IMPROVING ENERGY EFFICIENCY AND ENVIRONMENT FRIENDLINESS OF DIESEL LOCOMOTIVES OF INDIAN RAILWAYS...

IMPROVING ENERGY EFFICIENCY AND ENVIRONMENT FRIENDLINESS

OF DIESEL LOCOMOTIVES OF INDIAN RAILWAYS

RDSO, Lucknow, INDIA

IR - Resources

1.4 Million employees

108,500 Track Km

63,000 Route Km

7,000 Stations

7,900 Locomotives

230,000 wagons

45,000 coaches


IR - Operations

5 Billion Passengers per annumMoving Entire Swiss Population Twice in a day

8,000+ Passenger Trains per day

Computerised reservations – One million transactions per day

Amongst the largest IT applications in the world

670 Million tonnes Freight per annum3,000 Freight trains on the system

Revenue – US $ 12 Billion per annum


IR Service Profile - Passenger

Diverse Customer Base8 travel classes

Charge for 1000 Km range US $ 2 to 50

58% Suburban passengers150 Km Monthly Fare US $ 8

Amongst the Lowest Passenger to Freight rate ratios in the world = 0.3


IR Service Profile – Freight

Entire SpectrumBulk coal/ores – 63%

Bagged commodities – 23%

Iron & Steel – 4%

Petro Products – 6%

Containerised cargo – 4%



Growth in 2005-06

% Improvement

No. of Passengers 7.4

Freight loading 10.7

Passenger Earnings 9.5

Freight Earnings 17.9

Total Earnings 15.1


Growth in 2006-07 (six-month period )

% Improvement

No. of Passengers 7.9

Freight loading 9.9

Passenger Earnings 11.1

Freight Earnings 15.9

Total Earnings 15.3

Diesel vs. Electric TractionTotal Annual Consumption

Diesel Oil : 2 Billion LitresElectric Energy : 10 Billion Kwh

% Traffic


Passenger

(Train Km)

Freight(GTKM)

Diesel 52.5 37.4

Electric

47.5 62.6Total locomotives

Diesel : 4801

Electric : 3065

Diesel Traction in IndiaDiesel Locomotive Works (DLW), the manufacturing unit of Indian Railways produces 130 diesel locomotives per annum. Majority of Diesel Locomotives fleet includes

16-cylinder ALCO & EMD Engines;12-cylinder ALCO Engines; and6-cylinder ALCO Engines.

Fuel Bill of Indian Railways is US $1.3 Billion.To reduce high-energy costs, RDSO has worked to improve energy efficiency of their Diesel engines.


Test bed facilities in RDSO have four Test Cells housing four types of DLW manufactured Engines.

16 cylinder GM-EMD,

16 cylinder ALCO,

12 cylinder ALCO,

6 cylinder ALCO

Each test cell has Test Commander comprising of

microprocessor controlled Data acquisition systems; and

Video Display Unit (VDU)

Test beds have been provided with High Speed Data Acquisition System to

acquire 100 MHz frequency data.


Engine Test Bed Facilities

Test Bed

Test CommanderHSDA System

Sustained efforts made to improve the diesel locomotive technology of 1950s, entirely through in-house research and development.


Improvement in Energy Efficiency

Stage-wise improvement in BSFC and increase in Horse-Power per cylinder

250

SFC

gm/bhp-hr.HP/Cylinder

162.5

193.7

206.2

225

2600 HP

3100 HP

3300 HP

3600 HP

4000 HP

154

151.5

150

166

156

1960-90 1990-2000

Year

2000-2006 2006-2008


Energy Efficiency Improvements

First stage modifications in the 16-cylinder ALCO engines resulted in:

6% reduction of fuel consumption at full load from 166 gm/bhp/hr to 156 gm/bhp/hr.

15 % reduction in the % lube-fuel oil ratio from 1.5% to 1.27%.


Modifications Stage-I

Efficient After –CoolerModification In Cooling Water Piping

Size of the core increased.

Increase in cooling effectiveness from 50% to 75%.

Water to after-cooler fed directly from the radiator.


Modification of Fuel Injection Pump


Plunger diameter of fuel injection pump increased from 15 mm to 17 mm.

The modification resulted in increase of peak fuel line pressure from 750 to 850 bars.


Development of Improved turbochargers


Global Efficiency improved from 50% to 60%.

Increase in booster air pressure from 1.2 bars to 1.6 bars.


Development of 12.5 CR Steel Cap Pistons

Aluminium Dish Top

Steel Cap

Modification of Cam Shaft


Steel cap pistons provided to withstand higher firing pressures.

Change in Inlet and Exhaust air cam lobes profile as well as Increased valve overlap to improve scavenging.



In Second stage, power of the engine was increased along with the reduction in fuel consumption and lube-fuel oil ratio:

Power from 2600 HP (FE) to 3100 HP by increasing the engine rpm from 1000 to 1050 rpm

2% reduction of fuel consumption at full load from 156 gm/bhp-hr to 153 gm/bhp-hr at 8th notch

12 % reduction in the % lube-fuel oil ratio from 1.27% to 1.12%.


Multigrade Lube OilHigh Efficiency TurboFE Piston Rings

Modifications Stage-II

These oils have Viscosity Index Improver additive.

Increase in the Booster pressure from 1.6 to 1.9 bar.

Speed of rotor increased from 23,000 to 27,000 rpm.

Piston ring set changed to

barrel, taper, taper and

2 no. oil conformable



In the third stage, the technological improvements have been made to :

uprate the engine to 3300 HP in the year 2001 and to 3600 HP in 2002.

1% reduction of fuel consumption at full load from 153 gm/bhp-hr to 151.5 gm/bhp-hr on top notch.

11 % reduction in the % lube-fuel oil ratio from 1.12% to 1%.


Stiffer Unit Cam Shaft

New Generation Turbochargers

Modifications Stage-III

Camshaft strengthened to take increased stress.

Fuel cam lobe profile modified for sharper fuel injection.

These aircooled turbochargers have higher global efficiency.

Rotor speed of these turbochargers also increased resulting in increased BAP.


Development of Plus cylinder head

Modifications Stage-III

Air intake valve angle reduced to take care of increased heat load.

Location of cooling passages changed to give better heat transfer.



Modifications in the fourth stage have been tested on test Beds but yet to be implemented. With these modifications :

Fuel consumption has been reduced by more than 2% over duty cycle.

Lube oil consumption has been further reduced by more than 6%.


Electronic Fuel Injection System

Modifications Stage-IV

EFI pump sets the start and end of injection for each cylinder individually .

The system eliminates many mechanical engine components including the Governor itself.


Double Helix Fuel Injection Pump

Double Helix PlungerSingle Helix Plunger

Modifications Stage-IV

Additional Helix provided on top edge of plunger

so as to optimise the opening of spill port

resulting in optimisation of start of injection at part load as well.

So far, no Standards have been laid down in India for Emission norms of Diesel Locomotives.Indian Railways, being socially conscious organisation, is making efforts to

reduce Diesel engine pollutants namely NOx, SO2, HC, CO, CO2 and Particulates having serious effect on health and environment.


Diesel Traction in India


NOx emissions measurements made in Nov. 1996 on 6-cylinder engine using Chemiluminescent detector based equipment.

The measurements gave the NOx value of 11.09 gm./kW-hr.

Emissions from ALCO Engines


Test Bed measurements Measurements on 12 and 16 Cyl. Engine made by using a portable emission measuring equipment in November 2000.


Only gaseous emission measurements could be made with the portable equipment .

Emission measurements were made at different engine configurations. It has been seen that

Emissions are higher only for CO and NOx.

Since HC values in the ALCO engines are much lower than the limits, it will be possible to recuce CO and NOx .

Emissions from ALCO Engines


Emissions Measurements

Since portable equipments do not meet International standards, RDSO has procured the dedicated Mass emission measuring equipment.

The same is presently under commissioning on the test beds of RDSO. The equipment under commissioning includes


Trials with Bio-Diesel

Use of environmental friendly Bio-diesel as an alternate fuel has been tried out.

Testing on engine test bed has been conducted followed by field trials.

Following observations have been made : No significant power loss observed. Specific fuel consumption is higher. Exhaust gas temperatures have reduced. Boost air pressures have got reduced. Gaseous hydrocarbons have reduced.


Use of Bio-Diesel

Southern Railway and South Eastern Railway have got trans-esterification plant and are running few trains with B10 diesel.

All the Railways are growing Jatropha plants on their surplus land.

Indian Railways have signed an MOU with Indian Oil Corporation to plant Jatropha saplings on the land of Indian Railways.

Other action taken to promote use of Bio-Diesel in Indian Railways is as under:


Use of CNG in DEMU

• 30% savings in operation and maintenance cost.

• Savings of Rs.27 lakhs per engine per year.

• Reduced engine wear.• Reduced lubricating oil

consumption.• Substantial reduction in

Exhaust emissions.

Use of CNG as an alternate fuel has been investigated on DEMU engines to see the environmental impact.

One rake of CNG DEMU is presently running in Delhi area. The special Features of CNG DEMU include:


Action Plan to reduce Emissions

Base-line emissions measurement will start immediately after commissioning of Mass emission measurment equipment.

A trans-esterification plant is being planned at RDSO to optimize engine parameters with Bio-diesels produced from different plants.

Following future action plan has been made to measure and reduce Emissions:


Action Plan to reduce Emissions

A leading engine designer Consultant is being contacted to assist Railways in reducing Emissions.

Emission measurement Car for measuring in-use emissions in field is planned.


Results of Emissions and Particulates measurements made for 16 cylinder EMD 4000 HP engine in 2001:

Emissions from New Engines

Parameters EPA standards (Tier-2)

GM locomotive values (As per EPA procedure)

NOx 5.5 5.83 HC 0.3 0.31 CO 1.5 0.42

Particulates 0.2 0.29 All values in gm/bhp-hr.

It is seen from above that • HC, PM and NOx Emissions are marginally higher than limits. • Since CO values are lower than the limits in the standards, it

is possible to reduce HC, PM and NOx Emissions.


Uncontrolled effluents of diesel sheds have an impact on the environment. Following work has been done to achieve the above: An Environmental Management System (EMS) has

been laid down the head of the maintenance unit is responsible to

establish environmental policy. A Waste Management System (WMS) has been laid

down as per which the main hazardous wastes generated in the

maintenance unit have been identified and the procedures for disposal of these waste

materials have been laid down.

Effluents Control in Diesel Sheds


Main equipments for disposal of hazardous as well as non-hazardous wastes include: Effluent Treatment Plant (ETP) Incinerator

Need for above Equipment, Design parameters, Specifications and Agencies for installation have been specified.

The Landfill sites for disposal of above waste have been included in the above system.

Effluents Control in Diesel Sheds


Fuel Efficiency Indices

The following two fuel efficiency indices are popularly used on Indian Railways:Fuel Consumption on 8th NotchFuel consumption at this notch is one of the important fuel efficiency index since

Fuel consumption at 8th notch is highest; and Locomotives run at this notch for longer duration.

Fuel Consumption over Duty cycleNotch-wise percentage running of locomotive over duty cycle for passenger and freight operations of Indian Railways locomotives is as under:

Notch 8 7 6 5 4 3 2 1 Idle

Passenger 21 6 4 8 4 8 5 6 38 Duty cycle in % Freight 22 7 5 3.5 3.5 3.5 3 1.5 51

Fuel consumption (in kg/hr) over duty cycle is calculated by taking weighted average of fuel consumption at every notch over duty cycle.

ALCO Locomotives Emissions

- All values are in gm/bhp-hr- Measurements made with Portable equipment only

Parameter EPA Std.

(Tier-2)

UIC-624 3100 HP 2600 HP 2300 HP

NOx 5.5 6.7 10.44 12.94 16.28

HC 0.3 0.6 0.07 0.10 0.11

CO 1.5 2.2 4.60 4.55 2.12


Other equipments of Mass emission measuring equipment include:

Mass Emission measuring equipment


Environmental Management System

Nature, scale and environmental impacts of activities and products.

Commitment to continual improvement and prevention of pollution.

Minimisation of the waste material generated during activities.

Commitment to comply with environmental legislation / Regulation and other requirements.

Provide a framework for setting and reviewing the environmental objectives and targets.

The head of the maintenance unit has to establish environmental policy keeping in mind the following aspects :


Waste Management System

Collection and disposal of the waste generated in diesel loco sheds;

Disposal of waste oil; Measures to control spillage of fuel &

lubricating oil; Leakage / spillage of fuel oil from fuel

installation or fire anywhere in the shed; Acid spillage.

The procedures for disposal of waste materials includes:

Emissions limits as per International Standards

Parameter

EPA Std.

(Tier-2)

UIC-624

NOx 5.5 6.7

HC 0.3 0.6

CO 1.5 2.2

Particulates

0.2 0.19

All values in gm/bhp-hr

IMPROVING ENERGY EFFICIENCY AND ENVIRONMENT FRIENDLINESS OF DIESEL LOCOMOTIVES OF INDIAN RAILWAYS...

Documents

Transcript of IMPROVING ENERGY EFFICIENCY AND ENVIRONMENT FRIENDLINESS OF DIESEL LOCOMOTIVES OF INDIAN RAILWAYS...