FUEL OIL SYSTEM

P.Kumar, Lecturer/Dsl

FUEL OIL SYSTEM OF WDM2 LOCO

 Requirements

of fuel system.  Associated components of fuel system.  Schematic Diagrams of fuel oil system.  Fuel efficient kits of fuel oil system.  Trouble shooting of fuel oil system.

REQUIREMENT OF FUEL SYSTEM The fuel oil system is designed to introduce fuel oil in to the engine cylinders at correct time ,in correct quantity and at correct pressure.
 At

correct time: The

fuel should be introduce in to the combustion chamber within precisely defined period of the cycle. Fuel injection start18 15' before TDC Termination of injector 14 45'After TDC Total Period of injection -18 15'+14 45'=33

 CORRECT QUANTITY-.Correct quantity of fuel is QUANTITYimportant to maintain the variable speed of locomotive engine at variable load. Usually, The distribution of the fuel among each cylinder is done uniform. CORRECT PRESSURE: High pressure also helps in PRESSURE: proper atomization so that the small droplets come in better contact with the fresh air in the combustion chamber High pressure of fuel is required to lift the nozzle valve and for better penetration of fuel in to combustion chamber The beginning and the end of injection should be sharp,i.e sharp,i.e there should not be any dribbling or after injection.

FOP Gauge

REGULATING VALVE

Lt. FUEL OIL HEADER

Cross Over Pipe

FIP

Injector

Rt. FUEL OIL HEADER

LEAK OFF HEADER

SECONDARY FILTER
RELIEF VALVE

5.3 Kg/cm2
MOTOR

4.2 Kg/cm2

PUMP

Fuel tank

PRIMARY FILTER

FUEL OIL SYSTEM - WDM2

The fuel oil system consists two integrated system. (A) Fuel feed system. (B) Fuel injection system. system.

(A) Fuel feed system:- The fuel feed system provides the system: back up support to the fuel injection pump by maintaining steady supply of fuel at required pressure.

(B) Fuel injection system:- The Fuel injection pump started system: according to firing order. All F.I.P start & discharging fuel oil at high pressure to their respective nozzle.

Associated Components(Fuel feed system)system)(a)Fuel oil tank-Fabricated under the super structure of locomotive and tanklocated between two bogies.Capacity-5000lts bogies.Capacity(b)Fuel primary filter-(paper type filter) filter(c )Booster pump(fuel transfer pump) Pump capacity- 14 lts/ minutes(at 1725 rpm) capacity- lts/ pressurepressure-4-4.8 kg/cm2

(d)Fuel relief valve-The spring loaded relief valve( valve. Adjusted at-5kg/cm2(70 p.s.i) atp.s.i) (e) Fuel secondary valve- (Paper type filter ) valve(f)Fuel regulating valve-The spring loaded valve valve. Adjusted at- 4.0 to 4.2kg/cm2(50-55p.s.i) at4.2kg/cm2(50-

Associated components( Fuel Injection system) A.Fuel injection pump- It is single acting constant stroke
plunger type pump
Functiona.To raise the fuel oil pressure to nozzle which will efficiently atomize the fuel. b.To supply the correct quantity of fuel to nozzle as per power and speed requirement of the engine. c.To accurately time the delivery of the fuel for efficient economical operation of engine.

B.Fuel injection nozzle-a.To inject fuel at a sufficiently high

pressure so that the fuel enters the cylinder with a high velocity b.Fuel injection nozzle injects fuel oil to combustion chamber at 4000psi.

Fuel injection pump Some important parts of FIP are as below1. 2. 3. 4. 5. 6. 7. Control Rack Barrel & plunger Control sleeve Plunger spring Guide cup Lower spring seat. Snubber valve assembly.

Calibration of FIP
 Purpose: It is done after overhauling to ensure that it
delivers the same and stipulated amount of fuel at a particular rack position.

 

Process of FIP calibration & testing

The calibration and testing of FIPs are done on a specially designed machine. The blended test oil of recommended viscosity under controlled temperature is circulated through a pump at a specified pressure for feeding the pump under test. The oil discharged for 300 stroke of the pump is measured at idle and full load. For WDM2,it is as 9mm rack position(idle) 34 CC +1/-5 30 mm rack position (Full load )351 CC +4/-11 If test results are not within limit ,adjustment of fuel rack position is done by moving the rack pointer with addition or removal of shims behind it.

PHASING & CALIBRATION OF FIP

PHASING: CALIBRATION: Position Setting of Pump according to Injection Timing Calibrating delivery of the pump according to Rack

Checked by hartridge 1100 calibrating machine at 300 rpm and 300 stroke 9mm = 45 ml 28 mm= 401 ml

Fuel injection nozzle Some important parts of fuel injection nozzle are as below1. 2. 3. 4. 5. 6. Nozzle body Nozzle Valve Spacer Pressure adjusting spring Nozzle holder body. Cap nut

Testing of Fuel Injection Nozzle

Purpose: Good atomization ,correct spray pattern and no leakage or dribbling are the criteria of a good FIN.

The following tests are conducted on a specially designed machine Spray pattern( by taking impression on blotting paper)
 Spray pressure (3900-4050 PSI for new & 3700-3800 PSI for
reconditioned nozzle)

 Dribbling : This occur due to improper pressure setting or dirt stuck

up between the valve & valve seat. Or improper contact between the valve and valve seat.

TESTING OF NOZZLE
Opening Pressure: 3900-4050 psi (New), 3700- 3800 psi (Old) Spray Pattern/ Blotter test: Uniform pattern Dribbling: Holding at 3500 PSI for 10 secs ( No drop) Leak off: 3500 to 1000 PSI drop down time 6-16 secs Valve Lift: .026" (max), .005 to .007" (New)

Continue
 Nozzle

chatter: This sound creates due to free movement of the nozzle valve inside the valve body. it should be proper.  Nozzle leak off rate: the process of checking the leak off rate is by creating pressure in nozzle up to 3500 PSI and hold the pressure till it drop to 1000PSI.( 5sec)

ORIFICE TEST
Purpose: This test is conducted to check the efficiency of the fuel feed system under full load condition.

Process:  Fit a orifice plate of 1/8 inch in the system before the regulating V/V.  Place a container to collect the leak off oil.  Switch on the Fuel booster P/P for 60 sec.  The rate of leak should be about 9 ltrs per minute.

FUEL EFFICIENT KIT PURPOSEPURPOSETo improve specific fuel consumption by 6%,Reduction in existing exhaust gas temp by 100and 100 reduction in lub oil consumption.

1.Modified water connection to after cooler -Water inlet of the after cooler is connected from outlet of the radiator to provide water at min. possible temp into the after cooler. 2.17 mm fuel injection pump-15 mm pumps are replaced by 17mm pump to have sharper fuel injection.Max rack. it has increased injection rate also. 3.Modified cam shaft with 140 degree over lap-The cam shaft increase the over lap from 123 to140 degree to improve the scavenging.

4.Larger after cooler-increased core size, Introduced four passes instead of two passes,it has increased the effectiveness of after cooler to over 25%. Higher effectiveness has been introduced to provide cooled air to engine. 5.Steel cap pistons-In the fuel efficient engine ,peak firing 1800 psi ,lower lub oil consumption. steel cap piston provides greater strength compared to the all AL pistons used earlier. 6.High efficiency turbo charger-High efficiency turbo super charger ABB -VTC 304, NAPIER NA295 having capacity to develop 2.2kg/cm2 booster pressure.

TECHNOLOGY PROGRESSION
Successive Power Upgradation and Specific Fuel Consumption reduction

166 4500 HP 225

May,1990
156 206.25

3600 HP

Nov,2002
3300 HP

Oct,1995
154 HP/Cylinder 193.75

Oct,2001
152

3100 HP 162.5 2600 HP

Nov,2002
150

Oct,1993

SFC gm/bhp-hr.

1960-90 90-2000

2001 - 08

DLW

OUR LOCOS MOVE THE NATION

Reasons of low fuel oil pressure

 Due

to insufficient fuel in fuel oil tank.(less than 700Ltrs)  Primary or Secondary filter may be choked.  Defective Fuel booster pump & Motor.  Wrong adjustment/Sticking of Relief valve.  Due to fuel leakages in the system.  Wrong adjustment/Sticking of Regulating valve.

TROUBLES IN DIESEL ENGINE DUE TO FUEL OIL The use of dirty and unsuitable fuel frequently causes the following troubles
 Piston ring groove deposits- Dirty contaminated fuel oil is

responsible for gummy carbonaceous deposits in piston ring grooves which induce the rings to stick and causes Blow by, ineffective lubrication, Inefficient air compression ,Poor combustion, High fuel consumption and contamination of the crank case oil.  Exhaust valve deposit- Resulting in poor air compression, Poor combustion ,and high fuel consumption.  Cylinder wall deposit it will interfere with the lub oil film and causes excessive metallic wear.  Fuel pump wear-Due to heavy close fit between the plunger and their barrel ,impurities may causes seizures, reduce the quantity fuel delivery per stroke .

TO ENHANCE RELIABILITY OF FOS

The following preventive actions should be taken to avoid loco failures on account of fuel oil system and to enhance their reliability Torqueing of FIP foundation bolts,T-jumper bolts and Banjo bolts are to done in sequence during fitment and it should to tightened to the recommended torque range.  It must be a normal practice to fit matched fuel injector, H.P pipe and FIP duly calibrated and tested on test bench during yearly schedule or if removed together. Check fuel oil P/P vacuum in every schedule .if less, P/P should be removed for overhauling . It loco is giving repeated problem of el oil pressure ,clean the fuel oil tank by filling up the water and draining out the same after opening dummy provided at bottom of the fuel tank.

Continue--Continue-- Check

distorsion of Banjo bolt and fit copper washer of appropriate thickness in each removal.  Primary/ Secondary filter must be replaced in due time.  Ensure only Zyglo tested High pressure tubes to be fitted in loco.  Ensure that clamping of all fuel hoses has been done properly to avoid its rubbing.  During overhauling of FIP, avoid excessive clearance in barrel and plunger assembly to avoid fuel oil leakage from leak off hole which leads to its excessive consumption

Continue
 Drain

out water and Sludge from the fuel oil tank of loco at least in every monthly schedule by opening drain cock of the fuel tank. (Must do, if loco is giving repeated problem of fuel oil pressure dropping)  Before turn out of loco from shed, ensure that strainer at fuel filling plug of fuel tank is not in distorted condition through which foreign material like cotton waste, cloth, rag , jute etc may block suction line to fuel booster pump.

FUEL OIL TESTS AND SIGNIFICANCES

 Water contamination (by Crackle test)  Specific gravity (Co-relates with calorific value of fuel

so tested at 15C)  Viscosity ( Spray pattern affects)  Flash point(Temp.at which it gives sufficient vapour to form a mixture with air).  Carbon residue.  Sulphur content.( high sulphur contain may cause corrosion in engine parts)  Cetane number( indicate ignition quality )  Colour comparision (with potassium dichromate solution)

TROUBLE SHOOTING OF FUEL OIL SYSTEM

          

A.Fuel oil pressure not building up. B.Fuel pump motor not working. C.Fuel pump contactor not picking up. D. Oil leakage from fuel T jumper o ring. E.T jumper cap screws worked out. F.Fuel pump/support cap screw worked out. G.Fuel oil primary/secondary filter chocked. H.Fuel oil cross over pipe burst. I.Fuel oil hose pipes burst/damaged due to rubbing. J.Fuel oil leaking from hose pipe joint/union defective. K.Fuel oil contaminated with water.