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Submitted To: The Principal Supervisor Training Center Northern Railway Lucknow
Submitted By: Ahmad Shuja 3rd year Mechanical Engineering Jahangirabad Educational Trust Group Of Institutions Barabanki
CONTENTS INTRODUCTION TO LOCOMOTIVE WORKSHOP, LUCKNOW ABOUT INDIAN RAILWAYS INDIAN RAILWAY ZONES HISTORY OF RAIL TRANSPORT IN INDIA
*** UNDER BRITISH RULE *** THE LINKING OF INDIAN RAILWAYS *** START OF INDIAN RAILWAYS
INDIAN LOCOMOTIVE CLASS WDM-2 SPECIFICATIONS OF WDM-2 WORKING OF DIESEL LOCOMOTIVE POWER PACK (ENGINE) OF DIESEL LOCOMOTIVE TORQUE VALUES OF VARIOUS POWER PACK FITTINGS IMPORTANT SIZES OF ENGINE BLOCK MAIN PARTS AND ACCESSORIES OF POWER PACK REFERENCES INTRODUCTION TO LOCOMOTIVE WORKSHOP, LUCKNOW
This Locomotive Workshop was established by the princely state of Oudh & Rohilkhand Railway (O&RR) at Lucknow in 1867. After about sixty years, that is in the 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 Railway. 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.
administered by the Railway Board, which has a financial commissioner, five members and a chairman. Indian Railways has more than 64,215 kilometres (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 and China. 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 is one of the world's largest commercial or utility employers, with more than 1.6 million employees. As to rolling stock, IR owns over 230,000 (freight) wagons, 60,000 coaches and 9,000 locomotives. Railways were first introduced to India in 1853. By 1947, the year of India's independence, there were forty-two rail systems. In 1951 the systems were nationalised as one unit, becoming one of the largest networks in the world. IR operates both long distance and suburban rail systems on a multi-gauge network of broad, metre and narrow gauges. It also owns locomotive and coach production facilities.
divided into divisions under the control of Divisional Railway Managers (DRM). The divisional officers of engineering, mechanical, electrical, signal and telecommunication, accounts, personnel, operating, commercial and safety branches report to the respective Divisional Manager and are in charge of operation and maintenance of assets. Further down the hierarchy tree are the Station Masters who control individual stations and the train movement through the track territory under their stations' administration.
The history of rail transport in India began in the mid-nineteenth century. In 1849, there was not a single kilometer of railway line in India. By 1929, there were 41,000 miles of railway line serving every district in the country. At that point of time, the railways represented a capital value of some 687 million sterling, and they carried over 620 millions of passengers and approximately 90 million tons of goods each year. The railways In India were a group of privately owned companies. The military engineers of the Honorable East India Company, later of the British Indian Army, contributed to the birth and growth of the railways which gradually became the responsibility of civilian technocrats and engineers.
passenger traffic from Howrah station to Hooghly on 15 August 1854. The 541 miles (871 kilometres) to Benares opened to passenger traffic in December 1862.
In 1920, with the network having expanded to 61,220 km, a need for central management was mooted by Sir William Acworth. Based on the East India Railway Committee chaired by Acworth, the government took over the management of the Railways and detached the finance of the Railways from other governmental revenues.The period between 1920 and 1929 was a period of economic boom. Following the Great Depression, the company suffered economically for the next eight years. The Second World War severely crippled the railways. Trains were diverted to the Middle East and the railways workshops were converted to ammunitions workshops. By 1946 all rail systems had been taken over by the government.
in India the longest super fast train is between Thiruvananthapuram to Guwahati. Its distance is nearly 3000 km.
LOCOMOTIVES IN INDIA
Locomotives in India consist of ELECTRIC and DIESEL locomotives. STEAM locomotives are no longer used, except in heritage trains. Locomotives are also called locos or engines.
CLASSIFICATION OF LOCOMOTIVES:
In India, locomotives are classified according to their track gauge, motive power, the work they are suited for and their power or model number. The class name includes this information about the locomotive. It comprises 4 or 5 letters. The first letter denotes the track gauge. The second letter denotes their motive power (Diesel or Electric) and the third letter denotes the kind of traffic for which they are suited (goods, passenger, mixed or shunting). The fourth letter used to denote locomotives' chronological model number. However, from 2002 a new classification scheme has been adopted. Under this system, for newer diesel locomotives, the fourth letter will denote their horsepower range. Electric locomotives don't come under this scheme and even all diesel locos are not covered. A locomotive may sometimes have a fifth letter in its name which generally denotes a technical variant or subclass or subtype. This fifth letter indicates some smaller variation in the basic model or series, perhaps different motors, or a different manufacturer. With the new scheme for classifying diesel locomotives the fifth item is a letter that further refines the horsepower indication in 100 hp increments: 'A' for 100 hp, 'B' for 200 hp, 'C' for 300 hp, etc. So in this scheme, a WDM-3A refers to a 3100 hp loco, while a WDM-3F would be a 3600 hp loco.
1)
DIESEL-MECHANICAL: A diesel-mechanical locomotive uses a mechanical transmission in a fashion similar to that employed in most road vehicles. This type of transmission is generally limited to low-powered, low speed shunting (switching) locomotives, lightweight multiple units and self-propelled railcars. There is usually a fluid coupling interposed between the engine and gearbox, and the gearbox is often of the epicyclic (planetary) type to permit shifting while under load.
2)
DIESEL-ELECTRIC: In a Diesel-electric locomotive, the Diesel engine drives an electrical generator whose output provides power to the traction motors. There is no mechanical connection between the engine and the wheels. The important components of Diesel-electric propulsion are the Diesel engine (also known as the prime mover), the main generator, traction motors and a control system consisting of the engine governor as well as electrical and/or
electronic components used to control or modify the electrical supply to the traction motors, including switchgear, rectifiers and other components.
The class WDM-2 is Indian Railways' workhorse diesel locomotive. The first units were imported fully built from the American Locomotive Company (Alco) in 1962. Since 1964, it has been manufactured in India by the Diesel Locomotive Works (DLW), Varanasi. The model name stands for broad gauge (W), diesel (D), mixed traffic (M) engine. The WDM-2 is the most common diesel locomotive of Indian Railways. The WDM-2A is a variant of the original WDM-2. These units have been retro-fitted with air brakes, in addition to the original vacuum brakes. The WDM-2B is a more recent locomotive, built with air brakes as original equipment. The WDM-2 locos have a maximum speed of 120 km/h (75 mph), restricted to 100 km/h (62 mph) when run long hood forward - the gear ratio is 65:18.
SPECIFICATIONS OF WDM-2:
Builders: Alco, DLW Engine: Alco 251-B, V-16 cylinder, 2600hp (2430hp site rating) with Alco 710/720 turbocharger. 1000rpm max, 400rpm idle; 228mm x 266mm bore/stroke; compression ratio 12.5:1. Direct fuel injection, centrifugal pump
cooling system (2457 l/min @ 1000rpm), fan driven by eddy current clutch (86hp @ engine rpm 1000). Governor: GE 17MG8 / Woodwards 8574-650. Transmission: Electric, with BHEL TG 10931 AZ generator (1000rpm, 770V, 4520A). Traction motors: GE752 (original Alco models) (405hp), BHEL 4906 BZ (AZ) (435hp) and (newer) 4907 AZ (with roller bearings) Axle Load: 18.8 tonnes, total weight 112.8t. Bogies: Alco design asymmetric cast frame trimount (Co-Co) bogies (shared with WDS-6, WDM-7, WAM-4, WCAM-1, WCG-2). Starting TE: 30.4t, at adhesion 27%. Gauge: 1,676mm Wheel Diameter: 1,092mm Wheelbase: 12,834mm Total length: 17,120mm Width: 2,864mm Height: 4,185mm Length over buffer beams: 15,862mm. Distance between bogies: 10,516mm.
Most of the diesel locomotives (including WDM-2) are actually Diesel Electric Locomotives. An internal combustion diesel engine rotates an electric generator first, producing electric current. The electricity thus produced by the generator is fed to different electric motors, placed near to loco axles. This motor output is connected mechanically to the wheels through suitable gear systems.
This is the main power source for the locomotive. It comprises a large cylinder block, with the cylinders arranged in a V-shaped arrangement (generally V-12 or V16). The engine rotates the drive shaft at up to 1,000 rpm and this drives the various items needed to power the locomotive. As the transmission is electric, the engine is used as the power source for the electricity generator or alternator, as it is called nowadays.
ENGINE: Alco 251-B, V-16 cylinder, 2600hp (2430hp site rating) with Alco 710/720
turbocharger. 1000rpm max, 400rpm idle; 228mm x 266mm bore/stroke; compression ratio 12.5:1. Direct fuel injection, centrifugal pump cooling system (2457 l/min @ 1000rpm)
7 8 9 10 11 12 13 14 15 16 17 18 19
S.NO.
1
PARTICULAR/ ITEM
CRANKSHAFT:
## CRANKSHAFT MAIN JOURNAL DIA
NEW
8.498(min) 8.500(max) 5.998(min) 6.000(max) 0.010(min) 0.017(max)
LIMIT
8.496
5.996
0.035
BLOCK BORE:
## MAIN BORE WITHOUT SHELL 9.0355(min) 9.0370(max) 10.621(min) 10.623(max) 10.627(min) 10.629(max) 0.004(min) 0.008(max) 10.249(min) ## INTERNAL DIA OF SLEEVE AFTER PRESSING 10.252(max) 10.254 9.035 9.0385
## OVALITY PERMISSIBLE
0.003(max)
***All the dimensions and torque values of various engine parts and fittings should be taken under consideration during the power pack assembly process. The values should neither be exceeded nor should be less than the standard values. They should be kept within the provided range***
LUBE OIL HEADER, LUBE OIL SCREEN, LUBE DRAIN PIPE, LUBE OIL PUMP, WATER PUMP, S-PIPE, CRANKSHAFT, CAMSHAFT, CONTROL SHAFT, EXTENSION SHAFT, CYLINDER LINER, PISTONS, CYLINDER HEADS, ROCKER ARMS, PUSH RODS, WATER JUMPER, WATER CHANNEL, WATER RISER, EXHAUST MANIFOLD, COMPRESSION CHAMBER EXHAUSTER MOTOR, GOVERNOR, FIP(FUEL INJECTION PUMP), CAMSHAFT GEAR, SPLIT GEAR, TURBO SUPERCHARGER, AC(AFTER COOLING) CORE, OIL CATCHER, VIBRATION DAMPER, INJECTOR NOZZLES, INLET & EXHAUST VALVES, BUBBLE CRUSHERS, CROSSHEAD and many more
DESCRIPTION: LUBE OIL PUMP: This pump helps in the circulation of the lube oil to various
parts and accessories of the power pack for the purpose of lubrication. It draws the lube oil from lube oil header and circulates it with required optimum pressure to various parts. WATER PUMP: It is a type of centrifugal pump whose main function is to circulate water through parts and accessories of the power pack necessary to cool and reduce the temperature by absorbing heat.
LUBE OIL SCREEN: It acts as a filter which helps in filtering of the lube oil
coming to the sump after circulation to various parts. It separates impurities and metal parts from the lube oil.
FUEL
INJECTION PUMP: Ignition in a diesel engine is achieved by compressing air inside a cylinder until it gets very hot and then injecting a fine spray of fuel oil to cause a miniature explosion. The explosion forces down the piston in the cylinder and this turns the crankshaft. To get the fine spray needed for successful ignition the fuel has to be pumped into the cylinder at high pressure. The fuel injection pump is operated by a cam. The fuel is pumped into an injector, which gives the fine spray of fuel required in the cylinder for combustion.
COMPRESSION
CHAMBER EXHAUSTER MOTOR: Due to wear out of the piston rings, certain amount of compressed gases escapes to the sump. This motor helps in escaping of these blowby gases from the sump to avoid explosion and other harmful effects. This motor is also known as the CC MOTOR.
a rotating shaft, which is driven by the diesel engine. A pair of flyweights is linked to the shaft and they rotate as it rotates. The centrifugal force caused by the rotation causes the weights to be thrown outwards as the speed of the shaft rises. The flyweights are linked to a collar fitted around the shaft by a pair of arms. As the weights move out, so the collar rises on the shaft. If the weights move inwards, the collar moves down the shaft. The movement of the collar is used to operate the fuel rack lever controlling the amount of fuel supplied to the engine by the injectors.
OIL CATCHER: It is mounted on the generator side to avoid the any lube oil
entering the generator parts as it may damage the generator. It catches the lube oil and drain it to the sump.
VIBRATION
DAMPERS: The function of vibration damper is to damp the oscillatory and rotator vibrations that are caused due to the movement of the crankshaft and other rotator parts of the power pack.
MAIN
GENERATOR: The diesel engine drives the main generator which provides the power to move the train. The generator generates electricity which is used to provide power for the traction motors mounted on the trucks (bogies). Due to recent development, the replacement of the generator by an alternator is going on.
REFERENCES
www.wikipedia.com www.google.com www.howstuffworks.com