IPS Product Development Strategy Presentation - 29052021

SMPS based IPS System in
Indian Railways(RDSO/SPN/165/2012)
Contents Details
• Introduction
• Integrated power Supply
• IPS Overview
1. Technical Requirement.
2. Budget Requirement.
3. Strategical Requirement.
4. Labs & Certification.
5. Manpower Requirement.
Introduction
• Power supply arrangement is the heart of signaling system.
For a reliable signaling system installation the reliable power
supply system is most important.
• In railways the different type of power circuit for different
type of power supply is used so for that circuits maintenance
also increase so by integrating this power supply in one form
called as integrated power supply.
• In which we are using one centralized battery bank of 55cells
for signaling purpose.
Integrated Power Supply system
• In Indian Railways failures of IPS affect the punctuality of
trains.
• To overcome these problems a large power supply scheme
known as Integrated Power Supply system has been
developed.
• The IPS system is located at center of all power supply used
for backup of power in railway signaling.
• The SMPS based Integrated Power Supply (IPS) system is
meant to give continuous supply to both AC & DC signaling
circuits for signaling installation of RE & NON-RE areas.
Function of IPS
• The function of Integrated Power Supply system is to provide
a stable and reliable AC and DC power supply to the Railway
signaling installations against all AC mains variations or even
interruptions.
• This is very essential for proper movement of trains.
Uses of IPS
• Blanking of signals to drivers is avoided.
• Centralized system of power supply for complete AC & DC
signaling loads.
• Monitoring is easier through the SMR panel in ASM room.
• Failure chances are less due to MTBF is high.
• Redundancy provided for all AC & DC loads.
• Very low MTTR.
A.1 Technical Requirements
A.1] Power Convertors Technology
1. FRBC Module 110V/20A.

Input Supply : 230V AC (150V - 275V AC, 50 Hz. ± 2.5 Hz.)
LM Battery VRLA Battery
Output voltage : Float mode: 118.25V 123.75
Boost mode: 133.0V 126.5
Output Current : 20 Amps per module
Battery path Current limit : 5% to 15% of the Battery Ah capacity ( FRBC PANEL)
Ripple (without battery) : Less than 300 mV Peak to peak
Psophometric noise (without battery) : Less than 10mV
Regulation : Less than +/- 1% for 25% to 100% Load & Simultaneous variation of input voltage (150 -275V)
Efficiency : Greater than 90% at nominal input and rated load & > 85% for other conditions
Total Harmonic Distortion : Less than 10% at 50%-100% of rated load.
Power factor : 0.95 at nominal input & output voltages and full load & > 0.9 for other
Voltage undershoot / overshoot -
output voltage ±5% ±5%
Load 25% TO 100% 25% TO 100%
Steady state time 20milli-sec 10 milli-sec
Type of charging : Automatic Float - Boost.
2. Inverter Module up to 3kVA.
• Input Voltage : 110V (98V - 138V) DC
• Output Voltage : 230V AC
• Output Power : Rated as per requirement.
• Output Frequency : 50Hz ± 1%
• Voltage Regulation : <± 2% of 230V AC at 25-100% rated load
• Efficiency : Greater than 85% at rated load
• Waveform distortion : Less than 8%
• Voltage undershoot / overshoot : < 20% for first cycle
• Over Load Protection : Provided
• Short circuit Protection : Provided with auto reset facility
• No load current: At rated input voltage shall not exceed 10%of the full load input current.
• Digital display meter : These indication LEDs are provided on the main control card of the inverter.
1. O/P Overload :This indicates that the 230V AC output of the inverter is overloaded.
2. DC under Voltage :This indicates that the input DC voltage to the inverter is below 98V.
3. AC Over/ under Voltage : This indicates that the output AC voltage of the inverter has crossed the upper
set limit.
4. DC over Voltage :This indicates that the DC input of the inverter have crossed the upper set limit.
3. Dc to Dc Converter Module
• Input Voltage : 98V - 138V DC
• Output condition : As per sketch
• Efficiency : > 50% : 10VA to 50VA
• > 75% : 50VA to less than 150VA
• > 80% : 150VA and above
Note: Efficiency measured at maximum voltage of the given range of module.
• Regulation : ±1 of the set value for load variation of 10% to 100% rated, input supply 98V-138V DC
• Ripple : < 50 mV pp,
• Psophometric noise : < 4mV. - BLOCK LINE, BLOCK TELE
• Facility for current sharing : Within 10% for 50%-100% load, except Block-Tele.
• Over Load protection : Provided at 105% of the rated current
• Over voltage protection: Provided at 110% of the rated current(auto tracking type)
• No Load Current : Not more than 10% of rated input current at voltage variations from 98v-138v.
• Digital display meter : These indication LEDs are provided on the main control card of the inverter.
• Voltage Monitoring Socket: This is to monitor the voltage of DC-DC converter through Voltage monitoring
jack. Voltage can be monitored on the digital display meter provided on the front of the DC- Distribution
panel.
4. Transformer Module.
• Input Voltage : 230V± 2% AC
• Output condition : As per requirement. The primary of the transformer is
230v. The secondary winding shall have tappings at 0, 100, 110, 120 &
130 volts at no load.
• Efficiency : > 90% at rated load
• Regulation : ±5% at 230V
• No Load Current < 10 % OF Full Load Current.
• Digital display meter : These indication LEDs are provided on the main
control card of the inverter.
1. Voltage Monitoring Socket:This is to monitor the voltage of Transformer
Module through Voltage monitoring jack. Voltage can be monitored on the
digital display meter provided on the front of the AC- Distribution Panel.
5. CVT Module
1. Ferro resonant type AVR.

2. Regulation : ± 1% for input 160V – 270V & no load to full
load.
3. Operational with same line regulation at 0.8 pf.
4. Output voltage varriation ± 3% for ± 1 Hz frequency
varriation
5. Output voltage recovery within 3cycles (60ms) for sudden
change load / input voltage
A.2] Integrational Requirements.
1. DSCA.
• Terminals are provided at the rear of this panel for 230VAC input supply, 110VDC battery. The
cable entry for all the terminals is from the top.
• The DSA module is responsible for the control for current sharing of FRBC modules, total system
current limiting, battery current limiting, changeover from float charging to boost and vice-versa,
battery status monitoring, battery under voltage isolation of load, module failure alarm, system
annunciation and various parameter display by Sensing the output voltage, battery voltage, total
system current and battery current.
• The main circuits of DSA module are for temperature compensation, Float to boost change over,
battery current limit and battery depth of discharge alarms.
• In addition it provides protection and alarms for AC under/over voltage, system overload and DC
under voltage.
• It also has facility to send status and fail signal of modules, provided in all the panels, to the
Status monitoring panel which is mounted in the ASM room.
• Potential free contacts of different fail sensing relays are also wired up to the control terminal
block.
3. AC & DC metering
• Digital meter of 3 ½ digit with LCD/LED alphanumeric
• display having 12mm height shall be provided on the front door of the
• rack.
a) AC volt / ampere meter to read AC input voltage & current.
b) DC volt/Ampere meter to read system voltage, battery voltage,
• system total current and battery current.
• In case of AC failure the battery discharge current shall be displayed on
• DC Ampere meter/ DSA with negative sign /discharge indication
• irrespective of selector switch.
4. Fail Signal Cards
It contains amplifier cards & interconnection / interfacing cards
5. Cards for functional Requirement.
. It contains Potential free contact card, start / stop DG card, AC
under / over voltage protection card auxiliary power supplies,
battery under voltage isolation card & fail signal cards.
6. Static Switches.
These are solid state type static switches used to feed priority
wise load through inverter 1, inverter 2 & CVT in AC panel.
B. Budgetary Requirements
1. STR - Rs-14,73,859/-
2. Testing & Mesuring instruments - Rs-12,77,500/-
3. Sample cost -Rs-10,00,000/-
4. Process machinery & tooling -Rs-8,70,000/-
5. Spare & components for development -Rs - 22,00,000/-
6. Infrastructure & facility- Rs-9,20,000/-
7. NABL Accredited LAB Charges – Rs 800000/-
8. FMEA – Rs 200000/-
C. Stretgical Requirements
1. CCA
Conducted by RDSO Mumbai & Reviwed by RDSO LKO
2. Production Capacity
3. Acceptance Test
4. Type Test
Conducted by RDSO LKO & Reviwed by RDSO LKO
5. FMEA
By any aproved arrestor
D. Labs & Certification
• Environmental Testing from NABL Certified Lab.
• Vibration Testing from NABL Certified Lab.
• EMI/EMF Testing from NABL Certified Lab.
E. Manpower Requirements
1. PCB Designer - 1
2. Coil winder -1
3. Fitter - 1
4. Wireman - 1
5. PCB Soldering Person - 2
6. Testing Engineer - 2
7. Software Engineer -1 / Out-sourced

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SMPS based IPS System in

1. FRBC Module 110V/20A.

1. Ferro resonant type AVR.

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