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Page 1: EMD Loco Shubhranshu BNC2009
Page 2: EMD Loco Shubhranshu BNC2009

GM-EMD LOCOMOTIVES

ShubhranshuChief Motive Power Engineer/DieselSouth Western Railway

Page 3: EMD Loco Shubhranshu BNC2009

SCHEME OF PRESENTATION

• Brief History

• Specifications and features

• How it Works

• Performance in the Field

• Recent Developments

Page 4: EMD Loco Shubhranshu BNC2009

EMD LOCOMOTIVESA BRIEF HISTORY

Page 5: EMD Loco Shubhranshu BNC2009

DIESEL TRACTION– A Journey

- 1961 Setting-up of DLW

- 1964 First Diesel Locomotive with DC-DC traction arrangement

- 1994 Introduction of AC-DC technology

- 1999 Introduction of EMD Locos AC-AC technology with GTO based TCC’s

- 2006 Introduction of AC-AC technology with IGBT based TCC’s

Page 6: EMD Loco Shubhranshu BNC2009

EMD MILESTONES IN INDIA

127 YDM3 Locomotives in 1961 – at Sabarmati

Page 7: EMD Loco Shubhranshu BNC2009

EMD MILESTONES IN INDIA

72 WDM4 Locomotives in 1961 at MGS

Page 8: EMD Loco Shubhranshu BNC2009

EMD MILESTONES IN INDIA

Contract for 21 EMD Loco’s GT46MAC signed in 1995The First WDG4 with EMD Colour Scheme

Page 9: EMD Loco Shubhranshu BNC2009

EMD MILESTONES IN INDIA

The First WDP4- 2002

Page 10: EMD Loco Shubhranshu BNC2009

EMD MILESTONES IN INDIA

DLW sets-up a State of the Art Technology Centre in 1996

Page 11: EMD Loco Shubhranshu BNC2009

EMD MILESTONES IN INDIA

First WDG4 made indigenously in DLW in 2000

Page 12: EMD Loco Shubhranshu BNC2009

EMD MILESTONES IN INDIA

First WDP4 made indigenously in DLW - 2003

Page 13: EMD Loco Shubhranshu BNC2009

EMD MILESTONES IN INDIA

First 4500hp IGBT WDG4 made in DLW in 2006. Also known as GT46ACe

Page 14: EMD Loco Shubhranshu BNC2009

TRANSFER OF TECHNOLOGY

• GM-EMD selected after a world-wide search through Global Tender

• Contracts signed in October 1995

– For supply of 13 Assembled and 8 PKD kits for

assembly at DLW

– Transfer of Technology for design, manufacture

and maintenance of GT46MAC locos and Family

of 710 series of Diesel Engines

Page 15: EMD Loco Shubhranshu BNC2009

DIESEL LOCOMOTIVE WORKS

Page 16: EMD Loco Shubhranshu BNC2009

TRANSFER OF TECHNOLOGY- SCOPE

• DURATION: 10 YEARS FROM JAN `96

• FOR GT 46 MAC LOCOMOTIVES AND FAMILY OF

710 ENGINES ( 3000 HP, 4000 HP AND 5000 HP)

• FOR ALL ITEMS MADE IN-HOUSE BY GM

• TRAINING OF INDIAN RAILWAYS PERSONNEL IN– SYSTEM INTEGRATION DESIGN

– MANUFACTURE OF LOCOMOTIVES

– MAINTENANCE OF LOCOMOTIVES

• MUTUAL EFFORTS FOR SUPPL DEVELOPMENT

Page 17: EMD Loco Shubhranshu BNC2009

MODALITIES FOR TOT ABSORPTION

• Training of IR personnel in GM-EMD factories in USA and Canada

• Training by GM-EMD experts in India – DLW and Hubli

• Supply of Documents – Drawings/Specs

• GT46 MAC manufacturing video tapes

• Teleconferences

Page 18: EMD Loco Shubhranshu BNC2009

GT46MAC

Single Cab

Turbocharged16 Cylinder

Full Width Cab

A C

GT46 - A VARIANT OF SD70

Page 19: EMD Loco Shubhranshu BNC2009

DC-DC TRACTION

• The prime mover, i.e., Diesel engine drives an electric generator directly coupled to it and produces direct current output.

• The traction motors are of direct current type and are supplied the DC output of the electric generator.

• Thus the generation as well as utilisation ends deploy DC machines in this system.

Page 20: EMD Loco Shubhranshu BNC2009

DC-DC TRACTION - DISADVANTAGES

• Not amenable to high degree of control of traction characteristics.

• Maintenance intensive electrical machines

• Lower reliability

• Commutator-carbon brush system

• Heavier Equipment

Page 21: EMD Loco Shubhranshu BNC2009

AC-DC TRACTION

• In this system, the generator was replaced with an alternator.

• The maintenance requirements at the generation end were brought down considerably.

• This facilitated the development of higher capacity locomotives without much increase in size.

• However, the utilisation end still posed a constrained wherein DC motors were still in use.

Page 22: EMD Loco Shubhranshu BNC2009

AC-AC TRACTION

• AC machines introduced both at the generation end and the utilisation end.

• Made possible with advances in power electronics, which led to development of high capacity switches with very precise control.

• Deploys variable voltage, variable frequency system to meet all the traction needs.

• Initial locos were equipped with GTO based traction control converters for converting the DC into controlled AC supplies.

Page 23: EMD Loco Shubhranshu BNC2009

EMD LOCOMOTIVESSPECIFICATIONS AND

FEATURES

Page 24: EMD Loco Shubhranshu BNC2009

BASICS

• 710 G3B type 16 cylinder, 2-stroke diesel engine• Main Computer- EM2000• Computer controlled traction system• Computer controlled Brake system• High adhesion• Fuel efficient• Low maintenance

Page 25: EMD Loco Shubhranshu BNC2009

Continued….

• High adhesion levels – controlled creep >> high tractive effort

• Excellent dynamic brake

• High availability and reliability

• Operator friendliness

• Ergonomic control stand

• Fool-proof, non-fatiguing computer control alerter system

• Sealed twin beam headlight

• Easy interaction and guidance for trouble shooting (through EM2000)

• Ease of verification of safety devices

Page 26: EMD Loco Shubhranshu BNC2009
Page 27: EMD Loco Shubhranshu BNC2009
Page 28: EMD Loco Shubhranshu BNC2009
Page 29: EMD Loco Shubhranshu BNC2009

Unit exchange type Power assembly

Page 30: EMD Loco Shubhranshu BNC2009

BENEFITS OF GM LOCO

• Lower Maintenance means smaller

shed infrastructure

• Fewer locos mean fewer running staff

• Higher HP and tractive effort mean

longer and faster trains

• Longer trips mean greater operational flexibility

Page 31: EMD Loco Shubhranshu BNC2009

MAIN FEATURES

• AC-AC Traction

• High Tractive Effort due to state of the art Creep Control

• 4000hp – 54t Tractive Effort

• Highly effective Dynamic Braking System available up to near stand still.

• High Fuel Efficiency, Low Lube Oil Consumption

• Longer trips – 90 days

Page 32: EMD Loco Shubhranshu BNC2009

The locomotive is designed to achieve:

• Maximum stall starting torque of 54 Tonnes.

• Maximum dynamic braking effort of 27 Tonnes.

• The despatchable adhesion of 43%.

• Very low engine idle RPM 200.

• Higher fuel and lube efficiencies

• Low Maintenance requirement

MAIN FEATURES

Page 33: EMD Loco Shubhranshu BNC2009

• On-board fault diagnosis system and fault recording system.

• Computer controlled brake system with facility for self testing and self diagnostic features.

• On-board self test feature for working of important loco systems like relays and contactors, fans, blowers etc.

• Self test feature for ‘Available Traction Power’ from the locomotive through ‘Self Load Test’.

MAIN FEATURES (contd..)

Page 34: EMD Loco Shubhranshu BNC2009

• Sturdy, Bolsterless bogie design with Huck fastening arrangement leaving the undertruck virtually maintenance free.

• Use of hydraulic dampers ensures good ride index and availability of yaw dampers ensures smooth running at high speeds.

• Amenable for upgradation to haul longer trains in undulating terrains with installation of IDP or LOCOTROL Systems.

MAIN FEATURES (contd..)

Page 35: EMD Loco Shubhranshu BNC2009

WDG4/WDP4 locomotives are equipped with 4000HP, 2 stroke Turbocharged diesel engines.

Locomotive consists of four microprocessors.

1. One loco control computer EM2000

2. Two Traction computers ASG

3. One Air brake computer CCB

Page 36: EMD Loco Shubhranshu BNC2009

1) Head light2) Inertial Filter Air Inlet3) Starting Fuse and Battery Knife Switch4) Handrails5) Cooling System Air Inlet6) Radiator and Fan Access7) Coupler “E” Type8) Sanding Box (8)

9) Jacking Pads (4)10) Wheels (6)11) Fuel Tank12) Compressed Air System Main Reservoirs13) Battery Box14) Trucks (3 axle 3 motor HTSC type) Qty. 215) Underframe16) Dynamic Brake Grids17) Dynamic Brake Fans (2)

GT46MAC - LAYOUTGT46MAC - LAYOUT

Page 37: EMD Loco Shubhranshu BNC2009

14. Primary Fuel Filter15. Air Compressor16. Radiators17. AC Radiator Cool. Fans (Qty. 2)18. Draft Gear19. Compressor Filter20. Lube Oil Filter Tank21. Lube Oil Strainer22. Lube Oil Sump23. Main Generator Assembly24. No.1 Elect. Cntrl. Cab’t Air Filt.25. Traction Motors (Qty. 6)

1. #1 Electrical Control Cabinet2. Fuel Pump3. Engine Starting Motors (Qty. 2)4. Traction Control Cabinet5. Traction Motor Cooling Blower6. Main Gen. Assembly Blower7. Engine Exhaust Stack8. Engine Exhaust Manifold9. Diesel Engine10. Governor11. Engine room Vent12. Engine Water Tank13. Lube Oil Cooler

GT46MAC - LAYOUTGT46MAC - LAYOUT

Page 38: EMD Loco Shubhranshu BNC2009

EMD LOCOMOTIVESHOW IT WORKS

Page 39: EMD Loco Shubhranshu BNC2009

THE ENGINE – 710G3B

Page 40: EMD Loco Shubhranshu BNC2009

ENGINE ROOM

Page 41: EMD Loco Shubhranshu BNC2009

THE ENGINE

16 Cylinder two stroke 45 degrees V Engine.

Compression ration 1:16.

Swept volume 710 cubic inches.

Engine control through Woodward Governor.

Equipped with mechanical unit injectors.

Unit replacement facility for power assemblies.

No valve seat inserts

Page 42: EMD Loco Shubhranshu BNC2009

SALIENT FEATURES

710 G3B ENGINE

710 cu indisplacement

Turbo Model G Railroad Application

16 cylinders

Page 43: EMD Loco Shubhranshu BNC2009

THE ENGINE

• Engine Model(s): 710G3B• Number of Cylinders: 16• Engine Type: Two-Stroke, Turbocharged• Cylinder Arrangement: 45° “V”• Compression Ratio: 16:1• Displacement per Cylinder: 710 Cu inches (11 635 cc)• Cylinder Bore: 230.19 mm (9-1/16”)• Cylinder Stroke: 279.4 mm (11”)• Rotation (Facing Flywheel End): Counterclockwise• Max. Speed: 904 RPM• Normal Idle Speed: 269 RPM• Low Idle Speed: 200 RPM

Page 44: EMD Loco Shubhranshu BNC2009

710 G3B ENGINE

DIRECTLY DRIVES

- TRACTION ALTERNATOR

- COMPANION ALTERNATOR

- AUXILIARY GENERATOR

- AIR COMPRESSOR

- TRACTION MOTOR BLOWER

Page 45: EMD Loco Shubhranshu BNC2009

ENGINE SCHEMATIC

Page 46: EMD Loco Shubhranshu BNC2009

PISTON AND CON-ROD

Cast Steel PistonsSimple DesignSplash Lubrication

Page 47: EMD Loco Shubhranshu BNC2009

CYLINDER LINER

Cast IronLaser Hardened Water JacketedSide Ports for 2-stroke Design

Page 48: EMD Loco Shubhranshu BNC2009

GEAR TRAIN

Page 49: EMD Loco Shubhranshu BNC2009

THE CRANKSHAFT

Page 50: EMD Loco Shubhranshu BNC2009

THE CRANKSHAFT

Page 51: EMD Loco Shubhranshu BNC2009

TRACTION ALTERNATOR

Out put voltage ranges from 600 to 2600 Volts.

Consists of two independent stator windings and a rotating field common to both the windings.

AC output rectified to DC by rectifier banks and permanently connected in series.

The output of traction alternator is used only for traction power.

Page 52: EMD Loco Shubhranshu BNC2009

COMPANION ALTERNATOR

Built in the same housing of the traction alternator but electrically independent.

Rated at 250 KVA - produces maximum of 230 volts at 900 engine rpm.

Output is used to drive Radiator fans, exciting Traction alternator field and other AC blower motors.

Page 53: EMD Loco Shubhranshu BNC2009

Engine power is generated based on the following signals :

Barometric measure.Engine protection power limit (Dirty engine air filters).Turbo over speed power limit (surges)Engine overload protection limit through load regulator of Woodward Governor.Engine temperature power limit based on temperature signal from Engine temperature probes.

Page 54: EMD Loco Shubhranshu BNC2009

TRACTION CONTROL CABINET

– ONE INVERTOR PER BOGIE

– CONVERTS DC INTO VARIABLE VOLTAGE VARIABLE FREQUENCY 3-PH POWER FOR TRACTION MOTORS

– CONVERTS AC FROM DYNAMIC BRAKING INTO DC

– SIBAS 16 TRACTION CONTROL COMPUTER

Page 55: EMD Loco Shubhranshu BNC2009

TRACTION CONTROL COMPUTER

Page 56: EMD Loco Shubhranshu BNC2009

TCC COMPUTER

• This computer controls the actions of traction control converter.

• It interacts with the main locomotive control computer, i.e., EM 2000 through RS 485 serial link.

• The control of traction power is established through this computer in coordination with EM 2000. It also monitors various other parameters like temperature of various components, voltages, current, status of relays etc.,

• The computer performs all these functions through a set of 28 electronic modules. Each electronic module performs different functions & monitor different parameters.

Page 57: EMD Loco Shubhranshu BNC2009

• Two GTO based traction control converters for inverting the DC output of main generator into controlled AC supply for traction motors.

• Six AC traction motors in GT46MAC and 4 AC traction motors in GT46PAC locos at the utilisation end.

Page 58: EMD Loco Shubhranshu BNC2009

GATE UNITS & PHASE MODULES

The units actually involved in the process of inverting DC into AC

Page 59: EMD Loco Shubhranshu BNC2009

THE AC-AC SYSTEM OF EMD LOCOS

Page 60: EMD Loco Shubhranshu BNC2009

DC LINK CAPACITORS

Ensures constant DC voltage supply to Inverters

Page 61: EMD Loco Shubhranshu BNC2009

TRACTION MOTOR Four pole, 3-phase AC squirrel cage

induction motor.

Eliminates complexities of commutator, brushes and brush holders of DC motors.

AC motors eliminates the requirement of conventional transition systems.

Rugged and virtually maintenance free. Overhauling periodicity at 6 years.

Externally cooled nose suspended.

Sensors for speed and temperature measurements.

Oil lubricated bearing at the drive end.

Grease lubricated sealed bearing at non drive end.

Page 62: EMD Loco Shubhranshu BNC2009

AC Traction Motor

vs

DC Traction Motor

Size is considerablysmaller

Much simpler

Coupled with suitablecontrol system givessuperior traction

Page 63: EMD Loco Shubhranshu BNC2009

THE LOCO CONTROLLER

EM2000 Computer

Page 64: EMD Loco Shubhranshu BNC2009

EM 2000 COMPUTER- FEATURES

Uses a 32 – bit microprocessor.

Information can be downloaded to a lap top computer.

Flexible and expandable to accommodate future system enhancements.

Complete self – diagnostics.

Archived unit history data.

Provides self test feature.

Page 65: EMD Loco Shubhranshu BNC2009

EM 2000• The main locomotive control computer. Interacts with the

two Traction Controller Computers and the CCB computer.

• Important functions

– Traction alternator excitation control.– Monitoring position of various control devices– Displays various data which includes fault related information,

running totals, locomotive details etc.

• Data interchange through DIO and ADA Cards.

• Interacts with other computers through COM cards.

Page 66: EMD Loco Shubhranshu BNC2009

EM 2000 BLOCK DIAGRAM

Page 67: EMD Loco Shubhranshu BNC2009

EM2000 - Features

EM2000 helps conduct

Self load test without an external load box wherever and whenever required.

Contactors and relay test for self diagnostics

Blower motor test.

Excitation test of main generator field and its controls.

Air brake self test.

Page 68: EMD Loco Shubhranshu BNC2009

EM2000 – Safety Features

Alerter vigilance control system.Opposite direction brake.Automatic sanding of wheels for correcting

wheel slips.Automatic emergency braking to prevent

overspeeding.Tractive effort limiting feature while passing over

weak bridges and tunnels.Locked wheel/slipped pinion detection.

Page 69: EMD Loco Shubhranshu BNC2009

EM 2000 INTERACTION

Page 70: EMD Loco Shubhranshu BNC2009

CONTROL CONSOLE

Page 71: EMD Loco Shubhranshu BNC2009

DIAGNOSTIC DISPLAY PANEL

• It is the display unit of EM 2000 wherein the required parameters & fault messages are displayed.

• It also accepts inputs through the keys provided on the display.

• It is used by maintenance & operational people for interacting with EM 2000.

Page 72: EMD Loco Shubhranshu BNC2009

DDS

Page 73: EMD Loco Shubhranshu BNC2009

ENGINE CONTROL PANEL

Page 74: EMD Loco Shubhranshu BNC2009

LOCOMOTIVE TRUCK ASSEMBLY

Page 75: EMD Loco Shubhranshu BNC2009

HTSC BOGIE

High Tensile Steel Cast Bogie

Page 76: EMD Loco Shubhranshu BNC2009

Bolster-less design

Supports the weight of the loco and transfers traction to rails

Loco weight is transferred directly to bogie frame through secondary rubber springs.

Three AC Traction Motors

Although the frame itself is rigid, the design allows the end axlesto move or "yaw" within the frame.

This movement will allow the wheels toposition themselves tangent to the rails on curves for reduced wheel and rail wear.

LOCOMOTIVE TRUCK ASSEMBLY

Page 77: EMD Loco Shubhranshu BNC2009

LOCOMOTIVE TRUCK ASSEMBLY

• Uniform traction motor orientation and stiff secondary suspension improves weight transfer within the bogie for optimal adhesion.

• Primary suspension with coil springs for good ride quality.

• Secondary rubber springs (pads) also permit yaw on curves

• Provision of yaw dampers & vertical shock absorbers for better ride quality and stability at higher road speeds.

• Reduced no. of wear rubbing surfaces for extended maintenance intervals.

Page 78: EMD Loco Shubhranshu BNC2009

AIR BRAKE SYSTEM

– KNORR-NYAB CCB

– COMPUTER BASED ELECTROPNEUMATIC

– INTERFACE WITH EM 2000

– SUPPORTED IN INDIA BY KBI

Page 79: EMD Loco Shubhranshu BNC2009

CCB

Page 80: EMD Loco Shubhranshu BNC2009

CCB COMPUTER

• It is an electro pneumatic micro processor based system.

• The CCB computer is also known as computer relay unit. Other units of CCB are known as voltage conditioning unit (VCU) and pneumatic control unit (PCU).

• The control of braking system is established through CCB computer directly with inputs by the Loco Pilot through the brake controller.

• CCB communicates with EM 2000 through RS 485 serial link for displaying the data & recognising demands put by EM 2000 on CCB system based on the inputs by the driver.

Page 81: EMD Loco Shubhranshu BNC2009

BATTERY CHARGING SYSTEM

• The locomotive is equipped with an AC Auxiliary Generator rated at 18 KW at 55V AC.

• The 3-phase 55V AC output is rectified through a full wave rectifier assembly to obtain 74V DC output for charging of batteries.

• The output regulation of Auxiliary Generator is established through a digital voltage regulator module which controls the current flow to the field winding of Auxiliary Generator.

Page 82: EMD Loco Shubhranshu BNC2009

STARTING SYSTEM

• The locomotive is equipped with two dedicated starting motors which come into action only at the time of cranking the engine.

• The starting motors get their power supply from the batteries of the locomotive through starting contactors.

• Charging of the batteries is accomplished through an Auxiliary Generator directly coupled to the diesel engine.

Page 83: EMD Loco Shubhranshu BNC2009

• STARTING MOTORS

Two series wound DC motors operating at 64V.

Starting current 800 Amps.

Running current 77-120 Amps.

Page 84: EMD Loco Shubhranshu BNC2009

EMD LOCO - SPECIAL FEATURES

• AC-AC Traction

• High Tractive Effort due to state of the art Radar-based Creep Control

• 4000hp – 54t Tractive Effort

• Highly effective Dynamic Braking System available up to near stand still.

• High Fuel Efficiency, Low Lube Oil Consumption

• Longer trips – 90 days

Page 85: EMD Loco Shubhranshu BNC2009

RADAR ASSEMBLY

Radar Transceiver

Looks at the ground and detects mismatchbetween the linear speed and the rotational speed of wheel

Ensures limited creepof wheel on rails

Page 86: EMD Loco Shubhranshu BNC2009

RADAR ASSEMBLYLooks down at the ground and compares the linearspeed of the loco with the Rotary speed of the wheels

Controlled creep of wheels on rail maximizes adhesionand makes it possible to utilise maximum torque of traction motor for traction

Page 87: EMD Loco Shubhranshu BNC2009

ENHANCED DYNAMIC BRAKES

Dynamic Braking Effort of 27 t

Available up to near stand-still

Makes operations on steep gradients safer & economical

Page 88: EMD Loco Shubhranshu BNC2009

(WHEEL) CREEP CONTROL

The locomotive radar interacts with the loco computer.

Two sub functions

Wheel Creep Control - operates at all times in motoring and dynamic braking.

Improves tractive effort under adverse rail conditions (wet or oily rails) by adjusting wheel speed to maximize motor torque.

Enables the wheel to rotate at a rate slightly faster than ground speed.

Page 89: EMD Loco Shubhranshu BNC2009

(WHEEL) CREEP CONTROL

Second Function

Wheel Slip Control - operates if a wheel creep control failure occurs (radar failure, for example) or if rail conditions are too poor for successful wheel creep control.

The locomotive computer selects the appropriate wheel control to suit the operating conditions. It also applies sand if severe rail conditions exist.

Operation of the wheel control function may cause the control console WHEEL SLIP indicator to flash or light steadily.

Page 90: EMD Loco Shubhranshu BNC2009

PERFORMANCE

Page 91: EMD Loco Shubhranshu BNC2009

Greater requirements of traffic

Heavier and longer trains

Less time for maintenance - more utilization

Increase in Horse Power by several modifications

Page 92: EMD Loco Shubhranshu BNC2009

EMD LOCOS IN THE FIELD

Page 93: EMD Loco Shubhranshu BNC2009

COMPARE WITH WDM2

WDM2 GM LOCO

• Availability 81% >90% • Trip Schedule 7-10 days 90 days

• Starting Adhesion 27% 42%

• Starting Tract Effort 30.4 t 54 t

Page 94: EMD Loco Shubhranshu BNC2009

COMPARE WITH WDM2

WDM2 GM LOCO

• Balancing Speed (kmph)(4700t-level) 59 85

• Lube Oil Consumption (% of Fuel) 1.5 0.5

• SFC (gm/BHP Hr) 166 151

• Dynamic Breaking 48% applicable at all speeds

Page 95: EMD Loco Shubhranshu BNC2009

COMPARE WITH OTHER LOCOS

STARTING LOAD ON 1/150 GRADIENTCLASS LOAD

BOXN TONNES

WDM 2 33 2700

WDG 2 47 3850

WAG 5 38 3110

WAG 7 46 3767

WAG9 52 4258

WDG4 58 4750

Page 96: EMD Loco Shubhranshu BNC2009

COMPARISON OF WDG3A , WDG4 & WAG9

DescriptionDescription WDG3AWDG3A WDG4WDG4 WAG9WAG9

Length (Mtrs.)Length (Mtrs.) 19.1319.13 21.2421.24 20.620.6

Weight in TonsWeight in Tons 123123 126126 123123

Brake SystemBrake System PneumaticPneumatic Micro processorMicro processor Pneumatic/Pneumatic/

micro processormicro processor

HPHP 31003100 40004000 60006000

Starting Tractive effortStarting Tractive effort 398398 570570 520520

Continuous TEContinuous TE 313313 400400 325325

Slip controlSlip control Wheel Slip relay Wheel Slip relay controlcontrol

ComputerisedComputerised Relay control/Relay control/

ComputerisedComputerised

Starting capability in Starting capability in 1/200 gradient1/200 gradient

44004400 51905190 47004700

Page 97: EMD Loco Shubhranshu BNC2009

COMPARISON IN THE FIELD

PARAMETERS KSRA-IGP Ghat in CRly * QLM-CLR Ghat in S.W.Rly

Distance 15.95 km 26 km

Gradient 1 in 37 1 in 37

Curves Maximum of 5° Maximum of 7.8°

Load 59 BOXN loaded to CC+4t+2t

59 BOXN loaded to CC+8t+2t

Operational Speed

35 Kmph 40 Kmph

Locos Used 3xWAG7 leading + 3xWAG7 banking

2xWDG4 leading +3xWDG4 banking

Total HP 30,000 HP 20,000 HP*CRS/Central Circle Letter no. C-11(140)96-225 dated: 21-5-07

Page 98: EMD Loco Shubhranshu BNC2009

THE BRAGANZA GHAT (CLR-KLM)

Page 99: EMD Loco Shubhranshu BNC2009
Page 100: EMD Loco Shubhranshu BNC2009

HASSAN-MANGALORE LINE

Page 101: EMD Loco Shubhranshu BNC2009

SKLR-SBHR GHAT SECTION

Page 102: EMD Loco Shubhranshu BNC2009

GHAT OPERATIONS – UP THE GRADIENT

Earlier traction arrangement with ALCO (WDG-3)

3L + 44W + 3L + 14W + 2L

Current Traction arrangement with EMD (WDG-4)

2L + 59W + 3L

Page 103: EMD Loco Shubhranshu BNC2009

GHAT OPERATIONS – DOWN THE GRADIENT

Earlier traction arrangement with ALCO (WDG-3)

3L + 58W

Current traction arrangement with EMD (WDG-4)

5L + 59W

Page 104: EMD Loco Shubhranshu BNC2009

MOST DIFFICULT

Page 105: EMD Loco Shubhranshu BNC2009

MOST DEMANDING

Page 106: EMD Loco Shubhranshu BNC2009

AND THE MOST BEAUTIFUL

Page 107: EMD Loco Shubhranshu BNC2009

EMISSION STANDARDS• The 710 engine is NOx-reduction friendly

– NOx reduction is less than comparable four-stroke engines

– Exhaust gas recirculation reduces NOx with minimal fuel consumption increase

• Particulate matter is reduced through reducing oil consumption and improving combustion

• Bottom Line: EMD’s 710 engine has met every new set of emissions standards– UIC II (2003), EPA Tier 2 (2005)

– The 710 engine was the first locomotive engine to have EU Stage IIIA type approval

Page 108: EMD Loco Shubhranshu BNC2009

RECENT DEVELOPMENTSin

EMD LOCOMOTIVES

Page 109: EMD Loco Shubhranshu BNC2009

GTO TO IGBT UPGRADE

• Switchover to IGBT from GTO Thyristors

• IGBT overcomes following shortcomings of GTO

– Bulk

– Need for Excessive Cooling, Chlorinated coolants

– Slower Switching, need for absolute surge protection

– Prone to Failures, very expensive

• Insulate Gate Bipolar Transistor (IGBT)

– Provides high frequency switching

– More rugged/reliable

– Compact

– Purer sinewave

Page 110: EMD Loco Shubhranshu BNC2009

UPGRADE to 4500hp

• Achieved without any additional costs

• First 4500 Loco WDG4 (12114) made with EMD IGBT modules in May 2007

• Provides sustained high tractive effort for considerably longer than 4000hp locos.

• New Indigenous efforts have yielded encouraging resuts.

• First indigenously developed 4500hp IGBT based loco with traction convertors from M/S Medha, Hyderbad

• Commissioned in Dec 2008. WDG4 -12169

• ENABLES SINGLE-HEADING IN BORDERLINE CASES OF HEAVY LOAD, PREVENTS STALLING

Page 111: EMD Loco Shubhranshu BNC2009

ADVANTAGES OF 4500 HP WDG4

• LATEST UPGRADE MAKES IT POSSIBLE TO ACHIEVE 4500hp WITHOUT ANY ADDITIONAL COSTS

PROVIDES HIGHER PROVIDES HIGHER TRACTIVE EFFORT EVEN TRACTIVE EFFORT EVEN AFTER STARTING, UP TO AFTER STARTING, UP TO 15 kmph – 15 kmph – AN INNOVATION IN AN INNOVATION IN TRACTION CONTROL TRACTION CONTROL

4500 hp enableS WDG4 operations with 2+2 configuration without stalling in SKLR-SBHR Section.

Earlier need was 6+6 ALCO

Page 112: EMD Loco Shubhranshu BNC2009

INDIGENOUS TCC/LCC

Special Enabling Features of Medha

• LCC – MS696 – REPLACES EM2000

• INDIVIDUAL AXLE CONTROL – ONE PER MOTOR

• DISTRIBUTED POWER CONTROL (LOCOTROL)

• HOTEL LOAD

• OPTICAL FIBER COMM – BETTER REIABILITY

• HEAT TUBE COOLING INSTEAD OF EVOPARTIVE

• INTEGRATED EVENT RECORDER

• IDENTICAL TO THE EMD DESIGN IN DRIVER INTERFACE

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ALCO IS NOT FAR BEHIND

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UPGRADES ON ALCO

• UPGRADED POWER FROM 2600hp to 3300hp

• MICROPROCESSOR CONTROL OF EXCITATION AND LOCO SYTEMS

• MICROPROCESSOR BASED ENGINE GOVERNOR

• LCD GAGE PANEL

• ENABLED FOR DISTRIBUTED POWER/LOCOTROL

• REMOTE MONITORING – GPRS BASED

• END OF TRAIN TELEMETRY

• POWER SETTER FOR MU OPERATIONS ECONOMY

• INTELLIGENT LOW IDLE – FUEL ECONOMY

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ALCO LOCOS ARE NOW INTELLIGENT MACHINES

General Electric

MedhaSiemens

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MEDHA MEP 660 Microprocessor based diesel loco control

system: Loco No 13037

TFT LCD panel on control desk for communication with the loco pilots

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Maintenance

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MAINTENANCE AND TRAINING

• Diesel Shed at Hubli – 162 (153 G4, 9 P4)

• Diesel Shed at KJM – 36 P4 (Also homes ALCO)

• Diesel Loco Service Centres – Hospet, Sakleshpur

• Elsewhere on IR – Siliguri, Sabarmati

• Also being planned at

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DIESEL SHED - UBL

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• Trip Schedules: 30/90 Days

• Six Monthly Schedules

• Annual Schedules– Primarily Filter Change, Consumables, Bogies,

Compressor, Wheel Turning, Carbon Brushes

• Six Yearly – The first major schedule– Change of Power Assemblies, turbo,

Crankshaft Main Bearings etc.

DIESEL SHEDS – UBL, KJM

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TRAININGA well equipped training school

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LOCO SIMULATOR

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SIMULATOR – TRAINING ROOM

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TRAINING MODELS

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TRAINING MODELS

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PLANS OVER IR

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AND FINALLY

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UNITED COLOURS OF EMD

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UNITED COLOURS OF EMD

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UNITED COLOURS OF EMD

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UNITED COLOURS OF EMD

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UNITED COLOURS OF EMD

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THANK YOU