Annual Report 2010-2011

www.rdso.indianrailways.gov.in

ENGINE DEVELOPMENT
RESEARCH, DESIGN & DEVELOPMENT
TECHNICAL REPORTS Water temperature profile of EMD 16-cylinder engine At the request of DLW, Varanasi, a water temperature profile of the EMD 16-cylinder engine was developed on test bed number one using PT 100 Resistance Temperature Detector (RTD) and advised to DLW, Varanasi. Fuel Map of 3100/3300/3600 hp ALCO 16-cylinder diesel engine Microprocessor based control system and microcontroller based engine governing system have been introduced in ALCO 16-cylinder engines. For the optimisation of engine operating line by MP directorate, fuel maps for 3300 hp and 3600 hp were developed to establish the optimal engine operating points (speed, B M E P, a n d h p ) . T h e r e l e v a n t r e p o r t N o . TR/ED/2010/208 was issued. Testing of power assembly components of EMD 710 G3B engine (M/s GETS, USA) The testing of power assembly components supplied by M/s GETS, USA for the EMD 16-cylinder engine was undertaken to establish alternate sources of supply of these components. The relevant report No. TR/ED/2010/210 was issued in September 2010. report No. TR/ED/2010/211 was issued in December 2010. Single Exhaust Entry Manifold for ABB Turbo on 16

Compact brazed heat exchangers

Cylinder Diesel Engine Test Bed at 3100 hp, 3300 hp and 3600 hp A new design of single entry (modified) exhaust manifold for M/s ABBs turbo-charger TPR-61 was tested and Report No. TR/ED/2010/211 released. This

Power assembly components of EMD 710 G3B engine (M/s GETS, US)

Compact brazed heat exchangers testing on 16 Cylinder Diesel Engine Test Bed at 3100 hp, 3300 hp and 3600 hp In accordance with minutes of DMG, to curb failures of gaskets in plate type lube oil coolers, two makes of compact brazed type lube oil coolers were tested and reports released for further field testing. The relevant

Single Exhaust Entry Manifold for ABB Turbo on 16 Cylinder

new design of the manifold is expected to improve

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Annual Report 2010-2011

www.rdso.indianrailways.gov.in

Engine Development

reliability of ABB TPR-61 turbo-chargers on Indian Railways. Development of valve timing diagram drawing for ALCO locomotive with stiffer unit cam shaft The revised valve timing diagram drawing for 16cylinder ALCO engine with the larger base circle diameter unit camshaft has been prepared and Report No. TR/ED/2010/212 issued. TECHNICAL INFRASTRUCTURE DEVELOPMENTS

Valve Timing Diagram

Alteration and preparation of ALCO 16-cylinder Test Bed for EFI fitting, testing and optimisation The ALCO 16-cylinder engine of test bed number two was altered with necessary arrangements for fitting the Electronic Fuel Injection (EFI) system. The optimisation tests for the EFI system were carried out and finally fitted on the first EFI locomotive, which is under operational observation. Replacement of test bed control systems of 12cylinder and 6-cylinder ALCO engines The obsolete test bed control system for the 12-cylinder and 6-cylinder ALCO engine test beds are under replacement with modern test facilities. These are expected to complete in ensuing years. Improvements to test bed infrastructure on way RDSO has undertaken three new infrastructure enhancement works for improved testing facilities, namely: upgradation of dynamometer of ALCO 16cylinder test bed for catering to higher horse power

needs, augmentation of heat disposal arrangements for all test beds, and enhancement to air-compressor and air-starting motors to cater to the new higher horse power test beds. Training and development of knowledge and skills Officers and supervisors of Engine Development and Motive Power Directorate attended several workshops at IIT, Kanpur during the year to update the knowledge and skills for research in engines. The topics covered included Advances in Combustion and Transportation, Diesel Particulate and NOx Emissions, RESEARCH, DESIGN, AND DEVELOPMENTAL PROJECTS EMISSION IMPROVEMENTS Design and development of technical specifications for equipments of Emission Test Car After intense literature review, specifications for state of the art emission testing and measuring equipment were prepared for procurement and fitting on the Emission Test Car (ETC) for IR. The ETC is expected to become functional in ensuing financial year 2011-12. Reduction of emissions and development of emission compliant diesel engine for diesel locomotives of IR An EOI was floated in March 2011 and discussions were held with several vendors for preparation of the technical specifications. This project shall enable stepwise improvements in emission performance of both, the ALCO 16-cylinder 3100/3300/3600 hp and EMD 16-cylinder 4000/45000 hp engines. DEVELOPMENT OF NEW TECHNOLOGY ENGINES Development of technical specifications for Common Rail electronic Direct Injection (CReDI) System specifications for ALCO and EMD engines An EOI for the development of CRDI for ALCO 16cylinder engine was released in Nov, 2011. The detailed technical specifications have been prepared and approved. The tender is expected to finalise in the coming year. Development of dual fuel (CNG/LNG and diesel) ALCO Locomotives This project was primarily undertaken to benefit from the available supplies of CNG/LNG in India, reduce dependence on imported diesel, and further reduce the emissions from ALCO engines. The preliminary specifications were prepared and EOI floated. The project is likely to be completed in the year 2012-13.

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