Modernizing Locomotive Test Cells for Turbocharger Testing

Engineering a Single-Source Solution for Next-Generation Diesel Locomotive Turbocharger Systems

When a leading transportation manufacturer needed to upgrade its test infrastructure for modern Tier IV compliance, they faced the complex task of testing both single- and dual-stage systems within a legacy footprint. Discover how a single-source engineering partner integrated advanced fluid conditioning, safety PLCs, and high-pressure air systems to unlock testing capabilities across four distinct engine families.

The Challenge

In order to meet stringent Tier IV emissions compliance regulations, a leading global transportation manufacturer needed to modernize its existing testing infrastructure. Specifically, the company required an extensive upgrade to an existing diesel locomotive turbocharger test stand located within their diesel engine test lab. The primary objective was to enable precise, steady-state turbocharger testing for both traditional single-stage and advanced dual-stage configurations.

Reconfiguring the legacy cell presented a distinct engineering challenge: the new layout had to accommodate a vast range of engine families, including Inline 6, Inline 8, V12, and V16 layouts, while managing complex thermodynamic variations. The client needed to introduce high-pressure inter-stage cooling and advanced fluid conditioning within a tight footprint, but lacked the specialized internal resources to design, procure, integrate, and commission these interconnected mechanical and software systems simultaneously.

The Solution

Holding a single-source contract, the ACS team executed a comprehensive test facility design and construction management strategy to transform the space into a highly flexible asset. To support multi-stage turbocharger testing, ACS designed and integrated a custom inter-stage air-to-water cooling system capable of dropping high-pressure compressor air temperatures from 425°F down to 110°F.

The integration team also developed and supplied a cutting-edge controls and data acquisition system driven by a GE RX3i PLC with Proficy software to manage cell automation and safety protocols. To handle the unique physical demands of a heavy-duty diesel locomotive turbocharger, ACS engineered specialized auxiliary support loops. This included a combustor diesel fuel supply system delivering up to 3.75 gpm at a maximum of 600 psi to safely push turbine speeds up to 50,000 rpm, alongside a heavy-duty compressed air starting system and a combustor air supply system capable of delivering up to 0.2 lb/sec.

Finally, to guarantee repeatable test environments for every locomotive turbocharger variant, ACS designed and built dedicated fluid conditioning units: a water conditioning system maintaining cooling water between 120°F and 200°F, and a lube oil conditioning system designed to preheat and regulate oil temperatures between 140°F and 215°F.

The Outcome

The completed project provided the client with a fully modernized, turnkey test cell capable of validating high-efficiency locomotive turbocharger arrangements across all targeted engine families. By managing everything from component specification and equipment build to contractor installation, ACS successfully delivered a seamless integration of the mechanical hardware, facility utilities, and control software.

The final commissioning phase verified that the updated cell safely manages the intense thermal and fluid dynamics necessary for Tier IV compliance testing. The client now possesses a highly adaptable testing asset that expands their operational capabilities per capital dollar, ensuring long-term flexibility as their diesel locomotive turbocharger product lines continue to evolve.

Key Features

• Complete modernization of an existing diesel engine test lab cell for advanced turbocharger testing
• Multi-stage capabilities supporting single-stage, dual-stage, and Tier IV dual-stage configurations
• Integration of high-pressure air, fuel, and water systems to achieve turbine speeds up to 50,000 rpm
• Precision fluid loops including a 425°F to 110°F inter-stage cooler, oil preheaters, and water conditioning

ACS Services

• Single-source test facility design, equipment engineering, and component specification
• Full turnkey equipment build, procurement, and contractor installation management
• Comprehensive integration of facility utilities, mechanical equipment, and control systems
• Supply, programming, and commissioning of data acquisition and GE RX3i safety PLC systems