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March -2015
1. Main Parameters 1
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 1 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
2.7 Multiple Unit consist It should be possible to run the loco in multiple unit consist operation
operation of up to three units
2.8 Emission Norms The diesel engine on the locomotive shall follow the UIC-1, (UIC-624,
1st edition, 2002) standards or better.
Note: Tenderer shall be agreed to upgrade the emission norms of
diesel engine as per directives prevailing in future at the cost of
Railways.
2.9 NVH standards The locomotive design should take into consideration the engine
noise and the vehicle noise. The maximum permissible sound
pressure level, measured as per procedure given in Annexure 6 shall
not be worse than the following values:
2.10 Additional features The locomotive offered shall be equipped with a microprocessor-
based control system, including engine management system, with
fault diagnostics, self load-box test (at full load) feature, adhesion
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 3 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
Marker light should be LED type. Flasher light should be LED type
and visibility of working flasher light shall not be less than 2 km in
day light also. The flash rate should be 40 flashes/min.
The loco should be provided with toilet/urinal for crew.
Wheel and Axle shall confirm the IRS specifications R-34 & R-43
respectively.
Head light in both end should be provided which should be as per
FRA regulation no. 49-CFR-229.125 in PAR 56 sealed enclosure.
Halogen light is minimum requirement. LED type head light should
be preferred.
2.11 Compressor For Goods Loco hauling 59 BOXN Wagon train:
For compressors whose FAD is governed by engine rpm, the
minimum capacity at idle speed (350rpm) of the engine should be of
the order of 2130LPM.
2.12 Air operated horn Working pressure range from 3 to 10 Kg/cm2 and sound intensity of
the horn should be between 120-125dBA at a distance of 5m.
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 5 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
locomotive as contracted.
• Brake rigging diagram indicating max. B.C. Pressure during
independent and auto brake, gross brake power etc.
• Type of brake block used, brake block area, average co-efficient
of friction and curve of co-efficient of friction between wheel and
brake block.
• Specification of defogging arrangement, wind screen wiper along
with general arrangement drawing.
• Design details of compressor as a part of AES system should be
provided.
4.0 Guarantees for Availability, Reliability and Fuel Efficiency required to be provided:
S. No. Parameter Details
4.1 Contractor Availability As detailed in Annexure 1 of this specification
Guarantee
4.2 Locomotive Reliability As detailed in Annexure 2 of this specification
Guarantee
4.3 Fuel Efficiency Guarantee As detailed in Annexure 3 of this specification
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 6 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
a) The lateral/transverse forces lasting more than 2 meters shall not exceed 4.7 tonnes, when
measured at the wheel axle box level. Contractor shall also provide the suitable
internationally accepted system to measure the lateral force during oscillation trials.
b) Evaluation shall also be done in terms of ride index which shall not be greater than 4. As
international standard follows FFT method which gives approx. 20-25% lower RI value as
compared to IR’s Average RI method. Average R.I. based evaluated R.I. is equivalent to
approx. 3.2 FFT based R.I.
c) A derailment coefficient should be worked out in the form of the ratio between the lateral
force (Hy) and the wheel load (Q) continuously over a period of 1/20th second and the value
of Hy/Q shall not exceed 1.
d) The value of acceleration recorded as near as possible to the bogie pivot, shall be limited to
0.3g both in vertical and lateral mode. A peak value upto 0.35g may be permitted, if the
records do not indicate a resonant tendency in the region of the peak value.
e) A general indication of stable running characteristic of the locomotives as evidenced by the
movement of the bogie on straight and curved track and by the acceleration reading and
instantaneous wheel load variation/ spring deflections.
The measurements shall be done by RDSO in accordance with report no. MT-334, issued
April 2002.
5.5 Rating and performance trials: These tests shall be done on one prototype each by IR with
new wheels, covering the following:
Dynamometer car test to ascertain starting and rolling resistance of the locomotive and to
prove “tractive effort-speed” characteristics and “dynamic braking effort/speed”
characteristics.
5.6 Field trials: One 6000 hp & 4500 hp prototype locomotive each shall be subjected to field trials
on IR for at least one per month. The manufacturer shall depute a team of engineers for
commissioning, testing and field trials of the locomotive and its equipment in service. The
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 7 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
manufacturer shall associate in the field trials jointly with RDSO. The manufacturer shall ensure
availability of typical tools & spare parts in adequate quantity for field trials, to be done as part of
commissioning. Test cars and related instrumentation & its operators shall be provided by IR.
5.7 Prototype testing: Two prototype locomotives of each type shall be offered for the tests at
clause 5.3, 5.5 & 5.6 to enable IR to conduct tests and field trials simultaneously. It is expected
that the tests listed at clause 5.3 & 5.5 shall be completed by IR in four to five months.
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 9 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 10 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
Annexure 1
The contractor will have to guarantee 95% availability of locomotive (as a percentage of the total
locomotive hours of the fleet).
The time taken for the following maintenance activities shall be considered on the account of the
Contractor for the purpose of calculation of Contractor Downtime:
a) Major maintenance
b) Minor maintenance
c) Predictive major maintenance
d) Major out of course repairs
e) Predictive minor maintenance attributable to the contractor to the extent of the additional
time taken beyond the standard time for the maintenance schedule.
f) Minor out of course repairs attributable to the contractor.
g) Locomotives waiting for material on account of delay in supply attributable to the
contractor.
h) Movement of light or dead locomotive to the relevant location in the context of any of the
above maintenance activities, if the cause for such movement is attributable to the
Contractor. Maximum time attributable to the Contractor will be 24 hours. Time taken
beyond 24 hours will be to the account of the purchaser.
i) Safety certification as required after a major maintenance or major out of course repair.
Note: Details of maintenance schedule, predictive maintenance and out of course repairs are
given in Annexure 4.
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 11 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
Annexure 2
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 12 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
Annexure 3
a) DCNTSFC of a locomotive will be measured as per the procedure prescribed in Annexure 5 of this
specification.
b) BSFC of the first ten locos delivered by the contractor will be measured as per the procedure for
Quick Test of BSFC described in Annexure 5 of this specification for reference only.
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 13 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
Annexure 4
Major maintenance schedules – Major maintenance schedules will be those schedules in which
overhaul of major assemblies of the locomotive will be undertaken. The periodicity will not be less
than 6 years. The major assemblies referred to will include the following:
• Renewal of power pack assemblies
• Renewal of Turbocharger
• Re-qualification of all components of the gear train
• Re-qualification of Engine Crankshaft
• Renewal/Reconditioning of Crankshaft damper, air compressor
• Repairs/reconditioning of Traction Motor/traction alternator
• Attention to rectifier assemblies
• Major attention to Traction Control Converter, major electrical modules
Minor maintenance schedules – This will include all maintenance schedules other than the
major maintenance schedules.
Major predictive maintenance – Major predictive maintenance will include such maintenance
requirements for which the locomotives will be required to be sent to the contractor’s facility. The
following items will be included under the category of major predictive maintenance:
a) Power pack replacement
b) Replacement of Crankshaft
c) Replacement of Traction Alternator
d) Structural defects in Loco Under frame, Fuel Tank, Superstructure, Bogie Frames, Cab
e) Repairs requiring replacement of CCB panel, TCC, HV/LV cabinet modules
f) Repairs requiring intensive re-cabling
g) Replacement of worn out wheels
Minor predictive maintenance – All cases of predictive maintenance not covered in Major
Predictive Maintenance will be classified as Minor predictive maintenance and will be carried out
at the Purchaser’s facility.
Major out of course repairs – This will include all items covered under Predictive Major
Maintenance, and is differentiated from the latter only to the extent that these defects have
occurred on line and/or are not detected as part of a maintenance schedule. These repairs will be
carried out at the Contractor’s facility.
Minor out of course repairs – All cases of out of course maintenance not covered in Major out
of course repairs will be classified as Minor out of course repairs and will be carried out at the
Purchaser’s facility.
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 14 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
Annexure 5; page 1 of 6
DIESEL LOCOMOTIVE FUEL TESTING PROTOCOL FOR MEASURING DUTY CYCLE NET
TRACTION SPECIFIC FUEL CONSUMPTION (“DCNTSFC”) & QUICK TEST FOR BSFC
1. The Duty Cycle Net Traction Specific Fuel Consumption (“DCNTSFC”) and Quick Test for
BSFC shall be the basis for benchmarking fuel efficiency of Diesel Locomotives. The
procedure for fixing these benchmarks is given in Annexure 3. The methodology described
hereafter shall apply for:
a) Fixing fuel efficiency benchmarks of DCNTSFC and BSFC
b) For checking compliance to fuel efficiency benchmark on new locomotives
c) For checking compliance to fuel efficiency benchmarks on locomotives as referred to
elsewhere in different clauses of the maintenance contract:
2. (a) The duty cycle for purposes of the calculation shall be as per the representative Duty
Cycle given below.
(b) The Duty Cycle Net Traction Specific Fuel Consumption (“DCNTSFC”) data as
measured shall be corrected to the following standard conditions:
(i) 85 kilometres per hour locomotive speed,
(ii) 15.6 degrees C inlet air temperature,
(iii) 97.73 kPa barometric pressure, and
(iv) 10,747 kCal/kg higher heat value fuel
* Duty cycle is given above is for reference only, however tenderer should be able to
adjust the engine performance with modified duty cycle also if it is change in light of
latest traffic instructions.
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 15 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
Annexure 5; page 2 of 6
General Preparation
A locomotive being tested must be in satisfactory running condition and have new engine air
filters, fuel filters, and lube oil filters. Testing shall be done with the locomotive in self-load.
Traction alternator current, measured after the locomotive rectifiers, shall be measured using a
separate, calibrated shunt. All fuel connections to the engine shall be re-directed to a weigh tank
on an electronic scale. A wayside source of compressed air shall be connected to the locomotive
to prevent the air compressor from loading. A diagram of the test is shown below.
To DB Grids
GPIB 3
2
995
720
0.04
0.04
16.0
7.0
950
420
49.5
16.8
900.5
403.2
0.9656
0.9607
869.5
387.4
0.3708
0.3763
352.2
158.0
14.09
6.32
34.78
15.50
Data Acquisition
1 581 0.04 4.0 190 9.2 180.8 0.9182 166.0 0.4071 77.3 3.09 6.64
IDLE 440 0.15 9.0 26.3 26.3 3.94
LO IDLE 340 0.31 6.3 20.5 20.5 6.37
DB1 440 0.02 25.9 25.9 0.52
comm
DB2 580 0.02 44.1 44.1 0.88
DB3 720 0.02 60.8 60.8 1.22
DB4 888 0.03 96.2 96.2 2.89
TOTALS: 1.00 393.61 1076.25
Laptop
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 16 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
Annexure 5; page 3 of 6
Measured parameters
A minimum of the following parameters shall be measured during the tests:
Parameter Range Accuracy
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 17 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
Annexure 5; page 4 of 6
Should the locomotive be equipped with any shaft driven auxiliary loads, they shall be
accounted for using the manufacturer’s established power level for each of these,
corrected for engine speed, air temperature, and barometric pressure. The objective is
to accurately measure and account for all electrical and mechanical loads on the
locomotive.
The manufacturer shall provide authenticated tested value of the power consumed by
shaft-driven auxiliary machines/equipment as well as notch-wise alternator efficiency
data at the above standard conditions for use in working out the results, it being
understood that DCNTSFC & BSFC shall be worked out from the measured values of
Traction alternator output (after rectifiers).
3. No fuel saving add-ons like Automatic Start-Stop, Trip Optimizer, etc shall be included in
this testing.
4. After all instrumentation has been applied to the locomotive, start the locomotive and
check for fuel leaks. Put the locomotive in self-load, and verify in a loaded notch that all
measurements read appropriately.
5. Warm the engine at N8 at least 20 minutes, until normal operating temperatures are
reached.
6. Starting at N8 and going down in notch, take three SFC test runs per notch. A test run
consists of measuring the fuel burned in a defined period of time, while recording and
averaging all other parameters. If the average sfc from three runs differs from the
average of the first two runs, then an additional run or runs must be taken until the
average of all runs (n runs) differs from the average of n-1 runs by 0.2% or less (for
notches 5 thru 8, 0.5% for lower notches).
7. At notch 8, a suggested run time is 5 or 6 minutes. Runs at lower notches must be
longer to achieve satisfactory accuracy given the lower power and fuel burn rates.
8. Measure the fuel burn rate at idle or low idle (if the locomotive is so equipped).
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 18 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
Annexure 5; page 5 of 6
Calculations
The manufacturer’s provided correction factors for engine inlet air temperature, barometric
pressure, and fuel heating value shall be applied to the measured data to correct the results to
the standard AAR conditions stated above.
The locomotive builder shall provide the value of the average total auxiliary power at the following
standard conditions for use in the calculations.
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 19 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
Annexure 5; page 6 of 6
Alternator End
Turbo
End Pressure
Regulating
Fuel Filter Engine Block
Manual valve (closed)
Platform
Fuel
Transfer
Pump
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 20 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
Annexure 6
The manufacturer shall be required to demonstrate the NVH capabilities of the locomotive (on the
prototypes only), employing the method given below:
1. The microphone shall be calibrated to 94dBA @ 1000 Hz, and Type I certified.
2. The microphone will be located as follows:
- 100 ft from centreline of the track
- 4' off the ground
- A-side, centreline of locomotive
- B-side, centreline of locomotive
3. Measurement shall be A-weighted, slow response, 30-second average
4. No precipitation.
5. Wind speed < 15 mph
6. Locomotive shall be in standstill, connected to external load box and developing full power.
Load box will be located away from the locomotive.
7. Test shall be at standard AAR conditions.
8. Test location shall not have any structure, trees etc. close to the locomotive causing sound
wave reflections.
9. Air compressor shall be disabled.
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 21 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
Annexure 7; page 1 of 6
Extract from Rating & Performance Trial report no. MT–260 of WDG4 locomotive
SYNOPSIS
The WDG4 class of locomotives of 4000 h.p. with Co-Co bogies are imported locomotives
supplied by M/s. General Motors, U.S.A. The locomotives are designed for hauling goods trains
at a speed of 100 km/h. The locomotive is controlled with EM-2000 advanced computer utilising
32 - Bit microprocessor, which improves the reliability and performance. The information
regarding performance of the locomotive is stored in the computer and can be down loaded to a
lap top computer for further analysis. This report covers the result of investigation pertaining to
Rating, Performance, Starting Adhesion and Specific Resistance of WDG4 locomotive. The tests
were conducted on LKO-RAC-LKO section of Northern Railway.
Investigations have revealed that the locomotive is capable to develop an average tractive effort
of 52.5 t at start on 8th notch indicating starting adhesion percentage of locomotive as 41.7 %.
The Tractive Effort Vs. Speed curve at 8th notch based on test values, follows the design curve
closely.
The Rheostatic brake effort at 8th notch was observed following the design curve on higher side
in the speed range of 10 to 53 km/h and was found to be 18.75 t. However, for speed range of 58
km/h and above the brake effort developed followed the design curve on lower side having
average difference of 1 t.
The specific starting resistance of the locomotive was found to be 2.65 kg/t. The specific rolling
resistance was found to follow the equation
R=1.85+0.0342V+0.00021V2
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 22 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
Annexure 7; page 2 of 6
Extract from Rating & Performance Trial report no. MT–260 of WDG4 locomotive
1. INTRODUCTION
1.1 The WDG4 class of locomotives of 4000 HP with Co-Co bogies, are imported
locomotives from M/s. General Motors, U.S.A. General arrangement of the
locomotive is as per GM Drawing No. L-020328. Bogie arrangement drawing is as
per GM Drawing No. 40075079. The axle load of the locomotive is 21t. The
locomotives are designed for a speed of 110 km/h and are intended for hauling
goods trains at a speed upto 100 km/h.
1.2 This report gives the result of Rating, Performance, Starting adhesion, specific rolling
resistance trial of WDG4 locomotive over RAC - LKO - BSB section of Northern
Railway and most of the recordings were done on LKO - RAC section.
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 23 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
Annexure 7; page 3 of 6
Extract from Rating & Performance Trial report no. MT–260 of WDG4 locomotive
4. TEST PARTICULARS:
4.1 TEST LOCOMOTIVE:
The WDG4 locomotive No. 12010 was received from DLW/BSB in the month of July
2000. The locomotive was taken for Rating and Performance test after completion of
braking trials on 30.6.2000.
4.2 INSTRUMENTATION:
The locomotive was instrumented for Rating and performance tests at UP yard
Lucknow. However petty repair attention was given to locomotive in Diesel Shed,
Alambagh, Lucknow.
4.3 TEST SECTION:
The Rating, Performance, Starting Adhesion and Specific Rolling Resistance tests
were conducted on RAC - LKO – BSB section up to a test speed of 100 km/h. Most
of the recordings were done on LKO-RAC section of Northern Railway. Fig. 2 shows
the Index section of LKO-RAC section.
4.4 PERIOD OF TEST:
Rating and Performance tests were conducted from 1.7.2000 to 2.8.2000 on LKO-
RAC section of Northern Railway.
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 24 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
Annexure 7; page 4 of 6
60 Extract from Rating & Performance Trial report no. MT–2of WDG4 locomotive
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 25 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
Annexure 7; page 5 of 6
Extract from Rating & Performance Trial report no. MT–260 of WDG4 locomotive
4.8.2 Adhesion Tests:
For the starting adhesion tests, the test locomotive was kept leading while braking locos
were kept in rear. Braking locos were used for developing enough load so that leading test
loco slips but does not move. Adhesion at start was determined by measuring the drawbar
pull of the locomotive at the time of wheel slip while starting fully braked train. The braking
was achieved by applying brakes from the control locomotives. The test locomotive was
gradually notched up till any of the wheel slipped. During this operation the following
parameters were recorded:
• Drawbar Pull.
• Notch Position.
• Sequence of wheel slipping.
• Location of the test.
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 26 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
Annexure 7; page 6 of 6
Extract from Rating & Performance Trial report no. MT–260 of WDG4 locomotive
6. CONCLUSIONS
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 27 of 28
Technical specification for 1676 mm gauge 6000 HP & 4500 HP IGBT-based three-phase AC-AC diesel-electric locomotives
Annexure 8
Motive Power Directorate, RDSO, Lucknow Spec No. 0.08.00-74 (Rev.02), March 2015 Page 28 of 28