STATEMENT OF TECHNICAL REQUIREMENTS FOR GT/GTG STARTING RECTIFIER EED-50-03 May 2005 M A T E R I A L B R A N C H I N T E G R A T E D H E A D Q U A R T E R S M O D ( N A V Y ) D WING, SENA BHAWAN N E W D E L H I 1 1 0 0 1 1 i
EED-50-03 I. AMENDMENT RECORD Amendment No. Date Text Affected Signature/Dat e NIL NIL II. REVISION NOTE No revision incorporated. III. HISTORICAL RECORD This standard supersedes the following:- NIL. CONTENTS ii
Sl No Description Page No 1 Introduction. 1 2 System Configuration 1 3 System Design 1 4 Requirements of System Design 1 to 3 5 Switching Controls 3 6 Duty Cycle 3 7 Technical Specifications 4 to 5 8 System Performance 6 9 Reparability Aspects 6 10 Quality Assurance, Quality Control and 6 to 7 Inspection 11 EMI/EMC Specifications 7 12 Naval Specifications 7 13 Maintenance 7 14 Equipment spares 8 15 Documentation 9 16 Weight and dimensions 10 17 Warranty 10 18 Technical Services 10 19 Training 11 iii
1. Introduction. The Gas Turbines are main prime movers for propulsion and power generation on board IN ships. Each gas turbine is fitted with a DC motor to give initial torque and pre defined speed essential to fire the self sustained turbine ignition chamber. Further each GT/GTG is provided with a dedicated DC starting unit which is intended for converting 380 V 50 HZ ships mains power supply to DC supply to power the DC starting motor of the connected turbine. 2. System Configuration. The input supply to the rectifier unit is 380 V 50 HZ 3 phase ships mains supply. The DC out put of the rectifier through a set of cables shall be connected to the DC motor fitted on the turbine. The starting circuit of the rectifier be integrated with the gas turbine starting controls system. The switching on of the rectifier will be from remote Turbine Control Room and the rectifier shall cut off automatically by the turbine control system after elapse of set time. 3. System Design. The system should be modular in design and should be modular extension of a few basic building blocks. The rectifier should be dual channel and the change over from channel I to channel II should be through a suitable switch provided on the unit itself. The design of both the channels should be similar. The unit shall convert alternating current into direct current and adjust output parameters in conjunction with the automatic equipment system. The commonality between the PCBs may be maintained in form fit and function to the extent feasible. The DC rectifier should be state of the art using Gate Turn off thyristers /MOS Turn off thyristers/ MOS Controlled Thyrister / Isolate Gate Bipolar transistors (IGBTs). 4. Requirements of System Design. The rectifier unit shall confirm to following design/functional requirements:- (a) The design of rectifier to meet the out put characteristics as specified by the NSM under most adverse environmental and the electric conditions. (b) Input supply interruption during the operation of the rectifier must be cause malfunction of the unit. Further the equipment shall be automatically ready for normal performance on restoration of the input supply. (c) distortion (d) operating load. Switching on of the rectifier should not cause harmonic to the input supply more than 0.035 maximum. The equipment is to be capable of withstanding for the time when running at any load between full load to no 1
(e) shall be limit of Sufficient cooling arrangement by natural air convection provided in the rectifier in order to meet the permissible temperature rise. (i) Further damage within the equipment, subsequent to a fault. (ii) Damage to the converted power loads. (iii) Prevent the primary supply going out of specification. (iv) Damage to the equipment, subsequent to a fault external to the equipment. (v) Conditions under which the equipment shall trip be specified. (g) All control supplies for the operation of the rectifier be derived from the main input power supply to the equipment and the rectifier should be self sustained. (h) Power supplies to control circuits are to be protected by fuse. Fuses for control and protection circuits are to be kept separate. (j) Closed loop voltage control is to be provided in the rectifier for controlling the rectifier output voltage characteristics within the specified limit. (f) The rectifier shall be provided with protection circuit to protect the unit against impermissible over currents and short circuit currents. Further, protection against damage to the equipment both internal and external under following conditions be also provided:- (l) The equipment shall be provided with following indications:- (i) Equipment supply available - Lamp (Green) (ii) Equipment ON - Lamp (Green) (iii) Trip -Lamp (Red) (iv) Local /Remote control available (v) 3 phase Input supply voltmeter (v) DC Voltmeter and Ammeter. 5. Switching Controls. The rectifier shall have a starting circuit to provide connection and disconnection of the rectifier unit and selection of current and voltage duty. The rectifier unit will be remotely controlled by commands from the control station by means of closing and opening contacts whose circuits are connected to the remote control panel. In manual mode the rectifier could be switched on and off by push button S1 and S2 mounted on front panel of the rectifier. 6. Duty Cycle. The rectifier shall be provided with suitable stabilisation circuit to maintain the out put parameters at the preset 2
values and ensures a continuous smooth rise in current during starting of the article. The rectifier out put shall have a provision to select current of 1800, 1200, 900 A duties and voltage 70, 60, 50 V values. The rectifier will be tested to meet the starting current envelope of the system as given below:- (a) When the system is started the rectifier ensures smooth adjustment of the output current from 0 to the value being set within 5-6 seconds. By the time current stabilizes the output current voltage should be 15 to 30 V. (b) The rectifier shall withstand the complete starting cycle of 70 seconds duration. (c) The rectifier should be capable to supply designed output for consecutive three starts within 120 seconds which constitute the one operating cycle of the rectifier. Further the rectifier will be tested for its normal operation for four such operating cycles continuously. STARTING CURRENT ENVELOPE OF THE RECTIFIER Time (Seconds) Output Voltage(Amps) Out put Current (Volt) 0-4 800 10 5-6 1800 22 10 1800 25 15 1800 28 20 1850 38 25 1850 50 30 1850 58 35 1850 60 40 1750 70 45 1500 70 50 1450 70 55 1400 70 65 400 70 70 Rectifier cuts off - 7. Technical Specifications. Sl PARAMETERS VALUES N o (i) Input Supply 380V±19V, 50Hz±1.5Hz, 3Ph (ii) Power Consumption at 1800A 175 KVA & O/P Voltage 70V (iii) Max. Output Current 2000A (iv) Max. Output Voltage 70V (v) Output Power at Max. Current 140 KW 3
(vi) (vii) Sl N o (viii) (ix) (x) & Voltage Output voltages limitation stages Limits of Output and Current regulation PARAMETERS Output Current estimated deviation from given level %, not more Output Voltage stages established deviation from given level % Electrical Insulation resistance and normal climatic conditions In cold state MΩ not less 50V, 60V, 70V 800-1200A VALUES ±7% 10% to 3% 50 MΩ (xi) Efficiency at Output current 85% 1800A, Output Voltage 70V (xii) Service life of the Units 20 Years (xiii) Middle Service life 06 Years (xiv) Mean Time Between Failure 10,000 Cycles (Starts) (xv) Overall Dimensions: The dimensions should not be more than those specified. However the smaller dimension unit meeting the operational and technical specifications is acceptable. Height: 1256 mm Width: 740 mm Depth: 660 mm Weight: Not exceeding 675 Kg (xvi) Environmental Conditions - Ambient Temp. 50 0 C -Relative Humidity at 50 0 C: 98%. (xvii) Shocks Tilts up to 45 0 to either side or rolling up to 45 0 with rocking period of 16S (xviii) Control facility The control desk/panel would have facility for local control 4
and monitoring of the system. (xix) Cables Suitable LFH cables would be required to ensure EMI/EMC compatibility. (xx) Starting cycle During starting of the turbine (active load operation) the rectifier is required to with stand a specific time verses current output cycle required for smooth and trouble free starting of the gas turbine as mentioned at para 6 (c) above. 5
Sl PARAMETERS VALUES N o (xxi) Vibration and Noise The self induced airborne noise and vibration level (xxii) Short circuit and over current protection:- must not exceed 60 db. The rectifier should have short circuit and over current protection which should actuate at 2200 to 2400 Amperes. The protection circuit shall also have a provision of adjustment. 8. System Performance (a) Reliability. The system performance will degrade in the event of failure. The system will 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 reconfiguration within shortest possible time. The design will cater for adequate fail safe features. (b) Maintainability. The system has a System Control Panel to run online and off-line maintenance diagnostics. The monitor panel along with built-in test equipment (BITE) of individual units will be capable of selecting and localizing faults down to a single replaceable PCB/Module within 5 minutes of the fault occurrence. The monitoring system will 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 hardware maintenance system will be designed as an off-line one and isolation of faulty units in the maintenance mode will be on a not-to interfere basis with healthy system. The manufacturer will prepare and submit the following data on maintainability:- (i) (ii) Maintainability programme. Calibration Programme. 9. Reparability Aspects. The repair facilities for the PCB level repairs would be eventually set up in the naval dockyards. The test jigs and repair facilities may also have to be provided by the OEM. The other aspects that would be applicable as and when equipment developed by a particular firm is cleared for induction in Navy are enumerated in the succeeding paragraphs. 6
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Quality Assurance, Quality Control and Inspection 10. The system and units would be required to undergo type testing as per JSS-55555 at CQAE Bangalore and technical evaluation will be carried out by ETMA (Mumbai) followed by actual on board performance trials. 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 will be provided to the Indian Navy:- (a) The details of Test Procedure and method of proving the performance of the system both in factory and on board ship. (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. (d) List of specifications that cannot be conclusively demonstrated /proved during System Acceptance Tests and for which documentary evidence will be furnished by the manufacturer. The manufacturer will undertake to make good, free of cost, any defects noticed during ship-borne tests/trials/operations. 11. EMI/EMC Specifications. The equipment should confirm to MIL STD 461 C. 12. Naval Specifications. The system should confirm to Naval Engineering Specifications NES-501, 511, 536 and 537 for design, testing and general specifications. Logistic Support 13. Maintenance. (a) On Board Repair/Maintenance. The system is to be susceptible to first level of preventive/repair maintenance by replacement up to PCB level. (b) Shore Repair /Maintenance. Shore repairs/maintenance on the rectifier will be carried out at Naval Dockyards. The firm will be required to provide and install necessary test jigs /facilities required to carry out complete repairs / maintenance. 8
14. Test Equipment. The OEM to provide details of following test equipment that would be required:- (a) Onboard Test Equipment. This should be adequate to meet the requirement of all repairs/ maintenance expected to be carried out on board the ship by the ship staff. (b) Special Test Equipment. Certain special to-type test equipment shall be available in the shore base for specific tests/ checks on the equipment. 15. Equipment Spares (a) Manufacturers Recommended Spares. The manufacturer will prepare the list of spares taking into account the IN s maintenance philosophy and test equipment policy. The basis for ranging and scaling of the spares will be clearly indicated. 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 format of the Indian Navy. The lead-time for the supply of items is also to be specified. The following are the requirements of the Indian Navy in so far as the spares are concerned: (i) Provision of On Board spares based on two year s requirement with a maximum mission time of 90 days. (ii) Scope, modalities and pricing for long term supply of pares during the life of the system and undertake to maintain the supply of same for at least a period of 12 years. (iii) Provide working substitutes for those components becoming obsolete during a period of 12 years. 16. Documentation. The manufacturer will deliver 10 sets of documentation along with the first system with one of the above sets as a reproducible master. The delivery of documentation may be phased during the execution of the project, as mutually agreed. The scope and contents of documentation will be as per JSS 0251 specification. Documents are also to be supplied on electronic media as per EED-P-23 specifications. Basic content break-down of the requirement is as follows:- (a) (b) (c) System description. Operating Instruction. Technical description. 9
(d) (e) (f) Maintenance instruction along with drawings. Repair instructions along with drawings. Fault location procedures and service diagrams. and (g) Electrical spares parts catalogue including those for test measuring equipment. (h) (j) Interface Control Document. Test and Calibration procedure Non Electrical Catalogue and General Data (k) (l) (m) ESD control and protection. Installations instructions /schedules. Instructions for setting to work, testing and tuning. (n) Test procedures/plans for factory acceptance and HATS and SATs. (p) (q) (r) (s) Comprehensive parts lists and parts identification list List of on board spares Performance figures including MTBF and MTTR EMI/EMC protection 17. Weight and Dimensions. Details are to be intimated as part of the documentation. 18. Warranty. On site warranty for hardware will be for a period of 18 months from the date of commissioning. 19. Technical Services. The system is to be fitted on board the ship at India. This would entail additional requirements as follows: (a) Installation Supervision. The representative of OEM is to be positioned at the ship during the installation of the system. This is required for supervision of the installation process and to assist to resolve any technical holdups. (b) STW and Commissioning. The OEM is responsible for Setting to Work, and commissioning of the system. 10
20. Training. The OEM is to provide on site training for Indian Naval personnel as follows. (a) for of the Operators.Training for one day duration is to be imparted minimum of 20 personnel on the operation and exploitation system. (b) Maintainers. Training for five days duration is to be imparted for minimum of 10 personnel on the first and second level of maintenance of the system. 11