project on wdm-2

8/13/2019 Project on WDM-2

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ON

WDM2

INDIAN RAILWAYS

(Diesel Shed, Shakur Basti)


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Submitted By:

Group 15

Neeraj Kumar Tiwari Neeraj Kumar Tiwari

VIth semester(B. Tech) VIth semester(B. Tech)

Mechanical & Automation Engineering Mechanical & Automation Engineering

Northern India Engineering College HM Institute o! Technolog" and Management

#hastri $ar% 'elhi**+, Hamid-ur'elhi **,


3/43

ACKNOWLEDGEMENT

WE are very thankful to Northern Railay for !rovidin" us the # eeksSu$$er %rainin" in Diesel Shed, shakur &asti'

Sh' iay Arora (Sr' D*E + DSL+SSB) S-' S R .athak(SSE+%+DSL+SSB) and *rs' Alka /alra (%r"' 0o') has assisted thestudents very ell' %hey 1ondu1ted 1lasses and $ade 1larifi1ation onvarious to!i1s re"ardin" diesel lo1os'

We are also very $u1h thankful to the offi1ers, su!ervisors and staff

$e$&ers for their 1o2o!erative and hel!ful su!!ort' %hey s!ent their!re1ious ti$e ith us to e3!lain various o&e1ts'

%he !roe1t of WD*4 has !roved to &e very knoled"ea&le' It hel!edus to learn the various ty!es of &rake syste$ orkin" in IndianRailays, their !erfe1t $e1hanis$s'

%he knoled"e e have "ained here ould definitely !rove to &e aste!!in" stone into our 1areer' %he trainin" has &een !roved as a &i"advanta"e for us'


4/43

PREFACE

5En"ineerin" students "ain theoreti1al knoled"e only throu"h &o o k s '%heoreti1al knoled"e is not of $u1h use ithout knoin" I%S .RA0%I0ALi$!le$entation' i t h a s & e e n e3!erien1ed that theoreti1al knoled"e isvolatile in nature6 hoever !ra1ti1al knoled"e i$!arts solid foundation inour $ind7'

%o a11o$!lish this as!e1t, 89R9 8:BIND SIN8- INDRA.RAS%-A9NIERSI%Y,DEL-I has in1luded trainin" for student of B'te1h ;rdyear of < to# eeks in our 1urri1ulu$'We have 1overed in this re!ort the history of Indian railays, history ofDiesel lo1o shed, Shakur&asti' We laid s!e1ial e$!hasis on WD*24 as it asour !roe1t '%his re!ort in1ludes various te1hni1al as!e1ts of WD*24 like fueline1tor, !oer !a1k and other !arts'

%his re!ort is the su$$ary of hat e learnt durin" trainin" in 5Northernrailay, Delhi7

Neera /u$ar %iari (NIE0)

Neera /u$ar %iari (-*RI%*)

(;rd year)


5/43

INDEX

=' IN%R:D90%I:N AND -IS%:RY :> INDIAN RAILWAYS

4' -IS%:RY :> DIESEL S-ED S-A/9RBAS%I

;' IN%R:D90%I:N %: WD*

DIESEL ELE0%RI0 L:0:*:%IES

'DYNA*I0 BRA/IN8

' RE>ERAN0E


6/43

INTRODUCTION & HISTORY OF INDIAN

RAILWAYS:

T"-e Ministr" (go/ernment de-artment)

Industr" ail0a"s

1ounded A-ril 2+,

Head3uarters Ne0 'elhi India

#er/ices $assenger rail0a"s, !reightser/ices$arcel carrier, Catering and Tourism #er/ices-ar%ing loto-erations other related ser/ices

e/enue 44.54 6illion (7#89.:9 6illion) (:*:;,)

Net income 5+ 6illion (7#8:.+ 6illion) (:*:;,)

O0ner(s)


7/43

$arent Ministr" o! ail0a"sthroughail0a" Board (India)

'i/isions 4 ail0a" >ones

?ength +*** %m

'ates o! o-eration A-ril 2+,;$resent

Trac% gauge 4 mm@ *** mm@ 4: mm@ * mm

Electri!ication :,+5 %m

Indian Railways (re!ortin" $arkIR) is an Indian state2onedenter!rise,oned and o!erated &y the 8overn$ent of Indiathrou"h the *inistry ofRailays' It is one of the orldCs lar"est railay netorks 1o$!risin"==?, k$ (@=, $i) of tra1k over a route of #?, k$ (


8/43

distan1eand su&ur&an rail syste$son a $ulti2"au"enetork of &road,$eterand narro"au"es' It also ons lo1o$otiveand 1oa1h!rodu1tionfa1ilities at several !la1es in India and are assi"ned 1odes identifyin" their"au"e, kind of !oer and ty!e of o!eration' Its o!erations 1over tenty fourstates and three union territoriesand also !rovides li$ited international

servi1es to Ne!al, Ban"ladeshand .akistan'Indian Railays is the orldCs ninth lar"est 1o$$er1ial or utility e$!loyer,&y nu$&er of e$!loyees, ith over ='< $illion e$!loyees' As for rollin"sto1k, IR holds over 4;,4= >rei"ht Wa"ons, ?,@=; .assen"er 0oa1hesand,?


9/43

HISTORY OF!N"RLY" DSL SH#D

SHA$UR%ASTI

'((:) Shed as esta&lished'

'(*:)#N:S *E%ER 8au"e rail 1ars fitted ith fiat en"ine (Italy) as

de!loyed &eteen Dli2to2Loharu se1tions'

'(+:)%he shed 1onstru1tion as 1o$!leted and $aintenan1e ork startedin the nely &uilt shed' %here as only one &ay, hi1h is !resently 1alled

runnin" re!air &ay'

'(,:)# nos &road "au"e rail 1ars fitted ith Leyland en"ine ere donated

&y Australian and the sa$e ere utiliHed &eteen DLI2.N. via R:/ on S.R

se1tion'


10/43

'*:)@ nos 'WDS; lo1o (=


11/43

/00, !Introdu1tion of WD./sLo1o$otives'

/00' !Introdu1tion of Rail 0ar ith &oth side driver 1a&s'

/00 !Introdu1tion of $ail+e3!ress WD./ lo1o$otive'

2R#S#NT NO" OF LOCOS IN TH#SH#D:


12/43

WDM2 30 WDS! 0"

WDM2S!2" WDS#!1"

D$M%!15&1'15!100 (()D)* 01!+50 () T*!53

DT*!0+


13/43


14/43

%he 1lassifi1ation WD.)/A is a!!lied to those that ere re2fitted ith air&rakes ($ost of these therefore have dual &rakin" 1a!a&ility), hile WD.)/% is a!!lied to $ore re1ent lo1os &uilt ith air &rakes as the ori"inaleui!$ent (these very rarely have va1uu$ &rakin" 1a!a&ility in addition,es!e1ially if they have &een re&uilt &y 8olden Ro1k)' (-oever, in the !ast,&efore the ides!read use of air2&rakes, a fe $odified versions ith a loshort hood at one end like the WDS2# ere also 1lassified WD*24A') A feWD*24 lo1os of the Erode shed have &een $odified and s!ort a full2forard1a& at one end, ith the dyna$i1 &rake "rid, &loer, et1' $oved &eteenthe 1a& and the tra1tion alternator'

%he ori"inal Al1o desi"ns had a =2day, ;k$ $aintenan1e s1hedule,hi1h as later e3tended &y so$e $odifi1ations to a =C as they $i"ht&e in the ne s1he$e &ased on their horse!oer' %he first one su!!lied &yAl1o as =


15/43

shed) is knon to have had 1a& air21onditionin" fitted' %his as the first lo1oto have air21onditionin" in India6 this as done &y the ERS shed in =@ ri"htafter re1eivin" the lo1o fro$ DLW, &ut it as disa&led later as the au3iliaryalternator !roved too eak to run the air21onditioner ell' A fe WD*24lo1os don"raded for shuntin" duties have &een seen $arked ith a WD.)

/S 1lass na$e6 e'"', so$e at Itari shed P4;Q and so$e at /urla' A fehave also &een s!otted &earin" the 1lass na$e WDS)/, e'"', those at the/alyan shed here they are used for shuntin"' %hese a!!ear to &e uirks ofthe lo1al shed staff and not offi1ially re1o"niHed 1lassifi1ations'

D0W .atiala has re&uilt so$e WD*24 units to 1lass WD.)-A8WD.)/Cs!e1ifi1ations' %hese are a little different fro$ the nor$al WD*240 fro$DLW' %hey look very si$ilar to WD*24Cs, e31e!t for a &ul"e on one of thedoors of the hood6 this is due to the !resen1e of a 1entrifu"al fuel filter hi1h$oved there &e1ause the $odel reuired lar"er after 1oolers' %here areso$e other sli"ht differen1es in a!!earan1e' %hese units have a 8Etur&o1har"er and a different e3!resser ith inte"ral air dryin" fa1ility' %heyhave a Woodards "overnor hi1h leads to even runnin" and idlin", and (tothe "reat disa!!oint$ent of Al1o s$oke fans) redu1es the a$ount of &la1ks$oke durin" intense a11eleration' %hese also have roller &earin"s for the

sus!ension, i$!rovin" on the lon"standin" !ro&le$ of &earin" failures onthe re"ular WD*24 $odel'

WD./

%he 1lass WD.)/is Indian RailaysC orkhorse diesel lo1o$otive' %he firstunits ere i$!orted fully &uilt fro$ the A$eri1an Lo1o$otive0o$!any(Al1o) in =#4' Sin1e =#


16/43

eui!$ent' %he WD*24 lo1os have a $a3i$u$ s!eed of =4 k$+h(@? $!h), restri1ted to = k$+h (#4 $!h) hen run lon" hood forard 2 the"ear ratio is #?O='

%he first fe !rototy!e WD*24s ere i$!orted' After Diesel Lo1o$otive

Works (DLW) 1o$!leted 1onstru1tion of its fa1tory in aranasi, !rodu1tion ofthe lo1o$otives &e"an in India' %he first =4 lo1os ere &uilt usin" kitsi$!orted fro$ AL0: in the 9nited States' After that DLW started$anufa1turin" the WD*24 lo1o$otives fro$ their on 1o$!onents' Sin1ethen over 4, lo1o$otives have &een $anufa1tured and the WD*24 has&e1o$e the $ost !o!ular lo1o$otive in India' -oever, even &efore thearrival of WD*24 another ty!e of diesel lo1o$otive as i$!orted fro$ AL0:&e"innin" in =?@' %his lo1o$otive as 1lassified as WD*2=' Later a nu$&erof $odifi1ations ere $ade and a fe su&1lasses ere 1reated' %his in1ludesWD*24A, WD*24B and WD*2;A (for$erly WD*240)'

%he WD*24 is the diesel orkhorse of the Indian Railays, &ein" veryrelia&le and ru""ed' %he 1lass WD*24 is Indian RailaysC orkhorse diesello1o$otive' %he first units ere i$!orted fully &uilt fro$ the A$eri1anLo1o$otive 0o$!any (Al1o) in =#4' Sin1e =#


17/43

A 'M: locomoti/e !rom?udhianaat al%a

)ower type Die/e

Buider Alco'?

Mode '?+*C

Buid date 9: on0ards

Tota produ.ed :4**

%,* .a//ii.atio- CoCo

Gaue 4 mm (+ !t in)

Wee diameter *9: mm (, !t 4.* in)

Weeba/e :.2,5 m (5: !t ., in)

4e-t 4.: m (+ !t : in)

Widt :.25 m (9 !t 5.2 in)

(eit 5.2+ m (, !t 2.2 in)

6e oad 22** %g (5*** l6)

4o.omoti7e weit :2** %g (:59*** l6)

8ue .apa.ity +*** l (** im- gal@ ,** 7# gal)

)rime mo7er A?CO :+B

$-i-e9)Mra-e 5** *** r-m
http://en.wikipedia.org/wiki/Ludhianahttp://en.wikipedia.org/wiki/Ludhianahttp://en.wikipedia.org/wiki/Ludhianahttp://en.wikipedia.org/wiki/Kalkahttp://en.wikipedia.org/wiki/American_Locomotive_Companyhttp://en.wikipedia.org/wiki/American_Locomotive_Companyhttp://en.wikipedia.org/wiki/Diesel_Locomotive_Workshttp://en.wikipedia.org/wiki/ALCO_DL560Chttp://en.wikipedia.org/wiki/UIC_classificationhttp://en.wikipedia.org/wiki/Track_gaugehttp://en.wikipedia.org/wiki/Wheelbase#Railhttp://en.wikipedia.org/wiki/Axle_loadhttp://en.wikipedia.org/wiki/Prime_mover_(locomotive)http://en.wikipedia.org/wiki/ALCO_251http://en.wikipedia.org/wiki/Revolutions_per_minutehttp://en.wikipedia.org/wiki/Revolutions_per_minutehttp://en.wikipedia.org/wiki/Revolutions_per_minutehttp://en.wikipedia.org/wiki/File:WDM_2.jpghttp://en.wikipedia.org/wiki/Ludhianahttp://en.wikipedia.org/wiki/Kalkahttp://en.wikipedia.org/wiki/American_Locomotive_Companyhttp://en.wikipedia.org/wiki/Diesel_Locomotive_Workshttp://en.wikipedia.org/wiki/ALCO_DL560Chttp://en.wikipedia.org/wiki/UIC_classificationhttp://en.wikipedia.org/wiki/Track_gaugehttp://en.wikipedia.org/wiki/Wheelbase#Railhttp://en.wikipedia.org/wiki/Axle_loadhttp://en.wikipedia.org/wiki/Prime_mover_(locomotive)http://en.wikipedia.org/wiki/ALCO_251http://en.wikipedia.org/wiki/Revolutions_per_minute


18/43

/piratio- Tur6osu-ercharged

*yi-der/

Top /peed :* %mDh (4+ m-h)

)ower output :5** h- (2** %)

8a.tor o

ade/io-

*.:4

Di/po/itio- acti/e

TECHNICALSECI!ICATIONS:-

Manufacturers Alco, DLW

Engine

Alco 251!, 1" c#lin$er, 2,"%% &'(2,)*% &' site rating+ it& Alco -1%.-2% tur/o su'erc&arge$engine0 1,%%% r' a, )%% r' i$le3 224 2"" /ore.stroe3 co'ression ratio 1205610Direct fuel in7ection, centrifugal 'u' cooling s#ste (2,)5- l.in at 1,%%% r'+, fan $ri8en /# e$$#current clutc& (4" &' at 1,%%% r'+

9o8ernor 9E1-M94 . Woo$ar$:s 45-)"5% . Me$&a ME9 "%1

;ransission Electric, it& ! generator (1,%%% r', --% ?, ),52% a'eres+

;raction otors9E-52 (original Alco o$els+ ()%5 &'+, !


19/43

Disl l4c4643i9 4wr ack:

.oer !a1k of an en"ine $eans the various syste$ reuired !oer for

the runnin" of the en"ine' %he various syste$s are

=' >uel oil syste$

4' Lu&e oil syste$

;' 0har"e air syste$


20/43

>uel oil syste$ is one hi1h !rovides fuel su!!ly to the en"ine fordevelo!in" or !rodu1tion of !oer for runnin" of lo1o$otive en"ine'

>uel oil syste$ is "enerally 1lassified into to su& 1ate"ories

>uel feed syste$

>uel ine1tion syste$


21/43

All lo1o$otive units have individual fuel oil syste$'

%he fuel oil syste$ is desi"ned to introdu1e fuel oil into the en"ine1ylinders at the 1orre1t ti$e, at 1orre1t !ressure, at 1orre1t uantity and1orre1tly ato$iHed'

%he syste$ ine1ts into the 1ylinder 1orre1tly $etered a$ount of fuel inhi"hly ato$iHed for$'

Ful 4il sys36:

Reuire$ents of fuel oil syste$

Asso1iate 1o$!onents of fuel oil syste$

%rou&le shootin" of fuel oil syste$

R;uir6n3s 4< uel !ri$ary filter( !a!er ty!e filter)

Booster !u$! (fuel transfer !u$!)

.u$! 1a!a1ity 2=< liters + $in (at =@4?r!$)

.ressure F < to


22/43

>uel relief valve O the s!rin" loaded relief valve adusted at?k"+1$4(@!si)

>uel se1ondary filter (!a!er ty!e filter)

>uel re"ulatin" valve O the s!rin" loaded valve adusted at < to


23/43

Ful in=c3i4n n4>>l 3s3:

%he 1riteria for "ood noHHle are "ood ato$iHation, 1orre1t s!ray !atternand no leaka"e or dri&&lin"'

%he fuel ine1tion noHHle is tested on a s!e1ially desi"ned test stand'

S!ray !attern (&y takin" i$!ression on &lottin" !a!er)

S!ray !ressure (;2


24/43

Tr4u7l s?443ing 4< uel oil !ressure not &uildin" u!'

>uel !u$!s $otor not orkin"'

>uel oil 1onta$inated ith ater

>uel oil !ri$ary+se1ondary filter 1ho1ked'

>uel oil leakin" fro$ !i!e oint'

>uel oil hose !i!es &urst+da$a"ed due to ru&&in"'

>uel 1ross over !i!e &urst'


25/43

C44ling sys36:

24wr 2ack 4< WD./ L4c4643i9 Disl #nginO

%he !oer !a1k 1onsists of various syste$s like lu&e oil syste$, fuel oil syste$,and ater 1oolin" syste$ and 1har"e air syste$'

Every syste$ has its on fun1tion to a11o$$odate !ro!er orkin" of the

en"ine' >uel oil syste$ fun1tion is, to su!!ly fuel and $aintains fuel of reuireduantity ith reuired !ressure for the fuel hi1h enters into the 1o$&ustion1ha$&er of the en"ine'

T? Disl L4c4643i9%he $odern diesel lo1o$otive is a self 1ontained version of the ele1tri1lo1o$otive' Like the ele1tri1 lo1o$otive, it has ele1tri1 drive, in the for$ oftra1tion $otors drivin" the a3les and 1ontrolled ith ele1troni1 1ontrols' Italso has $any of the sa$e au3iliary syste$s for 1oolin", li"htin", heatin",

&rakin" and hotel !oer (if reuired) for the train' It 1an o!erate over thesa$e routes (usually) and 1an &e o!erated &y the sa$e drivers' It differs!rin1i!ally in that it 1arries its on "eneratin" station around ith it, insteadof &ein" 1onne1ted to a re$ote "eneratin" station throu"h overhead ires ora third rail' %he "eneratin" station 1onsists of a lar"e diesel en"ine 1ou!ledto an alternator !rodu1in" the ne1essary ele1tri1ity' A fuel tank is alsoessential' It is interestin" to note that the $odern diesel lo1o$otive!rodu1es a&out ;? of the !oer of an ele1tri1 lo1o$otive of si$ilar ei"ht'


26/43

a"ts o# a Diesel-Elect"ic Locomotive

Diesel En$ine

%his is the $ain !oer sour1e for the lo1o$otive' It 1o$!rises a lar"e

1ylinder &lo1k, ith the 1ylinders arran"ed in a strai"ht line or in a ' %heen"ine rotates the drive shaft at u! to =, r!$ and this drives the variousite$s needed to !oer the lo1o$otive' As the trans$ission is ele1tri1, theen"ine is used as the !oer sour1e for the ele1tri1ity "enerator or alternator,as it is 1alled noadays'

.ain 2ar3s 4< an #ngin

Main Alte"nato"%he diesel en"ine drives the $ain alternator hi1h !rovides the !oer to

$ove the train' %he alternator "enerates A0 ele1tri1ity hi1h is used to!rovide !oer for the tra1tion $otors $ounted on the tru1ks (&o"ies)' Inolder lo1o$otives, the alternator as a D0 $a1hine, 1alled a "enerator' It!rodu1ed dire1t 1urrent hi1h as used to !rovide !oer for D0 tra1tion$otors' *any of these $a1hines are still in re"ular use' %he ne3tdevelo!$ent as the re!la1e$ent of the "enerator &y the alternator &ut stillusin" D0 tra1tion $otors' %he A0 out!ut is re1tified to "ive the D0 reuiredfor the $otors'


27/43

A%&ilia"' Alte"nato"Lo1o$otives used to o!erate !assen"er trains are eui!!ed ith an au3iliaryalternator' %his !rovides A0 !oer for li"htin", heatin", air 1onditionin",

dinin" fa1ilities et1' on the train' %he out!ut is trans$itted alon" the trainthrou"h an au3iliary !oer line' In the 9S, it is knon as head end !oeror hotel !oer' In the 9/, air 1onditioned !assen"er 1oa1hes "et hat is1alled ele1tri1 train su!!ly (E%S) fro$ the au3iliary alternator'

Moto" (lo)e"%he diesel en"ine also drives a $otor &loer' As its na$e su""ests, the$otor &loer !rovides air hi1h is &lon over the tra1tion $otors to kee!the$ 1ool durin" !eriods of heavy ork' %he &loer is $ounted inside thelo1o$otive &ody &ut the $otors are on the tru1ks, so the &loer out!ut is1onne1ted to ea1h of the $otors throu"h fle3i&le du1tin"' %he &loer out!utalso 1ools the alternators' So$e desi"ns have se!arate &loers for the"rou! of $otors on ea1h tru1k and others for the alternators' Whatever thearran"e$ent, a $odern lo1o$otive has a 1o$!le3 air $ana"e$ent syste$hi1h $onitors the te$!erature of the various rotatin" $a1hines in thelo1o$otive and adusts the flo of air a11ordin"ly'

Ai" Inta*es%he air for 1oolin" the lo1o$otiveCs $otors is dran in fro$ outside thelo1o$otive' It has to &e filtered to re$ove dust and other i$!urities and its

flo re"ulated &y te$!erature, &oth inside and outside the lo1o$otive' %heair $ana"e$ent syste$ has to take a11ount of the ide ran"e ofte$!eratures fro$ the !ossi&le T


28/43

one tru1k) fails then the unit is only a&le to !rodu1e ? !er 1ent of itstra1tive effort' :ne inverter !er a3le is $ore 1o$!li1ated, &ut the 8E vie isthat individual a3le 1ontrol 1an !rovide the &est tra1tive effort' If an inverterfails, the tra1tive effort for that a3le is lost, &ut full tra1tive effort is stillavaila&le throu"h the other five inverters' By 1ontrollin" ea1h a3le

individually, kee!in" heel dia$eters 1losely $at1hed for o!ti$u$!erfor$an1e is no lon"er ne1essary'

$e.tri.a *o-tro/Al$ost every !art of the $odern lo1o$otiveCs eui!$ent has so$e for$ of

ele1troni1 1ontrol' %hese are usually 1olle1ted in a 1ontrol 1u&i1le near the1a& for easy a11ess' %he 1ontrols ill usually in1lude a $aintenan1e$ana"e$ent syste$ of so$e sort hi1h 1an &e used to donload data to a!orta&le or hand2held 1o$!uter'

*o-tro Sta-d%his is the !rin1i!al $an2$a1hine interfa1e, knon as a 1ontrol' %he 1o$$onty!e of stand is !ositioned at an an"le on the left side of the drivin" !ositionand, it is said, is $u1h !referred &y drivers to the $odern desk ty!e of1ontrol layout usual in Euro!e and no &ein" offered on so$e lo1o$otives inthe 9S.

Batterie/ust li%e an automo6ile the diesel engine needs a 6atter" to start it and to -ro/ide electrical-o0er !or lights and controls 0hen the engine is s0itched o!! and the alternator is not running.


29/43

The locomoti/e o-erates on a nominal 5/olt electrical s"stem. The locomoti/e has eight 2/olt6atteries@ each 0eighing o/er ,** -ounds (, %g). These 6atteries -ro/ide the -o0er needed tostart the engine (it has a huge starter motor) as 0ell as to run the electronics in the locomoti/e.Once the main engine is running an alternator su--lies -o0er to the electronics and the 6atteries

*ab*ost diesel lo1o$otives have to 1a&s' Lo1os are also desi"ned ith narroen"ine 1o$!art$ents and alkays alon" either side' %his "ives areasona&le forard vie if the lo1o$otive is orkin" hood forards' It isdiffi1ult to tell the differen1e &eteen a frei"ht and !assen"er lo1o$otive&e1ause the desi"ns are al$ost all ide &odied and their use is often $i3ed'%he 1a& of the lo1o$otive rides on its on sus!ension syste$, hi1h hel!sisolate the en"ineer fro$ &u$!s' %he seats have a sus!ension syste$ asell'

T"action Moto"Sin1e the diesel2ele1tri1 lo1o$otive uses ele1tri1 trans$ission, tra1tion$otors are !rovided on the a3les to "ive the final drive' %hese $otors eretraditionally D0 &ut the develo!$ent of $odern !oer and 1ontrolele1troni1s has led to the introdu1tion of ;2!hase A0 $otors' %here are&eteen four and si3 $otors on $ost diesel2ele1tri1 lo1o$otives' A $odernA0 $otor ith air &loin" 1an !rovide u! to =, h!'

2r4ulsi4n:%he 3rac3i4n 6434rs !rovide !ro!ulsion !oer to the heels'%here is one on ea1h a3le' Ea1h $otor drives a s$all "ear, hi1h $eshes

ith a lar"er "ear on the a3le shaft' %his !rovides the "ear redu1tion thatallos the $otor to drive the train at s!eeds of u! to == $!h'


30/43

>i"'2 %ra1tion *otor

Ea1h $otor ei"hs #, !ounds (4,@44 k") and 1an dra u! to =,=@ a$!sof ele1tri1al 1urrent'

8ue Ta-A diesel lo1o$otive has to 1arry its on fuel around ith it and there has to

&e enou"h for a reasona&le len"th of tri!' %he fuel tank is nor$ally under the

lo1o fra$e and ill have a 1a!a1ity of say =, i$!erial "allons (9/ 0lass

?, ;, h!) or ?, 9S "allons in a 8eneral Ele1tri1 A0


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Go7er-or:n1e a diesel en"ine is runnin", the en"ine s!eed is $onitored and1ontrolled throu"h a "overnor' %he "overnor ensures that the en"ine s!eedstays hi"h enou"h to idle at the ri"ht s!eed and that the en"ine s!eed ill

not rise too hi"h hen full !oer is de$anded' %he "overnor is a si$!le$e1hani1al devi1e hi1h first a!!eared on stea$ en"ines' It o!erates on adiesel en"ine as shon in the dia"ra$ &elo'%he "overnor 1onsists of a rotatin" shaft, hi1h is driven &y the dieselen"ine' A !air of flyei"hts is linked to the shaft and they rotate as itrotates' %he 1entrifu"al for1e 1aused &y the rotation 1auses the ei"hts to&e thron outards as the s!eed of the shaft rises' If the s!eed falls theei"hts $ove inards' %he flyei"hts are linked to a 1ollar fitted around theshaft &y a !air of ar$s' As the ei"hts $ove out, so the 1ollar rises on theshaft' If the ei"hts $ove inards, the 1ollar $oves don the shaft' %he$ove$ent of the 1ollar is used to o!erate the fuel ra1k lever 1ontrollin" the

a$ount of fuel su!!lied to the en"ine &y the ine1tors.

$;)9$SS$9

In Indian Railays, the trains nor$ally ork on va1uu$ &rakes and the diesello1os on air &rakes' As su1h !rovision has &een $ade on every diesel lo1o for&oth va1uu$ and 1o$!ressed air for o!eration of the syste$ as a

1o$&ination &rake syste$ for si$ultaneous a!!li1ation on lo1o$otive andtrain'>i"'?'=2 E3!ressureIn AL0: lo1os the e3hauster and the 1o$!ressor are 1o$&ined into one unitand it is knon as EV.RESS:R' It 1reates 4; of va1uu$ in the train !i!e and=


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1rank shaft' %he to are 1ou!led to"ether &y fast 1ou!lin" (/o!!erCs1ou!lin")' Naturally the e3!ressor 1rank shaft has ei"ht s!eeds like theen"ine 1rank shaft' %here are to ty!es of e3!ressor are, #0D,


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and sha!e' %he retainer stud in &oth the asse$&lies $ust !roe1t u!ard toavoid hittin" the !iston'

%he !ressure differential &eteen the availa&le !ressure in the va1uu$ train!i!e and inside the e3hauster 1ylinder o!ens the inlet valve and air is dran

into the 1ylinder fro$ train !i!e durin" su1tion stroke' In the ne3t stroke ofthe !iston the air is 1o$!ressed and for1ed out throu"h the dis1har"e valvehile the inlet valve re$ains 1losed' %he differential air !ressure alsoauto$ati1ally o!en or 1lose the dis1har"e valves, the sa$e ay as the inletvalves o!erate' %his !ro1ess of su1tion of air fro$ the train !i!e 1ontinues to1reate reuired a$ount of va1uu$ and dis1har"e the sa$e air toat$os!here' %he A2= 1ontrol valve hel!s in $aintainin" the va1uu$ toreuisite level des!ite 1ontinued orkin" of the e3hauster'

'

*ompre//or

%he 1o$!ressor is a to sta"e 1o$!ressor ith one lo !ressure 1ylinderand one hi"h !ressure 1ylinder' Durin" the first sta"e of 1o$!ression it isdone in the lo !ressure 1ylinder here su1tion is throu"h a ire $esh filter'After 1o$!ression in the L. 1ylinder air is delivered into the dis1har"e$anifold at a !ressure of ; + ;? .SI' Workin"s of the inlet and e3haustvalves are si$ilar to that of e3hauster hi1h auto$ati1ally o!en or 1loseunder differential air !ressure' >or inter21oolin" air is then !assed throu"h aradiator knon as inter21ooler' %his is an air to air 1ooler here 1o$!ressedair !asses throu"h the ele$ent tu&es and 1ool at$os!heri1 air is &lon on

the out side fins &y a fan fitted on the e3!ressor 1rank shaft' 0oolin" of air atthis sta"e in1reases the volu$etri1 effi1ien1y of air &efore it enters the hi"h2!ressure 1ylinder' A safety valve knon as inter 1ooler safety valve set at #.SI is !rovided after the inter 1ooler as a !rote1tion a"ainst hi"h !ressuredevelo!in" in the after 1ooler due to defe1t of valves'After the first sta"e of 1o$!ression and after21oolin" the air is a"ain1o$!ressed in a 1ylinder of s$aller dia$eter to in1rease the !ressure to=;?2=


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D"ive Sa#t%he $ain out!ut fro$ the diesel en"ine is trans$itted &y the drive shaft tothe alternators at one end and the radiator fans and 1o$!ressor at the other

end'

+adiato" and +adiato" !an%he radiator orks the sa$e ay as in an auto$o&ile' Water is distri&utedaround the en"ine &lo1k to kee! the te$!erature ithin the $ost effi1ientran"e for the en"ine' %he ater is 1ooled &y !assin" it throu"h a radiator&lon &y a fan driven &y the diesel en"ine'

T%".o Ca"$in$%he a$ount of !oer o&tained fro$ a 1ylinder in a diesel en"ine de!ends onho $u1h fuel 1an &e &urnt in it' %he a$ount of fuel hi1h 1an &e &urntde!ends on the a$ount of air availa&le in the 1ylinder' So, if you 1an "et$ore air into the 1ylinder, $ore fuel ill &e &urnt and you ill "et $ore!oer out of your i"nition' %ur&o 1har"in" is used to in1rease the a$ount ofair !ushed into ea1h 1ylinder' %he tur&o1har"er is driven &y e3haust "asfro$ the en"ine' %his "as drives a fan hi1h, in turn, drives a s$all1o$!ressor hi1h !ushes the additional air into the 1ylinder' %ur&o 1har"in""ives a ? in1rease in en"ine !oer'%he $ain advanta"e of the tur&o1har"er is that it "ives $ore !oer ith no

in1rease in fuel 1osts &e1ause it uses e3haust "as as drive !oer' It doesneed additional $aintenan1e, hoever, so there are so$e ty!es of loer!oer lo1o$otives hi1h are &uilt ithout it'

Mecanical T"ansmissionLike an auto$o&ile, a diesel lo1o$otive 1annot start itself dire1tly fro$ astand' It ill not develo! $a3i$u$ !oer at idlin" s!eed, so it needs so$efor$ of trans$ission syste$ to $ulti!ly torue hen startin"' It ill also &ene1essary to vary the !oer a!!lied a11ordin" to the train ei"ht or the line"radient' %here are three $ethods of doin" thisO $e1hani1al, hydrauli1 or

ele1tri1' *ost diesel lo1o$otives use ele1tri1 trans$ission and are 1alleddiesel2ele1tri1 lo1o$otives' *e1hani1al and hydrauli1 trans$issions are stillused &ut are $ore 1o$$on on $ulti!le unit trains or li"hter lo1o$otives'.c?anical Trans6issi4nA diesel2$e1hani1al lo1o$otive is the si$!lest ty!e of diesel lo1o$otive' Asthe na$e su""ests, a $e1hani1al trans$ission on a diesel lo1o$otive1onsists a dire1t $e1hani1al link &eteen the diesel en"ine and the heels'In the e3a$!le &elo, the diesel en"ine is in the ;?2? h! ran"e and the


35/43

trans$ission is si$ilar to that of an auto$o&ile ith a four s!eed "ear&o3'*ost of the !arts are si$ilar to the diesel2ele1tri1 lo1o$otive &ut there areso$e variations in desi"n $entioned &elo'

Gearbo6%his does the sa$e o& as that on an auto$o&ile' It varies the "ear ratio&eteen the en"ine and the road heels so that the a!!ro!riate level of!oer 1an &e a!!lied to the heels' 8ear 1han"e is $anual' %here is noneed for a se!arate 1lut1h &e1ause the fun1tions of a 1lut1h are already!rovided in the fluid 1ou!lin"'

Fluid C4ulingIn a diesel2$e1hani1al trans$ission, the $ain drive shaft is 1ou!led to theen"ine &y a fluid 1ou!lin"' %his is a hydrauli1 1lut1h, 1onsistin" of a 1asefilled ith oil, a rotatin" dis1 ith 1urved &lades driven &y the en"ine andanother 1onne1ted to the road heels' As the en"ine turns the fan, the oil isdriven &y one dis1 toards the other' %his turns under the for1e of the oiland thus turns the drive shaft' :f 1ourse, the startu! is "radual until the fans!eed is al$ost $at1hed &y the &lades' %he hole syste$ a1ts like anauto$ati1 1lut1h to allo a "raduated start for the lo1o$otive'

!inal D"ive%he diesel2$e1hani1al lo1o$otive uses a final drive si$ilar to that of a stea$en"ine' %he heels are 1ou!led to ea1h other to !rovide $ore adhesion'%he out!ut fro$ the


36/43

-ydrauli1 trans$ission orks on the sa$e !rin1i!al as the fluid 1ou!lin" &utit allos a ider ran"e of sli! &eteen the en"ine and heels' It is knonas a torue 1onverter' When the train s!eed has in1reased suffi1iently to$at1h the en"ine s!eed, the fluid is drained out of the torue 1onverter sothat the en"ine is virtually 1ou!led dire1tly to the lo1o$otive heels' It is

virtually dire1t &e1ause the 1ou!lin" is usually a fluid 1ou!lin", to "ive so$esli!' -i"her s!eed lo1o$otives use to or three torue 1onverters in aseuen1e si$ilar to "ear 1han"in" in a $e1hani1al trans$ission and so$ehave used a 1o$&ination of torue 1onverters and "ears'So$e desi"ns of diesel2hydrauli1 lo1o$otives had to diesel en"ines andto trans$ission syste$s, one for ea1h &o"ie' %he desi"n as !o!lar in8er$any (the 4 series of lo1o$otives, for e3a$!le) in the =?s and asi$!orted into !arts of the 9/ in the =#s' -oever, it did not ork ell inheavy or e3!ress lo1o$otive desi"ns and has lar"ely &een re!la1ed &ydiesel2ele1tri1 trans$ission'

Te Diesel En$ine%he diesel en"ine as first !atented &y Dr Rudolf Diesel (=?2==;) in8er$any in =4 and he a1tually "ot a su11essful en"ine orkin" &y =@'By ==;, hen he died, his en"ine as in use on lo1o$otives and he had setu! a fa1ility ith SulHer in SitHerland to $anufa1ture the$' -is death as$ysterious in that he si$!ly disa!!eared fro$ a shi! takin" hi$ to London'%he diesel en"ine is a 1o$!ression2i"nition en"ine, as o!!osed to the !etrol(or "asoline) en"ine, hi1h is a s!ark2i"nition en"ine' %he s!ark i"nitionen"ine uses an ele1tri1al s!ark fro$ a s!ark !lu" to i"nite the fuel in theen"ineCs 1ylinders, hereas the fuel in the diesel en"ineCs 1ylinders is i"nited&y the heat 1aused &y air &ein" suddenly 1o$!ressed in the 1ylinder' At this

sta"e, the air "ets 1o$!ressed into an area =+4?th of its ori"inal volu$e'%his ould &e e3!ressed as a 1o$!ression ratio of 4? to =' A 1o$!ressionratio of =# to = ill "ive an air !ressure of ? l&s+in (;?'? &ars) and illin1rease the air te$!erature to over U> (


37/43

0o$!ression and 1o$&ustion o11urs on the u!stroke' As one $i"ht "uess,there are ti1e as $any revolutions for the to2stroke en"ine as foreuivalent !oer in a four2stroke en"ine'%he four2stroke en"ine orks as follosO Don stroke = 2 air intake, u!stroke= 2 1o$!ression, don stroke 4 2 !oer, u!stroke 4 2 e3haust' alves are

reuired for air intake and e3haust, usually to for ea1h' In this res!e1t it is$ore si$ilar to the $odern !etrol en"ine than the 42stroke desi"n'In the 9/, &oth ty!es of diesel en"ine ere used &ut the


38/43

trans$ission &eteen the diesel en"ine and the heels' :ne thin" orthre$e$&erin" is that the !oer !rodu1ed &y the diesel en"ine is not allavaila&le for tra1tion' In a 4,? h! diesel ele1tri1 lo1o$otive, so$e


39/43

$ore !oer fro$ the $otors, e $ust "et $ore 1urrent fro$ the alternatorso the en"ine needs to run faster to "enerate it' %herefore, to "et theo!ti$u$ !erfor$an1e fro$ the lo1o$otive, e $ust link the 1ontrol of thediesel en"ine to the !oer de$ands &ein" $ade on the alternator'%he 1ore of the syste$ as a load re"ulator, &asi1ally a varia&le resistor

hi1h as used to vary the e31itation of the "enerator so that its out!ut$at1hed en"ine s!eed' %he 1ontrol seuen1e (si$!lified) as as follosO=' Driver $oves the !oer 1ontroller to the full !oer !osition'4' An air o!erated !iston a1tuated &y the 1ontroller $oves a lever, hi1h1loses a sit1h to su!!ly a lo volta"e to the load re"ulator $otor';' %he load re"ulator $otor $oves the varia&le resistor to in1rease the $ain"enerator field stren"th and therefore its out!ut'


40/43

A !ro&le$ ith en"ine 1oolin" is 1old eather' Water freeHes at U0 or ;4U>and froHen 1oolin" ater ill ui1kly s!lit a !i!e or en"ine &lo1k due to thee3!ansion of the ater as it freeHes' So$e syste$s are self drainin" henthe en"ine is sto!!ed and $ost in Euro!e are desi"ned to use a $i3ture ofanti2freeHe, ith 8y1ol and so$e for$ of rust inhi&itor' .ro&le$s ith leaks

and seals and the e3!ense of !uttin" a = "allons (;@'? liters) of 1oolantinto a ;, h! en"ine, $eans that en"ines in the 9S have traditionallyo!erated ithout it' In 1old eather, the en"ine is left runnin" or thelo1o$otive is ke!t ar$ &y !uttin" it into a heated &uildin" or &y !lu""in" ina shore su!!ly' Another reason for kee!in" diesel en"ines runnin" is thatthe 1onstant heatin" and 1oolin" 1aused &y shutdons and restarts, 1ausesstresses in the &lo1k and !i!es and tends to !rodu1e leaks'

Lu7rica3i4nLike an auto$o&ile en"ine, a diesel en"ine needs lu&ri1ation' In anarran"e$ent si$ilar to the en"ine 1oolin" syste$, lu&ri1atin" oil is

distri&uted around the en"ine to the 1ylinders, 1rankshaft and other $ovin"!arts' %here is a reservoir of oil, usually 1arried in the su$!, hi1h has to &eke!t to!!ed u!, and a !u$! to kee! the oil 1ir1ulatin" evenly around theen"ine' %he oil "ets heated &y its !assa"e around the en"ine and has to &eke!t 1ool, so it is !assed throu"h a radiator durin" its ourney' %he radiatoris so$eti$es desi"ned as a heat e31han"er, here the oil !asses throu"h!i!es en1ased in a ater tank hi1h is 1onne1ted to the en"ine 1oolin"syste$'

T"ansmissions

Like an auto$o&ile, a diesel lo1o$otive 1annot start itself dire1tly fro$ astand' It ill not develo! $a3i$u$ !oer at idlin" s!eed, so it needs so$efor$ of trans$ission syste$ to $ulti!ly torue hen startin"' It ill also &ene1essary to vary the !oer a!!lied a11ordin" to the train ei"ht or the line"radient' %here are three $ethods of doin" thisO $e1hani1al, hydrauli1 orele1tri1' *e1hani1al and hydrauli1 trans$issions are still used &ut are $ore1o$$on on $ulti!le unit trains or li"hter lo1o$otives'Diesel2ele1tri1 lo1o$otives 1o$e in three varieties, a11ordin" to the !eriod inhi1h they ere desi"ned' %hese three areOD0 2 D0 (D0 "enerator su!!lyin" D0 tra1tion $otors)6A0 2 D0 (A0 alternator out!ut re1tified to su!!ly D0 $otors) and

A0 2 D0 2 A0 (A0 alternator out!ut re1tified to D0 and then inverted to ;2!hase A0 for the tra1tion $otors)'

Dyna6ic 7raking

A 1o$$on o!tion on Diesel2ele1tri1 lo1o$otives is dyna$i1 (rheostat)&rakin"'


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Dyna$i1 &rakin" takes advanta"e of the fa1t that the tra1tion $otorar$atures are alays rotatin" hen the lo1o$otive is in $otion and that a$otor 1an &e $ade to a1t as a "enerator &y se!arately e31itin" the fieldindin"' When dyna$i1 &rakin" is utiliHed, the tra1tion 1ontrol 1ir1uits are1onfi"ured as follosO

%he field indin" of ea1h tra1tion $otor is 1onne1ted a1ross the $ain"enerator'

%he ar$ature of ea1h tra1tion $otor is 1onne1ted a1ross a for1ed2air

1ooled resistan1e "rid (the dyna$i1 &rakin" "rid) in the roof of thelo1o$otiveCs hood'

%he !ri$e $over R.* is in1reased and the $ain "enerator field ise31ited, 1ausin" a 1orres!ondin" e31itation of the tra1tion $otor fields'

>i"' Air Brake Syste$

%he a""re"ate effe1t of the a&ove is to 1ause ea1h tra1tion $otor to "enerateele1tri1 !oer and dissi!ate it as heat in the dyna$i1 &rakin" "rid' >or1ed air21oolin" is !rovided &y a fan that is 1onne1ted a1ross the "rid' 0onseuently, the fanis !oered &y the out!ut of the tra1tion $otors and ill tend to run faster and!rodu1e $ore airflo as $ore ener"y is a!!lied to the "rid'9lti$ately, the sour1e of the ener"y dissi!ated in the dyna$i1 &rakin" "rid is the$otion of the lo1o$otive as i$!arted to the tra1tion $otor ar$atures' %herefore,the tra1tion $otors i$!ose dra" and the lo1o$otive a1ts as a &rake' As s!eedde1reases, the &rakin" effe1t de1ays and usually &e1o$es ineffe1tive &eloa!!ro3i$ately =# k$+h (= $!h), de!endin" on the "ear ratio &eteen the tra1tion

$otors and a3les'Dyna$i1 &rakin" is !arti1ularly &enefi1ial hen o!eratin" in $ountainous re"ions,here there is alays the dan"er of a runaay due to overheated fri1tion &rakesdurin" des1ent (see also 1o$$ents in the air &rake arti1le re"ardin" loss of &rakin"due to i$!ro!er train handlin")'


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In su1h 1ases, dyna$i1 &rakes are usually a!!lied in 1onun1tion ith the air&rakes, the 1o$&ined effe1t &ein" referred to as &lended &rakin"' %he use of&lended &rakin" 1an also assist in kee!in" the sla1k in a lon" train stret1hedas it 1rests a "rade, hel!in" to !revent a run2in, an a&ru!t &un1hin" oftrain sla1k that 1an 1ause a derail$ent' Blended &rakin" is also 1o$$only

used ith 1o$$uter trains to redu1e ear and tear on the $e1hani1al&rakes that is a natural result of the nu$erous sto!s su1h trains ty!i1ally$ake durin" a run'Advanta"esO

Re"enerative &rakin"'

No "ear shiftin"'

No &a1klash and &reakin" of 1ou!lin"s durin" shiftin"'

0onstant availa&ility of $a3i$u$ diesel "enerator !oer'

Easy addition of $ulti!le !oer units'

Less $aintenan1e ith $odern a1 "enerators and $otors ithout

1o$$utators'

Disadvanta"esO

*ore ei"ht'

Less effi1ient in fuel use'

Needs hi"h te1h ele1troni1s ith use of a1 "enerators and $otors

R#F#R#NC#S

Disl S?d@ S?akur %as3i

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43/43

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project on wdm-2

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