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7. Testing SmartStart automatic engine stop-start controls to reduce switcher locomotive idling time and fuel consumption

Testing SmartStart automatic engine stop-start controls to reduce switcher locomotive idling time and fuel consumption

The analysis and conclusions contained in this case study are those of the authors alone and do not necessarily represent the point of view of the Government of Canada.

Organization
Southern Railway of British Columbia

Major Findings
The SmartStart^® controls reduced fuel consumption by 30%.

Project Timeline
July 2003 to March 2007

Please note that some figures such as diesel prices are based on data from the period that this project took place.

Introduction

Transportation accounts for about one quarter of Canadian greenhouse gas (GHG) emissions and freight transportation - moving goods by air, rail, trucks and vessels - is a

major user of fossil fuels that cause these emissions. Transport Canada's Freight Sustainability Development Program (FSDP) and Freight Incentives Program (FIP) were two of several initiatives for reducing the freight sector's fuel consumption and related emissions. This case study presents the results of two projects undertaken by the Southern Railway of British Columbia, with financial support from Transport Canada. The projects investigated the use of automatic engine stop-start controls to reduce the idling time of diesel switcher locomotives.

The project found that the SmartStart^® stop-start controls reduced fuel consumption in the locomotives fitted with the systems by 30%. The payback period was under two years and could be even less with a volume purchase discount.

Project Description

Under the demonstration phase of this project, the Southern Railway of British Columbia acquired, installed, and tested commercially available controls to automatically manage the shutdown and restart of two diesel switcher locomotives and compared results to baseline available for these locomotives. Subsequent to the demonstration, SmartStart^® idle reduction controls were installed on 18 additional locomotives under the FIP.

The automatic stop-start control selected for testing and service installations was SmartStart^®, manufactured by ZTR Control Systems. The operational requirement was for the outfitted locomotives to reduce idle time and fuel consumption when the units were on standby, without sacrificing their ability to move freight cars when needed.

Project Objectives

The demonstration phase objective was to demonstrate how well the SmartStart^® technology manufactured by ZTR Control Systems can reduce switcher locomotive idling and its associated fuel consumption and greenhouse gas emissions. Other performance factors such as ease of installation, reliability, performance, and whether the stop-start cycles had any adverse effect on engine and component life, were also monitored. The incentives phase's objective was to install idle reduction equipment in 18 additional locomotives and monitor results over a broader range of locomotive types and working conditions.

Project Methodology

In the demonstration phase, locomotives SRY153 (1,500 hp GM) and SRY124 (1,750 hp GM) were fitted with SmartStart^® controls and returned to service in March 2004. During the 20-month testing period, these locomotives were monitored to quantify the amount of fuel conserved by the automatic stop-start. The locomotive fuel consumption was recorded on a monthly basis in relation to miles traveled and hours worked. Data collection was aided by the fact that SmartStart^® automatically recorded locomotive operational information. The performance of these locomotives was compared to four locomotives of similar horsepower that were subject only to manual shutdown procedures.The final data analysis took place at the end of 2005. In the incentives phase, 18 additional idle reduction units were installed in 18 locomotives and monitored over a period of 11 months.

Results

The Southern Railway of British Columbia reported that the SmartStart^® equipment was straightforward to install, and that the controls have worked reliably since installation. It took only two hours of training and operational experience for train engineers to acquire a comfort level with the automatic stop-start mode of operation.

Table 1 shows the demonstration operating data and fuel savings for the test locomotives SRY 124 and SRY 153 for the demonstration period.

       Table 1

	Locomotives
	SRY 124	SRY 153
Days of operation with SmartStart® controls	496	478
Reduction in idle time (hours)	1,455	921
Shutdown hours achieved (hours)	2,776	2,007
Fuel savings (litres)	36,427	33,859

Table 2 shows the reduction in fuel consumption for SRY 124 and SRY 153 compared to locomotives without automatic shutdown capability. It shows a significant reduction in fuel consumption. For SRY 124, fuel consumption was reduced by 26%. For SRY 153, fuel consumption was reduced by 31%.

       Table 2 - Fuel Consumption Comparison

Locomotives		Average litres/hour (at year end)
Without auto-shutdown	With auto-shutdown	Before study	During Study
		2002	2004	2005
1750 hp series
SRY 122		55.61	41.25	42.26
SRY 129		61.11	36.92	36.93
	SRY 124	54.42	41.24	40.32
1500 hp series
SRY 151		50.05	42.91	40.42
SRY 152		48.38	45.46	43.54
	SRY 153	48.68	36.49	33.63

The SmartStart^® controls not only delivered fuel savings, but also continually monitored and verified fuel savings. The controls also provided the following operational advantages:

• Monitoring of locomotive operating parameters and automatic initiation of:
  • engine shutdown during locomotive parked idle periods based on preset parameters and
  • engine restart based on preset parameters
• Supervisory control and diagnostic self-checks of the SmartStart^® system and locomotive to ensure safe and reliable shutdown and restart operation.
• Real-time recording of data relating to the performance of the SmartStart^® system and pertinent locomotive equipment status, which can be used by maintenance staff to ensure proper operation.
• Analysis software for evaluating total fuel savings and engine shutdown/restart statistics.
• Interface that allows locomotive mechanics to change certain preset conditions, evaluate the system status and to view or download system statistics.
• Expansion capabilities for additional add-on features and options.

During the two-year evaluation period, there were no system breakdowns or failures. Although the data analysis ended in July 2005, the controls remain in service with no performance problems from the microprocessors or abnormal wear on locomotive engine components.

According to Chief Mechanical Officer Michael Moy, “Southern Railway views this important locomotive emissions project as a success. From both an operational and maintenance point of view, the systems were integrated into Southern Railway's fleet of locomotives with minimal disruption. The systems operated as designed and without any operational failures.”

In the incentives phase, the idle reduction equipment was installed in the 18 locomotives sequentially over 11 months. This meant that the last locomotives upgraded were monitored for only a few months. In addition, four locomotives were not monitored at all due to mechanical problems unrelated to the idle reduction equipment. In spite of these two factors, 261,000 litres were saved in 11 months by the 14 functioning locomotives. These savings resulted in a reduction of 800 tonnes of greenhouse gas emissions. The reliability of the idle reduction equipment exhibited in the demonstration phase was also apparent in the incentives phase.

Costs and Payback

Table 3 shows the cost savings resulting from use of the SmartStart^® automatic stop-start controls in the demonstration phase. It indicates a payback period of about nine months, based on 2004/05 fuel prices. Higher fuel prices would make the payback period even shorter.

       Table 3 - Cost / Savings Comparison

Item	Cost or Saving
Costs
Purchase (2 - SmartStart systems)	$23,000
Installation labour	$5,900
Installation materials	$1,100
Data collection costs	$400
Total installation/and operation costs	$30,410
Savings
Fuel saving for SRY 124 as reported by SmartStart equipment (March 2004 to July 2005) 496 days	$20,300
Fuel saving for SRY 153 as reported by SmartStart equipment (March 2004 to July 2005) 478 days	$18,900
Total fuel cost savings	$ 39,200

Conclusion

The Southern Railway of British Columbia, with financial support from Transport Canada, installed and evaluated SmartStart^® automatic stop-start controllers. The controls reduced fuel consumption and emissions, automatically provided useful information about engine service and did not appear to have an adverse effect on engine components. The automatic stop-start controls provided the railway with an excellent payback period of about nine months.

The test location enjoys the mildest winters in Canada. Since one of the system parameters for permitting shutdown is an ambient temperature above 0^oC, the number of days that automatic shutdown can occur would be reduced by colder temperatures. The payback period could therefore be longer in colder areas of Canada.

In both the demonstration phase evaluation stage (based on two switcher locomotives) and the incentives phase application stage (based on 18 installations), the Southern Railway of BC found the SmartStart^® automatic stop-start controllers easy to install and did not result in any major operational or maintenance issues.

Additional Information

• The Southern Railway of British Columbia
• ZTR Control Systems
• Chicago Locomotive Idle Reduction Project, EPA Case Study, April 2004
• SmartStart Fact Sheet
• Reduction of Impacts from Locomotive Idling, Center for Transportation Research, Argonne National Laboratory

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Date modified:

2012-02-08

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