1400hp diesel engine for b.g. diesel electric locomotive · with the offer, furnish complete data...

LME:012:C

LOCOMOTIVE ENGINEERING DEPTT.

PURCHASE SPECIFICATION

LME /DESLIM/050 ISSUE DT :10.05.1986 REV. No.-02 REV DJ :30.01.2019 Sheet: 1 of 18

1400HP DIESEL ENGINE FOR B.G. DIESEL ELECTRIC LOCOMOTIVE

Enclosures:

Re Date Re Date 01 14.03.2006

Re Date 02 30.01.2.19

Re Date v

Prepared

Specification generally revised Specification generally revised

Prepared

A roved

Prepared by:

Re Date

A roved

CheCked~

Distribution: Loco Prod. (001)

Loco PPC (002)

Loco OC (003)

Re Date Prepared

A roved

Tech. (004)

COX (005)

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LOCOMOTIVE ENGINEERING DEPTT. LME /DESLIM/050 ISSUE DT :10.05.1986 REV. No. - 02 REV DT :30.01.2019 Sheet: 2 of 18

LME:012:C PURCHASE SPECIFICATION

1. GENERAL

This specification relates to diesel engines required for application on diesel electric locomotives. Locomotives fitted with these diesel engines shall be required for heavy shunting duties in steel plants and other similar arduous duty areas.

1.1.1 The particular model of diesel engine offered shall be one which has been well proven in rail traction service. Background data in this connection shall be furnished along with the offer.

1.1.2 The diesel engine offered shall be operating at the speed range: Minimum idling - 750 rpm Normal rated power output at - 1800 rpm

1.2. The engine shall be suitable for operation using high speed diesel oil, generally conforming to IS:1460 (1974) Grade-A with sulphur content up to 1.0%.Specific fuel consumption shall be prime consideration in the selection of engine. For the comparative evaluation this shall be quoted at the low heat value of the fuel oil.

1.3. The locomotive shall be required to operate in various climatic conditions. The range of such conditions is as follows:

Temperature inside loco Altitude Relative Humidity Maximum sun Temperature

0° to 55° C o 1000 M 40% 100% 70°

However, for purposes of comparative evaluation of engine output, an ambient condition of 55 degrees C and 600 m altitude shall be adopted. .

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1.4 The operating conditions would be extremely dusty. Particular attention on air filtration is required. Secondary air filter of dry type shall be offered with the engine. The engine-hood of the locomotive shall be provided with Inertia car body type primary air filters.

1.5 The design of the engine shall be such that the engine with its associated auxiliary equipment shall be suitable for running for long periods at idling speed or at any speed within the working range, and shall be able to withstand sudden and wide fluctuations in operating conditions without suffering undue thermal or mechanical stress or wear.

1.6 A copy of engine test report as laid-down in UIC code 623-0R is required to be furnished with the offer. Also required is, expected engine performance data (all performance parameters covered by the test report mentioned above) at an ambient temp. of 55 degree C. The tenderer shall guarantee this performance data.

1.7 The diesel engine shall be supplied complete with all standard, special and supplementary auxiliaries, accessories and mountings. Inter alia, these shall include: i) Secondary air intake filtration system ii) Exhaust gas outlet system iii) Fuel oil pumping and filtration system iv) Lubricating oil filtration and cooling system v) Engine mounting pads (if any)

Schematic diagrams alonq with the list of components for all such auxiliaries, accessories and mountings shall be submitted with the offer.

1.8 The diesel engine shall be water-cooled. The tenderer shall, along with the offer, furnish complete data concerning heat balance, temperature gradients, necessary for providing a suitable cooling system using engine driven fan and panel type radiators. Such data shall also include a schematic diagram showing the various engine heat dissipation circuits and preferred connections.

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LME:012:C



1.9 The tenderer shall, in the offer, confirm that the sound level shall not be in excess of 90 dB(A) at any throttle setting except idle, and 75 dB(A) at idle, when measured at a distance of 30 m from the geometric center of the engine and perpendicular to its longitudinal center line. This shall be achieved with engine exhausting directly upwards to the atmosphere and without use of sound mufflers in exhaust or air intake system. The tenderer shall also furnish values of sound level at idle and at full speed with use of muffler in the exhaust system.

2. CAPACITY:

2.1 The engine shall deliver powers in various notches at its corresponding speed as specified for various notches, speeds shall be as given below. The HP output of the offered engine shall be' given for all notch speeds as per format given below:

NOTCH Condition Severest Gross Net Output Output

Rated speed (RPM)

lead Climatic Standard Gross Net Output Out put

1800 1700 1600 1450 1300 1050 900 750 750

8. 7. 6. 5. 4. 3. 2. 1. Idle

Remarks: • 'Standard' climatic conditions shall be as per UIC Code 623-

OR. • 'Severest' conditions shall be as defined in Para 1.3 above.

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• Net output is power available to traction generator and loco auxiliaries including engine cooling fan

2.2 The required power input to traction alternator and locomotive auxiliaries including cooling fan shall be in the most economic specific-fuel-consumption range of the engine .The guaranteed values of specific fuel which shall be binding at the time of testing of engine at manufacturer's works and subsequently during testing at BHEL works. The supplier shall indicate brake specific fuel consumption of the diesel engine with tolerance band at rated output under UIC conditions indi.cated in UIC-623- OR.He will also furnish the fuel map for entire range of operation of the engine. Fuel oil consumption at idle shall also be indicated. Average lube oil consumption as a percentage of fuel-oil consumption shall be furnished at rated output.

2.3 Having regard to the duties involved, the required output of the engine shall be its intermittent traction rating in accordance with British Standard Specification BS:5514:1987.

3. ENGINE FEATURES:

The exhaust outlet from the turbocharger shall be so arranged so as to facilitate vertical discharge through engine hood roof. The dimensioned GA drawing of the exhaust system shall be furnished with offer. The dimensioned OGA drawing of muffler shall also be submitted along with the offer.

3.1 The engine air intake shall be so positioned as to facilitate location of the air filter and air intake openings in a separate compartment alonqside the engine. The dimensioned GA drawing for the intake air filter shall be submitted with the offer. Adequate filtration of air is essential, and it shall be of the type described in Para 1.4.

3.2 The drive for locomotive auxiliaries shall be taken from the non driven end of the diesel engine FPTU. From the FPTU an

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LME:012:C

LME /DESLIM/050 ISSUE DT :10.05.1986 REV. No. - 02 REV DT :30.01.2019 Sheet: 6 of 18



compressor model 15T (IR make) or equivalent shall be driven. The power consumption of the machine shall be 25 HP at 1100-· 1200 RPM. Since engine shall run at 1800 RPM pulley belt arrangement shall be used to drive compressor.

3.3 The diesel engine shall be water cooled type.

3.3.1 It is proposed to use hydrostatically operated engine water cooling system. This hydrostatically operated cooling system shall be in engine manufacturer's scope of supply. In case the system is procured from other source the engine supplier shall ensure compatibility of the system with the diesel engine. The engine shall be provided with a separate power take off for hydrostatic pump, which shall be mounted directly on engine. The supplier shall submit hydraulic schematic drawing along with the offer.

3.4 Fuel Oil System

3.4.1 As the fuel tank shall be located below the mounting level of the engine, a suitable electrically driven fuel transfer pumping system shall be incorporated in the supply, suitable for lifting of fuel for an 'effective head' of at least 3.5 m. Details of fuel transfer pump shall be submitted with the offe

3.4.2 Flexible hose connection end pieces shall be supplied to connect fuel supply to and from the engine

3.4.3 Water separator, deaerator device and suitable NRVs shall be supplied along with the engine.

3.4.4 Supplier shall submit fuel oil schematic drawing along with offer

3.5 The diesel engine shall perform satisfactorily with lubricating oils selected from those which are available in India. Supplier must specify grade and quantity of lube oil with offer. The first fill of lube oil shall be in supplier scope. Supplier shall also submit lube oil schematic drawing along with offer.

3.6 Engine shall be suitable for 72-64V DC electric control system. ., Complete electric wiring diagram for the engine system shall be <. 'submitted with the offer.

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LOCOMOTIVE ENGINEERING DEPTT. LME /DESUM/050 ISSUE DT :10.05.1986 REV. No. - 02 REV DT :30.01.2019 Sheet: 7 of 18


3.6.1 Engine starter motor suitable for 72V system is required to be supplied. However, batteries and battery charging system shall not be supplied with the engine.

3.6.2· If considered necessary by the engine manufacturer, the engine shall incorporate suitable device for pre-lubrication before engine starts. .

3.7 Engine mounted compressor is not required.

3.8 The engine shall drive double bearing traction alternator TA 7003 AZ. The alternator rotor shall be directly coupled to the engine flywheel through a flexible Holset coupling. Copy of outline drawing no. 34301073001 of TA 7003 AZ is attached with the specifications. The suitable Holset coupling shall be supplied along with the engine.

3.9 GOVERNING SYSTEM:

3.9.1 The supplier may offer their own governing system which shall, inter alia, cater to the following requirements:

• Engine speed control (adjustable ramp) in eight notches

• Excitation control (adjustable ramp) of the exciter at each notch to match engine output. Maximum excitation current shall be 10 amps.

• Engine load control at each notch • Engine over speed protection • Wheel slip protection-excitation ramp down in

case of wheel slip • Protection against switching surges • Protection against loss of signal from magnetic

pick-up • Protection against short circuit on actuator

output

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Manually operated over-riding emergency shutdown - to be , .' :- provided fitted on the engine.

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LME:012:C

3.10.

3.10.1

3.10.2

3,10.3 3.10.4

3.10.5

3.10.6

3.10.7

3,10.8

3.10.9

3.1"0.9.1 . '" "

LME IOESLlM/050 ISSUE OT :10.05.1986 REV. No. - 02 . REV OT :30.01.2019 Sheet: 8 of 18

LOCOMOTIVE ENGINEERING OEPTT.


• Protection against short circuit on excitation output

• Feedback of speed, voltage to governing system

• System for current feedback (CT) shall be in BHEL scope

METERING AND PROTECTION SYSTEM:

All electrical terminals for connections to be taken to the locomotive control station for metering I indicating devices shall lead to a single terminal-board to be mounted on the engine at a suitable location. The All gauges shall be electrical, negative isolated and panel mounted type. All dial faces shall have black background with white lettering. All dial faces shall also carry the international symbols denoting the respective functions. Complete list along with diagrams for all such symbols shall be submitted with the quotation. All engine protection and .sensing devices shall be mounted directly on the engine All dimensional and mounting details for the devices to be mounted away from the engine shall be furnished along with the quotation The audio signals for annunciation shall lead to one horn, Horn to be supplied with the engine, The colours for visual indicator shall be as per standard international practice The supply shall include all meters, gauges, indicating devices and switches in duplicate i.e, 2 sets per engine for fitting on 2 nos. driver's operating consoles in the driver's cabin. Items to be supplied loose shall be mounted by BHEL on driver's operating consoles in the driver's cabin. List of all such mechanical type of gauges and meters shall be submitted with the quotation. The supply shall include:.

LME:012:C

3.10.9.2

3.10.9.3

3.10.9.4

3.10.9.5

3.10.9.6

3.10.9.7

3: 10.9.8

3.10.9.9

3.10.9.10

3.10.9.11

3.10.10

3.10.10.1 3.10.10.2 3.10.10.3

3.10.10.4 3.10.10.5 3.10.10.6 3.10.10.7 3.10.10.8 3.10.10.9 3.10.10.10 3.10.10.11 3.10.10.12

3.11

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Engine speed indicator with related sensing device - meter to be supplied loose. Water temp. gauge with related sensing device - gauge to be supplied loose. Lub oil temp. gauge with related sensing device - gauge to be supp.lied loose. Lub oil pressure gauge with related sensing device - gauge to be supplied loose. Fuel oil pressure gauge with related sensing device - gauge to be supplied loose Overspeed trip with audio and visual annunciator. Over-speed sensing and tripping device shall be of mechanical type Sensing and tripping device for high water temp. with audio and visual annunciator . Sensing and tripping device for low water level in radiator with audio and visual annunciator Sensing and tripping device for low lube oil pressure with audio and visual annunciator Sensing and tripping device for crank case over pressure with audio and visual annunciator Suitable arrangements including holes, plugs, adaptors etc. shall be provided at various locations on the diesel engine to record and monitor, if required, the pressure and temp. of : Exhaust gases from each cylinder Exhaust gases at inlet to the turbocharger Combustion air after the turbo-compressor and before inlet to the after cooler Combustion air at exit from the after cooler Combustion air in the intake air manifold Combustion air at entry to the turbo compressor Lub oil at entry to the turbocharger bearing Lub oil at entry into and exit from the lub oil cooler Lub oil at entry into and exit from the lub oil filter Cooling water at entry into the exit from the radiators Cooling water at entry into the exit from the lub oil cooler Cooling medium at entry into the exit from the after cooler

Following items for various circuits of engine as given below' shall be supplied with the engine:

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LME:012:C

3.11.1 3.11.2 3.11.3 3.11.4 3.11.5 3.11.6 3.11.7 3.11.8 3.11.9




Hose Hose clips Metal elbows Rubber elbows Connecting Pipe and pipe joints Connecting flanges Flexible connections Other connections Above items shall be supplied for the following ckts.

• Radiator water circuit (at engine end) • Fuel oil circuit • Intake air circuit ' • Exhaust circuit

Comprehensive list of above items as required for each of above circuits and as included in the offer, indicating quantity included in offer for each item shall be submitted with the offer along with individual drawing for each of above items.

3.12 The tenderer shall inform the values of various alignment values required for engine alternator coupling

4. TEST AND CERTIFICATES:

5.

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Each engine shall be tested in the manufacturer's works prior to despatch, in accordance with BS 5514: 1987. Testing and inspection shall be witnessed and certified either by BHEL engineers or third party to be authorized by BHEL. Three copies of detailed test/inspection report shall be submitted to BHEL. The following test schedule as stipulated in para 5 shall be followed

The successful bidder within 15 days of placement of order must submit quality assurance plan for our approval. It should necessarily cover the following points.

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LME:012:C


5.1

5.1.1

5.1.2

5.1.3

5.1.4 5.1.5

5.1.5.1 5.1.5.2 5.1.5.3

5.1.6 5.1.7 5.1.8

5.1.9

5.2

5.3



Each Engine shall be tested for rated output - 1400 HP @ 1800 RPM gross. Since engine will be tested without accessories like fan, radiator, alternator etc. the accessories power consumption will be added to arrive at the flywheel output power.

Engine power output at flywheel shall be measured at all notch speeds at the ambient conditions. Speed droop shall be measured at all notch speeds and recorded. This shall match with values indicated by tenderer in Para 2,1. Fuel consumption trials during engine output test will be carried out. Capability of fuel pump system to lift fuel for an effective head of minimum 3.5 meters shall be demonstrated. Smoke analysis during engine output test shall be carried out. Functional tests shall be carried out to demonstrate the ability of functioning of following safety devices to show that they respond correctly to the fault condition in which they should operate:

Over speed High jacket water temperature Low lub oil pressure

All electric wiring shall be checked for correctness Engine lub oil analysis shall be done after testing Calibration and test certificates for all indicating/measuring instruments and safety devices shall be given for all engines Lube oil level and diesel dilution to be checked after 3 hours running at full speed.

The power pack (engine coupled to alternator) shall be load tested after assembly on the locomotive. The engine manufacturer's engineer must associate and witness such tests at BHEL. Regarding delivery of the engine, Para 9.6 given shall govern. Supplier will do setting and calibration of electronic governor on actual load condition during power pack testing at Jhansi.

LME:012:C

6.

6.1

6.2 6.2.1 6.2.2 6.2.3 6.2.4

6.2.5

6.2.6

6.2.7 6.2.8 6.2.9

6.2.10 6.2.11

6.2.12

6.2.r3




TECHNICAL DATA TO BE FURNISHED BY THE TENDERER:

The tenderer shall furnish the under mentioned technical data with the offer in addition to information required in various clauses of this specification:

Technical information as per clause 9 Table of technical information' of UIC Code 623-0R with following further additions:

Data against items 18,19,20 shall be given for a temp. of +10 degree C also in addition to the +5 degree C indicated in the UIC code. Such data as is dependent on the ambient temperature will also be given at 55 degree ambient in addition to that at the standard conditions.

In addition, technical data in regard to the following: Peak firing pressure to which the engine has been designed Compression pressure at full and no load Smoke level at various notches Deration calculations and assumptions whether rating is limited by ambient temp., component temp. or air/fuel ratio Rates of blow-bye andmeans to ensure crank case vacuum, minimum vacuum level considered necessary Whether safety devices as called for in Para 3.10.9 above provided?

_ Details of injection pump, injectors and nozzles used Number of turbochargers used per engine, make and model Turbo inlet and outlet temp. and their variations with ambient temp. Conditions Exhaust gas pressure Material specification of turbines, turbine disc, rotor shaft, nozzle ring and castings Expected life rating of turbocharger under ambient conditions for individual component also

-- .. Any by-pass arrangement fitted to regulate the matching of the , .: "engine and turbocharger , ~ .' ._..i\ _

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LME:012:C



Engine governor details. Governor has been specified in Para 3.9 above Break-away torque, sustained torque and speed The under mentioned information is to be given in the form of characteristic curves of the diesel engine: Curves for torque, output power, exhaust gas temp. at entry to turbocharger and specific fuel consumption expressed in gram/metric HP hour and guaranteed without upper tolerances, as a function of engine speed, for different settings as the fuel injection pumps viz. Setting at which engine develops rated output when working at rated speed Setting at which engine develops 3/4 of rated output at rated speed Setting at which engine develops 1/2 of rated output at rated speed Setting at which engine develops 1/4 of rated output at rated speed. Note: Fuel consumption has to be given in relation to diesel fuel having a lower calorific value of 10000 K.cal/Kg. Curves as specified under clause 6.3.1 for ambient temp. of 55 degree C The curve of fuel consumption on no load running, commencing from the low idling speed to the maximum permissible speed of the engine . The tenderer will be required to guarantee the performance curves in respect of power, maximum exhaust gas temp. and specific fuel consumption stated above (see also clauses 1.7 and 2.2 above) Expected life of (in engine hours at 60% load factor) following parts: Turbo chargers bearings (separately for each bearing unit a Gas inlet casing Nozzle ring Turbine disc Cylinder head Exhaust manifold Exhaust valve Inlet valve

6.2.14

6.2.15 6.3

6.3.1

6.3.1.1

6.3.1.2

6.3.1.3

6.3.1.4

6.3.2

6.3.3

6.3.4

6.4

6.4.1 6.4.2 6 .. 4.3 6.4.4 6.4.5 6.4.6 6.4.7 6.4.8

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LME:012:C

LME /DESLIM/050 - ISSUE DT :10.05.1986 REV. No. - 02 REV DT :30.01.2019 Sheet: 14 of 18



6.4.9 Fuel injection nozzle 6.4.10- Fuel injection pump (plunger & barrel) 6.4.11 Flexible coupling 6.4.12 Engine mounting pads 6.4.13 Water pump seals 6.4.14 Governor bearing and springs (and other components to be

listed) - 6.4.15 Fuel filter elements (secondary) 6.4.16 Lubricating oil filter

7. TECHNICAL COMMENTS BY THE TENDERER:

Clause-wise technical comments against this specification no. DESLlM/050 and relating to the engine offered in accordance with the stipulated scope of supply must be furnished in triplicate along with the quotation. Any deviations shall be clearly mentioned in a separate comprehensive list of deviations to be submitted along with the quotation in triplicate. If no separate deviation list is submitted, it shall be assumed. that the specification is being met with in totality which shall also bind the scope of supply technically as well as commercially.

8. TORSIONAL VIBRATIONS:

The tenderer shall take into account in the offered design the proper matching of engine with all the connected rotating masses on the locomotive from the torsional vibration point of view. This system will be required to be free from dangerous vibrations at all speeds in the range from low idling to the maximum permitted speed. This condition should also be satisfied even in the case of one cylinder misfiring or

- not firing. In the event of an order being placed, the tenderer shall submit, within one month of placement of order, detailed TV analysis report in 3 copies to BHEL gIving all calculations and supporting data to the satisfaction of BHEL in this regard and undertake to furnish suitable performance guarantees. BHEL reserves the right to cancel the order in the event of results of TV analysis being found unsatisfactory. The input mass elastic data for other equipment required to carry out TVA analysis shall be provided by BHEL... ~~ _~

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LME:012:C

9.

9.1

9.1.1 9.1.2 9.1.3

9.2 9.3

9.3.1 9.3.2 9.3.3

9.3.4 9.3.5 9.3.5.1 9.3.5.2 9.3.6 9.4

9.5.1

9.5.2

9.6

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GENERAL:

Following schedules with item-wise quantity and price shall be submitted with the offer: Schedule of stand-by spares Schedule of maintenance spares for 3 years operation Schedule of consumable spares

Engine test/inspection report shall be supplied in triplicate. Following manuals/catalogues shall be supplied with every engine: Maintenance manual Operating manual. Spares part hand book / catalogues with details and diagrams wherever necessary - 6 Nos Special tools and plat catalogues -6 Nos. Special tools manual: .: 6 Nos. For maintenance staff -6 Nos. For operating staff - 6Nos. Service manual for overhauling of the engine -6 Nos. Engine supplier shall provide manufacturer's warranty of engine performance at locomotive user's premises.

- 6 Nos. -6 Nos.

The tenderer shall submit, along with the quotation, in 4 copies the fully dimensioned drawings in respect of complete assembly of diesel engine, major sub-assemblies of the diesel engine and all other equipment / sub-assemblies forming part of the design

In the event of order, the tenderer shall within 1 month of placement of order, submit to BHEL the fully dimensioned installation diagram of the engine with BHEL traction alternator TA 7003 AZ .

The delivery of the engine shall be considered to have been effected after it is matched on test-stand at BHEL works to confirm its compatibility with the alternator and control system. Engine supplier must participate in these tests and carry-out all

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LME:01.2:C PURCHASE SPECIFICATION

adjustments and modifications to the engine and other elements supplied, including total replacements as may be found necessary, at no cost to BHEL. During commissioning of the engine at BHEL works and at ultimate user's premises, engine supplier's representative must participate along with all necessary commissioning spars. List of necessary commissioning spares shall be submitted with the offer.

9.7 Two tins of one liter each of engine paint shall be supplied with each engine for touching-up the paint of engine after installation of engine.on the locomotive at BHEL works

9.8 Details of locomotive incorporating the diesel engine as per the offered design against this specification, in service in different countries, shall be furnished along with details of performance, behavior and experience. Copies of any available reports prepared by any of the user rail roads or on their behalf by other bodies describing the performance, behavior and experience should also be submitted along with the offer.

9.9 All correspondence, documents; drawings and manuals etc. submitted along with the offer and with subsequent supply shall be in the English language and in the metric system

10. Erection

During the erection of diesel engine on locomotive at BHEL Jhansi works, supplier representative must be present and all hydraulic piping and cooling water piping shall be in his scope.

11. SCOPE OF SUPPLY

The scope of supply shall inter alia cover the following modules beside the basic engine

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11.1 COOLING GROUP: The cooling group shall consist of radiators, fans, fan drive arrangement, AVM pads, hydraulic tank, hydraulic oil, safety devices, pipes, hoses and connectors etc.

11.2 EXHAUST GROUP: This group shall broadly cover the silencer, clamps, pipes, connectors.: manifolds, junction box if any and supporting brackets etc.

11.3 AIR INTAKE GROUP: This group shall broadly cover the secondary air filters, mounting clamps and filter elements etc

11.4 CONTROL GROUP: The control group shall cover the electronic governor suitable for 72V for engine speed and alternator excitation control.

11.5 METERING AND PROTECTION GROUP: It shall cover all the metering and protection devices as stipulated in para 3.11 of above.

11.6 COUPLING GROUP: Flexible coupling between engine and alternator with all mounting hardware etc

11.7 FUEL GROUP: Flexible hoses and connectors, NRVs, water separator, deaerator, fuel filters, fuel booster pump with motor and day tank etc.

11.8 Misc. Group: Toolbox, lube oil, hydraulic oil, maintenance manuals, parts catalogues and troubleshooting manuals etc.

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1400hp diesel engine for b.g. diesel electric locomotive · with the offer, furnish complete data...

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