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Our Special Thanks TO: Joginpally B.R. Engineering College Hyderabad
Our Special Thanks TO: Joginpally B.R. Engineering College Hyderabad
Our Special Thanks TO: Joginpally B.R. Engineering College Hyderabad
ENGINEERING COLLEGE
HYDERABAD
DIESEL LOCOMOTIVE
AT
BY
K.PRUTHVI RAJ (14J21A0378)
DECLARATION
BY
K.PRUTHVI RAJ
ACKNOWLEDGEMENT
I take this opportunity to express our sincere gratitude to all the people who have
Been associated in the successful completion this mini project work. we would
like to show our greatest appreciation to the highly esteemed and devoted technical staff,
supervisors of Diesel Loco Shed, Kazipet. I highly indebted to
them and their tremendous support and help during the completion of our project.
I thank Sri M.RAVI KIRAN(PRINCIPAL DTCC)for his esteemed co-operation and guidance
throughout the period of our training without which we wouldn’t have seen the great insight and
expertise of INDIAN RAILWAYS.
I would also like to show our gratitude to Sri.K.MAHENDAR(CI,DTTC).we thank all the
staff of DIESEL LOCO SHED, KAZIPET for their support during this onemonth.
Finally, we have strived hard to gain knowledge during the training and present a good project
work.
CONTNENTS
DIESEL LOCOSHED KAZIPET
LOCOMOTIVES IN INDIA
COMPONENTS OF LOCOMOTIVES
POWER TRANSIMISSION
CONCLUSION
WELCOME
‘
INRODUCTION TO THE DIESEL LOCO SHED
KAZIPET
LOCOS HOLDING:
Type of locomotives NO.of .locomotives
WDM3A 38
WDG3A 53
WDM2 10
WDG4 59
WDG4D 26
RAILWAY CONSUMER DEPOT FOR FUEL DIPENSATION:
DESCRIPTION QTY
HSD oil tank capacity 456KL(2 tanks)
Installed on 2 2 - 0 3 - 1 9 7 7 232KL+224KL
HSD oil daily issues 25KL
Lube oil tank capacity 100KL(2 tanks)
LOCOMOTIVES IN INDIA:
A locomotive or engine is a rail transport vehicle that provides the motive power
for a train. The word originates from the Latin loco – "from a place", ablative of
locus, "place" + Medieval Latin motivus, "causing motion", and is a shortened
form of the term locomotive engine, first used in the early 19th century to
distinguish between mobile and stationary steam engines.
A locomotive has no payload capacity of its own, and its sole purpose is to
move the train along the tracks. In contrast, some trains have self-propelled
payload-carrying vehicles. These are not normally considered locomotives, and
may be referred to as multiple units, motor coaches or railcars. The use ofthese
self-propelled vehicles is increasingly common for passenger trains, but rare for
freight (see CargoSprinter). Vehicles which provide motive power to haul an
unpowered train, but are not generally considered locomotives because they
have payload space or are rarely detached from their trains, are known as power
cars.
Traditionally, locomotives pulled trains from the front. However, push-pull
operation has become common, where the train may have a locomotive (or
locomotives) at the front, at the rear, or at each end.
WDP4D WDM3A
b)Type offuel.
c)Typeof combustion.
Number of strokes:
According to no.of.strokes :
a)Four stroke engines:The engines in which piston takes four rotataions to
complete one cycle.
a)Spark ingnition.
Type of combustion:
a)External combustion.b)internalcombustion
Engine :
The engine may be defined as selfpropelled system in which power is produced
by chemical energy.
Types of transmission:
Power:2100hp,3100hp,4000hp,4500hp
Type:passenger,goods,mixed.
D-FUEL –DIESEL
G-GOODS
P-PASSENGER
M-MIXED
S-SHUNT
rotation. The shaft is one solid piece made from cast iron or forged steel.
Steel is usually used in high loading
situations, such as diesel or turbocharged engines. Oil passages are
either cast or drilled into the crankshaftto
distribute lubricant to the main and rod journals
SHAFT: Shaft is a mechanical component for transmitting torque and
rotation, and usually used to connect other
components of a drive train that cannot be connected directly because of
distance or the need to allow for relative
movement between them. Here one side of the shaft is connected to the
flywheel and the other end is connected tothe clutch plate and gear box
assembly.
CONNECTING ROD:
In a reciprocating piston engine, The connecting rod connects the piston to the
crankshaft. It is fastened to the piston
at its small end, by a piston pin, also known as a gudgeon pin. Together with the
crank, they form a simplemechanism that converts linear motion into rotating
motion. The big end is attached to the crankshaft at the crankpinjournal.
Connecting rods convert rotating motion into linear motion. A connecting rod is
rigid, it may transmit either apush or a pull and so the rod may rotate the crank
through both halves of a revolution, i.e. Piston pushing andpiston
pulling. In a few twostroke
engines, the connecting rod is only required to push.They are cast or forged to
form an H near the small end and an I near the big end. This shape provides
greaterstrength to resist the stresses than a solid rod of the same mass. To
maintain engine balance, all the connecting rodsin an engine are a matched set.
It Carry the engine motive energy directly to crank, attaining high level
performance. Connecting rods must be light
and yet strong enough to transmit the thrust of the pistons to the crankshaft.
Connecting rods are drop forged from a
steel alloy capable of withstanding heavy loads without bending or twisting.
Holes at the upper and lower ends are
machined to permit accurate fitting of bearings. These holes must be parallel.
DESIGN: Our HI
beam design is stronger and more durable than traditional rods. The thickness of
the web at the
beam is increased. This reduces the early signs of fatigue, providing a long life
rod that can withstand stress of high
revolution engines.
MATERIALS: Only a handful of materials are considered appropriate for the
use in engine connecting rod
construction. Titanium and aluminum are two popular materials used in the
construction of connecting rods,
specifically for performance vehicles. Drop forging steel alloys into connecting
rods results in a connecting rod that
is capable of handling heavy loads without bending, breaking or twisting.
CROSS GRAIN FLOW: Our exclusive process creates a memory actionthat
keeps the caps round even during
extreme high revs. When our rods are made, they have grain patterns, just like
wood. We make the body/neck ofthe
rods with the vertical grain direction, while the caps are made in the horizontal
direction.
FACTS: Connecting rods for internal combustion engines need to be durable
but relatively light weight. They need
to be able to withstand piston thrust and effectively transmit thrust to the
crankshaft, Connecting rods are available in
an assortment of sizes.
ENGINE ACTION
To produce power through an interval of time, a diesel engine must perform a
definite series of
operations over and over again. This series is known as a cycle in which
suction, compression, ignition,
and exhaust take place in the order listed. If the engine requires four strokes of
the piston and two
revolutions of the crankshaft to complete a cycle, it is known as a four-stroke-
cycle engine; one
completing the cycle in two strokes of the piston and one revolution of the
crankshaft is a two-strokecycle
engine. Figure 1.5 illustrates the operating cycles of the two types of engines.
In the four-stroke-cycle engine, air is drawn into the cylinder through the intake
valve as the
piston descends on the intake
PRESSURE CHARGING
Air enters the cylinder at high pressure. The amount of fuel entering the
cylinder is therefore limited because it has to be related to the amount of oxygen
available to mix with it.
If too much fuel enters the cylinder and is left unburned, it settles on the
cylinder wall and pistonand
dilutes the lube oil film. This prevents a tight fit and causes leakage of air and loss
of power. Therefore,
used to furnish supercharging air. The kind most commonly used on diesel-
electric locomotives is the amount of entering fuel must be carefully regulated.
Also, it must enter the cylinder so that the first
fuel entering begins burning before the rest of the fuel enters, providing gradual,
even combustion. If all
the fuel enters the cylinder before ignition begins, it all burns at once--explodes-
-and a loud knock from
the explosion, called combustion knock, occurs.
A pressure-charged engine provides a method of putting more air, more fuel, and
resulting greater power into cylinder
b) Cam flywheel:It is attached at another end to run the cam shaft
according to speed of crankshaft.
Water jackets :It is placed around the cylinder inorder to cool the
engine.
Lubricration sump:It is a resorvior which collects the
drained,dissposed lube oil in thesystem.
Exhuast manifold:It is a pipe which collects the exhaustgases
produced in the engine.
Turbosupercharger:It is a equipment which is a combination of
turbo&super charger.It consists a turbibe&compressor.
a)Fuel tank b)Fuel pipes c)Fuel filters d)Fuel motor e)Fuel pump
Fuel tank:It is a resorviour to store the fuel tobe supplied to the engine.It has a
capacity of 6000ltrs. The fuel is contained in a tank fitted with
baffle plates to prevent surging and with a pit to catch sludge and
water so that they can be drained out. Since the fuel pumps alone
cannot raise the fuel to the cylinder's intake port, two alternative
methods of supplying fuel can be used. A small service tank can
be located above the pumps and the fuel can enter the pumps by
gravity or, if the service tank is not used, fuel can be pumped from
the main tank by a mechanical or electric pump.
Fuel pipes:These are used to supply the fuel to the required parts without
leakage.
Since dust and grit in the fuel are the main causes of diesel engine trouble, the
most important of all precautions is fitting efficient filters in the fuel oil
supplyline.
The equipment is
quickly ruined if fine particles of dust and grit are allowed to enter the fuel line;
irregular running, loss
of power, and poor starting will result. The plunger in the fuel pump and the
helix opposite the spill port are usually worn
first when dirt is in the fuel.
1)primary
2)secondary.These are cylindrical in shape in which iron shell is rounded with
Fuel pump:Fuel pump is the major mechanical device which increase the
pressure of the fuel as required &stores the fuel to be sent to injector. A fuel
injection pump, not only creates the injection pressure but determines
the amount of fuel injected. Its toothed rack, controlled by the
engine governor or by the speed control lever, varies the amount of
fuel and actuates all the pump elements. The pump is primarily a
piston or plunger, sliding in a barrel. The lower end of the plunger
has two projections which engage slots in the control sleeve. Oil
enters the intake port and is trapped above the helical groove and
slot whenever it rises to cover the spill port. Various positions of
the groove and slot are shown in figure 1.8. Position (a) shows the
plunger at its lowest point and position (b) shows it when both
ports are closed during its rise in the cylinder. Positions (c), (d), and
(e) show the plunger when the locomotive
The fuel pump consists of some other mechanical devices namely:
Casing:It is iron body that surronds the internal parts.
Barrel:It is a internal part of fuel pump.It is a circular shape with
two holes used for injection of fuel.it stores the fuel
cam.
supplied.
Fuel injector:It is aa mechanical device in which the pressure of the
fuel is increased then the pressure of the air in the cylinder.It has a
nozzle through which fuel is sprayed with 9 holes.
BLOCK DIAGRAM
OF
FUEL INJECTION SYSTEM
TURBO SUPERCHARGER
A naturally-aspirated engine is one common type reciprocating piston I.C engine
that depends solely on atmospheric pressure to counter the partial vacuum in the
induction tract to draw in combustion air. In a naturally aspirated engine; air for
combustion or an air/fuel mixture is drawn into the engines cylinders by
atmospheric pressure acting against a partial vacuum that occurs as the piston
travels downwards toward bottom dead centre during the induction stroke. Due
to restriction at intake track, a small pressure drop occurs as air is drawn in,
resulting in a volumetric efficiency of less than 100 percent - and a less than
complete air charge in thecylinder.
A turbocharger is a small radial fan pump driven by the energy of the exhaust
gases of an engine. A turbocharger consists of a turbine and a compressor on a
shared shaft. The turbine converts exhaust heat to rotational force, which is in
turn used to drive the compressor. The compressor draws in ambient air and
pumps it in to the intake manifold at increased pressure, resulting in a greater mass
of air entering the cylinders on each intake stroke.
The pressure in the atmosphere is no more than 1atm ,there ultimately will be a
limit to the pressure difference across the intake valves and thus the amount of
airflow entering the combustion chamber.
Because the turbocharger increases the pressure at the point where air is entering
the cylinder, a greater mass of air (oxygen) will be forced in as the inlet manifold
pressure increases.
The additional air flow makes it possible to maintain the combustion chamber
pressure and fuel/air load even at high engine revolution speeds, increasing the
power and torque output of the engine. The increase in the inlet pressure of air by
any means is called as boost. General setup of turbo charger is shown.
1Compressor Inlet
2Compressor Discharge 3
4 Intake Valve
3 Exhaust Valve
4 Turbine Inlet
LUBRICATING SYSTEM
Sometimes, oil is used for cooling as well as for lubricating. When this is done,
a separate oil
radiator with its own cooling fan is provided with the main radiator. Usedfor
bearing lubrication, the
oil's circulation rate is lower than when it is used for piston cooling and
lubrication. Oil hits the
underside of the piston in a fine spray. The crankshaft, end bearings, operating
gear, and camshaft are
lubricated by oil under pressure; oil without pressure, free return oil, lubricates
the camshaft driving
gears and cylinder walls. Contaminating particles can usually be filtered out.
Contamination:
Some contamination of oil is inevitable. For example, the oil itself will oxidize
and form corrosive acids. These acids are prevented from harming the engine
by additives
which either keep the oil from oxidizing or provide a protective coating on the
parts they touch? In
addition, the oil should possess some detergent properties to keep the
contaminating matter in
suspension so that it will be drained off when the crankcase isdrained.
Contaminating materials found
in the oil may be any of the following: metal bits caused by wear of the engine,
carbonaceous particles
resulting from fuel incorrectly burned or caused by breakdown of the oil itself,
sunburnt fuel, cooling
water that has leaked in, and acid water caused by cooling of burnt gases which
have passed by the
piston.
Filters:
Oil circulation pumps are protected from contamination by gauze screens that
remove the heavier substances from the oil; smaller particles are removed by
metallic strainers made of
very fine gauze, steel wool, or closely spaced plates. The finest materials and
carbon carried in
suspension in the oil are removed by absorbent filters made of special papers,
cotton, or felt. Two
methods of routing the oil through the filters are used: full -flow filtering, which
passes all the oil through the filter; and bypass filtering where only a part of the
oil
is continuously bypassed through the filter. Full-flow filters have relief valves
that can open to take the
oil out of the filter's path when the pressure drop across the filter is excessive.
COOLING SYSTEM
Heat originating in the engine is absorbed by circulating water and dissipated in a
fan-cooled
radiator. In a diesel-electric locomotive, the fan is driven by a motor powered
by an auxiliary generator.
Since heated water helps the engine to reach its best operating temperature more
quickly, the radiator is
not brought into the water circuit until the water is quite hot. Temperature of the
water can be regulated
by louvers on the front of the radiator.
The water is circulated by a pump driven from the engine. It goes through water
jackets between
the cylinders and cylinder liners, and is then routed through the radiator to be
cooled. With a well regulated
radiator, water enters the engine at 100°-120° F. and leaves it at 150°-180° F.
Because heat
and cold cause metal to expand and contract, it is better to use a high rate of
water circulation with a
small difference in temperature of the water entering and leaving the engine
than to circulate the water more slowly and have a larger difference in entering
and
leaving temperatures.
Water in the cooling system is treated to remove hardness, to minimize
corrosion, and to remove
suspended impurities. Hardness, a term used to express the presence of scale-
forming salts in raw water,
can be removed by a water softener. Dry compounds should not be poured into
the radiator as they may
clog the system. Water should be treated in a separate container first and solids
allowed settling before
drawing solution off for the engine. If treatment is improper or ineffective,
radiators and water jackets
will become clogged and cylinder liners corroded.
Radiators: Radiators are used to cool the engine .It is a heat exchanger which
exchanges the heat.
ance vehicles or stationary applications. In particular MW-class installations,
coppeRadiators are heat exchangers used to transfer thermal energy from one
medium to another for the purpose of cooling and heating. The majority of
radiators are constructed to function in automobiles, buildings, and electronics.
The radiator is always a source of heat to its environment, although this may be
for either the purpose of heating this environment, or for cooling the fluid or
coolant supplied to it, as for engine cooling. Despite the name, most radiators
transfer the bulk of their heat via convection instead of thermal radiation.
Spacecraft radiators necessarily must use radiation only to reject heat.
The Roman hypocaust, is an early example of a type of radiator for building
space heating. The heating radiator was invented by Franz San Galli, a Prussian-
born Russian businessman living in St. Petersburg, between 1855 and
1857.Radiation and convection
Heat transfer from a radiator occurs by all the usual mechanisms: thermal
radiation, convection into flowing air or liquid, and conduction into the air or
liquid. A radiator may even transfer heat by phase change, for example, drying a
pair of socks. In practice, the term "radiator" refers to any of a number of
devices in which a liquid circulates through exposed pipes (often with fins or
other means of increasing surface area). The term "convector" refers to a class
of devices in which the source of heat is not directly exposed.
Radiators Of WDG4
Radiators of WDM 3A
Intercooler attched to
compressor
Intercooler connected to compressor
HEAT EXCHANGER:
A heat exchanger is a device used to transfer heat between a solid object and a
fluid, or between two or more fluids. The fluids may be separated by a solid wall
to prevent mixing or they may be in direct contact.They are widely used in space
heating, refrigeration, air conditioning, power stations, chemical plants,
petrochemical plants, petroleum refineries, natural-gas processing, and sewage
treatment. The classic example of a heat exchanger is found in an internal
combustion engine in which a circulating fluid known as engine coolant flows
through radiator coils and air flows past the coils, which cools the coolant and
heats the incoming air. Another example is the heat sink, which is a passive heat
exchanger that transfers the heat generated by an electronic or a mechanical
device to a fluid medium, often air or a liquid An intercooler is any mechanical
device used to cool a fluid, including liquids or gases, between stages of a
multi-stage compression process, typically a heat exchanger that removes waste
heat in a gas compressor. They are used in many applications, including air
compressors, air conditioners, refrigerators, and gas turbines, and are widely
known in automotive use as an air-to-air or air-to-liquid cooler forforced
induction (turbocharged or supercharged) internal combustion engines to
improve their volumetric efficiency by increasing intake air charge density
through nearly isobaric (constant pressure) cooling.
Heat exchanger of WDG3A
ELECTRICAL COMPONENTS:
In understanding the electric system, it may help to compare it to a water system
.The path of the water system, the pipe, compares to the wires of the
electric system, which form a path called a circuit. In the water
system, the pump supplies energy and the turbine absorbs it. Similarly, in the
electric system, the
generator supplies energy and the motor absorbs it.
In the water system, the pressure the pump supplies varies; the size of the pipe
must allow for
this variance of pressure. Different size pipes offer different resistance so that
the quantity of water
flowing through the pipe is affected. The characteristics of the water system are
paralleled by like
factors in the electric system where they are called volts, ohms, and amperes.
These and other basic
principles which govern the flow of electricity and its related magnetic effects
are discussed in this
VOLTAGE
Voltage is the pressure that forces current through a circuit. The pressure is
supplied by an
electric generator or battery and is often called potential difference or
electromotive force (elf). When
a circuit is available, the voltage causes a current to flow; when the circuit is
closed or broken, the
current will not flow. In practice, a volt is defined as a potential difference of
pressure that will cause
one ampere to flow through a resistance of one ohm. Voltage is the pressure that
forces current through
a circuit.
RESISTANCE
Resistance is the property of a material, or conductor, which opposes the flow
of current when
voltage is applied and which converts electrical energy into heat. An ohm is the
unit used to measure
resistance. Very small resistances are measured in millionths of an ohm, called
micromesh. Large
resistances are measured in millions of ohms, called me ohms.
Materials that offer very large resistance are called insulators orconductors.
Conductors carry
electric current easily, while insulators offer more resistance to the flow of
current. Although there are
no perfect insulators and conductors, organic and vitreous substances such
as rubber, oil, ceramics, and glass usually make good insulators;
metals usuallymake
good conductors. The resistance of an insulator is expressed in me
ohms and is measured by an
instrument called a mugger.
ALTERNATOR:
Altenators are divided in to two types:
a)Main alternator:The diesel engine dives the main alternator which provides the
power to move the train.The generator generates electricity which is used to
provide power for the traction motors mounte on the trucks.
The main alternator converts the power output of the diesel engine into
electric power for the operation of the traction motors. Directly connected to the
diesel engine, the
generator's speed varies with engine speed. The alternator r is self-ventilated by
a fan mounted on its
shaft. The main field of the generator is supplied by a battery or by an exciter
controlled by a load
regulator. A differential field, in series with the generator, is wound to oppose
the main field. The purpose is to vary the total field strength to obtain a constant
kilowatt output. Other fields, such as starting fields, are used when cranking.
The main pole pieces of the generator are of laminated steel riveted together and
bolted to the
frame. The field coils are impregnated and baked with insulating compounds to
guard against
movement and chafing within the coil and to permit flow of heat to the surfaces.
Built to withstand high
speed and vibrations, the armature of this generator is balanced both before and
after winding to reduce
vibration. It is supported at one end by an antifriction bearing and at the other
by the engine crankshaft
b)Auxiliary alternator:
Locomotives used to operate passenger trains equipped with an auxiliary
alternator .This provides power for lighiting ,heating ,aircondittioning .on the
loco.used to start system.
Traction motor :
Circuits:
Power from the main generator is carried by electric cables to the traction
motors, which are
geared to the driving axles. The main power circuit is this path of current
flowing from the generator
through the cables and motors, and back to the generator. Locomotives have
three types of circuits:
series, parallel, and series-parallel. In a series circuit, the same current passes
through each device and
connection in completing its path to the source of supply, and the total
resistance of the circuit is equal
to the sum of the resistance of all its portions. In a parallel circuit, the current
from the source divides
through two or more parallel paths and the total current from the source equals
the sum of the current in
the parallel paths. The resistance of a parallel circuit is always lower than the
resistance of any of its
individual parallel paths. A series of Christmas tree lights in which all go out
when any one burns out
(opens the circuit) is a familiar example of a series circuit; each bulb can stand
only a portion of the
voltage from a house circuit. The lights in which the other bulbs continue to
burn when one burns out is
a parallel circuit; each bulb operates on house voltage. If motors are connected
in the same manner as
the lamps, the same circuit characteristics apply. The difference in operating
characteristics of motors at
different voltages is a chief reason for the relatively greater number of methods
used for connecting
traction motors.
Many different designs of main power circuits are used. Each circuit
independent of the
others, except for the small wires in the wheel slip relay circuit. Connections in
many locomotives are
permanently joined in series-parallel. A tie between the motor circuits exists
when portions of the
circuits are in series-parallel and no contactors are used. In order that full
generator voltage can be
applied when the motors are in series connection, a contractor will close if the
tying circuit is in use and
other contactors will open the circuit to and from the generator.
In electric drive, power can be easily varied. The throttle adjusts voltage,
current, and attractive
effort. While the throttle remains in the first notch, the current, or amperage,
decreases rapidly because
the motors, which are increasing speed, develop a greater counter-voltage. If the
throttle is moved to a
higher position, the fuel supply is increased and the engine and generator can
deliver more power.
When the throttle is advanced as far as possible, engine speed and generator
voltage are at their
maximum.