Electronic injection control from HEINZMANN reduces diesel consumption in locomotives.

The diesel-electric drive on a Russian locomotive type TEM-7 was successfully converted from conventional to electronic fuel injection control. The fuel consumption of the Kolomna D49 combustion engine used was reduced by over 10 per cent. For this project, HEINZMANN supplemented a mechanical fuel injection system with an electronically actuated high-pressure valve for the first time in field use as a turnkey system solution for locomotives.

As a provider of complete engine controls, HEINZMANN is able to offer retrofit solutions for a large number of existing engines, individually adapted from the design stage through to commissioning. In addition to fuel savings, a significant reduction in emissions is also achieved. The operating characteristics and maintenance requirements are improved.

A large number of diesel powered locomotives are still in use all over the world. The stock is set to remain extremely high in the future in many countries on non-electrified lines. Operating periods of 30 years and more are not unusual. And the age of the engines in field reflects this. Consumption and emission values do not even come close to meeting the current requirements.

Improvements can be achieved by retrofitting the diesel injection system with an electronic control. This specifies the injection quantities and times precisely over the entire operating range. Significant consumption savings of over 10 per cent have already been realised with this approach.

Efficient locomotive operation with E-PPN

The heart of the HEINZMANN solution is the high-pressure control valve E-PPN (Electronically Controlled Pump-Pipe-Nozzle). It helps conventional mechanical injection systems to achieve completely new qualities. Together with the high-performance control electronics MVC 01-20 from HEINZMANN, it optimises the combustion process in a map-controlled approach. Smooth engine running and reduced engine loads are achieved via balanced injection quantities across all cylinders.

A high proportion of idle running is typical for many locomotives. Locomotive engines are seldom switched off, meaning that the level of idle-running consumption can be high. This mode of operation is particularly prevalent with shunting locomotives. In idle state, the E-PPN system enables a significant speed reduction through cylinder balancing. This can be supplemented with cylinder switch-off, where half of the cylinders are shut down alternately.

The extended options afforded by the injection design result in combustion optimisation and fuel savings over the entire operating range. This includes precise mapping of start of injection, injection quantity and injection quantity limitation. The black smoke formation is also reduced and the load acceptance behaviour improved. The level of the savings also depends heavily on the load profile of the locomotive. With a high part load share in particular, this results in significantly lower specific consumptions.

Flexible conversion for a wide variety of diesel engines

Converting a conventional, plug-in pump based injection system to E-PPN requires no special effort. Modifications on the engine itself are not usually required. The electronically controlled injection valve can be adapted to practically any fuel injection pump using corresponding adapters. A large power range up to 350 kW per cylinder is covered. Due to the modified connection geometry, only the high-pressure pipe has to be adapted. The injector remains unchanged. The solution is suitable for a wide range of different engines thanks to the high system flexibility. E-PPN is particularly suited for the often limited space available in locomotives.

The modified system is controlled via the universal control unit MVC 01-20, which, in addition to the injection control, also offers additional functions for engine monitoring. Sensors for speed, pressure and temperature recording round off the system. The HEINZMANN locomotive control system PEGASOS can also be integrated. This guarantees optimal operation with diesel-electric drives.

The pump converted to the E-PPN system no longer has a quantity control function. It is set permanently to full delivery. The start of injection and injection quantity are only specified by the start and duration of the control valve opening. When the valve is closed, quantities supplied by the pump are returned practically unpressurised to the tank.

Intelligent control in operation

This solution was used successfully for the first time on a KOLOMNA D49 diesel engine installed on a TEM-7 locomotive and has proven itself in continuous operation.

HEINZMANN supplies tailored system solutions for converting a wide range of different engines and applications, including all required components. Installation, commissioning, tuning and aftersales service are included in the scope of service. The E-PPN concept offers major benefits with regard to fuel savings and emissions reduction, with comparatively low conversion costs.