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TRAINING PERIOD: 12.06.207 to 11072017
TYPES OF PISTON USED IN DIESEL LOCOMOTIVE AND ITS MAINTAINANCE
PRESENTED BY Vishal Yadav
Introduction to Locomotive Workshop, Lucknow
About Indian Railways
History of Rail Transport In India
Technical Details Of Indian Railways
Loco Brief Data
Classification Of Code
Diesel electric locomotive part
Engine
Engine Action
Cylinder Head
Piston and Piston Rings
Types of Piston Rings
Connecting Rod
Piston and Connecting Rod Assembling
Fuel System
Power Pack Assembly
This Locomotive Workshop was established by the princely state of Oudh &Rohilkhand Railway
(O&RR) at Lucknow in 1867.
in year 1925 the O&RR was taken over by the Eastern
Indian Railway(EIR) along
with all assets and liabilities. Subsequently in 1952 the
EIR merged with Northern
Railways.
In order to attain the optimal degree of productivity a lot
of changes of
product mix have been witnessed in this workshop
over the last 140 years.
Currently, the periodical overhauling (POH) and maintenance of diesel
locomotives like WDM-2, WDM-3A and WDM-3D is
done in the workshop
NORTHERN RAILWAY – CHARBAGH
VITAL STATISTICS1. Senctioned Strength 4309
2. On Roll Strength 3554
3. No. of Officers 22
4. No. of Supervisors 252
5. Total Area 129300 sq.m.
6. Covered Area 57500 sq.m.
7. Power Consumption 231313 unit/month
8. Water Consumption 1070 KL/month
9. Annual Budget Rs. 173 Cr.
The railways traverse the
length and breadth of the
country and carry over 30
million passengers and 2.8
million tons of freight daily.
It has more than 1.6
million employees. As to
rolling stock, IR owns over
230,000 (freight) wagones,
60,000 coaches and 9,000
locomotives.
Indian Railways has more
than 64,215 kilometers
(39,901 miles) of track
and
7,083 stations. It has the
world’s fourth largest
railway network after
those of the
United States, Russia,
China
Railways were first introduced to India in 1853.
By 1947, the year of India’s independence, there were forty-two rail systems.
Indian Railways is divided into zones, which are further sub-divided into divisions.
The number of zones in Indian Railways increased from six to eight in 1951, nine in 1952, and finally 17 in 2010.
Following independence in 1947, India inherited a decrepit rail network. About 40
per cent of the railways then passed through the newly independent republic of
Pakistan.
A rail system in India was first proposed in 1832 in Madras but it never materialised
The first train in India was operational on December 22, 1851, used for the hauling
of construction material in Roorkee
on April 16, 1853, the
first passenger train between Bori Bunder, Bombay and Thane covering a distance
of 34km (21miles) was inaugurated, formally heralding the birth of railways in
India.And then the passenger railway line in North India opened from Allahabad and Kanpur on March 3, 1859. This was followed in 1889, by the Delhi-Ambala-
Kalka line.
The East Indian Railway Company’s Chief Engineer George Turnbull built the
first railway from Calcutta (the then commercial capital of India). It opened for
passenger traffic from Howrah station to Hooghly on 15 August 1854. The 541
miles (871kilometers) to Benares opened to passenger traffic in December 1862.
Under British Rule
WEIGHT OF COMPLETE LOCO - 123 TONS
WEIGHT OF LOCO BODY IS - 73 TONS
WEIGHT OF COMPLETE BOGIE IS - 25 TONS
LOAD EXERTED PER AXLE IS - 20.5 TONS
WEIGHT OF TRACTION MOTOR IS - 3.80 TONS
WHEEL SET WITH GEARS IS APPROX. - 2.15 TONS
COST OF ONE LOCO - 12 TO 14 crore (EMD)
7 TO 8 crore (ALCO)
FUEL CONSUMPTION : FUEL LOAD - 540lit/hr.
IDLE LOAD - 40 lit/hr.
MAX. SPEED - 160 Km/hr.
DIA OF WHEEL - 1092mm
WHEEL TO WHEEL DISTANCE - 1596.5mm
LENGTH OF UNDER FRAME - 19962 mm
WDM - Broad Diesel Mixed
WDP - Broad Diesel Passenger
WDG - Broad Diesel Goods
WDS - Broad Diesel Shunting
WCDS - Broad Converted Diesel
Shunting
A diesel engine is an internal-combustion, oil-burning engine using compression ignition. Such an engine gets its power from the burning of a charge of fuel within a confined space called a cylinder. Ignition occurs when the fuel is ignited solely by the heat of compression, caused by injecting the fuel into the highly compressed air in the cylinder.
The engine is supported by the bedplate, mounted
on the locomotive frame, which
serves as a housing for the crankshaft and as a
reservoir for the engine lubricating
oil. The main structural part of the engine, the
cylinder block. Between the inner
and outer walls of a cylinder is space for a water
jacket containing water that helps
to cool the engine.
Moving up and down inside the cylinders are pistons,
connected by connecting
rods to the crankshaft. The crankshaft transmits
mechanical action from the pistons
to drive the generator. The generator changes the
mechanical action into electricity
and transmits it through cables to the traction motors,
which change it through a
gear arrangement back into mechanical force to turn the
wheels.
All diesel-electric locomotive engines have essentially the same parts and work the same
way. The major difference among them is in the arrangement of the cylinders. The three
most common cylinder arrangements are the V-type, the vertical in-line, and the horizontal.
Shows parts of a V-type engine, so called because the arrangement forms a "V"; it is used in
the most powerful locomotives.
The vertical in-line arrangement is used mostly in low-power engines, and the horizontal
arrangement where a very flat, underfloor mounting is desired.
A cylinder head is a cast iron
engine or a cast aluminium alloy
engine component fastened to the
end of the cylinder block farthest
from the crank shaft. A headgasket
is a filler material placed between
the cylinder block and cylinder
head toseal the combustion
chamber. Head gasket are made of
soft materials. Head gaskets
allows for even heat distribution
between the cylinder block and
cylinder head for efficient heat
dissipation.
A piston is a cylindrical component that slides back & forth in the cylinder bore by forces produced during
compression process. The piston acts as the movable part of the combustion chamber. The stationary end of
the combustion chamber is cylinder head. The piston is generally made up of cast iron aluminium alloy for
excellent & light weight thermal conductivity. Aluminium expands when heated & proper clearance must
be provided for free piston movement in the cylinder bore. Excessive clearance can cause a loss of
compression & an increase in piston noise.
Piston includes the piston head,
piston pin, skirts, ring grooves, ring
land & piston rings. The piston head
is the top surface of the piston which
is subjected to tremendous forces &
heat transfer during normal engine
operation. The shape of the piston
head is either flat or contoured,
depending upon engine design.
A piston bore is a through hole in the side of the piston perpendicular to piston
travel that receives the piston pin. A piston pin is a hollow shaft that connects the
small end of the connecting rod to the piston.
The skirt of the piston is the portion
of the piston closest to the crank shaft that help
to align the piston as it moves in the cylinder
bore. Some skirts have profiles cut into them
to reduce piston mass & to provide clearance.
5RV PISTON
RING
• Indian Railways plan to develop 5-ring version piston and piston rings for EMD locomotives, to reduce lube oil consumption (LOC) and piston ring wear.
• The existing ERA0 locomotive power pack has 6-ring groove piston configuration in which top 4 rings are compression ( 3 thromeplated and 1- ferrox filled) rings while bottom 2 are oil scraper rings. The cylinder liner is laser hardened. A judicious combination of lesser number of piston rings can be expected to reduce LOC and piston ring wear. It is therefore proposed to switch over to 5-ring configuration on IR's EMO type locomotive engines.
3RV PISTON
RINGS
• 3 RV Piston Ring comprises of two compression ring and one oil ring. As the name suggest compression ring creates the pressure by which working inside the piston is carried out and on the other hand oil ring helps in the lubrication of the piston assembly. Depending upon the block use of 3 RV and 5 RV piston rings is done. Mainly use of 5 RV piston ring is done nowadays.
A connecting rod is an engine component
that transfer motion from the piston to the
crankshaft & function as a lever arm.
Connecting rod are commonly made from
cast aluminium alloy & are design to
withstand sudden impact stresses from
combustion & piston movement. The small
end of the connecting rod connects to the
piston with a piston pin.
The large end of the connecting rod connects to the crank pin
journal to provide a pivot point on the crankshaft.
Connecting rod are producedone piece or two piece
component. A rod cap is the removable section of a two
piece connecting rod that provides a bearing surface for the
crankpin journal
In locomotive workshop piston section is present for the maintenance of the piston
and piston ring.
The fuel system, often referred to as the heart of the diesel engine, squirts the
proper amount of fuel into the cylinder at the proper time. The most importanTpart of the system is the injector, which measures out the right amount of fuel, injects it into the cylinders under high pressure, and reduces it to a fine spray. Other parts of the fuel system are a tank to hold the fuel; a fuel-oil pump, driven by the motor, to get oil from the tank to the injectors; filters to clean the oil as it passes through the system; an injection nozzle to direct fuel into the combustion chamber in the best
pattern.
Fuel tank.
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.
Fuel injection pump
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.
Fuel filter
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 supply line. The
equipment is quickly ruined if fine particles of dust and grit are allowed to enter
the fuel line.
1. Exhaust manifold
2. Water channel
3. PGEV governor
4. Crank case motor
5. Cylinder
6. Piston
7. Fuel oil injector
8. Rocker arm
9. Lube oil header pipe
10. Cam shaft
11. Crank shaft
12. Cross head & pipe
13. Fuel injector pump
14. FIP cover
15. Gear case
16. Cylinder head
17. Inlet & exhaust valve
18. Turbo super charger
19. Housing
20. Water pump
21. Lube oil pump
22. Generator
I have completed my training from the DIESEL LOCOMOTIVE
WORKSHOP,LUCKNOW .I have observed many shop in the workshop.
I mainly performed my training in the PISTON SECTION.
In the locomotive workshop all the S.S.E & J.E. & SUPERVISIORS of
all the shops helped very much. Without his or her supervision I would
have not been able to perform the training in all the workshop. I am very
grateful to him or her.
We have learned too much in the workshop, DIFFERENT TYPE OF
WORKSHOP TECHNOLOGY, TESTING OF THE PARTS OF THE
LOCOMOTIVE AND THE PROPER FUNCTIONING of the different
locomotive part as an AIR BRAKE, LOAD BOX,
TURBOSUPERCHGER, EXPRESSOR, POWER PACK, RADIATOR,
and AND BOGIE AND FABRICATION OF THE BODY OF
LOCOMOTIVE.
CONCLUSION
www.nr.indianrailways.gov.in/About Us/History
Google.com/PISTON RING PDF SEARCH
INFORMATION GAINED BY LOCOMOTIVE WORKSHOP
Wikipedia-LOCOMOTIVE WORKSHOP
Wikipedia- HISTORY OF RAILWAY UNDER BRITISH RULE