D U a L-M O D E Lo Co M O Tive S Ystem S En G in Eer in G
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FRA/ORD-80/82.II DUAL-MODE LOCOMOTIVE SYSTEMS ENGINEERING V O L U M E 2 DETAILED DESCRIPTION AND ANALYSIS L.J. Lawson L .M . Cook The Garrett Corporation 2525 W. 190th Street Torrance, California 90509 FEBRUARY 1981 FINAL REPORT Document is available to the U S. public through the National Technical Information Service, Springfield, Virginia 22161 i Prepared for U.S. DEPARTMENT OF TRANSPORTATION FEDERAL RAILROAD ADMINISTRATION WASHINGTON, DC 20590 04 - Locomotives NOTICE This document is disseminated under the sponsorship of the Department of Transportation in the interest of information exchange. The U nited S ta te s Government assumes no l i a b i l i t y fo r its contents or the use th e re o f. The United States Government does not endorse products or manufacturers. Trade or manufacturerfs names appear herein solely because they are considered essential to the object of this report. Technical Report Documentation Page 1. Report No. 2. Government Accession No. 3. Recipient's Catalog No. FRA/0RD-80/82. 4. Title and Subtitle 5. Report Date February 1981 DUAL-MODE LOCOMOTIVE SYSTEMS ENGINEERING 6. Performing Orgonization Code VOLUME Detailed Description and Analysis. 8. Performing Organization Report No. 7. Author(s) L. M. Cook, L. J. Lawson 80-17253-2 9. Performing Organization Name and Address 10. Work Unit No. (TRAIS) AiResearch Manufacturing Company of California A D iv is io n o f The G a rre tt Corporation 11. Contract or Grant No. 2525 W. 190th Street DTFR53-80-C00010 - Torrance, CA 90509 13. Type of Report and Period Covered 12. Sponsoring Agency Name and Address Final Report U.S. -Department of Transportation December 1979 through Federal Railroad Administration November 1980 Office of Research and Development 14. Sponsoring Agency Code Washington, DC 20590 15. Supplementary Notes Wayside'Energy Storage Study, FRA/0RD 78/78, IV Dual Mode Locomotive Systems Engineering 16 16. Abstract This report, Volume II, provides a detailed description of the analysis of the dual mode locomotive (DML) systems engineering.study undertaken as Phase I of a proposed five-phase program. The intent of the overall DML program is the development, in-service demonstration, and ultimate deployment of dual-mode locomotives. This study has confirmed the technical via b ility of the DML based on a modified diesel- el eCtronic locomotive model SD40-2, which can operate from either a high voltage catenary electrified at 60 Hz or from an onboard diesel engine. The DML can be made available in either 50- or 25-kv versions and could have a regenerative elec tric brake capabiIity • if required. The weight of a 50-kv, regenerative DML (the heaviest option) is under 398,000 lb, with' normal options included. The space requirements fo r the e le c tr ic components are compatible with in s ta lla tio n on e x is t ing locomotive platforms without interfering with the diesel power equipment. The cost of the conversion of an SD40-2 to the DML configuration at locomotive rebuild ranges from $367*014 to $414,097. This .conversion will make possible an initial electrificat ion project that will result jn a return on investment that is superior to conventional electrification for a fraction of the initial cost. The DML permits incremental electrification, which allows the reduced dependence on imported petroleum products associated with electrification to be achieved at a rate compatible with the available capital funds. This re p o rt comprises two volumes as fo llo w s : Volume I - Surrmary and Volume II - Detailed Description and Analysis. 17. Key Words 18. Distribution Statement Locomotives, railroads, electrification, Document is a va ila b le to the public regenerative braking, dual-mode locomo through the NationaI Technical Information tives, electric locomotives, energy Service, Springfield, Virginia 22161. conservation. 19. Security Classif. (of this report) 20. Security Classif. (of this page) 21. No. of Pages 22. Price Unclassified Unci assi fied 202 Form DOT F 1700.7 (8-72) Reproduction of completed page authorized i METRIC CONVERSION FACTORS 23 Approximate Conversions to Metric Measures Approximate Conversions from Metric Measures 22 Symbol When You Know Multiply by To Find Symbol Symbol When You Know Multiply by To Find _ Symbol 8 LENGTH LENGTH mm millimeters 0.04 inches in cm centimeters 0.4 inches in in inches •2.5 centimeters cm m meters 3.3 feet ft ft feet 30 centimeters cm m meters 1.1 yards yd yd yards 0.9 meters m km kilometers 0.6 miles mi mi miles 1.6 kilometers km ------16 AREA AREA = ------16 cm2 square centimeters 0.16 square inches in2 in2 square inches 6.5 square centimeters cm? = m2 square meters 1.2 square yards yd2 0.09 square meters m2 km2 . square kilometers 0.4 square miles mi2 <t* square feet ------14 yd2 square yards 0.8 square meters m2 ha hectare! (10,000 m?) 2.5 acres mi2 square miles 2.6 square kilometers km2 13 H* acres 0.4 hectares ha 5 H- MASS (weight) MASS (weight) 12 g grams 0.035 ounces oz oz ounces 28 grams g = 1 ■------11 kg kilograms 2.2 pounds lb lb pounds 0.45 kilograms kg = ------ t tonnes (1000 kg) 1.1 short tons short tons 0.9 tonnes t 4- (2000 lb) = ------ ------10 : VOLUME VOLUME =■ -------9 =5 milliliters 0.03 fluid ounces fl oz tsp teaspoons 5 milliliters ml -------8 ml Tbsp tablespoons 15 milliliters ml = I liters 2.1 pints pt = I liters 1.06 quarts qt fl oz fluid ounces 30 milliliters ml -------7 c cups 0.24 liters I I liters 0.26 gallons gal Pt pints 0.47 liters I , =------ m3 cubic meters 36 cubic feet f»3 qt quarts 0.95 liters l I =------ -----“ 6 m3 cubic meters 1.3 cubic yards yd3 gal gallons 3.8 liters I i ft3 cubic feet 0.03 cubic meters m3 TEMPERATURE (exact) yd3 cubic yards 6.76 cubic meters m3 4 TEMPERATURE (exact) °C Celsius 9/5 (then Fahrenheit °F temperature add 32) temperature 3 ®F Fahrenheit 5/9 (after Celsius °c temperature subtracting temperature OF 32) °F 32 98.6 212 40 0 40 60 120 160 200) 1 1 1 l 1 I 1 l 1 | 1 1 I I i I l i i l 1 1 l 1 1 1 *1 In. - 2.54 cm (exactly). For other exact conversions and more detail tables see 1 r i i 1 1 1 1 1 1 1 NBS Mi sc. Publ. 286. Units of Weight and Measures. Price $2.25 SD Catalog i 40 -20 20 40 60 80 100 No. C13 10 286. inches °C 37 °C PREFACE This final report sunmnarizes the results of the dual-mode locomotive (DML) systems engineering study. ■It is submitted to the Federal Railroad Administration (FRA) by the AiResearch Manufacturing Company of California> a division of the Garrett Corporation, in accordance with U.S. Department of Transportation (DOT) Contract No. DTFR53-80-C-00010. This final report comprises two volumes: Volume No. Title I Summary II Deta iIed Descr i pt i on of ° Ana Iys i s This DML study represents the joint efforts of Garrett; GEC Traction (U.K.) Ltd., who assisted in the determination of component sizes; and Morrison-Knudsen, who conducted an equipment installation analysis. The continued assistance and guidance of the FRA Contracting O fficer's Technical Representative, Mr. John Koper, Program Manager, Energy/Environment, and several members of the FRA, Transportation Systems Center (TSC), and Department of Energy (co-sponsor) staffs were invaluable to the success of the program. The interest and support for the DML concept given by Mr. Peter Eggleton, Director General, Transport Canada Research and Development Centre, and his staff have contributed to the likelihood of DML deployment throughout North America. Major contributions were made by the Association of American Railroads and by many individual U.S. railroads, who provided comprehensive information that was used to establish and maintain the necessary data base. Many of these railroads also acted as sounding boards in the formulation and review of the DML concept. Their comments and suggestions have been incorporated into the final recommendations of this report, with the result that the concept favored for preprototype construction and for ultimate fleet deployment is representative of equipment that railroads would consider for future procurement. The fol lowing raiInpads have given substantial assistance or have expressed interest in the DML concept to Garrett during the study: Am trak Atchison, Topeka, and Santa Fe Burlington Northern C h e ssie C h ic a go and N o rth W estern .Chicago Milwaukee St. Paul and Pacific Consolidated Rail Corporation Denver and Rio Grand Western Duluth Missabe and Iron Range Louisville and Nashville Missouri Pacific Norfolk and Western Seaboard Coast Line Soo Southern Southern Pacific Union Pacific In addition, many equipment suppliers were helpful in defining the equipment that would be required to achieve the locomotive modification and in the review of the proposed modification. The suppliers contributing to the study were: Dow C o rn i ng F a iv e le y General Electric Industrial Sales Division General Motors (Electro-Motive Division) Ingersoll Rand Kim Hotstart Matra Electric Inc. Power Energy Industry ■ Ringsdorf Southern California Edison Vapor Corporation Western Compressor Service (Sul lair) iii/iv blank CONTENTS Sect i on Page 1 INTRODUCTION 1-1 Program Outline 1-1 Phase I Methodology 1-3 Train Performance Calculator (TPC) 1-3 Format of Final Report 1-4 2 TECHNICAL AND ECONOMIC REQUIREMENTS '* ■ 2-1 Railroad Operating Classifications 2-1 Economic Analysis 2-28 Locomotive Population ' 2-53 Prototype Selection 2-53 3 ' BASELINE CONCEPT ' 3-1 Catenary Voltage 3-1 Operational Characteristies 3-1 Power Sources 3-2 Methods of Deployment 3-2 Locomotive Weight 3-3 Locomotive Height 3-3 Locomotive Operating Range 3-3 ■’*> ’■ Engineer Interface 3-4 Braking • i.- 3-4 Power Circuit ’ 3-5 Energy Management 3-13 Power Enhancement 3-13 ■ Adhesion Utilization 3-14 Auxi Maries 3-14 Service Life ■ 3-17 Maintenance Requirements 3-17 4 PRELIMINARY DESIGN DEFINITION 4-1 Configuration of Selected Candidate Locomotive 4-1 Modification to Locomotive Controls 4-2 Preliminary Design .