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