loco diesel shed, pulera
TRANSCRIPT
LOCO DIESEL SHED , PHULERA
About Indian Railways Indian Railways has one of the largest & busiest rail networks in
the world. It comes under the Ministry of Railways. It is the world’s largest commercial employer, with more than 105
million employees. The fleet of includes over 200,000 wagons, 50,000 coaches, 8,000
locomotives. It also owns locomotives & coaches production facilities. Indian Railways transporting over 20 million passengers. Indian Railways are divided into 16 zones. & each zones is made
up of a certain no. of divisions. There are 67 divisions. The total length of the track used by Indian Railways is about
108,805 KM (67,608miles.) About 50% of the total track KM is Diesel . It also operates the Kolkata, Delhi metro.
WHAT IS DIESEL SHEDDiesel locomotive shed is an industrial – technical setup, where
repair & maintenance works of diesel of diesel locomotives is carried out, so as keep loco working properly.
It contributes to increase the operational life of diesel locomotives Minimize the line failureThe technical manpower of a shed also increases the efficiency of
the loco. Diesel shed usually has -;Berths & plate for loco maintenancePits for under frame maintenance.Heavy cranes, lifting jacks.Fuel storage & lube oil storage, water treatment plant & testing labs
etc.Sub-assembly overhauling 7 repairing sections.Machine shop & welding facilities.
SHED INFRASTRUCTURESHED AREA ----------------------------------------------------------- 2261 sq.m .
M.G SETELITE SHED----------------------------------------------- 1965- 1997. M.G HOME SHED---------------------------------------------------- FROM 1997 HOLDINGS ------------------------------------------------------------- 64. SHEDULES------------------------------------------------------------FOUR(TI1,TI2,M3,M9 )
STAFF CADER----------------------------------------------------------- 100 BEARTHING SPACE---------------------------------------------- 9 LOCO SHEDULE PIT 2 LOCO LOAD PIT
MANUFACTURER----------------------------------------------------- ALCO/ DLW
SHED LAYOUT
MAIN STORE
ELECTIRCAL CONTROL ROOM
PIT WHEEL LATHE
INJETION & FUEL ROOM
CLEANING & WASHING PLANTS
OFFICE BLOCK
OVER HANDLING SECTION
HEVRY REPAIR BAY / SMALL PART OF CRANE
VEHICLE STAND
CANTEEN
BAY MAIL LIGHT REPAIR
LAB / TESTING
DEMINERALISED WATER PLANTS
BRAKE ROOM RUNNING STORE
THREE GENERAL CLASS OF LOCOMOTIVES
Freight locomotive – For designed with slower speed, acceleration and have capacity to pull heavier load as compared to another. Ex. (WDG2, WDM4)
Passenger locomotive-- For designed with high speed, fast acceleration & light loads. Ex. (WDP2, YDP4)
Shunting locomotive-- For designed with slower speed, low HP and suitable for shunting purpose onl. Ex. (WDS4, WDS6)
CLASSIFICATION OF LOCOS The first digit [gauge] W= Broad Gauge Y= Meter Gauge Z= Narrow Gauge WDM3
The second digit [power] D= Diesel C= DC traction A= AC traction CA= Dual-power AC/DC traction B= Battery electric (rare) YDM3
The third digit [load] M= Mixed Traffic P= Passenger G= Goods U= Multiple Unit ( EMU/ DEMU) ZDM3 R= Railcar
How to start LOCO
Compression ignition engineFiring order - 1,4,2,6,3,5Cycle of operations – suction, compression, power,
exhaust
Sections view of Diesel Engine
LOCO Specification YDM4Engine Model:- YDM4Engine Company:- ALCONo. of Cylinder:- 6 Cylinder Arrangement:- Inline Cylinder Shape:- I shapeEngine BHP:- 1200Max. Weight:- 72 tone Traction HP:- 1200HPGross HP:- 1280HPStarting Speed: 100-150 r.p.mCompression Ratio:- 12:1 Full Speed:- 400-1100 r.p.mMax. Speed:- 1200 r.p.mFuel Tank Capacity:- 3000 lit.Wheel Arrangement:- co-coRadiator Fan:- 41HPFiring order is:- 1-4-2-6-3-5Dia. Of Wheel:- 965 mmCompressor:- 1100 r.p.mBattery:- Series Compound Shunt
SIX MAIN COMPONENTS OF ENGINENOSE – It consists head light, sand box, resistance grid.
DRIVER’s CAB – It consists long hood, short hood, control stand, air brake control stand, booster air pressure , indicating lube oil, pressure gauges, mechanical control & electrical speedometer and load meter.
MAIN GENERATOR COMPARTMENT – It consists traction motor, excitation generator, auxiliary generator, front traction motor blower and housed in this compartment.
ENGINE ROOM - It consists after cooler, turbocharger governor, fuel injection pump, fuel oil filters, lube oil filters, water pump, extension shaft, expressor spline coupling.
EXPRESSOR COMPARTMENT – It produces a vacuum compressed air which is used for braking purpose, pump for hydraulic governor fuel booster pump & fuel booster pump motor are also kept.
RADIATOR - Radiator fan, radiator panel, lube oil, right angle gear box, driving radiator fan, eddy current clutch which converts right angle gear box to diesel engine’s extension shaft.
Parts of loco
ARRANGEMENT OF WHEELS IN THE LOCOWheels are first
arranged into bogies.It provides greater
flexibility.They are represented in
two blocks separated by (-) sign.
This type of bogies are called CO-CO.
Function of components Main Generator
The diesel engine drives the main generator which provides the power to move the train. The alternator generates DC electricity which is used to provide power for the traction motors mounted on the trucks (bogies).
Auxiliary Generator This provides DC power for lighting, heating, air conditioning, dining facilities etc. on the train.
Motor Blower Motor blower provides air which is blown over the
traction motors to keep them cool during periods of heavy work.
Air IntakesThe air for cooling the locomotive's motors is drawn in from outside the locomotive. It has to be filtered to remove dust and other impurities
BatteriesThe diesel engine needs a battery to start it and to provide electrical power for lights.
Traction MotorTraction motors are provided on the axles to give the final drive. These motors were traditionally DC
Fuel TankThe fuel tank is normally under the loco frame and will have a capacity of 3000 lts.
Air ReservoirsAir reservoirs containing compressed air at high pressure are required for the train braking and some other systems on the locomotive. These are often mounted next to the fuel tank under the floor of the locomotive.
Drive ShaftThe main output from the diesel engine is transmitted by the drive shaft to the generators at one end and the radiator fans and compressor at the other end.
Radiator and Radiator FanWater is distributes around the engine block to keep the temperature within the most efficient range for the engine.
Air brake Air Brake System (Loco Brake System) SA-9 Valve : for loco brakes only Release position :-running loco is in released position Application position :- stopped pressure of 3.5kg/cm2
Vacuum Brake System:- A-9 Valve : for loco & train brake system 1. Release position: - pressure to 5.0kg/cm2of MR. vacuum is about 55-60 cm. 2. Minimum position:- pressure in brake pipe= 4.5 kg/cm2, vacuum =50-55 cm 3. Service application:- Brake pipe pressure = 3.5 kg/cm2 , Vacuum =25-30 cm 4. Over reduction:- Brake pipe pressure = 2.5 kg/cm2, Vacuum =20 cm 5. Emergency:- Brake pipe pressure = 0.0kg/cm2, engine is in idle condition
EXPRESSORExpresser is made with combination of EXhauter +
comPRESSOR.It is located at free end of the engine block and driven through
the extension shaft attached to the engine crank shaft.Exhauster suck air from train pipe to create required amount
of vacuum to brake system. There are 6 cylinder are arranged in a W type, 2 cylinder in
vertical, 4 in V shaped.
Turbo Supercharger
It is used increase the amount of air pushed into cylinder.
Pressure of air is 3-6 kg/cm2
It gives a 50% increase in engine power.
Advantage is that it gives more power with no increase in fuel cost because it uses exhaust gas as driving power.
It also increase the air pressure, better ignition & efficiency.
CAUSES OF TURBO CHARGER
Intermediate casing, turbine casing, nozzle failure.
FUEL OIL SYSTEM
WATER COOLING SYSTEM
Failure AnalysisUltra sonic testIn ultrasonic testing very short ultrasonic pulse – waves
with center frequencies ranging from 0.1 – 15 MHz.US testing is performed on steel ,metals and alloy. It is a form of non destructive testing.
Zyglo testZyglo test is a of non destructive testing It is quick & accurate process for locating surface flaws
such as shrinkage cracks, fatigue cracks, grinding cracks etc.
Zyglo test is performed on metals & non metals materials like Al, Mg, Cu, brass, bronze, sintered carbide, non – magnetic alloys, ceramics, plastic & glass.
Schedule ExaminationMinor Schedule
Trip -1 & Trip -1 Fuel oil, lube oil& filter are checked. Expressor discharge valve. Record oil level in the axle caps for suspension bearing. Turbo super charger is checked. Under frame are checked.
Major Schedule Run engine; check operation of air system safety valves & expressor crank case lube
oil pressure. Stop engine; carry out dry run operational test, check FIP timing & uniformity of rack
setting & correct if necessary. Engine crankcase cover:- remove crankcase cover and check for any foreign material,
renew gasket. Clean strainer & filters, replace paper elements. Compressor air & vacuum system:- check, clean and recondition rings, intake
strainers, & inlet, exhaust valve, lube oil relief valve. Drain, clean & refill crankcase. Roller bearing axle boxes. Check for loose bolts, lose of grease. sign of overheating.
Remove covers,. Carry out ultrasonic test of axles. Renew airflow indicator valve.
SPECIAL PLANTTo provide pollution free environment, an ETP is
installed.Various effluents emitted from diesel shed are passed
through the plant.Pollution free water is collected & Water is used for non
drinking purposes – gardening & washing of the locomotives.
Thanking you