Michael Iden, General Director, Car & Locomotive Engineering
Michael Iden, General Director, Car & Locomotive Engineering
Michael Iden, General Director, Car & Locomotive Engineering
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Freight rail, locomotives & fuels<br />
Natural Gas as a Transportation Fuel<br />
<strong>Michael</strong> <strong>Iden</strong>, P.E. , Union Pacific Railroad<br />
ASME Internal Combustion Engine Division Fall Conference<br />
Vancouver, BC, Canada September 24-25, 2012<br />
1
Purpose<br />
• US energy sources & uses<br />
• Freight railroads<br />
• The network and the systems<br />
• How locos. are used by and between systems<br />
• Freight locomotive overview<br />
• Nuts, bolts and bytes<br />
• Distributed Power<br />
• Previous projects re gaseous fuels 1936-1998<br />
• Loco. & tender design factors & challenges<br />
• LNG as a freight RR fuel: challenges<br />
<strong>Michael</strong> <strong>Iden</strong>, P.E. , Union Pacific Railroad<br />
ASME Internal Combustion Engine Division Fall Conference<br />
Vancouver, BC, Canada September 24-25, 2012<br />
2
Energy 101: where it comes from, what it does<br />
• Frt. RRs: ~3.5B US gal. diesel/year (0.5% of all US energy)<br />
1 Quad equals 7.2008 Billion US gallons = 27.258 Billion liters of diesel fuel equivalent *<br />
Ton-mile statistics from US DOT Bureau of Transportation Statistics<br />
<strong>Michael</strong> <strong>Iden</strong>, P.E. , Union Pacific Railroad<br />
ASME Internal Combustion Engine Division Fall Conference<br />
Vancouver, BC, Canada September 24-25, 2012<br />
3<br />
Frt. RR 0.5 Quads/year<br />
= 0.5% total US energy<br />
& produces ~40% of<br />
total ton-miles *<br />
Trucks 4.8 Quads/year<br />
= 4.8% total US energy<br />
& produces ~29% of<br />
total ton-miles *
RRs 101: N. American freight rail network<br />
1 international network in 3 countries<br />
5 *Class I RRs in US<br />
2 *equiv. Class I in Canada<br />
2 *equiv. Class I in Mexico<br />
* Class I RR defined as having at least US$346.8 million revenue in 2006<br />
Interoperability of equipment based on:<br />
Standard track gauge (4' 8-1/2")<br />
Standard couplers, air brakes, etc<br />
Standards for rolling stock design<br />
~1.3 million freight cars , most for<br />
interchange service between RRs<br />
~25,000 locomotives<br />
(25,000+ internal combustion engines)<br />
<strong>Michael</strong> <strong>Iden</strong>, P.E. , Union Pacific Railroad<br />
ASME Internal Combustion Engine Division Fall Conference<br />
Vancouver, BC, Canada September 24-25, 2012<br />
4<br />
Canada<br />
United States<br />
Mexico
RRs 102: Class I rail systems<br />
UP<br />
BNSF<br />
CN<br />
<strong>Michael</strong> <strong>Iden</strong>, P.E. , Union Pacific Railroad<br />
ASME Internal Combustion Engine Division Fall Conference<br />
Vancouver, BC, Canada September 24-25, 2012<br />
KCS<br />
(incl. KCS de<br />
Mexico)<br />
Ferromex<br />
(not shown)<br />
5<br />
CP<br />
CSX<br />
NS
RRs 103: Locos. v RR systems<br />
• RRs increasingly "share" locos. to expedite trains<br />
• Keeping locomotives with a train at interchange points reduces time<br />
• "Run thru" trains: RR A gives entire train (w/ locos.) to RR B<br />
<strong>Michael</strong> <strong>Iden</strong>, P.E. , Union Pacific Railroad<br />
– Example: Stockton CA (UP) > Chicago IL (CSX) > Albany NY<br />
• Also, "trackage rights": RR A's train runs on RR B's track<br />
– Example: Oakland CA (BNSF operates on UP track) > Denver CO<br />
Joliet IL (UP operates on BNSF track) > Kansas City MO<br />
ASME Internal Combustion Engine Division Fall Conference<br />
Vancouver, BC, Canada September 24-25, 2012<br />
Train operations<br />
<strong>Locomotive</strong>s Traffic flows<br />
Routes<br />
6
60-day GPS track of a UP locomotive*<br />
* 4000 HP DC locomotive normally assigned to long-distance operations<br />
<strong>Michael</strong> <strong>Iden</strong>, P.E. , Union Pacific Railroad<br />
ASME Internal Combustion Engine Division Fall Conference<br />
Vancouver, BC, Canada September 24-25, 2012<br />
7<br />
Run-thru Run thru<br />
operation<br />
by CN<br />
Run-thru<br />
operation<br />
by CSX<br />
Run-thru<br />
operation<br />
by NS
Locos. 101: locos. have trucks (trucks have tires)<br />
Tier 3 line-haul<br />
locomotive ...<br />
<strong>Michael</strong> <strong>Iden</strong>, P.E. , Union Pacific Railroad<br />
Power<br />
electronics<br />
Truck (bogie)<br />
ASME Internal Combustion Engine Division Fall Conference<br />
Vancouver, BC, Canada September 24-25, 2012<br />
11-to-15 liter/cylinder engine<br />
(400 gal. lube oil)<br />
5,000 gal. diesel tank<br />
8<br />
400 gal. cooling<br />
system<br />
~50,000 parts ~2 million lines of computer code<br />
Struct. steel underframe<br />
10'3" W x 16' H x ~73' L 208-to-217 tons fully-fueled
Locos. 102: Models v applications<br />
• Different models for different services (& requirements)<br />
<strong>Michael</strong> <strong>Iden</strong>, P.E. , Union Pacific Railroad<br />
ASME Internal Combustion Engine Division Fall Conference<br />
Vancouver, BC, Canada September 24-25, 2012<br />
4300-4400 HP 6 AC motors long-distance trains<br />
4000 HP 6 DC motors long-distance trains<br />
3800 HP 6 DC motors regional operations<br />
3000 HP 6 DC motors regional operations<br />
1500-2300 HP 4 DC motors yard & local operations<br />
2000 HP 4-6 DC motors yard & local ops.<br />
> Tier 2 ultra-low-emitting Genset multiple engines<br />
9
Distributed Power: 1 train, multiple locos.<br />
<strong>Michael</strong> <strong>Iden</strong>, P.E. , Union Pacific Railroad<br />
ASME Internal Combustion Engine Division Fall Conference<br />
Vancouver, BC, Canada September 24-25, 2012<br />
Head-end power (w/ crew)<br />
4400+4000 HP<br />
Mid-train DP power<br />
4400 HP<br />
Rear-end DP power<br />
4000+4400 HP<br />
10<br />
>65% of UP's<br />
gross ton-miles are<br />
generated by trains using<br />
DP technology<br />
Since year 2000, UP's<br />
fuel efficiency (ton-miles<br />
per gallon of fuel) has<br />
improved by 19%<br />
Train shown is a double-stack container train from Oakland to Chicago, at Donner Summit, California
Gas fuels for North American locomotives<br />
Plymouth<br />
<strong>Locomotive</strong><br />
Company<br />
builds propane<br />
locomotive<br />
1 spark (450hp)<br />
<strong>Michael</strong> <strong>Iden</strong>, P.E. , Union Pacific Railroad<br />
ASME Internal Combustion Engine Division Fall Conference<br />
Vancouver, BC, Canada September 24-25, 2012<br />
UPRR tests an LPG fuel gas turbine locomotive<br />
between LA and Las Vegas<br />
Several railroads collaborate<br />
with committee on potential of propane<br />
SwRI develops a laboratory program<br />
to test fuel blends<br />
SwRI Two Cylinder Research<br />
BN CNG Effort<br />
11<br />
BN Effort with ECI and Air Products<br />
BN operations with natural<br />
gas-fueled locomotives<br />
UPRR LNG R&D program<br />
with engine builders<br />
GasRail Initiative<br />
MK Rail LNG switch<br />
locomotives<br />
1935 1940 1945 1950 1955 1960 1965 1970 1975 1980 1985 1990 1995 2000 2005 2010<br />
R&D which did not reach revenue operations<br />
R&D which did reach revenue operations<br />
1 spark<br />
1750hp<br />
Timeline from page 4: http://www.arb.ca.gov/railyard/ryagreement/112807lngqa.pdf<br />
1 turbine<br />
4500hp<br />
Southern California LNG line haul locomotive project<br />
CAPTS Rail project with ECI conversion kit<br />
2 low-P<br />
3000hp<br />
4 high-P<br />
3800-4000hp<br />
4 spark<br />
1200hp<br />
11 known locomotives operated<br />
in revenue train service<br />
on gaseous fuels in US 1936-1998
Union Pacific's dual-fuel project<br />
• $15 million+ program 1991-1998 (+ OEM investments)<br />
• (4) 3800-and-4000 HP line-haul locomotives @ 2 OEMs<br />
<strong>Michael</strong> <strong>Iden</strong>, P.E. , Union Pacific Railroad<br />
– 95% gas substitution using high-pressure injection<br />
• (2) 30,000 US gallon cryogenic fuel tenders<br />
• Program suspended in '98, locos. never reached revenue operation<br />
– Cryogenic pump & injector failures<br />
– OEM resources needed to focus on EPA Tier 0<br />
• (2) 1200 HP spark-ignition switchers (diesel-converted-to-gas)<br />
ASME Internal Combustion Engine Division Fall Conference<br />
Vancouver, BC, Canada September 24-25, 2012<br />
12
LNG locomotives: design factors & challenges<br />
• Safety, reliability, efficiency,<br />
operability & maintainability<br />
• EPA loco. emissions regulations<br />
• Tier 0 in 2000, Tier 1 in 2002, Tier 2 in 2005, Tier 3 in 2012<br />
• Tier 4 (diesel aftertreatment) required for new locos. January 1, 2015<br />
<strong>Michael</strong> <strong>Iden</strong>, P.E. , Union Pacific Railroad<br />
– Tier 4 is a major R&D and engineering challenge for loco. OEMs<br />
– Repeat of late 1990s? (Engrg resources: dual-fuel v prep for emissions regs)<br />
• Tier 4 diesel ... Tier 4 diesel + gas ... or ... Tier 4 Gas-predominant<br />
• Need US EPA federal test protocol (FTP) emissions data<br />
ASME Internal Combustion Engine Division Fall Conference<br />
Vancouver, BC, Canada September 24-25, 2012<br />
13
LNG tenders: design factors & challenges<br />
• Safety & compliance<br />
• Energy density (1 US gal diesel ~ 1.75 LNG)<br />
• CNG insufficient energy density; impractical to carry LNG onboard<br />
• Matching loco. fuel demand, tender cap'y. & fuel<br />
• Varying # of locomotives in a consist (1, 2, 3 or 4)<br />
• Distributed Power (DP) locomotives in trains (mid- and/or -rear)<br />
• Compatibility (standards)<br />
<strong>Michael</strong> <strong>Iden</strong>, P.E. , Union Pacific Railroad<br />
– Tender-to-locomotive & refilling connections<br />
– Fuel-to-locomotive criteria (liquid/gas, pressure?)<br />
• Refueling infrastructure & re-fueling criteria<br />
Tender photo from http://utahrails.net<br />
ASME Internal Combustion Engine Division Fall Conference<br />
Vancouver, BC, Canada September 24-25, 2012<br />
14
LNG as a freight rail fuel: challenges<br />
1. Fuel source (gas)<br />
2. Fuel prep. (liquefaction) & refueling infrastructure<br />
<strong>Michael</strong> <strong>Iden</strong>, P.E. , Union Pacific Railroad<br />
Fuel demand Production capacity Storage Locations<br />
3. Tenders to carry the fuel<br />
Safety Design Capacity (vol.) Technology Manage & dispatch<br />
4. <strong>Locomotive</strong>s & engines which can use the fuel<br />
Safety Design Power Reliability Maintainability Shops<br />
5. Train & locomotive operational adjustments<br />
Safety Traffic flows Power demands DP Routes Schedules<br />
Interoperability (run-thru trains?) Refueling locations<br />
ASME Internal Combustion Engine Division Fall Conference<br />
Vancouver, BC, Canada September 24-25, 2012<br />
15
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