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  • R.D.S.O

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    GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

    SPECIFICATION FOR

    UP-GRADATION OF 4500 HP DUAL CAB HHP LOCOMOTIVES

    Specification No. MP.0.08.00.112 (Revision - 00)

    August’ 2016

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  • Specification for Up-gradation of HHP Locomotives

    Motive Power Directorate Spec No. MP.0.08.00.112 (Rev.00) of August 2016 Page 1 of 12

    SPECIFICATION FOR UP-GRADATION OF HHP LOCOMOTIVES

    1. Introduction DLW has produced approximately 1300 Nos. of HHP locomotives (WDG4/WDP4/WDP4B/WDP4D/WDG4D) since 1998 and these locomotives are being manufactured with AC-AC traction equipment and control system along with features provided by M/s EMD under ToT during 1995-96. In the last 15-20 years, lot of new engineering concepts evolved by the world leaders like M/s GE and M/s EMD in the high horse power low speed diesel engine locomotives. All the latest generation locomotives in the world are built with new features like Inverter driven Auxiliaries, separate After cooling, low lube oil consumption power assemblies, Modular integrated control cabinet system (E-locker), Electronic Fuel Injection (EUI) etc. There is need to bridge the gap between the HHP locomotives currently built in DLW and the state of art locomotive produced by leading Diesel loco builders of the world to achieve better fuel economy and improved reliability.

    2. Proposed up-gradation of the HHP locomotive & benefits for the IR RDSO studied the latest new engine technology and proven out concepts available worldwide and had deliberations with M/s EMD, the original ToT partner of HHP locomotives to evolve the up gradation of the HHP locomotives built at DLW. Accordingly, a proposal for adapting advance and upgraded features as given below for achieving fuel economy, emissions & energy management for traction application.

    New technological advancement proposal for adoption

    Benefits for Indian Railways

    TA17-CA9 combination along with E-locker with DIALS • Auxiliary Power Converter(APC) • Inverter Driven Blowers &

    cooling Fans

    1. Inverters driven Auxiliaries will reduce the parasitic load and help in improve the Traction Specific Fuel consumption. This will improve the fuel economy of the locomotive by 2% approx.(dependent on duty cycle and maintenance)

    2. The E-Locker will replace the complex Five (ECC1, 2, 3 and 2-TCCs) cabinet system of current Dual Cab locomotive. This creates more space and will save manufacturing/Integration work of DLW.

    3. The number of components will be reduced, which will improve the reliability and availability of the locomotive.

    4. The APC will increase the capacity of the Auxiliary systems by 80% approx. which provides capacity for additional auxiliary equipment (for future).

    Engine Improvements: • Electronic Fuel Injector (EUI)

    1. The combustion of EUI and separate after cooling will improve the fuel economy by 2% approx.(dependent on duty cycle and

  • Specification for Up-gradation of HHP Locomotives

    Motive Power Directorate Spec No. MP.0.08.00.112 (Rev.00) of August 2016 Page 2 of 12

    • Separate After Cooling • Low Lube Oil consuming Power

    assemblies • High efficiency Hybrid air

    filtration

    maintenance) 2. The Emission level of Tier-1 can achieve easily

    with optimum fuel economy. 3. The Emission level up to Tier-3 can be

    achievable with minor fuel penalty. 4. Lube oil Consumption will reduce by 50% approx. 5. Compliance for desert and mines application.

    CAB • NVH standard

    As per 49 CFR to comply future noise norms of India

    Condition Monitoring System for improving reliability (RAMS)

    Provision of on board condition monitoring and fault diagnostics system with Video recording in CAB to help investigation and ensuring system health.

    This specification intends to specify the requirements for adapting advance and upgraded features as mentioned above will enable HHP locomotive (WDG4D/WDP4D) more fuel economy, emissions & energy management for traction application.

    3. Design and details of modifications Existing design of WDP4D/ WDG4D locomotive shall be suitably modified to accommodate items of up-gradation kit with a new General Arrangement, duly incorporating the proposed changes.

  • Specification for Up-gradation of HHP Locomotives

    Motive Power Directorate Spec No. MP.0.08.00.112 (Rev.00) of August 2016 Page 3 of 12

    CHAPTER – 2

    Sl.No. Items Specification

    WDP4D

    WDG4D

    1. General / Design Data

    General arrangement and Equipment layout

    The general arrangement and equipment layout of the locomotive shall be jointly worked out by RDSO, DLW and the firm based on the envelope of the additional equipment offered.

    The general arrangement and equipment layout of the locomotive shall be jointly worked out by RDSO, DLW and the firm based on the envelope of the additional equipment offered.

    Diesel Engine (Data as per UIC 623) 4500 HP DLW/EMD 16 cylinder 710G3B 4500 HP DLW/EMD 16 cylinder 710G3B

    Installed power/ input to traction under site conditions 4500/4000 HP 4500/4000 HP

    Bogie Fabricated hybrid bogies similar to WDG5 Fabricated hybrid bogies similar to WDG5

    Gauge 1676 mm 1676 mm Axle-load & arrangement 20.5 T/ Co-Co 21.7 T/ Co-Co Weight in working order 123 T 130.2 T

    Sharpest curve to be negotiated Single unit without buffer Double unit with buffer

    174m radius and 1 in 8½ turnout in either direction.

    174m radius and 1 in 8½ turnout in either direction.

    Locomotive Speed :Maximum/Continuous 130/22.5 kmph 105/22.5 kmph

    Wheel diameter: New/Condemning 1092/1016 mm 1092/1016 mm

    Load to be hauled 26 AC coaches in 1:37 gradient As per load chart

    Ambient temperature & Max. RH 47 0C (Occasionally 550C)

    Up to 100% 470C (Occasionally 550C) Up to 100%

    2. Traction performance at full power at site conditions As per annexure-I As per annexure-II

    3. Electrical Transmission Main/ Companion Alternator Model GM TA-17/CA-9 GM TA-17/CA-9 Rated Voltage/Current 2600 V DC/1250 A DC 2600 V DC/1250 A DC

    Traction Motor:Make&Type SIEMENS ITB-2622/2525-0TB02 SIEMENS ITB-2622/2525- 0TB02

    Auxiliary Generator/APC APC shall be used APC shall be used

    Transmission

    IGBT based AC-AC traction system shall be as per RDSO spec no. MP- 0.2400.67(Latest Revision)

    IGBT based AC-AC traction system shall be as per RDSO spec no. MP- 0.2400.67(Latest Revision)

    Battery : Type Similar to existing WDP4D Similar to existing WDG4D Dynamic Brake tower type DB grids tower type DB grids 4. Operation control and regulation Similar to existing WDP4D Similar to existing WDG4D 5. Brake system Similar to existing WDP4D Similar to existing WDG4D 6. Air Dryer Similar to existing WDP4D Similar to existing WDG4D

    7. Compressor: Model/Type Compressor of required capacity shall be motor driven with a 3-phase inverter based motor drive

    Compressor of required capacity shall be motor driven with a 3-phase inverter based motor drive

  • Specification for Up-gradation of HHP Locomotives

    Motive Power Directorate Spec No. MP.0.08.00.112 (Rev.00) of August 2016 Page 4 of 12

    arrangement. The motor shall be suitably designed for working with variable frequency ranging from 20 Hz to 140 Hz should be selected.

    arrangement. The motor shall be suitably designed for working with variable frequency ranging from 20 Hz to 140 Hz should be selected.

    8. Sanding Similar to existing WDP4D Similar to existing WDG4D 9. Horns Similar to existing WDP4D Similar to existing WDG4D 10. Main reservoir capacity Similar to existing WDP4D Similar to existing WDG4D 11. Piping Similar to existing WDP4D Similar to existing WDG4D 12. Journal Bearings Similar to existing WDP4D Similar to existing WDG4D 13. Fire Extinguisher Similar to existing WDP4D Similar to existing WDG4D

    14. Blowers for TA & TM Cooling Inverter driven blowers shall be used as per specification no.

    Inverter driven blowers shall be used as per specification no.

    15. Optional features for improvement to be incorporated in Existing WDP4D/WDG4D Locomotives.

    (a) Inverter, Chopper & Contactor Unit for Hotel Load Similar to existing WDP4D N.A

    (b) Remote Control Equipment with antenna (DPC) Similar to existing WDP4D N.A

    (c)

    Remote Monitoring and Management of Locomotives and Trains with antenna (REMMLOT)

    Similar to existing WDP4D

    N.A

    APU N.A.

    APU Shall be provided as per RDSO spec no. MP.0.2400.64 with latest revision

    16. Driver’s Cab Similar to existing WDP4D Similar to existing WDG4D

    17. Superstructure

    Semi monocoque bonnet type super-structure, removable roof and hatches shall be provided for effortless maintenance of top deck equipments.

    Semi monocoque bonnet type super-structure, removable roof and hatches shall be provided for effortless maintenance of top deck equipments.

    18. Coupler&Draft gear assembly/Side Buf

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