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