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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ekud uxj] y[kuÅ & 226 011, Hkkjr

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


Emissions on a DLW build 16 –Cylinder ALCO engine shall be so designed that safety of the

locomotive and personnel are not compromised.

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Preventive Maintenance


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


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.

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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.

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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.

****************

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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

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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.


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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

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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


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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.

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Annexure-VI

VALVE TIMING DIAGRAM FOR STIFFER UNIT CAMSHAFT

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