The Anonymous Widower

First Passenger Journey In The UK With mtu Hybrid PowerPack

The title of this post, is the same as that of this press release from Rolls-Royce.

This is the first paragraph.

The mtu Hybrid-PowerPack has passed another milestone successfully: In the UK, a train with mtu hybrid drive carried passengers for the first time as part of a special journey.

So how did mtu, a German manufacturer of large diesel engines for trains and ships, end up in bed with Rolls-Royce?

Wikipedia says this.

MTU Friedrichshafen remained a subsidiary of DaimlerChrysler until 2006 when it was sold off to the EQT IV private equity fund, becoming a part of the Tognum Corporation.

Rolls-Royce Holdings and Daimler AG acquired Tognum in 2011. In 2014, Tognum was renamed Rolls-Royce Power Systems, having become a 100 per cent subsidiary of Rolls-Royce Holdings.

A bit tortuous, to say the least!

This paragraph from the press release describes the journey.

The journey of the train – called HybridFLEX – was part of celebrations to mark the 25th anniversary of UK rail operator Chiltern Railways, which will use the train on its routes. It is a converted Turbostar DMU, which was previously equipped with a conventional mtu drive system.

It doesn’t sound very special, but it’s the equivalent of taking your BMW, Jaguar or Mercedes from twenty years ago and converting it to a full hybrid car with batteries, to assist the diesel engine.

Fuel and emission savings of 25 per cent are claimed, with the additional benefit that the train will not use the diesel engines in stations or sensitive areas.

In HybridFLEX Battery-Diesel Train Continues Programme Of Testing, I said this.

In the UK, the following diesel multiple units are fitted with modern MTU engines and could be candidates from a replacement power pack.

That is a total of 990 diesel engines.

As some of the Class 196 and Class 197 trains have yet to be delivered, I do wonder, if it would be sensible to deliver them as diesel-battery hybrid trains.

That is a lot of diesel engines, that could be replaced by MTU Hybrid Power Packs.

Conversions of other trains are also ongoing in Germany and Ireland.

This article from Rolls-Royce, is entitled  Hybrid Train Trials and gives a lot more details.

This is a quote from the article on fuel savings.

A fuel saving of 15 per cent is a
fantastic result and means that under
optimum conditions, 20 to 25
per cent should be possible. 

The savings certainly fit with Chiltern’s findings.

I have a few questions.

Can Locomotive Size PowerPacks Be Built?

As an engineer, I don’t see why not!

And there is certainly a need for them to cut diesel usage and carbon emissions with locomotives.

Conclusion

These conversions could be a very good interim solution.

 

July 25, 2021 Posted by | Transport | , , , , , | 22 Comments

HybridFLEX Battery-Diesel Train Continues Programme Of Testing

The title of this post, is the same as that of this article on Global Railway Review.

This is the first two paragraphs.

The HybridFLEX battery-diesel train is currently undertaking a programme of tests between Duffield and Wirksworth, prior to returning to Chiltern Railways in the summer.

Fitted with a Rolls Royce MTU hybrid drive, the HybridFLEX will cut noise emissions in stations and deliver zero emissions when operating under battery power.

All seems to be going well, according to the article.

I like the concept, as to replace a diesel engine with a diesel-battery hybrid power pack must surely be a sensible way to at least partially decarbonise.

In the UK, the following diesel multiple units are fitted with modern MTU engines and could be candidates from a replacement power pack.

That is a total of 990 diesel engines.

As some of the Class 196 and Class 197 trains have yet to be delivered, I do wonder, if it would be sensible to deliver them as diesel-battery hybrid trains.

 

 

May 29, 2021 Posted by | Transport | , , , , , | 2 Comments

Trimode Class 93 Locomotives Ordered By Rail Operations (UK)

The title of this post, is the same as that of this article on Railway Gazette.

This is the introductory paragraph.

Stadler and Rail Operations (UK) Ltd have signed a framework agreement for the supply of 30 Class 93 trimode locomotives, with an initial batch of 10 scheduled for delivery in early 2023.

Note that the order may have been a long time coming, but it is now for thirty locomotives. In this article on Rail Magazine from December 2018, which is entitled Rail Operations Fuels its Ambitions With Tri-Mode Class 93s, only ten locomotives were to be ordered.

A Few More Details

This article on Rail Engineer, which is entitled, Re-Engineering Rail Freight, gives a few more details about the operation of the Class 93 locomotives.

It says this about operation in electric mode.

In electric mode, the batteries are charged when braking or from the transformer. As the batteries use the space occupied by the braking resistors in the Class 88, when the batteries are fully charged, the locomotive has only its friction brake.

This about operation in diesel-hybrid mode.

In diesel/battery hybrid mode, the batteries are charged both as the train brakes and by the diesel engine when it is not operating under full load. When the train accelerates, the batteries give it the extra power needed to get up to speed. This is a significant benefit as accelerating a freight train of over 1,000 tonnes up to its operating speed can take several minutes.

This is said about the batteries and their effect on performance.

It has two Lithium Titanate Oxide liquid-cooled battery packs, which have a rapid charge and discharge rate. These each have a 40kWh capacity with a peak power of 200kW. Thus, whilst the train is accelerating, the Class 93 will have a peak power of 1,300kW for up to ten minutes, which is almost twice that of a Class 88 in diesel mode.

The batteries would appear to be quite small when you consider, that Vivarail are talking about 424 KWh in one of their Class 230 trains.

This is said about performance.

As a result, the 86-tonne Class 93 is capable of hauling 1,500 tonnes on non-electrified routes and 2,500 tonnes on electrified routes. With a route availability (RA) of seven, it can be used on most of the rail network.

It may not be the largest of locomotives, but it could have a very high performance.

I have a few thoughts.

Regenerative Braking Performance

The Rail Engineer  article says this about the Class 93 locomotive.

  • The train has a total of 80 kWh of battery storage to store braking energy.
  • The locomotive weighs 86 tonnes
  • It can haul 1,500 tonnes on non-electrified lines.

Using a train weight of 1586 tonnes and Omni’s Kinetic Energy Calculator, gives a kinetic energy of 8 kWh at 42.6 mph.

Does this mean that the locomotive is designed to trundle around the countryside at around forty mph?

These are timings from Real Time Trains.

  • Haughley Junction and Ely – 40 miles – 60 minutes – 40 mph
  • Werrington Junction and Doncaster – 86 miles – 130 minutes – 40 mph
  • Werrington Junction and Nuneaton – 67 miles – 123 minutes – 32.7 mph
  • Southampton and Oxford – 74 miles – 120 minutes – 37 mph

There will be savings compared to the current diesel timings, with a Class 93 locomotive.

  • Either side of these sections, the locomotive can use electric power to cut pollution, noise and carbon emissions.
  • Stops and starts on sections without electrification will save diesel and cut carbon emissions.
  • The train will be faster on electrified sections.

I also feel that with its smaller diesel engine, it will be able to maintain similar timings to current trains hauled by Class 66, Class 68 and Class 70 locomotives.

It can haul 2,500 tonnes on non-electrified lines.

Assuming a train weight of 2586 tonnes, the train energy at various speeds is as follows.

  • 40 mph – 114 kWh
  • 60 mph – 258 kWh
  • 80 mph – 459 kWh
  • 100 mph – 718 kWh
  • 110 mph – 868 kWh

Am I right to assume that once the batteries are full, the regenerative braking energy can be returned through the catenary to power other trains?

Operation With 750 VDC Third Rail Electrification

Will some locomotives be fitted with third-rail shoes to work into and out of Southampton?

They would not need to use diesel between and Basingstoke.

Access To Ports And Rail Freight Terminals

I recently wrote Rail Access To The Port Of Felixstowe.

Looking in detail at Felixstowe and how trains will serve the port, this was my conclusion.

I very much feel, that the specification of the Class 93 locomotive with its trimode capability is ideal for working to and from ports and freight terminals.

Looking at the specification, I am certain, that these locomotives can haul a heavy freight train out of Felixstowe on diesel, with help from the batteries.

  • The distance without electrification is around fifteen miles.
  • It takes around thirty minutes.
  • It is fairly flat Suffolk countryside with the possible exception of the climb over Spring Road Viaduct.

The batteries would need to be charged and surely in Felixstowe’s case the best way would be to electrify the two single track access routes between Trimley station and the Port.

  • On leaving, the trains would pass Trimley with full batteries.
  • They could also be at line speed after accelerating using the two miles or so of electrification.
  • They could also enter the Port with full batteries, after charging the batteries on the short length of electrification.

The batteries may be large and powerful enough, to enable diesel free operations in the Port.

Does this partially explain the increase in the order for Class 93 locomotives? There’s not really been a genuine Last-Mile locomotive in the UK before.

Enabling Carbon-Free Ports And Rail Freight Terminals

Regularly, I read reports of ports wanting to do carbon-free.

Class 93 locomotives can help the process, by not using their diesel engines in ports and rail freight terminals.

It might just need a short length of electrification between the port or terminal and the main line, to make sure batteries are fully-charged.

But not at London Gateway!

This Google Map shows the couple of kilometres of track without electrification, that connects London Gateway to the electrified route through East Tilbury station.

London Gateway would appear to be ready for low or possibly zero-carbon access, using Class 93 locomotives.

High Speed Freight Trains

Consider.

  • These Class 93 locomotives will have an operating speed of 110 mph, when running on electrified lines.
  • Currently, many multimode freight trains run at speeds of under 90 mph, as Class 66 locomotives don’t have the power to go faster and the wagons carrying the containers have a lower speed limit.

So with new or refurbished wagons capable of travelling at 110 mph, there will be speed improvements in some containerised freight.

As an example of what happens on the UK rail network, at the present time, I have found a freight train that goes between Felixstowe and Coatbridge near Glasgow,

  • The route is via Ipswich, London, The North London Line and the West Coast Main Line.
  • It can weigh 1600 tonnes.
  • The distance is 483 miles.
  • The service takes around 16 hours.
  • With the exception of between Felixstowe and Ipswich, the route is fully electrified.

I estimate that if this service could run at up to 100 mph on the Great Eastern Main Line and up to 110 mph on the West Coast Main Line, that several hours could be saved.

Electrification Gap Bridging

As I indicated earlier, I believe these Class 93 locomotives will be able to haul a freight train out of Felixstowe to the electrified Great Eastern Main Line.

In Thoughts On A Battery/Electric Replacement For A Class 66 Locomotive, I gave a list of typical gaps in the electrification in the UK.

  • Didcot and Birmingham – Around two-and-a-half hours
  • Didcot and Coventry – Just under two hours
  • Felixstowe and Ipswich – Around an hour
  • Haughley Junction and Peterborough – Around two hours
  • Southampton and Reading – Around one-and-a-half hours
  • Werrington Junction and Doncaster via Lincoln – Around two hours
  • Werrington Junction and Nuneaton – Just under two hours

How many of these gaps could be bridged by a Class 93 locomotive working in a diesel hybrid mode?

Stadler have not confirmed the size of the battery, but have said that it can provide 400 kW of power, which gives a maximum of 1.3 MW, when the batteries are working as afterburners for the diesel engine!

If the article in Rail Engineer is correct, I feel there is a high chance, that a Class 93 locomotive can bridge these gaps, with a load of 1500 tonnes in tow.

It is worth looking at current timings between Haughley Junction and Ely, when hauled by a Class 66 locomotive.

  • The distance is around 40 mph
  • The time taken is around an hour.
  • A Class 66 locomotive would put 2.2 MW at the rail.

This locomotive could need up to 2.2 MWh to bridge the gap.

But I don’t believe that a forty mile gap will be impossible for a Class 93 locomotive.

  • Stadler will have all the performance data of the bi-mode Class 88 locomotive to draw on.
  • The Class 93 locomotive has regenerative braking to help charge the batteries at any stops.
  • Several of the large electrification gaps on the UK rail network are in the flat lands of East Anglia and Lincolnshire.
  • Modern control systems would be able to eke out the power of the batteries.

I wouldn’t be surprised to find that Stadler have had an objective to design a locomotive that can perform like a Class 66 locomotive for two hours.

Conclusion

If Stadler get the specification, performance and reliability of this locomotive right, they will sell a lot of locomotives for operations like these! And not just in the UK!

 

 

January 16, 2021 Posted by | Transport | , , , , , | 4 Comments

Hitachi Targets Next Year For Testing Of Tri-Mode IET

The title of this post, is the same as that of this article on Rail Magazine.

This is the first two paragraphs.

Testing of a five-car Hitachi Class 802/0 tri-mode unit will begin in 2022, and the train could be in traffic the following year.

It is expected that the train will save more than 20% of fuel on Great Western Railway’s London Paddington-Penzance route.

This is the Hitachi infographic, which gives the train’s specification.

I have a few thoughts and questions.

Will The Batteries Be Charged At Penzance?

Consider.

  • It is probably not a good test of customer reaction to the Intercity Tri-Mode Battery Train, if it doesn’t work on batteries in stations through Cornwall.
  • Every one of the eight stops in Cornwall will need an amount of battery power.
  • London trains seem to take at least half-an-hour to turn round at Penzance.
  • London trains seem to take around 7-13 minutes for the stop at Plymouth.

So I think, that batteries will probably need to be charged at Penzance and possibly Plymouth, to achieve the required battery running,

There is already sufficient time in the timetable.

A charging facility in Penzance station would be a good test of Hitachi’s method to charge the trains.

Will Hyperdrive Innovation’s Battery Pack Be A Simulated Diesel Engine?

At the age of sixteen, for a vacation job, I worked in the Electronics Laboratory at Enfield Rolling Mills.

It was the early sixties and one of their tasks was at the time replacing electronic valve-based automation systems with new transistor-based systems.

The new equipment had to be compatible to that which it replaced, but as some were installed in dozens of places around the works, they had to be able to be plug-compatible, so that they could be quickly changed. Occasionally, the new ones suffered infant-mortality and the old equipment could just be plugged back in, if there wasn’t a spare of the new equipment.

So will Hyperdrive Innovation’s battery-packs have the same characteristics as the diesel engines that they replace?

  • Same instantaneous and continuous power output.
  • Both would fit the same mountings under the train.
  • Same control and electrical power connections.
  • Compatibility with the trains control computer.

I think they will as it will give several advantages.

  • The changeover between diesel engine and battery pack could be designed as a simple overnight operation.
  • Operators can mix-and-match the number of diesel engines and battery-packs to a given route.
  • As the lithium-ion cells making up the battery pack improve, battery capacity and performance can be increased.
  • If the computer, is well-programmed, it could reduce diesel usage and carbon-emissions.
  • Driver conversion from a standard train to one equipped with batteries, would surely be simplified.

As with the diesel engines, all battery packs could be substantially the same across all of Hitachi’s Class 80x trains.

How Many Trains Can Eventually Be Converted?

Great Western Railway have twenty-two Class 802/0 trains.

  • They are five-cars.
  • They have three diesel engines in cars 2, 3 and 4.
  • They have a capacity of 326 passengers.
  • They have an operating speed of 125 mph on electrification.
  • They will have an operating speed of 140 mph on electrification with in-cab ERTMS digital signalling.
  • They have an operating speed of 110 mph on diesel.
  • They can swap between electric and diesel mode at line speed.

Great Western Railway also have these trains that are similar.

  • 14 – nine-car Class 802/1 trains
  • 36 – five-car Class 800/0 trains
  • 21 – nine-car Class 800/3 trains

Note.

  1. The nine-car trains have five diesel engines in cars 2,3, 5, 7 and 8
  2. All diesel engines are similar, but those in Class 802 trains are more powerful, than those in Class 800 trains.

This is a total of 93 trains with 349 diesel engines.

In addition, there are these similar trains in service or on order with other operators.

Note.

  1. Class 801 trains have one diesel engine for emergency power.
  2. Class 803 trains have no diesel engines, but they do have a battery for emergency power.
  3. Class 805 trains have an unspecified number of diesel engines. I will assume three.
  4. Class 807 trains have no batteries or diesel engines.
  5. Class 810 trains have four diesel engines.

This is a total  of 150 trains with 395 diesel engines.

The Rail Magazine finishes with this paragraph.

Hitachi believes that projected improvements in battery technology, particularly in power output and charge, could enable diesel engines to be incrementally replaced on long-distance trains.

Could this mean that most diesel engines on these Hitachi trains are replaced by batteries?

Five-Car Class 800 And Class 802 Trains

These trains are mainly regularly used to serve destinations like Bedwyn, Cheltenham, Chester, Harrogate, Huddersfield, Hull, Lincoln, Oxford and Shrewsbury, which are perhaps up to fifty miles beyond the main line electrification.

  • They have three diesel engines, which are used when there is no electrification.
  • I can see many other destinations, being added to those reached by the Hitachi trains, that will need similar trains.

I suspect a lot of these destinations can be served by five-car Class 800 and Class 802 trains, where a number of the diesel engines are replaced by batteries.

Each operator would add a number of batteries suitable for their routes.

There are around 150 five-car bi-mode Hitachi trains in various fleets in the UK.

LNER’s Nine-Car Class 800 Trains

These are mainly used on routes between London and the North of Scotland.

In LNER Seeks 10 More Bi-Modes, I suggested that to run a zero-carbon service to Inverness and Aberdeen, LNER might acquire rakes of carriages hauled by zero-carbon hydrogen electric locomotives.

  • Hydrogen power would only be used North of the current electrification.
  • Scotland is looking to have plenty of hydrogen in a couple of years.
  • No electrification would be needed to be erected in the Highlands.
  • InterCity 225 trains have shown for forty years, that locomotive-hauled trains can handle Scottish services.
  • I also felt that the trains could be based on a classic-compatible design for High Speed Two.

This order could be ideal for Talgo to build in their new factory at Longannet in Fife.

LNER’s nine-car Class 800 trains could be converted to all-electric Class 801 trains and/or moved to another operator.

There is also the possibility to fit these trains with a number of battery packs to replace some of their five engines.

If the planned twenty percent fuel savings can be obtained, that would be a major improvement on these long routes.

LNER’s Class 801 Trains

These trains are are all-electric, but they do have a diesel engine for emergencies.

Will this be replaced by a battery pack to do the same job?

  • Battery packs are probably cheaper to service.
  • Battery packs don’t need diesel fuel.
  • Battery packs can handle regenerative braking and may save electricity.

The installation surely wouldn’t need too much test running, as a lot of testing will have been done in Class 800 and Class 802 trains.

East Coast Trains’ Class 803 Trains

These trains have a slightly different powertrain to the Class 801 trains. Wikipedia says this about the powertrain.

Unlike the Class 801, another non-bi-mode AT300 variant which despite being designed only for electrified routes carries a diesel engine per unit for emergency use, the new units will not be fitted with any, and so would not be able to propel themselves in the event of a power failure. They will however be fitted with batteries to enable the train’s on-board services to be maintained, in case the primary electrical supplies would face a failure.

The trains are in the process of being built, so I suspect batteries can be easily fitted.

Could it be, that all five-car trains are identical body-shells, already wired to be able to fit any possible form of power? Hitachi have been talking about fitting batteries to their trains since at least April 2019, when I wrote, Hitachi Plans To Run ScotRail Class 385 EMUs Beyond The Wires.

  • I suspect that Hitachi will use a similar Hyperdrive Innovation design of battery in these trains, as they are proposing for the Intercity Tri-Mode Battery Train.
  • If all trains fitted with diesel engines, use similar MTU units, would it not be sensible to only use one design of battery pack?
  • I suspect, that as the battery on a Class 803 train, will be mainly for emergency use, I wouldn’t be surprised to see that these trains could be the first to run in the UK, with a battery.
  • The trains would also be simpler, as they are only battery-electric and not tri-mode. This would make the software easier to develop and test.

If all trains used the same battery pack design, then all features of the pack, would be available to all trains to which it was fitted.

Avanti West Coast’s Class 805 Trains

In Hitachi Trains For Avanti, which was based on an article with the same time in the January 2020 Edition of Modern Railways, I gave this quote from the magazine article.

Hitachi told Modern Railways it was unable to confirm the rating of the diesel engines on the bi-modes, but said these would be replaceable by batteries in future if specified.

Note.

  1. Hitachi use diesel engines with different ratings in Class 800 and Class 802 trains, so can probably choose something suitable.
  2. The Class 805 trains are scheduled to be in service by 2022.
  3. As they are five-cars like some Class 800 and Class 802 trains will they have the same basic structure and a powertrain with three diesel engines in cars 2, 3 and 4?

I think shares a basic structure and powertrain will be very likely, as there isn’t enough time to develop a new train.

I can see that as Hitachi and Great Western Railway learn more about the performance of the battery-equipped Class 802 trains on the London and Penzance route, that batteries could be added to Avanti West Coast’s Class 805 trains. After all London Euston and North Wales and London Paddington and Cornwall are routes with similar characteristics.

  • Both routes have a high speed electrified section out of London.
  • They have a long section without electrification.
  • Operating speeds on diesel are both less than 100 mph, with sections where they could be as low as 75 mph.
  • The Cornish route has fifteen stops and the Welsh route has seven, so using batteries in stations will be a welcome innovation for passengers and those living near the railway.

As the order for the Avanti West Coast trains was placed, whilst Hitachi were probably designing their battery electric upgrade to the Class 800 and Class 802 trains, I can see batteries in the Class 805 trains becoming an early reality.

In Hitachi Trains For Avanti, I also said this.

Does the improvement in powertrain efficiency with smaller engines running the train at slower speeds help to explain this statement from the Modern Railways article?

Significant emissions reduction are promised from the elimination of diesel operation on electrified sections as currently seen with the Voyagers, with an expected reduction in CO2 emissions across the franchise of around two-thirds.

That is a large reduction, which is why I feel, that efficiency and batteries must play a part.

Note.

  1. The extract says that they are expected savings not an objective for some years in the future.
  2. I have not done any calculations on how it might be achieved, as I have no data on things like engine size and expected battery capacity.
  3. Hitachi are aiming for 20 % fuel and carbon savings on London Paddington and Cornwall services.
  4. Avanti West Coast will probably only be running Class 805 trains to Chester, Shrewsbury and North Wales.
  5. The maximum speed on any of the routes without electrification is only 90 mph. Will less powerful engines be used to cut carbon emissions?

As Chester is 21 miles, Gobowen is 46 miles, Shrewsbury is 29.6 miles and Wrexham General is 33 miles from electrification, could these trains have been designed with two diesel engines and a battery pack, so that they can reach their destinations using a lot less diesel.

I may be wrong, but it looks to me, that to achieve the expected reduction in CO2 emissions, the trains will need some radical improvements over those currently in service.

Avanti West Coast’s Class 807 Trains

In the January 2020 Edition of Modern Railways, is an article, which is entitled Hitachi Trains For Avanti.

This is said about the ten all-electric Class 807 trains for Birmingham, Blackpool and Liverpool services.

The electric trains will be fully reliant on the overhead wire, with no diesel auxiliary engines or batteries.

It may go against Hitachi’s original design philosophy, but not carrying excess weight around, must improve train performance, because of better acceleration.

I believe that these trains have been designed to be able to go between London Euston and Liverpool Lime Street stations in under two hours.

I show how in Will Avanti West Coast’s New Trains Be Able To Achieve London Euston and Liverpool Lime Street In Two Hours?

Consider.

  • Current London Euston and Liverpool Lime Street timings are two hours and thirteen or fourteen minutes.
  • I believe that the Class 807 trains could perhaps be five minutes under two hours, with a frequency of two trains per hour (tph)
  • I have calculated in the linked post, that only nine trains would be needed.
  • The service could have dedicated platforms at London Euston and Liverpool Lime Street.
  • For comparison, High Speed Two is promising one hour and thirty-four minutes.

This service would be a Marketing Manager’s dream.

I can certainly see why they won’t need any diesel engines or battery packs.

East Midland Railway’s Class 810 Trains

The Class 810 trains are described like this in their Wikipedia entry.

The Class 810 is an evolution of the Class 802s with a revised nose profile and facelifted end headlight clusters, giving the units a slightly different appearance. Additionally, there will be four diesel engines per five-carriage train (versus three on the 800s and 802s), and the carriages will be 2 metres (6.6 ft) shorter.

In addition, the following information has been published about the trains.

  • The trains are expected to be capable of 125 mph on diesel.
  • Is this speed, the reason for the fourth engine?
  • It is planned that the trains will enter service in 2023.

I also suspect, that like the Class 800, Class 802 and Class 805 trains, that diesel engines will be able to be replaced with battery packs.

Significant Dates And A Possible Updating Route For Hitachi Class 80x Trains

I can put together a timeline of when trains are operational.

  • 2021 – Class 803 trains enter service.
  • 2022 – Testing of prototype Intercity Tri-Mode Battery Train
  • 2022 – Class 805 trains enter service.
  • 2022 – Class 807 trains enter service.
  • 2023 – First production Intercity Tri-Mode Battery Train enters service.
  • 2023 – Class 810 trains enter service.

Note.

  1. It would appear to me, that Hitachi are just turning out trains in a well-ordered stream from Newton Aycliffe.
  2. As testing of the prototype Intercity Tri-Mode Battery Train proceeds, Hitachi and the operators will learn how, if batteries can replace some or even all of the diesel engines, the trains will have an improved performance.
  3. From about 2023, Hitachi will be able to design tri-mode trains to fit a customer’s requirements.
  4. Could the powertrain specification of the Class 810 trains change, in view of what is shown by the testing of the prototype Intercity Tri-Mode Battery Train?
  5. In parallel, Hyperdrive Innovation will be building the battery packs needed for the conversion.

Batteries could be fitted to the trains in three ways,

  • They could be incorporated into new trains on the production line.
  • Batteries could be fitted in the depots, during a major service.
  • Trains could be returned to Newton Aycliffe for battery fitment.

Over a period of years as many trains as needed could be fitted with batteries.

Conclusion

I believe there is a plan in there somewhere, which will convert many of Hitachi’s fleets of trains into tri-mode trains with increased performance, greater efficiency and less pollution and carbon emissions.

 

 

January 8, 2021 Posted by | Transport | , , , , , , , | 3 Comments

Thoughts On Batteries In East Midland Railway’s Class 810 Trains

Since Hitachi announced the Regional Battery Train in July 2020, which I wrote about in Hyperdrive Innovation And Hitachi Rail To Develop Battery Tech For Trains, I suspect things have moved on.

This is Hitachi’s infographic for the Regional Battery Train.

Note.

  1. The train has a range of 90 km/56 miles on battery power.
  2. Speed is given at between 144 kph/90 mph and 162 kph/100 mph
  3. The performance using electrification is not given, but it is probably the same as similar trains, such as Class 801 or Class 385 trains.
  4. Hitachi has identified its fleets of 275 trains as potential early recipients.

It is also not stated how many of the three diesel engines in a Class 800 or Class 802 trains will be replaced by batteries.

I suspect if the batteries can be easily changed for diesel engines, operators will be able to swap diesel engines and battery packs according to the routes.

Batteries In Class 803 Trains

I first wrote about the Class 803 trains for East Coast Trains in Trains Ordered For 2021 Launch Of ‘High-Quality, Low Fare’ London – Edinburgh Service, which I posted in March 2019.

This sentence from Wikipedia, describes a big difference between Class 803 and Class 801 trains.

Unlike the Class 801, another non-bi-mode AT300 variant which despite being designed only for electrified routes carries a diesel engine per unit for emergency use, the new units will not be fitted with any, and so would not be able to propel themselves in the event of a power failure. They will however be fitted with batteries to enable the train’s on-board services to be maintained, in case the primary electrical supplies would face a failure.

Nothing is said about how the battery is charged. It will probably be charged from the overhead power, when it is working.

The Intercity Tri-Mode Battery Train

Hitachi announced the Intercity Tri-Mode Battery Train in this press release in December 2020.

This is Hitachi’s infographic for the Intercity Tri-Mode Battery Train.

Note.

  1. The train is battery-powered in stations and whilst accelerating away.
  2. It says that only one engine will be replaced by batteries.
  3. Fuel and carbon savings of 20 % are claimed.

Nothing has been said in anything, I’ve read about these trains, as to whether there is regenerative braking to batteries. I would be very surprised if fuel and carbon savings of 20 % could be attained without regenerative braking to batteries.

In Do Class 800/801/802 Trains Use Batteries For Regenerative Braking?, I discussed the question in the title.

This is a shortened version of what I said in that post.

If you type “Class 800 regenerative braking” into Google, you will find this document on the Hitachi Rail web site, which is entitled Development of Class 800/801 High-speed Rolling Stock for UK Intercity Express Programme.

If you search for brake in the document, you find this paragraph.

In addition to the GU, other components installed under the floor of drive cars include the traction converter, fuel tank, fire protection system, and brake system.

Note that GU stands for generator unit.

The document provides this schematic of the traction system.

Note that BC which is described as battery charger.

Is that for a future traction battery or a smaller one used for hotel power as in the Class 803 train?

As a Control and Electrical Engineer, it strikes me that it wouldn’t be the most difficult problem to add a traction battery to the system.

From what Hitachi have indicated in videos, it appears that they are aiming for the battery packs to be a direct replacement for the generator unit.

Generator Unit Arrangement In Class 810 Trains

When I wrote Rock Rail Wins Again!, which was about the ordering of these trains, the reason for four engines wasn’t known.

It now appears, that the extra power is needed to get the same 125 mph performance on diesel.

The formation of a five-car Class 802 train is as follows.

DPTS-MS-MS-MC-DPTF

Note.

  1. The three generator units are in the three middle cars.
  2. The three middle cars are motored.
  3. The two driver cars are trailer cars.

How are Hitachi going to put four generator units into the three middle cars?

  • I wonder if, the engines can be paired, with some auxiliaries like fuel-tanks and radiators shared between the generators.
  • A well-designed pair might take up less space than two singles.
  • A pair could go in the centre car and singles either side.

It will be interesting to see what the arrangement is, when it is disclosed.

Is there the possibility, that some of the mathematics for the Intercity Tri-Mode Battery Train has indicated that a combination of generator units and battery packs can give the required 125 mph performance?

  • Battery packs could need less space than diesel generators.
  • Regenerative braking could be used to charge the batteries.
  • How far would the train be able to travel without electrification?
  • Trains would not run the diesel engines in the station.
  • Could the fuel and carbon savings of 20 %, that are promised for the Intercity Tri-Mode Battery Train, be realised?

There may be a train buried in the mathematics, that with some discontinuous electrification could handle the East Midlands Railway Intercity services, that generates only a small amount of carbon!

Would A Mix Of Diesel Generators And Battery Packs Enable 125 mph Running?

Consider.

  • The trial Intercity Tri-Mode Battery Train intended for the London Paddington and Penzance route, will probably have two diesel generators and a battery pack according to what Hitachi have said in their infographic for the Intercity Tri-Mode Battery Train.
  • East of Plymouth some of the stretches of the route are challenging, which resulted in the development and ordering of Class 802 trains, that are more powerful, than the Class 800 trains used on easier routes.
  • An Intercity Tri-Mode Battery Train with two diesel generators and a battery pack, needs to be as powerful as a Class 802 train with three diesel generators.
  • So effectively does that mean that in the right installation with top class controlling software, that in fast running, a battery pack can be considered equivalent to a diesel generator?

I don’t know, but if it’s possible, it does bring other advantages.

  • Fuel and carbon savings of 20 %
  • No diesel running in stations or whilst accelerating away.
  • Better passenger environment.

Configurations of 3-plus-1 and 2-plus 2 might be possible.

 

 

December 27, 2020 Posted by | Transport | , , , , , , , | 3 Comments

Diesel-Battery Hybrid TER Train To Be Tested Next Year

The title of this post, is the same as that of this article on Railway Gazette International.

These are the two introductory paragraphs.

Testing of a Coradia Polyvalent electro-diesel regional trainset fitted with a battery hybrid traction system is to begin early next year and passenger services are planned for 2022, Alstom has announced.

Two of the trainset’s four diesel engines are to be replaced by lithium-ion batteries, which will be used to recover and store braking energy for reuse. It is hoped that this will reduce energy consumption and greenhouse gas emissions by 20%, as well as reducing operating and maintenance costs.

Other points from the article.

  • Testing is planned for 2021, with service entry, the year after.
  • There are 300 of these Polyvalent trains in service.
  • TER trains will stop using diesel by 2030.
  • France intends to run its last diesel train in 2035.

It looks like Alstom are using a similar approach to that of Hitachi in the UK.

It looks like the French are ahead of us in the decarbonisation timetable for rail.

December 2, 2020 Posted by | Transport | , , , , | Leave a comment

Financing For 135 Hybrid Trainsets Agreed

The title of this post, is the same as this article on Railway Gazette International.

This is the introductory paragraph.

The European Investment Bank agreed a €450m financing package on July 23 which will support Trenitalia’s plans to order 135 electric-diesel-battery hybrid regional multiple-units at total cost of €960m.

The trains are from Hitachi’s Caravaggio family and will be built in their Italian plant at Pistoia. Their operation is described in this sentence.

They will use conventional overhead electrification where available, with ‘cutting-edge’ engines for operation onto non-electrified routes as well as batteries to eliminate emissions for the ‘last mile’ and in urban areas.

That sounds extremely sophisticated to me.

Is The Powertrain Technology Transferrable To The UK?

I have republished this post with a link to the original article, as it occurs to me, that Avanti West Coast, East Midlands Railway, Great Western Railway. LNER and other train operating companies could be in need of a train with a sophisticated Diesel/Electric/Battery Hybrid powertrain.

So will Hitachi be using a powertrain like this in the UK?

 

July 27, 2020 Posted by | Finance, Transport | , , , | 2 Comments

Iarnród Éireann Orders Stage V MTU PowerPacks

The title of this post, is the same as that as this article on Railway Gazette International.

The IE 22000 Class trains appear to be the main rolling stock of Irish Rail.

The Railway Gazette International article describes in detail how MTU are updating the standard diesel engines in these trains with their latest Hybrid PowerPacks.

The aim is to achieve a reduction of over thirty percent in both fuel consumption and carbon dioxide emissions.

From reading the article, it doesn’t appear to be a challenging project, once the testing is complete.

It does appear that MTU seem to get these conversion projects right.

Progress On The Porterbrook HybridFLEX Project

There is another engine conversion project, that uses MTU PowerPacks, underway in the UK, which I wrote about in Rolls-Royce And Porterbrook Launch First Hybrid Rail Project In The UK With MTU Hybrid PowerPacks, in September 2018.

Porterbrook call it the HybridFLEX project. I wonder how it is getting on.

This article on Diesel and Gas Turbine Worldwide, which is entitled Ricardo Leading Hybrid Train Project In UK, is the last reference I can find in January 2019.

As there are over two hundred trains, that can be converted in the UK, I’m looking forward to the rolling out of Porterbrook’s HybridFLEX project.

I suspect operators are too, as they’d like to save all that diesel.

July 27, 2020 Posted by | Transport | , , , | 1 Comment

Our Sustainability Journey

The title of this post, is the same as that of this press release on the Rolls-Royce web site.

It is sub-titled.

Paul Stein’s Thoughts On Sustainability And Electrification

Paul Stein is Rolls-Royce’s Chief Technology Officer, so what he says is important.

This press release was the source of the information behind Distributed Propulsion ‘Maybe The Only Means’ For Small Electric Flight Progress, which I wrote about Rolls-Royce’s beer keg-sized 2.5 MW generator.

This is the third paragraph.

We’ve taken great steps at Rolls-Royce with our three-pillar sustainability approach of developing the gas turbine to even greater efficiency, supporting the introduction of Sustainable Aviation Fuel and creating new, disruptive technologies such as electrification.

These are definitely, the three pillars of wisdom, when it comes to sustainable aviation.

E-Fan X

This paragraph is Paul Stein’s view of the E-Fan X.

One of the great endeavours in the latter category has been our E-Fan X programme in partnership with Airbus. From our side, this has involved creating a hybrid-electric power generation system at a scale never previously seen in our industry, comprised of an embedded AE2100 gas turbine driving a 2.5MW generator and 3000V power electronics and an electric propulsion unit. What has been particularly encouraging has been the amount of industry interest and support for this programme, and I know everyone at Rolls-Royce and Airbus has been truly grateful for that.

He states that the E-Fan  has now concluded, but a several valuable lessons have been learned.

2.5 MW Generator

He describes the generator like this.

Amongst the many great achievements from E-Fan X has been the generator – about the same size as a beer keg – but producing a staggering 2.5 MW. That’s enough power to supply 2,500 homes and fully represents the pioneering spirit on this project.

The press release discloses that the heart of this staggering generator is a Rolls-Royce AE2100 gas turbine, which powers the latest version of the legendary Lockheed Hercules; the C-130J Super Hercules.

Wikipedia gives this data for the AE2100D2 version of the engine.

  • Length – three metres
  • Diameter – 0.73 metres
  • Weight – 783 kilograms
  • Maximum Power Output – 3458 kW
  • Fuel Consumption – 0.25/kW/h

It looks like in the E-Fan X application, the engine is not at full power.

Use With Aviation Biofuel

Aviation Biofuel is described like this in the first sentences of its Wikipedia entry.

Aviation biofuel is a biofuel used for aircraft. It is considered by some to be the primary means by which the aviation industry can reduce its carbon footprint. After a multi-year technical review from aircraft makers, engine manufacturers and oil companies, biofuels were approved for commercial use in July 2011.

But it doesn’t necessarily mean growing large amounts of crops and converting it to the fuel. Altalto, who are backed by British Airways, Shell, Oxford University and the British Government are building a plant at Immingham to convert household and industrial waste into aviation biofuel.

I would expect that Rolls-Royce have made sure that the generator will work with aviation biofuel.

A Memory Of Emergency Power Generation

About twenty-five years, there was a major power failure after a thunder storm, where I lived in Suffolk and C and myself went to bed in the dark. We awoke to full power in the morning, after a good night’s sleep with no disturbance.

Imagine my surprise, when I let the dogs out to find parked in the field in front of the house, a very large articulated truck.

I was greeted by an engineer, who asked if I minded, his generator in my field. I seem to remember my response was to offer him a cup of tea, which he refused, as he said he had everything he needed in the truck.

It turned out that the main sub-station for the area had received a direct lightning strike and had been destroyed. So to supply power to all the nearby villages, as my farm was at the end of the supply, it was the most convenient place to plug in a transportable gas-turbine generator. The generator was in the field for about ten days and the whole operation impressed me with its professionalism.

But with this new 2.5 MW generator from Rolls-Royce, there would only need to be a small 3.5 tonne four-wheeled truck, to include the generator, fuel and living quarters for the engineer

We have made a lot of progress in twenty-five years.

A Modern Railway Locomotive

The power of this new Class 68 diesel locomotive, that was built in Spain, by Swiss company Stadler is a very healthy 2,800 kW.

Consider these facts about a Class 68 locomotive.

  • Thirty-four of these locomotives have been produced for the UK.
  • They are powered by a Caterpillar C175-16 engine, which weighs thirteen tonnes.
  • The transmission of these locomotives is electric, which means that the diesel engine drives a generator and the train is driven by electric traction motors.
  • The locomotive is equally at home hauling intermodal freight trains and passenger trains for Chiltern Railways or TransPennine Express.
  • According to Wikipedia, Class 68 locomotives comply with Stage III A of the European emission standards but not Stage III B. But that is much better than most of our noisy, smelly and polluting diesel locomotives.

Class 68 locomotives are members of the UKLight family of locomotives, which contains, these two other locomotives.

  • Already in service is the Class 88 locomotive, which is a bi-mode locomotive, which is capable of running on electrification or the on-board 0.7 MW diesel engine.
  • Under development is the Class 93 locomotive, which is a tri-mode 110 mph locomotive, which is capable of running on electrification, the on-board 0.7 MW diesel engine or battery power.

Stadler seem to be able to mix-and-match various power sources to provide versatile and highly-desirable locomotives.

I feel it would be feasible to design a railway locomotive with the following power sources.

  • 25 KVAC  overhead or 750 VDC third-rail electrification, providing up to perhaps the four MW of a Class 88 locomotive.
  • A Rolls-Royce gas-turbine generator running on aviation biofuel, providing up to perhaps three MW.
  • Batteries up to a weight of perhaps ten tonnes.

I am sure that it could handle many of the routes still run with diesel locomotives in the UK.

  • It would handle all locomotive-hauled passenger services and would be electric-only in stations.
  • It certainly solves the problem of hauling long intermodal freight trains between Felixstowe and the Midlands and the North.
  • To handle the heaviest stone and aggregate trains, it might need a more powerful generator, but I’m sure Rolls-Royce would oblige.

In Thoughts On A Battery/Electric Replacement For A Class 66 Locomotive, I gave a list of routes, that would need to be handled by a battery electric locomotive.

  • Didcot and Birmingham – Around two-and-a-half hours
  • Didcot and Coventry – Just under two hours
  • Felixstowe and Ipswich – Around an hour
  • Haughley Junction and Peterborough – Around two hours
  • Southampton and Reading – Around one-and-a-half hours
  • Werrington Junction and Doncaster via Lincoln – Around two hours
  • Werrington Junction and Nuneaton – Just under two hours

Will Rolls-Royce’s generator be able to supply 2.5 MW for up to four hours?

This would need two-and-a-half tonnes of aviation biofuel, which would be around 3,200 litres, which could be carried in the 5,000 litre tank of a Class 68 locomotive.

It certainly seems feasible to replace diesel locomotives with gas-turbine locomotives running on aviation biofuel, to reduce net carbon emissions and reduce noise and pollution.

But this is not just a UK problem and many countries, who rely on diesel-hauled rail freight, would look seriously at such a locomotive.

Underfloor Mounting In Passenger Trains

These pictures show the space underneath a Hitachi Class 800 train.

The red cap visible in some pictures is the filler for the oil or diesel for the MTU 12V 1600 R 80L diesel engine used to power the trains away from electrification.

This diesel engine has this specification.

  • It produces 560 kW of power.
  • It weighs around six tonnes.
  • Its is about 4 x 2.5 x 1 metres in size.

The diesel engine produces about a fifth of the power as the gas-turbine generator, which is also smaller and very much lighter in weight.

It should also be noted, that a nine-car Class 800 train has five of these MTU diesel engines.

At a first glance, it would appear Hitachi could find one of Rolls-Royce’s gas-turbine generators very useful.

  • It might even enable self-powered high speed trains to run on lines without electrification at speeds well in excess of 140 mph.
  • I can certainly see, High Speed Two’s classic-compatible trains having one or possibly two of these generators, so they can extend services on lines without electrification.

We shouldn’t forget that one version of British Rail’s Advanced Passenger Train was to be gas-turbine powered.

A Class 43 Diesel Power-Car

Rolls-Royce would need a test-bed for a trial rail application of their 2.5 MW generator and there is probably no better trial vehicle, than one of the numerous Class 43 power-cars waiting to be scrapped. They could probably obtain a complete InterCity 125, if they wanted one for a realistic weight, test equipment and a second power-car for comparison and rescue.

But seriously, if we are going to remove diesel from UK railways by 2040, a solution needs to be found for the GWR Castles, ScotRail’s Inter7Citys and NetworkRail’s New Measurement Train.

One of the great advantages of these staggering (Rolls-Royce’s Chief Technology Officer’s word, not mine!) generators is that they are controlled by Full Authority Digital Engine Control or FADEC.

FADEC will give the pilots in a Hercules or other aircraft, all the precise control they need and I doubt Rolls-Royce will leave FADEC out of their gas turbine generator, as it would give the operator or driver extremely precise control.

A driver of a GWR Castle equipped with two gas-turbine power-cars, would be able to do the following.

  • Adjust the power to the load and terrain, with much more accuracy, than at present.
  • Shut the engines down and start them quickly, when passing through sensitive areas.
  • Cut carbon-dioxide emissions, by simply using a minimum amount of fuel.

I would put a battery in the back of the Class 43, to provide hotel power for the passenger coaches.

Running current MTU engines in the Class 43s, on biodiesel is surely a possibility, but that not an elegant engineering solution. It also doesn’t cut carbon emissions.

As there are still over a hundred Class 43s in service, it could even be a substantial order.

It should also be noted, that more-efficient and less-polluting MTU engines were fitted in Class 43s from 2005, so as MTU is now part of Rolls-Royce, I suspect that Rolls-Royce have access to all the drawings and engineers notes, if not the engineers themselves

But it would be more about publicity for future sales around the world, with headlines like.

Iconic UK Diesel Passenger Trains To Receive Green Roll-Royce Jet Power!

COVID-19 has given Rolls-Royce’s aviation business a real hammering, so perhaps they can open up a new revenue stream by replacing the engines of diesel locomotives,

A Class 55 Locomotive

Why Not?

A Class 55 locomotive is diesel electric and there are thousands of diesel locomotives in the world, built to similar basic designs, that need a more-efficient and more environmentally-friendly replacement for a dirty, smelly, noisy and polluting diesel power-plant.

Marine Applications

The Wikipedia entry for the Cat C175, says this.

The Cat C175 is often used in locomotives and passenger-class ships.

I suspect there will be marine applications for the gas-turbine generator.

Conclusion

I’m very certain that Rolls-Royce’s pocket power station has a big future.

Who said that dynamite comes in small parcels?

 

 

July 19, 2020 Posted by | Energy, Transport | , , , , , , , , , , , | 11 Comments

Thoughts On The Actual Battery Size In Class 756 Trains And Class 398 Tram-Trains

A Freedom of Information Request was sent to Transport for Wales, which said.

Please confirm the battery capacity and maximum distance possible under battery power for the Tram/Train, 3 & 4 Car Flirts.

The reply was as follows.

The batteries on the new fleets will have the following capacities: –

  • Class 756 (3-car) Flirt – 480 kWh
  • Class 756 (4-car) Flirt – 600 kWh
  • Class 398 tram-trains – 128 kWh

I will now have thoughts on both vehicles separately.

Class 756 Trains

In More On Tri-Mode Stadler Flirts, I speculated about the capacity of the batteries in the tri-mode Stadler Flirts, which are now called Class 756 trains, I said this.

I wonder how much energy storage you get for the weight of a V8 diesel, as used on a bi-mode Flirt?

The V8 16 litre diesel engines are made by Deutz and from their web site, it looks like they weigh about 1.3 tonnes.

How much energy could a 1.3 tonne battery store?

The best traction batteries can probably store 0.1 kWh per kilogram. Assuming that the usable battery weight is 1.2 tonnes, then each battery module could store 120 kWh or 360 kWh if there are three of them.

I also quoted this from the July 2018 Edition of Modern Railways.

The units will be able to run for 40 miles between charging, thanks to their three large batteries.

Since I wrote More On Tri-Mode Stadler Flirts in June 2018, a lot more information on the bi-mode Stadler Class 755 Flirt has become available and they have entered service with Greater Anglia.

Four-car trains weigh around 114 tonnes, with three-car trains around a hundred. I can also calculate kinetic energies.

How Good Was My Battery Size Estimate?

These are my estimate and the actual values for the three batteries in Class 756 trains

  • My estimate for Class 756 (3- & 4-car) – 120 kWh
  • Class 756 (3-car) Flirt – 160 kWh
  • Class 756 (4-car) Flirt – 200 kWh

So have Stadler’s battery manufacturer learned how to squeeze more kWh into the same weight of battery?

In Sparking A Revolution, I talked about Hitachi’s bullish plans for battery-powered trains, in a section called Costs and Power.

In that section, I used Hitachi’s quoted figures, that predicted a five tonne battery could hold a massive 15 MWh in fifteen years time.

If Stadler can get the same energy density in a battery as Hitachi, then their battery trains will have long enough ranges for many applications.

Class 398 Tram-Trains

In Sheffield Region Transport Plan 2019 – Tram-Trains Between Sheffield And Doncaster-Sheffield Airport, I showed this map of the route the trams would take.

I also said this about the tram-trains.

The distance between Rotherham Parkgate and Doncaster is under twelve miles and has full electrification at both ends.

The Class 399 tram-trains being built with a battery capability for the South Wales Metro to be delivered in 2023, should be able to reach Doncaster.

But there are probably other good reasons to fully electrify between Doncaster and Sheffield, via Meadowhall, Rotherham Central and Rotherham Parkgate.

The major work would probably be to update Rotherham Parkgate to a through station with two platforms and a step-free footbridge.

Currently, trains take twenty-three minutes between Rotherham Central and Doncaster. This is a time, that the tram-trains would probably match.

If you adopt the normal energy consumption of between three and five kWh per vehicle mile on the section without electrification between Rotherham Parkgate and Doncaster, you get a battery size of between 108 and 180 kWh.

It looks to me, that on a quick look, a 128 kWh battery could provide a useful range for one of Stadler’s Class 398/399 tram-trains.

Class 398 Tram-Trains Between Cardiff Bay and Cardiff Queen Street Stations

The distance between these two stations is six chains over a mile,

Adding the extra bit to the flourish might make a round trip between Cardiff Queen Street and The Flourish stations perhaps four miles.

Applying the normal energy consumption of between three and five kWh per vehicle mile on the section without electrification between Cardiff Queen Street and The Flourish, would need a battery size of between 36 and 60 kWh.

Conclusion

The battery sizes seem to fit the routes well.

 

 

March 11, 2020 Posted by | Energy Storage, Transport | , , , , , , | 3 Comments

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