— TU R B OCH A RG I NG SUCCE SS S TO RY

Turbocharger retrofit for TATA Steel locomotivesImproved performance and reliability

TATA Steel operates a fleet of locomotives. To counter reliability and spare part availability problems of the non-ABB turbochargers a retrofit was carried out. The posi-tive results include: lower exhaust gas temperatures, higher boost air pressures and an overhaul interval of three years instead of one trans-lating to improved performance, better reliability and lower cost of ownership.

High demands are placed on locomotives operating in steel, coal and fertilizer plants. For example, business sustainability is often critically dependent on locomotive availability, so reliability becomes a key factor. Performance is important, too, as is cost – total cost of ownership must be reduced to an optimal level and the best value should be ob-tained from the locomotive over its life time.

Challenges of maximizing reliability and availabilityTATA Steel – a long-established Indian steel producer with a global presence (they are the second-largest steel company in the entire industry) was experienc-ing difficulties with the reliability of nine ALCO 350C turbochargers on its DLW-built WDS6 locomotives as well as availability of spare parts. The turbo-chargers were installed on 1,350 HP ALCO 251D four-stroke diesel engines. They presented an additional challenge to TATA in requiring overhaul every year.

Retrofit upgrade brings technical benefitsInvestigating these issues, ABB identified the possi-bility to reduce thermal loading and exhaust gas temperatures and to increase boost air pressure by retrofitting ABB VTC214 turbochargers. Already in use by Indian Railway the VTC214 also enables improved time between overhauls of one to three years. As a result of these specific benefits, TATA Steel was confident in the benefits of retrofitting their turbochargers to resolve these challenges.

The outcomeOnce the turbocharger was installed and commis-sioned, tests were carried out. The results were very satisfactory: Exhaust gas temperature at the 7th notch found to be reduced by 100°C; at the 8th notch by 79°C; and boost air pressure was found to be higher than the previous turbocharger. These results indicate improved turbocharger efficiency.

“Reliable operation of the turbocharger was our aim for the retrofit. ABB has satisfactorily retrofitted the turbocharger with a VTC214 type and confirmed the benefits promised for our locomotive.” said Mr. Nitin Chawla, Senior Manager of TATA Loco Shop Equipment Maintenance Services, which maintains the complete TATA locomotive fleet.

Following this positive outcome, TATA Steel ordered two further turbochargers, which are now success-fully installed on their locomotives.

Despite the constraints imposed by the 20-year-old locomotive, the design of the VTC214 enabled the retrofits to be carried out easily and swiftly – the fastest was accomplished in two days as opposed to the seven days anticipated. This emphasizes the flexibility of the VTC214 and why many industrial locomotive operators choose to upgrade their turbochargers.

—After removing the non-ABB turbocharger (ALCO 350C), the loco-motive is now ready to get fitted with an ABB VTC 214 turbocharger

—We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. ABB does not accept any responsibility whatsoever for potential errors or possible lack of information in this document.

We reserve all rights in this document and in the subject matter and illustrations con-tained therein. Any reproduction, disclo-sure to third parties or utilization of its contents – in whole or in parts – is forbid-den without prior written consent of ABB.Copyright © 2017 ABB Turbo Systems Ltd, Baden, Switzerland

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—01 WDS6 Locomotive with ABB VTC 214 turbocharger ready for field operation after successful load box test—02 ABB VTC 214 turbo-charger successfully retrofitted on WDS6 locomotive

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Challenge Solution Outcome

• Problems with turbocharger reliability• Difficulties with availability of

spare parts• Time-between-overhauls at one year,

was short – increasing TCO

• ABB retrofitted the VTC 214 turbo-charger on one locomotive

• Lifecycle approach from ABB focused on addressing these specific issues while reducing TCO

• ABB’s global footprint enables high availability of spare parts

Higher reliability through:• Reduced thermal loading• Lower exhaust gas temperatures• Higher boost air pressure• Time between overhauls,

extended three fold

This trend is driven by recent rapid advances in turbocharger technology: Improved construction materials allow turbochargers to operate at higher, more efficient temperatures; new, sophisti-cated tools allow the designs of bearings, blades and housings to be optimized and performance increased across the full load range; and better direct fuel injection techniques allow higher com-pression ratios.

ABB Turbocharging provides such customized and local rail service solutions that increase the reliability of a fleet and optimize performance over the entire life cycle – at the lowest total cost of ownership. These solutions are available for new rolling stock or can be fitted as quick and easy upgrades or retrofits in existing locomotives. Whereas an upgrade is a process of replacing an older generation turbocharger or turbocharging component with a new and improved one, a retrofit involves the replacement of a non-ABB turbocharger with an ABB turbocharger for better efficiency and more savings.