Uploaded - Draft Spec - Upgradation - HHP Loco PDF
Uploaded - Draft Spec - Upgradation - HHP Loco PDF
Uploaded - Draft Spec - Upgradation - HHP Loco PDF
O
R.D.S.O
SPECIFICATION FOR
UP-GRADATION OF 4500 HP DUAL CAB HHP LOCOMOTIVES
August’ 2016
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.
¾ TA17-CA9 combination along with 1. Inverters driven Auxiliaries will reduce the
E-locker with DIALS parasitic load and help in improve the Traction
Specific Fuel consumption. This will improve the
• Auxiliary Power Converter(APC)
fuel economy of the locomotive by 2%
• Inverter Driven Blowers & approx.(dependent on duty cycle and
cooling Fans 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).
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
¾ Condition Monitoring System for Provision of on board condition monitoring and fault
improving reliability (RAMS) 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.
Motive Power Directorate Spec No. MP.0.08.00.112 (Rev.00) of August 2016 Page 2 of 12
Specification for Up-gradation of HHP Locomotives
CHAPTER – 2
Specification
Sl.No. Items
WDP4D WDG4D
1. General / Design Data
The general
The general
arrangement and
arrangement and
equipment layout of the
equipment layout of the
locomotive shall be
locomotive shall be
General arrangement and jointly worked out by
jointly worked out by
Equipment layout RDSO, DLW and the firm
RDSO, DLW and the
firm based on the
based on the envelope of
envelope of the
the additional equipment
additional equipment
offered.
offered.
4500 HP DLW/EMD 16 4500 HP DLW/EMD 16
Diesel Engine (Data as per UIC 623)
cylinder 710G3B cylinder 710G3B
Installed power/ input to traction
4500/4000 HP 4500/4000 HP
under site conditions
Fabricated hybrid bogies Fabricated hybrid bogies
Bogie
similar to WDG5 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
174m radius and 1 in 8½ 174m radius and 1 in 8½
Single unit without buffer turnout in either direction. turnout in either direction.
Double unit with buffer
Locomotive Speed
130/22.5 kmph 105/22.5 kmph
:Maximum/Continuous
Wheel diameter: New/Condemning 1092/1016 mm 1092/1016 mm
26 AC coaches in 1:37 As per load chart
Load to be hauled
gradient
470C (Occasionally 550C) 470C (Occasionally 550C)
Ambient temperature & Max. RH
Up to 100% Up to 100%
Traction performance at full power
2. As per annexure-I As per annexure-II
at site conditions
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
SIEMENS ITB-2622/2525- SIEMENS ITB-2622/2525-
Traction Motor:Make&Type
0TB02 0TB02
Auxiliary Generator/APC APC shall be used APC shall be used
IGBT based AC-AC traction IGBT based AC-AC traction
system shall be as per system shall be as per
Transmission
RDSO spec no. MP- RDSO spec no. MP-
0.2400.67(Latest Revision) 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
Compressor of required Compressor of required
7. Compressor: Model/Type capacity shall be motor capacity shall be motor
driven with a 3-phase driven with a 3-phase
inverter based motor drive inverter based motor drive
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Specification for Up-gradation of HHP Locomotives
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Specification for Up-gradation of HHP Locomotives
CHAPTER - 3
Mechanical Design
3.1 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.
3.2 Underframe
Design of under frame shall be suitably modified to suit the new Equipment layout.
3.3 Bogie
HTSC Fabricated hybrid bogies similar to WDG5 shall be used with fabricated hybrid bogie
frame with TBU.
3.4 Driver’s cab
3.4.1 The locomotive shall be provided with two full width cabs.
3.4.2 Each cab shall be provided with one driver’s control desk (with a single unified Master Controller
for both diesel and electric traction).
3.4.3 Left hand drive shall be used.
3.5 Superstructure
Semi monocoque bonnet type superstructure shall be used; removable roof and hatches shall be
provided to enable easy maintenance of top deck equipments. The superstructure shall be made
of stainless steel to achieve weight reduction.
3.6 Fuel tank
A detachable type Fuel Tank of same capacity of existing WDP4D/WDG4D locomotive.
3.7 Coupler, Draft gear & Side buffers
3.7.1 The locomotive shall be fitted with AAR approved H-type centre buffer coupler and draft gear
assembly to EMD drawing no. 10661374 and coupler parts should conform to AAR specification no
M201, 901E, 901G.
3.7.2 The locomotive shall be fitted with side buffers to RDSO drawing no. SKDL- 4561 or SKDL-4748.
3.8 Cattle guard
Cattle guard design as per existing WDP4D/WDG4D locomotive.
3.9 Brakes
3.9.1 Locomotive will be equipped with CCB 2.0 (computer controlled air brake) system to RDSO
Specification No.MP.0.01.00.24 (Rev.01) January 2010.
3.9.2 Suitable and proven design of air dryer shall be provided for the supply of dry and good quality air
to brake system and other systems / sub-systems using compressed air.
3.9.3 Spring-actuated air release type parking brake shall be provided for use on stabled locomotive and
for holding a locomotive on grade in emergency.
3.10 Compressor
Compressor of required capacity shall be motor driven with a 3-phase inverter based motor drive
arrangement. The motor shall be suitably designed for working with variable frequency ranging
from 20 Hz to 140 Hz should be selected.
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Specification for Up-gradation of HHP Locomotives
3.11 Piping
"Bundy weld" copper brazed steel will be used on the piping of 5/8" nominal diameter and less. In
other cases, Wrought Steel shall be used. This shall be pickled and oiled for pipes of 3/4" nominal
diameter and above in the air system.
Existing piping arrangement with suitable modification shall be adapted. Heavy-duty seamless
pipes to IS: 1239 shall be used for pneumatic brake system.
3.12 Sanding
Automatic sanding during wheel slip shall be provided. Eight No’s side sill mounted sand boxes
shall be provided with 0.4 cubic meter sand capacity.
3.13 Horns
Locomotive will be provided with Dual tone horns air horns on both cab end with Provision for
operating horns for either of the directions from both control stands.
The two horns shall have different tones but shall be in harmony with each other when blown
together. Push buttons will be provided for operation of both of the horns at any time by the driver
or his assistant. (Total of four buttons - two per cab)
3.14 Journal Bearings
Locomotive shall be equipped with cartridge type grease lubricated journal bearings.
3.15 Fire Extinguisher
Two Dry Chemical Powder type fire extinguishers (Gas Cartridge type) of 5 kg capacity approx. of
well-known make shall be provided one in each cab. The fire extinguisher shall conform to IS:
2171 – 1985 and gas cartridge shall conform to IS: 4947-1985.
3.16 Use of lightweight material for weight reduction.
It is proposed to use air reservoir, air intake grills in radiator assembly made of aluminium alloy and
identify some other areas where FRP can be used to reduce the weight.
Motive Power Directorate Spec No. MP.0.08.00.112 (Rev.00) of August 2016 Page 6 of 12
Specification for Up-gradation of HHP Locomotives
CHAPTER - 4
Power Equipment
Diesel Traction
4.2 Supplies/Capacities
1 Lube oil system capacity 950 Litres (TBD)
2 Cooling System Capacity 1045 Litres (TBD)
3 Fuel oil capacity 3000 Litres
4.2.1 Mechanically bonded, enhanced capacity radiator for 3000 kW heat load to be used.
4.2.2 Stream lined lube oil and water piping network.
4.2.3 Insulated exhaust gas manifold.
4.4 Controls
4.4.1 The locomotive shall be provided with microprocessor based locomotive control system (LCC, i.e.
similar to EM 2000 of EMD), which will be suitably configured to meet the provision of six traction
motors, and modified TE versus Speed performance to work successfully on both modes of
traction.
4.5 Cables
4.5.1 Electron-beam irradiation cross-linked type Power and Control cables of standard metric sizes shall
be provided as per specification no. EDPS – 304 and EDPS – 179 respectively.
Motive Power Directorate Spec No. MP.0.08.00.112 (Rev.00) of August 2016 Page 7 of 12
Specification for Up-gradation of HHP Locomotives
CHAPTER - 5
5.1 General
All electrical machines and control equipment shall generally conform to relevant IEC standards
and shall be tested as per RDSO approved test program. The temperature rise limits of the IEC
standards shall be reduced by 20°C for traction motor and by 30°C for Traction Alternator and
Companion Alternator to account for higher ambient temperatures in India.
5.2 AC-AC Traction Control System
5.2.1 Functional Requirement of Locomotive Control System:
All applicable requirements such as Traction control, Brake Blending, Event Recorder, VCD,
User settable parameter, not specifically mentioned in this specification shall be adhered as
per existing WDP4D, RDSO Specification No.MP.0.2400.43 (Rev.05/latest).
5.2.2 Functional requirements of Traction Converter
i) Individual axle control shall be provided (one inverter driving one motor). If each inverter
cannot be individually isolated, physical isolation device (contactor, isolation switch) can be
provided at bogie level. However motor cut-out through software should be possible at each
motor level. (or) As an alternative method Truck control similar to the S3/EMD HHP Diesel
Electric loco is also acceptable.
ii) Suitable redundancy shall be provided so that locomotive failure, degradation in performance
and disabling the train is minimized in the event of their failure.
iii) Traction Converter shall use either forced air cooling or water cooling.
5.2.3 The following audio-visual signals or indication(s) shall be provided in both the cabs for single and
multiple operation of the locomotives as per RDSO specification No. MP.0.0400.10 (Latest).
1. Sanding
2. Wheel slip
3. Auto-flasher
4. TE limit
5. Alerter
6. PCS Open
7. Brake Warning
5.2.4 All special purpose cables other than regular control cables shall also be in the scope of supply of
the supplier of TCC.
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Specification for Up-gradation of HHP Locomotives
Insulation Class H
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Specification for Up-gradation of HHP Locomotives
CHAPTER - 6
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Specification for Up-gradation of HHP Locomotives
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Specification for Up-gradation of HHP Locomotives
CHAPTER - 7
Miscellaneous
7
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Specification for Up-gradation of HHP Locomotives
Annexure-I
Tentative Weight Reduction / Additional in the proposed upgraded WDP4D locomotive to keep the axle
load within 20.5 T
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Specification for Up-gradation of HHP Locomotives
Annexure-II
Tentative Weight Reduction / Additional in the proposed upgraded WDG4D locomotive to keep the axle
load within 21.7 T
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Specification for Up-gradation of HHP Locomotives
Annexure-III
5. Dynamic Brake
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Specification for Up-gradation of HHP Locomotives
Annexure-IV
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Specification for Up-gradation of HHP Locomotives
Annexure-V
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Specification for Up-gradation of HHP Locomotives
Annexure-VI
CL OF LOCO
7
292
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Specification for Up-gradation of HHP Locomotives
Annexure-VII
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Specification for Up-gradation of HHP Locomotives
Annexure-VIII
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Specification for Up-gradation of HHP Locomotives
Annexure-IX
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Specification for Up-gradation of HHP Locomotives
Annexure-X
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