MINISTRY OF RAILWAYS, GOVERNMENT OF INDIA RESEARCH DESIGNS AND STANDARDS ORGANISATION ... ·...
Transcript of MINISTRY OF RAILWAYS, GOVERNMENT OF INDIA RESEARCH DESIGNS AND STANDARDS ORGANISATION ... ·...
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MINISTRY OF RAILWAYS, GOVERNMENT OF INDIA
RESEARCH DESIGNS AND STANDARDS ORGANISATION
MANAK NAGAR, LUCKNOW – 226 011
ENGINE DEVELOPMENT DIRECTORATE
GLOBAL NOTICE FOR EXPRESSION OF INTEREST (EOI)
EOI Notice No.: RDSO/ED/EOI/2012/06
RDSO is the sole Research, Design and Standards organisation of Indian Railways,
dedicated to creation and adoption of technology solutions for Indian Railways. Engine
Development Directorate of RDSO is engaged in design and development of diesel engines,
their systems and parts for Rail traction of Indian Railways.
Engine Development Directorate, RDSO, Indian Railways, Lucknow invites EOI for
undertaking the work of:
‘Design and Development of Turbocharger to suit Miller Cycle Timings for Higher Fuel
Efficiency and Reduced Emissions for DLW built 16 Cylinder 3100/3300/3600 HP ALCO
Engines of Indian Railways as per draft technical specification no. TS/ED/2012/64’.
The EOI documents and the above draft specification can be purchased from the
office of Executive Director (ED)/CNG, Engine Development Directorate, RDSO, Manak
Nagar, Lucknow – 226 011 on payment of INR 3000.00 through a demand draft.
The EOI documents and the draft specification can also be downloaded from the
RDSO website (www.rdso.indianrailways.gov.in Tenders EOI) and a demand draft
for INR 3000.00 submitted along with the EOI.
Demand Draft submitted should be issued by an Indian Nationalised Bank in favour
of Executive Director/Finance, RDSO, Lucknow payable in INR at Lucknow, India. No
request for sending EOI documents by post shall be entertained.
Interested parties can drop their offer in a sealed envelope labelled “EOI as per draft
technical specification no. TS/ED/2012/64” in the EOI box kept at Room No. 12,
Engine Development Directorate, RDSO, Manak Nagar, Lucknow, India – 226 011 during
office hours (IST 900 hrs to IST 1730 hrs). Clarifications if any can be sought by email to
[email protected] or [email protected], or by telephone at +91-522-2465719 /
+91-522-2451017 during office hours.
The sealed EOI can be submitted on or before 14/08/2012 and shall be opened on
14-08-2012 at 15.30 hrs. In case the day is declared a holiday, the EOI shall be opened on
next working day at 15.30 hours.
Executive Director (ED)/CNG
Engine Development Directorate
RDSO, Lucknow – 226 011
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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
EXPRESSION OF INTEREST
FOR
DESIGN AND DEVELOPMENT OF
TURBOCHARGER TO SUIT MILLER CYCLE
TIMINGS FOR HIGHER FUEL EFFICIENCY
AND REDUCED EMISSIONS FOR DLW BUILT
16 CYLINDER 3100/3300/3600 HP ALCO
ENGINES OF INDIAN RAILWAYS
RDSO/ED/EOI/2012/06
Engine Development Directorate
Research Designs and Standards Organisation
Manak Nagar, Lucknow- 226 011(India)
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DISCLAIMER
Engine Development Directorate (EDD) of Research Designs and Standards
Organisation (RDSO) has prepared this document to give interested parties background
information on the project. While EDD has taken due care in the preparation of the
information content herein and believes it to be accurate, neither EDD nor any office
authorities, officers, employees, agents/and advisors gives any warranty or make any
representations, express or implied as to the completeness or accuracy of the information
contained in this document or any information contained in this document or any information
which may be provided in connection therewith.
The information is not intended to be exhaustive. Interested parties are required to
make their own inquiries and respondents will be required to confirm in writing that they
have done so and they do not rely on the information provided in the Expression of Interest
(EOI) document in submitting their response. The information is provided on the basis that it
is non –binding on EDD or any of its authorities or agencies or any of their respective
officers, employees, agents or advisors.
Engine Development Directorate reserves the right not to proceed with the project, to
alter the timetable reflected in this document or to change the process or procedure to be
applied for selection of enquiry partners. It also reserves the right to decline to discuss the
project further with any party expressing interest.
No reimbursement of cost of any type whatsoever will be paid to persons, or entities,
expressing interest in the project.
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INTRODUCTION
Research Designs and Standards Organization (RDSO) under Ministry of Railways at
Lucknow is the central research organization of Indian Railways (IR) and headed by Director
General, RDSO. Director General is assisted by Additional Director General, Sr. Executive
Directors and Executive Directors, heading different directorates. RDSO has various
directorates for smooth functioning including Engine Development Directorate (EDD). EDD
is engaged in design and development of railway traction diesel engines and has CAD, engine
simulation and computer centre, dedicated engine test cells, fuel injection lab,
instrumentation lab and other facilities to carry out diesel engine development work.
EDD has taken up projects in the area of Reduction of Fuel consumption and
reduction of Exhaust Emission from Diesel Locomotives of Indian Railways. As part of the
ongoing efforts to reduce fuel consumption and harmful exhaust emissions from diesel
locomotives of IR, it is planned to develop a Turbocharger to suit Miller cycle timings for
higher fuel efficiency and reduced emissions. It is envisaged to develop a package of
components for implementation of the Miller Cycle timing turbocharger. This will broadly
consist of a Turbocharger of requisite capacity for higher boost pressure air flows and
suitable Camshaft with modified air and exhaust lobes to suit Miller timings.
OBJECTIVE OF THE EOI
Indian Railways intends to invite EOI from reputed designers and manufacturers for
design, development, supply, installation and commissioning of a Turbocharger to suit Miller
cycle timings for higher fuel efficiency and reduced emissions for DLW built 16 cylinder
3100/3300/3600 HP Alco engines of Indian Railways along with camshaft. The objective of
the EOI is to ensure transparency in finalization of the technical specifications for the project.
This will not be used to shortlist the vendors and this exercise is mainly to get valuable
feedback from the Industry.
SCOPE OF THE PROJECT
1. It is planned to design, develop, supply, install and commission a Turbocharger to suit
Miller cycle timings for higher fuel efficiency and reduced emissions for DLW built
16 cylinder 3100/3300/3600 HP Alco engines of Indian Railways along with
camshaft.
2. No other component besides the turbocharger and the camshaft is proposed to be
changed to meet the desired performance.
3. The turbocharger being offered has to be compliant to various blends of
biodiesel,(considering upto 100%) and high speed diesel.
4. The project is proposed to be covered under the ambit of CDM and the carbon credits
so accrued will be owned by Indian Railways.
PROCESS
General process would be as indicated below-
1. Calling for Expression of Interest to develop the specifications for the system [draft
technical specifications attached for further discussions] through wide publicity and
advertisement.
2. Meeting in RDSO if required to discuss the specifications including presentations if
any by the firms. The presentations shall be held separately for each firm to ensure
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Intellectual Property (IP) safety. Input from the firms shall be taken as deemed fit
regarding any suggestions/ comments/ objections/ etc. for the technical specifications.
3. Finalization of specification by EDD, RDSO and publishing on the Web to solicit any
further comments from vendors/ other organizations.
4. Calling of Global Open Tender
CREDENTIALS OF THE FIRMS DESIROUS OF PARTICIPATING IN THE EOI
Following are the expected credentials of the firms desirous of participating in the EOI-
1. The firm should be in the line of design, development and manufacture of Turbocharger
to suit Miller Cycle Timings for higher Fuel efficiency and reduced Emissions for at
least past five years. The firm itself must possess this qualification. Representation on
behalf of a reputed manufacturer or designer/consultant will not be sufficient. This inter-
alia means the interested firm should have the requisite expertise in the design and
development of the offered Turbocharger to suit Miller Cycle Timings for higher Fuel
efficiency and reduced Emissions or its manufacturing or both. It can tie-up with
complimentary firm(s) to offer the design, development, manufacturing, proto-testing,
field proving and freezing of specification of the kit. However the Turbocharger
manufacturer will only need to quote in the tender to Indian Railways (IR) and will be
solely responsible for the satisfactory performance of the complete kit.
2. The firm and/or its partners should have necessary expertise in the following areas : -
a. Design of the various types of Turbocharger and Cam shaft as given in the Scope of
the project.
b. Have sufficient manufacturing, programming, integration and troubleshooting
capabilities for hardware and software production
c. Should have designed and developed similar turbocharger and cam shafts for diesel
locomotive engines
d. Should be willing to support the IR program for the development of the Engine
Turbocharger to suit Miller Cycle Timings for higher Fuel efficiency and reduced
Emissions for DLW build 16 –Cylinder ALCO engine through all steps as
mentioned above.
e. The firm should not have been indicted by any court of law or any regulatory body
or any state/central government agency in India or abroad.
f. Should be of sound financial standing
3. Tenderer should be willing to take the responsibility of the overall System Integration,
Testing / Optimization & Validation of the Engine Emission Compliant Miller
Turbocharger Kit on the test engine of ALCO as well as the ALCO locomotive in
coordination with Indian Railways
4. Interested parties may participate in the EOI by filling in the Application form given at
Annexure 1 & 2.
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USE OF INFORMATION
EDD, RDSO reserves the right to use information received in the replies to EOI for further
development of the project. Mere fact of responding to the EOI, however, shall not confer
any Right on the parties to preferential treatment at the subsequent bid/ development stage.
DISQUALIFICATION
RDSO would like to caution that the respondents shall be ineligible to bid for or participate in
the EOI discussions to be held at RDSO in the following cases: -
a. In regard to matters relating to the security and integrity of the country, any charge
sheet by any agency of the government/ conviction by a court of law for an offence
committed by the company or any sister concern of the company would result in
disqualification. The decision in regard to the relationship between the sister concerns
would be taken by RDSO, based on the relevant facts and after examining whether the
two concerns are substantially controlled by the same person / persons.
b. In regard to mattes other than security and integrity of the country, any conviction by
a court of law or indictment / adverse order by a regulatory authority against the
company or against any sister concern which relates to a grave offence, or would
constitute disqualification. Grave offence is defined to be of such a nature that it
outrages the moral sense of the community. The decision in regard to the nature of the
offence would be taken on case to case basis after considering the facts of the case
and relevant legal principals by RDSO.
c. In regard to matters of International Trade, any conviction by an International Agency
like U.N or any other Government besides the Government of India, against the
company or against any sister concern which relates to grave offence, or would
constitute disqualification.
RIGHT TO ACCEPT OR REJECT ANY OR ALL APPLICATIONS
Notwithstanding anything contained in this EOI, the authority reserves the right to accept or
reject any application to annul application process and reject all applications, at any time
without any liability or any obligation for such acceptance, rejection or annulment and
without assigning any reasons thereof.
The authority reserves the right to reject any application if
a. At any time, a material misrepresentation is made or uncovered, or
b. The applicant does not provide, within the time specified by the authority, the
supplemental in formations sought by the authority for evaluation of the application.
Such misrepresentation/ improper response shall lead to the disqualification of the
Applicant .If the applicant is a Consortium, then the entire Consortium shall be
disqualified / rejected. if such disqualification/rejection occurs after the applications
have been opened and the applicant gets disqualify/ rejected, then the Authority
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reserves the right to take any such measure as may be deemed fit in the sole direction
of Authority, including annulment of the Application process.
c. The Authority reserves the right to verify all statements, information and documents
submitted by the Applicant in response to the EOI. Failure of the Authority to
undertake such verification shall not relieve the Applicant of its obligations or its
liabilities hereunder nor will it affect any rights of the Authority there under.
EXPECTED CONTENTS OF EXPRESSION OF INTEREST
Expression of interest should be sent in format given in Annexure 1 & 2 and shall contain the
documents and details listed below for the firm/partners if any-
a. Capability statement (not more than four pages) ,illustrating the skills and experience of
the firm in providing the services required under this advertisement ;
b. A write up on the understanding of the assignment (not more than two pages)
c. Short CVs (two pages maximum) of the key personnel expected to be deployed in the
assignment.
d. Company/ Organization profile giving details of current activities and management
structure (not more than four pages.)
e. Evidence of incorporation
f. Annual Report including audited Balance Sheet and Profit and Loss Account statement
for past three years.
g. Details of relevant experience of last five years including cost, project structure and other
partner details.
DRAFT SPECIFICATIONS
Draft technical specifications are enclosed at Annexure 3. These may be referenced for the
discussions to be held at RDSO. Questions if any may be addressed to:
Executive Director (ED)/CNG,
Engine Development Directorate, Research Design & Standards Organisation,
Ministry of Railways – Govt. of India Manak Nagar, Lucknow – 226 011, India
Phone: 91-0522-2465719, Fax: 91-0522-2451017, Mobile: +919794863148
email: [email protected]
Director, Engine Development Directorate, Research Design & Standards Organisation,
Ministry of Railways – Govt. of India
Manak Nagar, Lucknow – 226 011, India
Phone: 91-0522-2451017, Fax: 91-0522-2451017, Mobile: +919794863225
email: [email protected]
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Annexure 1: Expression of Interest
(To be forwarded on the letterhead of the firm)
Reference No............................ Date..................
Executive Director/Engine Development/CNG
RDSO
Manak Nagar
Ministry of Railways
Lucknow -11
Sub: Notice inviting Expression of Interest (EOI) for design & development of Turbo
charger to suit Miller cycle timings for higher fuel efficiency and reduced emissions
for DLW built 16 cylinder 3100/3300/3600 HP Alco engines of Indian Railways.
Sir,
This is with reference to the advertisement dated .....................2012 inviting
Expression of Interest for design & development of Turbo charger to suit Miller cycle
timings for higher fuel efficiency and reduced emissions for DLW built 16 cylinder
3100/3300/3600 HP Alco engines of Indian Railways. As specified in the advertisement, we
have read and understood the contents of the EOI document and are desirous of participating
in the discussions for giving input towards finalisation of the proposed technical
specifications. For this purpose we propose to visit RDSO on..... to participate in the
discussions. We would like to make a presentation for..... minutes to convey our point of
view.
OR
We have formed / proposed to form a consortium comprising.....of members as
follows: -
1. Xx
2. Yy
We believe that we / our consortium / proposed consortium satisfy / satisfy the credentials
required to participate in these EOI discussions in relevant section of the EOI document no.
............................
We have submitted clause wise comments to the EOI document along with this covering
letter and also attach a copy of the presentation that we intend to give during the EOI
discussions.
We shall be glad to receive further communication on the subject.
Yours faithfully,
Enclosures
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Annexure 2: Details of Credentials
(To be submitted in respect of interested party / each member of the consortium on their
respective letter head)
Name of the Interested Party(ies)/ Member(s)
..............................................................................
1. Indian/ Foreign company/ Single/ Consortium/ JV
2. Date of Incorporation and country of incorporation
3. Date of commencement of business
4. Full address including phone no. / fax no.
a. Registered office
b. Head office
c. Local liaison office if any
5. Address for correspondence
6. Basis of credentials for participation in the process (Please mention details of your
credentials) as under (whichever is applicable)
7. Brief description of Company’s General Profile covering focus areas of operations,
expertise, number of employees
8. Please attach the audited balance sheet and profit and loss account for the last three
financial years
9. Operating revenue for last three financial years
10. Brief description of how the participant meets the credentials criteria of the EOI
document
11. Contact Persons
12. Name
13. Designation
14. Phone No.
15. Mobile No.
16. Fax No.
17. Email
Yours faithfully,
Authorised Signatory Authorised Signatory
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Annexure 3: Draft Specifications
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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
DRAFT TECHNICAL SPECIFICATION
FOR
DESIGN AND DEVELOPMENT OF
TURBOCHARGER TO SUIT MILLER CYCLE
TIMINGS FOR HIGHER FUEL EFFICIENCY
AND REDUCED EMISSIONS FOR DLW BUILT
16 CYLINDER 3100/3300/3600 HP ALCO
ENGINES OF INDIAN RAILWAYS
TECHNICAL SPECIFICATION NO. TS/ED/2012/64
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ENGINE DEVELOPMENT DIRECTORATE Research Designs and Standards Organisation
Manak Nagar, Lucknow– 226 011, India
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TABLE OF CONTENTS
Para No. Description Page No.
1.0 Background 12
2.0 Objective of the Project 13
3.0 General Requirements 13
4.0 Methodology 15
5.0 Deliverables 16
6.0 Technical Data and Drawings 16
7.0 Performance Tests on RDSO Engine Test Bed 17
8.0 Performance Tests on Locomotive 17
9.0 Confidentiality of Test Results 17
10.0 Training and Inspection 17
11.0 Warranty 18
12.0 Payment Terms 18
Annexure I to VI 19-24
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1.0 Background-
Engine Development Directorate (EDD) of Research Design and Standards Organization,
Lucknow (RDSO) under Ministry of Railways is proposing to develop a Turbo charger to suit
Miller cycle timings for higher fuel efficiency and reduced emissions for DLW built
16 cylinder 3100/3300/3600 HP Alco engines of Indian Railways (IR).
The Alco engines are large bore diesel engines capable of producing power from 3100 to
3600 HP.
Technical specification of the engine is as given below:
Configuration V-16, DI, 4S, Turbocharged, Inter-cooled Diesel engine
Bore/ Stroke (mm) 228.6/ 266.7
Displacement 10.95 liter/ cylinder
Compression Ratio 11.75 (static)
Fuel Injection Equipment Mechanical pump line nozzle system**
Nozzle Opening Pressure 275 bar
Rated Power 2312 kW at 1050 rpm
Torque at max. speed 22000 Nm at 1050 rpm
** This is being replaced by Electronic Fuel Injection System and there is a likely hood
that the Miller timing turbocharger kit may be fitted on locomotives fitted with
Mechanical fuel injection system or an Electronic fuel injection system
Based on literature survey and a report as available with IR on reduction in emissions it
is opined that the following path shall be followed-
a) By changing the existing turbocharger with a Miller based turbocharger.
b) Developing a camshaft to suit the above requirement.
c) Timing of opening and closing of exhaust and inlet valve.
d) Varying the scavenging period.
e) Improving the compression ratio of the piston. [For the purpose of this project it is
proposed to use the existing 12.5 CR pistons available with EDD. It is proposed to
carry out a 3-D combustion CFD using KIVA open code software to develop
combustion chamber for the 12.5 compression ratio piston which is optimized for
the Miller timing turbocharger boost pressures and modified timing diagram to
suit the Miller timings].
Wide scale implementation of this kit shall depend upon the outcome of the development
process and results achieved. However while proposing the tenderers may keep in mind that
it may be used on newly built locomotives or also as a retro fitment solution on the existing
diesel locomotives.
It is proposed to replace only the turbocharger and the camshaft in the existing
configuration to achieve the desired objectives. For the purpose of this project one loco set
of 12.5 CR pistons shall be supplied by EDD. The camshaft development would be limited
to include design and development of the air and exhaust cam lobes. The existing after
cooler may be adapted to suit the requirement so that the air reaches the same air
temperature before intake as in current configuration or is better. The tenderer would need
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to study and certify that the design of the existing fuel lobe on the camshaft would meet its
requirement and that the new designs of air and exhaust cam lobes can be accommodated
along with the existing fuel lobe design on the same camshaft without any other
modification. The tenderer is supposed to work on the existing unit cam shaft envelope
only.
Consultants report, drawings of existing unit cam shaft, base line Electronic fuel injection
and Mechanical fuel injection systems fitted engine performance, emissions and combustion
data will be shared on signing of a Non Disclosure Agreement with EDD and certifying that
this information shall be used only for development aid in this project and nowhere else.
2. Objective of the Project-
Following minimum broad objectives are required to be met: -
a) Reduced NOx emissions by 20% vis-a-vis an Alco engine fitted with Electronic
Fuel Injection System(16mm plunger diameter)
b) Reduced BSFC by 2% vis-a-vis an Alco engine fitted with Electronic Fuel
Injection System. (16mm plunger diameter)
c) Reduction in exhaust gas temperature upto 50 degree centigrade vis-a-vis an Alco
engine fitted with Electronic Fuel Injection System(16mm plunger diameter)
d) No increase in the PCP of the engine beyond 125 bars.
e) Envelope of the components offered to be within the existing envelope.
f) Sufficient surge margin of the Turbocharger
g) Increase air/fuel ratio at part load
h) Reduced Life Cycle costs
i) Prolonged Maintenance and Time Between Overhaul intervals
j) The turbo charger being offered should be certified that it is compliant to use of
Biodiesel also in addition to the high speed diesel. (For blends upto 100%).
k) No other component besides the turbocharger and the camshaft should be required
to be changed to meet the desired performance.
l) The project is proposed to be covered under the ambit of CDM and the carbon
credits so accrued will be owned by Indian Railways.
m) The existing fabricated engine block/ crankcase of the 3100 hp rated ALCO
16 cylinder is rated at 125 bar PCP. The tenderer should ensure that the PCP
should not exceed this limit without any detriment to in-vogue fuel efficiency of
the engine. Envelop constraints of the locomotive may be adhered to. [IR has a
separate programme to develop a 165 bar PCP cast block. Likelihood exists in
future that this developed kit may be fitted on this cast block]
n) The tenderer shall plan to develop design iterations for prototype of the associated
components so that the desired objective is achieved.[however the tenderer should
be prepared to provide against the project requisite number of iterations as
required to meet the laid down objectives.]
3. General Requirements-
Details of the present Cam shaft and EFI are as given below: -
Parameter Cam Shaft of ALCO 16 V
Type Stiffer Unit Cam Shaft
IVO BTDC 72 degrees
IVC ABDC 48 degrees
EVO BBDC 66 degrees
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EVC ATDC 66 degrees
Note: Copy of valve timing diagram is enclosed as Annexure-VI. Data is
indicative.
Electronic Fuel Injection System
EDD has developed Electronic fuel injection system with 16 mm plunger diameter
and Electronic Control Unit along with required software for one ALCO Locomotive,
16502 R which is at present in service at Diesel Locomotive Shed, Alambagh, Northern
Railway.
The Miller timing turbocharger kit must exhibit the following improvements in duty
cycle fuel consumption and regulated emissions. These values are based on the measurements
done on the Electronic Fuel Injection system fitted Alco engine on the test bed.
Parameter Minimum reduction
targets to be achieved
Rated horsepower range (kW) 2312.6/2461.8/2685.6
bsfc (g/kwh) 202.4 Minimum 2% over
current value.
NOx emissions As achieved in EFI Minimum 20% over
measured values.
Indicative Engine data for ALCO engines is given at Annexure–I and performance
data for ALCO engine at full power is given at Annexure- II. The typical Indian Railway
operating duty cycle for diesel locomotives is given at Annexure-III.
Rail Traction Characteristics
The Turbo charger Kit to suit Miller Cycle Timings for higher Fuel efficiency and reduced
Emissions shall be suitable for Rail traction service; which is characterized by wide,
fluctuating, cyclic load patterns, and extended intervals of operation at idle & full load.
Operating conditions
It shall be sturdy and reliable in operation and incorporate components that can withstand the
hostile environmental conditions in the engine room such as dust, water, fuel/ lubricating oil,
vibration, extreme temperatures, Electrostatic / Electromagnetic interference, and an
extremely noisy power supply.
Mounting Arrangement
The complete system shall be mounted on the engine first at EDD Test Bed and after
successful trials at EDD test bed shall be mounted on an actual locomotive in the field.
Safety Requirements
The Turbo charger Kit to suit Miller Cycle Timings for higher Fuel efficiency and reduced
Emissions on a DLW build 16 –Cylinder ALCO engine shall be so designed that safety of the
locomotive and personnel are not compromised.
Page 15 of 24
Preventive Maintenance
The Turbo charger Kit to suit Miller Cycle Timings for higher Fuel efficiency and reduced
Emissions on a DLW build 16–Cylinder ALCO engine shall be so designed that no
maintenance including inspection of any type shall be required before 180 days. The
manufacturer shall specify the preventive maintenance schedule required. Care shall be taken
by the manufacturer to ensure that these schedules match the existing locomotive schedules,
and the least work content in these schedules shall be preferred.
Ambient Conditions
The Turbo charger Kit to suit Miller Cycle Timings for higher Fuel efficiency and reduced
Emissions on a DLW build 16–Cylinder ALCO engine shall be so designed that it should be
able to work in extremely dusty and desert terrain, coastal areas, withstand vibration levels on
test bed and run etc. Suction temperatures may be as high as 55 degree centigrade (ambient)
and would need to work over the territory of IR including tunnels.
Other Design Requirements
To ensure easy fitment, the following restrictions in the design shall apply:
a) The Turbo charger to suit Miller Cycle Timings for higher Fuel efficiency and
reduced Emissions Kit shall be designed in such a manner, that no major
modification to the existing engine shall be required for its fitment.
b) It should not be necessary to have reduced air manifold temperatures, or change in
air inlet requirements.
c) The Idle and light loads should not require throttling the air flow
d) The kit should be an easy retrofitable solution requiring one is to one replacement
of a Turbocharger and a camshaft set only.
e) Firm must be willing to carry out combustion chamber CFD using KIVA open
code software to ascertain the most optimum design to suit the changed valve
timings and boost pressures.
f) The converted engine should improve on the performance and efficiency of the
base diesel engine
g) Performance, emissions and durability test shall be conducted at EDD Test Bed.
Durability test shall consist of 100 hrs run of the Miller cycle kit fitted engine at
the rated engine speed and load. On successful completion of the performance,
emissions and durability test, reliability verification testing of the Miller Cycle kit
for a period of 6 months shall be done on a retrofitted diesel locomotive.
4.0 Methodology
It is planned to replace the present Turbocharger with after cooler with a Miller
technology based Turbocharger and Stiffer Unit Cam Shaft with one set new design cam
shaft. It should be compatible with existing components and shall consist of [but not
limited to] the following activities: -
a) Procurement of the parts of the Miller technology based Turbocharger, new design
cam shaft, as per the designs and specifications.
b) 3D CFD of the combustion chamber using KIVA open code source software to
optimize the combustion chamber geometry to suit the higher boost pressure and
miller cycle valve timings
c) System integration on the engine in the Engine Test Bed at RDSO
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d) Optimization and proving out of the Turbo charger kit to suit Miller Cycle
Timings for higher Fuel efficiency and reduced Emissions on the ALCO engine
on the Engine Test Bed at RDSO
e) Field trials and reliability verification testing in the field
f) Debugging and development of final technical designs, drawings, programs for
large scale field implementation
5.0 Deliverables
The requirement envisages inclusion in the offers, separately, of the following
proposed deliverables but not limited to-
a) One number Miller technology with optimized timing high efficiency turbo
charger with adaptation parts if any.
b) One finished loco set (16 Nos.) of stiffer unit cam shaft to suit the above turbo
charger with modified air and exhaust cam lobes and retaining the original fuel
lobe design. [It may be kept in mind by the tenderer that if iteration is called for
based on test bed result; same shall be in scope of supply of tenderer only till the
time stated objectives for performance are achieved.]
c) Manufacturing drawing of the revised camshaft for subsequent procurement use of
IR.
d) One complete set of Specifications, material test reports, apparatus instructions,
manual for the above, spare parts catalogue, including detailed dimensioned
drawings of the interfacing dimensions except the proprietary design details
e) Full technical support and update for a period of minimum two years after
successful installation and commissioning.
f) Training to the personnel nominated by RDSO in the field of design appreciation
and customization of above kit.
g) Report of 3D CFD of the combustion chamber optimization to suit the higher
boost pressure and miller cycle valve timings and manufacturing drawing of the
most optimum combustion chamber geometry(s) for the 12.5 CR pistons.
6.0 Technical Data and Drawings
To support the claims regarding the design, fitment, maintenance, operation,
performance, reliability etc. the tenderer is required to submit the following documents along
with their offer:-
a) Details of Turbo charger to suit Miller Cycle Timings for higher Fuel efficiency
and reduced Emissions Kit on similar engines or engines of similar power output.
b) Details of special tools and jigs required for the maintenance of Turbo charger to
suit Miller Cycle Timings for higher Fuel efficiency and reduced Emissions Kit on
a DLW build 16 –Cylinder ALCO engine. Tenderer should specify the details of
the specifications, data and drawings to be provided by RDSO.
c) For the entire major bought out items/components, the essential detail should be
given in the offer. In addition, the tenderer must give para-wise remarks to all the
clause of specification in absence of which the offer is likely to be ignored.
d) Tenderer may offer any other feature felt essential to achieve better performance
than stated objectives with technical aspects and price impact of these additional
features.
Page 17 of 24
7.0. Performance Tests on RDSO Engine Test Bed
The performance of the Turbo charger kit to suit Miller Cycle Timings for higher Fuel
efficiency and reduced Emissions in respect of fuel consumption, brake specific energy
consumption, and Emission reduction is most important. Any specific instrumentation
required to be provided by RDSO on the test bed engine (at RDSO) such as additional
sensors for measurement of parameter should be detailed in the offer.
The specified performance shall be validated on the test bed of ALCO engine at Engine
Development Directorate, Research Designs & Standards Organization (RDSO),
Lucknow, India.
The ALCO engine will be run at the predetermined speed and load points during the test
as per Annexure-IV. The optimization will be done under the identical conditions and
combination of components. The engine will be loaded by hydraulic dynamometer
controlled by AVL test commander. For calculation of corrected horsepower and brake
specific fuel consumption, ALCO formula will be used. The performance parameters
will be recorded in direction of descending order of load and speed.
The Tenderer in consultation with RDSO shall draw up the optimization programme.
The detail of data acquisition system of the test bed is at Annexure-V.
Performance tests on RDSO Engine Test beds shall be carried out for a period of two
months after complete assembly.
8.0 Performance Tests on Locomotive
After the validation of the system performance on ALCO engine test bed at Engine
Development Directorate, RDSO, the system would be fitted on ALCO-DLW diesel
locomotive. After proving out the performance requirement on the locomotive, its
maintainability and reliability under field conditions (Reliability Verification Testing)
would be jointly monitored by RDSO and the manufacturer for 6 months. All problems
noticed during this period be logged and a satisfactory solution shall be found.
9.0 Confidentaility of Test Results
All data that is generated as a result of testing of Turbo charger kit to suit Miller Cycle
Timings for higher Fuel efficiency and reduced Emissions based engine and/or the test
rigs by Indian Railways shall automatically become the sole property of RDSO. No part
of such information shall be disclosed to any third party without prior written consent of
RDSO, Ministry of Railways.
10.0 Training and Inspection
Inspection of the scoped supply shall be carried out by representative of Engine
Development Directorate at OEM’s manufacturing facility without any additional cost
before shipment for material deliverables. Expenses for travel to and fro to the
Tenderer’s premises, boarding and lodging of the IR personnel shall be borne by IR.
The Tenderer shall be willing to train IR personnel for short and long trainings in the
new technology.
Page 18 of 24
The tenderer shall indicate for each equipment the relevant specification to which the
equipment shall be type tested. If the tenderer is not prepared to conduct any type test
of particular equipment for any reason, it shall be clearly brought out.
The test programme shall be drawn up by the Tenderer in consultation with RDSO.
Type tests of all equipment shall be carried out by the manufacturer at his own
responsibility and cost in OEM’s premises in the presence of a representative of IR.
Such tests may include laboratory/ bench tests.
11.0 Warranty
The supplier shall guarantee that the above kit will be free from all defects in material,
and manufacture. The supplier shall, at his expense, replace any part of the above kit
failing or proving unsatisfactory in service, due to any reason whatsoever, within a
period of 24 months from the date of it’s commissioning into service in the locomotive.
The supplier must effect the replacement under the warranty within 90 days of the
failure and the warranty shall stand extended, by the period that is taken to effect
replacement.
The tenderer will have to provide full technical support with training and updates for a
period of five years after successful installation and commissioning
12.0 Payment Terms
Standard IRS conditions of payment shall be followed.
****************
Page 19 of 24
Annexure-I
ENGINE DATA – 16 CYLINDERS DLW built 251-B ALCO Engine
1. Application Rail traction diesel (Indian Railways,
Broad gauge) 3100,3300 HP, 3600 HP
2. Engine type DLW built 251-B engine
3. No. of cylinders 16
4. Configuration ‘V’
5. Cycle 4 stroke
6. Bore 9”(228.6 mm)
7. Stroke 10.5”(266.7mm)
8. Compression ratio 11.75:1
9. Ratio of con rod length to crank radius 4
10. Fuel injection (at full load)
Spill port closing 22.0 degree CA BTDC
Duration of injection Approx.34 degree CA
Pumps 17 mm plunger dia, 20mm stroke
Nozzles 0.35 mm dia. 9 holes, 157-degree spray
angle, 90-degree tip angle.
11. Firing order 1R 1L, 4R 4L, 7R 7L ,6R 6L, 8R 8L,
5R 5L, 2R 2L, 3R 3L
12. Valves (4 valve head) Air inlet open 72 degrees CA before TDC
Air inlet close 48 degrees CA after BDC
Exhaust open 66 degrees CA before BDC
Exhaust close 66 degrees CA after TDC
Valve dia 7.62 cm
Max. valve lift 2.04 cm
Port diameter 7.40 cm
13. Turbocharger One per engine
14. After cooler Single water-cooled.
NOTE: These figures are indicative and can be used only for approximate guidance
Page 20 of 24
Annexure-II
ENGINE PERFORMANCE DATA AT FULL LOAD- 16 CYLINDERS
DLW built 251-B engine (Mechanical fuel injection system) as available at
RDSO Test Bed-
1. Brake horse Power
3100HP 3300 HP 3600 HP
2. Engine speed 1050 rpm 1050 rpm 1050 rpm
3. BMEP
14.25 bar
approx. 15.75 bar approx. 17.17 bar approx.
4. BSFC 154 gm/BHP hr 154 gm/BHP hr 154 gm/BHP hr
5. Turbo inlet temperature 485ºC (approx.) 500ºC (approx.) 535ºC (approx.)
6. Average cylinder head
exhaust temperature
415ºC (approx.) 415ºC (approx.) 415ºC (approx.)
7. Max. Ambient temp.
Expected
55ºc 55ºc 55ºc
8. Specific air consumption
4.5
kg/sec.approx 6.5 kg/sec.approx. 6.54 kg/sec.approx.
9. Vacuum at compressor
air intake
400 mm H2O-g
approx.
550 mm H2O-g
approx.
10. Compressor outlet
pressor
1.60 bar-g
approx 1.82 bar-g approx. 2.20 bar-g approx
11. Pressure drop across after
cooler
0.1 bar approx. 0.1 bar approx. 0.12 bar approx.
12. Inlet manifold pressure
(engine air gallery)
1.55 bar approx. 1.77 bar approx. 2.02 bar approx.
13. Exhaust pressure before
turbine
1000 mm of Hg
approx 1000 mm of Hg
approx.
1120 mm of Hg
approx.
14. Turbine outlet pressure
(Exhaust)
440 mm H2O g
approx. on
engine test bed
440 mm H2O g
approx. on engine
test bed.
640 mm H2O g
approx. on engine
test bed.
15. Maximum cylinder
pressure
1800 psi. 1850 psi. 1950 psi.
NOTE: These figures are indicative and can be used only for approximate guidance
Page 21 of 24
Annexure-III
TYPICAL INDIAN RAILWAY OPERATING DUTY CYCLE FOR
DIESEL LOCOMOTIVES
NOTCH FREIGHT SERVICE % PASSENGER SERVICE %
Idle 60 49
1st 3 6
2nd
5 7
3rd
3 5
4th
4 4
5th
4 7
6th
5 5
7th
6 5
8th 10 12
Extracted from RDSO report no.-MP-Misc. – 204, Feb. - 2008
Page 22 of 24
Annexure-IV
OPERATING POINT AT VARIOUS NOTCHES FOR ALCO 251B ENGINE
NOTCH
3100 HP 3300 HP 3600 HP
RPM LOAD
(N)
POWER
(HP)
LOAD
(N)
POWER
(HP)
LOAD
(N)
POWER
(HP)
8 th
10503 2160050 3100 2299750 3300 2506550 3600
7th 9503 1908250 2500 2031650 2640 2216350 2880
6th 8503 1601850 1870 1702950 1980 1857750 2160
5th 7503 1382650 1430 1447550 1485 1597150 1620
4th 6503 1061650 950 1113550 990 1214750 1080
3rd
5503 813850 615 877350 660 957050 720
2nd
4503 547150 330 536150 330 584850 360
1st 3503 298450 145 333650 165 376050 180
Idle 3503 213150 105 213150 105 213150 105
NOTE: These figures are indicative and can be used only for approximate guidance
Page 23 of 24
Annexure-V
DATA ACQUISITION SYSTEM OF TEST BED
(a) AVL test commander, capable of real time only measurements on 176 channels,
controls the engine. The test commander controls the dynamometer coupled to the
diesel engine. Different parameters like speed, load, torque, power, temperature and
pressure at various critical location of engine are measured and recorded. The test
commander operates on “Window NT” operating system with “PUMA 5” engine
monitoring and testing software.
(b) The high-speed data acquisition system (HSDA) of M/s AVL is used to measure online
high-speed parameters of engine such as Cylinder pressure, Fuel line pressure, Injector
needle lift etc.
(c) AVL frequency based fuel balance measures the online Brake Specific Fuel
Consumption and rate of fuel flow. Fuel leak-off is measured separately. The rate of
leak off amount is subtracted from the rate of fuel flow to get the exact consumption of
fuel.
Page 24 of 24
Annexure-VI
VALVE TIMING DIAGRAM FOR STIFFER UNIT CAMSHAFT