Fixtures for handling core assembly with top &
bottom yokes. -
2.10 Fixtures for loading the winding conductors' drums.
211 Fixtures for loading and unloading winding drum on winding machine.
2.12 Fixtures for keeping ready coils in vertical conditions.
2.13 Fixtures/handling equipment for making various connections to winding.
2.14 Fixtures for handling bushings/bushings turrets/CTs.
2.15 Soldering/brazing/crimping facilities.
2.16 Oil storage facilities.
2.17 Facility of oil filling under vacuum.

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ANNEXURE-Il

Testing Facilities

Calibration of the Testing / Measuring Equipments should be done at least once in a year unless
stated otherwise. Inspection Staff conducting non-destructive testing shall be adequately trained
and qualified by recognized agency and shall have adequate experience. The rating of the
following machines should be adequate enough to perform the desired function satisfactorily and
also sufficient numbers of these machines should be available to ensure smooth operation.
Following testing facilities should be available with the Contractor:

1. Testing transformer complete with all associated equipment for conducting power frequency
tests & induced voltage test at double of the power frequency.
2. Impulse test with associated equipments (optional).
3. Ratio meter.
4. Digital Micro Ohmmeter equipment.
5. Megger- 1000V, 2500V & 5000V.
6. Ammeters, Wattmeters and volt meters of various ranges.
7. Noise level meter.
8. Thermometer.
9. Dissolved gas analyzer.
10. Equipment for BDV test for oil.
11. Equipment for short circuit test (optional).
12. Weighment (optional).
13. Hydraulic pressure test for oil leakage.
14. Facilities for temperature rise test
15. Digital Power Analyser.
16. Winding Resistance meter.
17. Clamp meter.

NOTE: All measuring instrument should have digital display.

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- ANNEXURE- III

List of Measuring Instrument

Calibration of the Testing / Measuring Equipments should be done at least once in a year unless
stated otherwise.

.1. Vernier calipers of appropriate ranges required during inprocess/assembl and dimensional
Checks.
2. Micrometers. of appropriate ranges required during in-process/ assembly
and dimensional Checks.
.3.- Various gauges for measuring OD/lD of the coil of different legs.
4. Steel measuring tape & scale.

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STR No. CL W/C-D&D/STR/O01 Rev'O' Issued in November'2015