1. IMPROVING ENERGY EFFICIENCY AND ENVIRONMENT FRIENDLINESS OF DIESEL LOCOMOTIVES OF INDIAN RAILWAYS
RDSO, Lucknow, INDIA

2. IR - Resources 1.4 Million employees 108,500 Track Km 63,000 Route Km
7,000 Stations
7,900 Locomotives
230,000 wagons
45,000 coaches
RDSO, Lucknow, INDIA

3. IR - Operations 5 Billion Passengers per annum
Moving Entire Swiss Population Twice in a day
8,000+ Passenger Trains per day
Computerised reservations – One million transactions per day
Amongst the largest IT applications in the world
670 Million tonnes Freight per annum
3,000 Freight trains on the system
Revenue – US $ 12 Billion per annum
RDSO, Lucknow, INDIA

4. IR Service Profile - Passenger
Diverse Customer Base
8 travel classes
Charge for 1000 Km range US $ 2 to 50
58% Suburban passengers
150 Km Monthly Fare US $ 8
Amongst the Lowest Passenger to Freight rate ratios in the world = 0.3
RDSO, Lucknow, INDIA

5. IR Service Profile – Freight
Entire Spectrum
Bulk coal/ores – 63%
Bagged commodities – 23%
Iron & Steel – 4%
Petro Products – 6%
Containerised cargo – 4%
RDSO, Lucknow, INDIA

6. Growth in 2005-06 % Improvement No. of Passengers 7.4 Freight loading
10.7
Passenger Earnings
9.5
Freight Earnings
17.9
Total Earnings
15.1
RDSO, Lucknow, INDIA

7. Growth in 2006-07 (six-month period )
% Improvement
No. of Passengers
7.9
Freight loading
9.9
Passenger Earnings
11.1
Freight Earnings
15.9
Total Earnings
15.3
RDSO, Lucknow, INDIA

8. Diesel vs. Electric Traction
Total Annual Consumption
Diesel Oil : 2 Billion Litres
Electric Energy : 10 Billion Kwh
% Traffic
Passenger
(Train Km)
Freight
(GTKM)
Diesel
52.5
37.4
Electric
47.5
62.6
Total locomotives
Diesel : 4801
Electric : 3065
RDSO, Lucknow, INDIA

9. Diesel Traction in India
Diesel Locomotive Works (DLW), the manufacturing unit of Indian Railways produces 130 diesel locomotives per annum.
Majority of Diesel Locomotives fleet includes
16-cylinder ALCO & EMD Engines;
12-cylinder ALCO Engines; and
6-cylinder ALCO Engines.
Fuel Bill of Indian Railways is US $1.3 Billion.
To reduce high-energy costs, RDSO has worked to improve energy efficiency of their Diesel engines.
RDSO, Lucknow, INDIA

10. Engine Test Bed Facilities
Test bed facilities in RDSO have four Test Cells housing four types of DLW manufactured Engines.
16 cylinder GM-EMD,
16 cylinder ALCO,
12 cylinder ALCO,
6 cylinder ALCO
Each test cell has Test Commander comprising of
microprocessor controlled Data acquisition systems; and
Video Display Unit (VDU)
Test beds have been provided with High Speed Data Acquisition System to
acquire 100 MHz frequency data.
HSDA System
Test Commander
RDSO, Lucknow, INDIA

11. Improvement in Energy Efficiency
Sustained efforts made to improve the diesel locomotive technology of 1950s, entirely through in-house research and development.
Stage-wise improvement in BSFC and increase in Horse-Power per cylinder
250
SFC
gm/bhp-hr.
HP/Cylinder
162.5
193.7
206.2
225
2600 HP
3100 HP
3300 HP
3600 HP
4000 HP
154
151.5
150
166
156
Year
RDSO, Lucknow, INDIA

12. Energy Efficiency Improvements
First stage modifications in the 16-cylinder ALCO engines resulted in:
6% reduction of fuel consumption at full load from 166 gm/bhp/hr to 156 gm/bhp/hr.
15 % reduction in the % lube-fuel oil ratio from 1.5% to 1.27%.
RDSO, Lucknow, INDIA

13. Modifications Stage-I
Modification In Cooling Water Piping
Efficient After –Cooler
Size of the core increased.
Increase in cooling effectiveness from 50% to 75%.
Water to after-cooler fed directly from the radiator.
RDSO, Lucknow, INDIA

14. Modifications Stage-I
Plunger diameter of fuel injection pump increased from 15 mm to 17 mm.
The modification resulted in increase of peak fuel line pressure from 750 to 850 bars.
Modification of Fuel Injection Pump
RDSO, Lucknow, INDIA

15. Modifications Stage-I
Global Efficiency improved from 50% to 60%.
Increase in booster air pressure from 1.2 bars to 1.6 bars.
Development of Improved turbochargers
RDSO, Lucknow, INDIA

16. Modifications Stage-I
Development of 12.5 CR Steel Cap Pistons
Aluminium Dish Top
Steel Cap
Modification of Cam Shaft
Change in Inlet and Exhaust air cam lobes profile as well as Increased valve overlap to improve scavenging.
Steel cap pistons provided to withstand higher firing pressures.
RDSO, Lucknow, INDIA

17. Energy Efficiency Improvements
In Second stage, power of the engine was increased along with the reduction in fuel consumption and lube-fuel oil ratio:
Power from 2600 HP (FE) to 3100 HP by increasing the engine rpm from 1000 to 1050 rpm
2% reduction of fuel consumption at full load from 156 gm/bhp-hr to 153 gm/bhp-hr at 8th notch
12 % reduction in the % lube-fuel oil ratio from 1.27% to 1.12%.
RDSO, Lucknow, INDIA

18. Modifications Stage-II
High Efficiency Turbo
FE Piston Rings 
Multigrade Lube Oil
Increase in the Booster pressure from 1.6 to 1.9 bar.
Speed of rotor increased from 23,000 to 27,000 rpm.
Piston ring set changed to
barrel, taper, taper and
2 no. oil conformable
These oils have Viscosity Index Improver additive.
RDSO, Lucknow, INDIA

19. Energy Efficiency Improvements
In the third stage, the technological improvements have been made to :
uprate the engine to 3300 HP in the year 2001 and to 3600 HP in 2002.
1% reduction of fuel consumption at full load from 153 gm/bhp-hr to gm/bhp-hr on top notch.
11 % reduction in the % lube-fuel oil ratio from 1.12% to 1%.
RDSO, Lucknow, INDIA

20. Modifications Stage-III
New Generation Turbochargers
Stiffer Unit Cam Shaft
Camshaft strengthened to take increased stress.
Fuel cam lobe profile modified for sharper fuel injection.
These aircooled turbochargers have higher global efficiency.
Rotor speed of these turbochargers also increased resulting in increased BAP.
RDSO, Lucknow, INDIA

21. Modifications Stage-III
Air intake valve angle reduced to take care of increased heat load.
Location of cooling passages changed to give better heat transfer.
Development of Plus cylinder head
RDSO, Lucknow, INDIA

22. Energy Efficiency Improvements
Modifications in the fourth stage have been tested on test Beds but yet to be implemented. With these modifications :
Fuel consumption has been reduced by more than 2% over duty cycle.
Lube oil consumption has been further reduced by more than 6%.
RDSO, Lucknow, INDIA

23. Modifications Stage-IV
EFI pump sets the start and end of injection for each cylinder individually .
The system eliminates many mechanical engine components including the Governor itself.
Electronic Fuel Injection System
RDSO, Lucknow, INDIA

24. Modifications Stage-IV
Double Helix Plunger
Single Helix Plunger
Additional Helix provided on top edge of plunger
so as to optimise the opening of spill port
resulting in optimisation of start of injection at part load as well.
Double Helix Fuel Injection Pump 
RDSO, Lucknow, INDIA

25. Diesel Traction in India
So far, no Standards have been laid down in India for Emission norms of Diesel Locomotives.
Indian Railways, being socially conscious organisation, is making efforts to
reduce Diesel engine pollutants namely NOx, SO2, HC, CO, CO2 and Particulates having serious effect on health and environment.
RDSO, Lucknow, INDIA

26. Emissions from ALCO Engines
NOx emissions measurements made in Nov on 6-cylinder engine using Chemiluminescent detector based equipment.
The measurements gave the NOx value of gm./kW-hr.
RDSO, Lucknow, INDIA

27. Test Bed measurements
Measurements on 12 and 16 Cyl. Engine made by using a portable emission measuring equipment in November 2000.
RDSO, Lucknow, INDIA

28. Emissions from ALCO Engines
Only gaseous emission measurements could be made with the portable equipment .
Emission measurements were made at different engine configurations. It has been seen that
Emissions are higher only for CO and NOx.
Since HC values in the ALCO engines are much lower than the limits, it will be possible to recuce CO and NOx .
RDSO, Lucknow, INDIA

29. Emissions Measurements
Since portable equipments do not meet International standards, RDSO has procured the dedicated Mass emission measuring equipment.
The same is presently under commissioning on the test beds of RDSO. The equipment under commissioning includes
RDSO, Lucknow, INDIA

30. Trials with Bio-Diesel
Use of environmental friendly Bio-diesel as an alternate fuel has been tried out.
Testing on engine test bed has been conducted followed by field trials.
Following observations have been made :
No significant power loss observed.
Specific fuel consumption is higher.
Exhaust gas temperatures have reduced.
Boost air pressures have got reduced.
Gaseous hydrocarbons have reduced.
RDSO, Lucknow, INDIA

31. Use of Bio-Diesel
Other action taken to promote use of Bio-Diesel in Indian Railways is as under:
Southern Railway and South Eastern Railway have got trans-esterification plant and are running few trains with B10 diesel.
All the Railways are growing Jatropha plants on their surplus land.
Indian Railways have signed an MOU with Indian Oil Corporation to plant Jatropha saplings on the land of Indian Railways.
RDSO, Lucknow, INDIA

32. Use of CNG in DEMU
Use of CNG as an alternate fuel has been investigated on DEMU engines to see the environmental impact.
One rake of CNG DEMU is presently running in Delhi area. The special Features of CNG DEMU include:
30% savings in operation and maintenance cost.
Savings of Rs.27 lakhs per engine per year.
Reduced engine wear.
Reduced lubricating oil consumption.
Substantial reduction in Exhaust emissions.
RDSO, Lucknow, INDIA

33. Action Plan to reduce Emissions
Following future action plan has been made to measure and reduce Emissions:
Base-line emissions measurement will start immediately after commissioning of Mass emission measurment equipment.
A trans-esterification plant is being planned at RDSO to optimize engine parameters with Bio-diesels produced from different plants.
RDSO, Lucknow, INDIA

34. Action Plan to reduce Emissions
A leading engine designer Consultant is being contacted to assist Railways in reducing Emissions.
Emission measurement Car for measuring in-use emissions in field is planned.
RDSO, Lucknow, INDIA

35. Emissions from New Engines
Results of Emissions and Particulates measurements made for 16 cylinder EMD 4000 HP engine in 2001:
It is seen from above that
HC, PM and NOx Emissions are marginally higher than limits.
Since CO values are lower than the limits in the standards, it is possible to reduce HC, PM and NOx Emissions.
RDSO, Lucknow, INDIA

36. Effluents Control in Diesel Sheds
Uncontrolled effluents of diesel sheds have an impact on the environment. Following work has been done to achieve the above:
An Environmental Management System (EMS) has been laid down
the head of the maintenance unit is responsible to establish environmental policy.
A Waste Management System (WMS) has been laid down as per which
the main hazardous wastes generated in the maintenance unit have been identified and
the procedures for disposal of these waste materials have been laid down.
RDSO, Lucknow, INDIA

37. Effluents Control in Diesel Sheds
Main equipments for disposal of hazardous as well as non-hazardous wastes include:
Effluent Treatment Plant (ETP)
Incinerator
Need for above Equipment, Design parameters, Specifications and Agencies for installation have been specified.
The Landfill sites for disposal of above waste have been included in the above system.
RDSO, Lucknow, INDIA

38. Thank You
RDSO, Lucknow, INDIA

39. Fuel Efficiency Indices
The following two fuel efficiency indices are popularly used on Indian Railways:
Fuel Consumption on 8th Notch
Fuel consumption at this notch is one of the important fuel efficiency index since
Fuel consumption at 8th notch is highest; and
Locomotives run at this notch for longer duration.
Fuel Consumption over Duty cycle
Notch-wise percentage running of locomotive over duty cycle for passenger and freight operations of Indian Railways locomotives is as under:
Fuel consumption (in kg/hr) over duty cycle is calculated by taking weighted average of fuel consumption at every notch over duty cycle.
RDSO, Lucknow, INDIA

40. ALCO Locomotives Emissions
Parameter
EPA Std.
(Tier-2)
UIC-624
3100 HP
2600 HP
2300 HP
NOx
5.5
6.7
10.44
12.94
16.28 HC
0.3
0.6
0.07
0.10
0.11 CO
1.5
2.2
4.60
4.55
2.12
- All values are in gm/bhp-hr
- Measurements made with Portable equipment only

41. Mass Emission measuring equipment
Other equipments of Mass emission measuring equipment include:
RDSO, Lucknow, INDIA

42. Environmental Management System
The head of the maintenance unit has to establish environmental policy keeping in mind the following aspects :
Nature, scale and environmental impacts of activities and products.
Commitment to continual improvement and prevention of pollution.
Minimisation of the waste material generated during activities.
Commitment to comply with environmental legislation / Regulation and other requirements.
Provide a framework for setting and reviewing the environmental objectives and targets.
RDSO, Lucknow, INDIA

43. Waste Management System
The procedures for disposal of waste materials includes:
Collection and disposal of the waste generated in diesel loco sheds;
Disposal of waste oil;
Measures to control spillage of fuel & lubricating oil;
Leakage / spillage of fuel oil from fuel installation or fire anywhere in the shed;
Acid spillage.
RDSO, Lucknow, INDIA

44. Emissions limits as per International Standards
Parameter
EPA Std.
(Tier-2)
UIC-624
NOx
5.5
6.7 HC
0.3
0.6 CO
1.5
2.2
Particulates
0.2
0.19
All values in gm/bhp-hr