Department Of Mechanical Engineering

A Presentation on
Vocational summer Training
Taken at
Diesel Loco Shed, Phulera Jn.

Presented To:
Mr. Vinit Kumar Gupta
Assistant Professor
AIET, Jaipur

Presented By:
Arjun Das
B. Tech 4th Year
AGI, Jaipur

Contents
1.
2.
3.
4.
5.
6.
7.
8.
9.

Introduction
Diesel Loco Shed, Phulera
Diesel Locomotive
Classification of Diesel Locomotive
Diesel Engine
Main parts of Locomotive
Power Transmission
Turbo super-charger
Fuel Oil System
continue..

Continuing
10.
11.
12.
13.
14.
15.
16.

Water Cooling System

Lube Oil System
Air Brake System
Dynamic Brake System
Expressor
Demineralization
Effluent Treatment Plant (ETP)

Introduction
Phulera Junction is located at a distance of approx 55
Kms from Jaipur (JP) and 80 Kms from Ajmer (AII).
The station consists of 5 platforms.
Its code is FL.
Diesel Loco Shed ,Phulera is headed by DME/D/FL. He
is assisted by ADME/D/FL and other subordinate Sr.
Supervisors such as SSEs at FL.
continue ..

Fig 1.1: Diesel Loco Shed, Phulera

Diesel Shed
Diesel locomotive shed is an technical setup, where repair
& maintenance works of diesel locomotive is carried out.
It contribute to increase the operational life of diesel
locomotives.
Minimize the line failure.
Diesel shed usually have: Heavy cranes & lifting jacks.
Fuel & lube oil storage,

Water treatment plant,

Testing labs

Machine shop & welding facilities

Classification of Locomotives

Indian Railways have classifies locomotives into different

classes taking into account all parameters like Gauge,
Traction, Usage, Version, Power etc.

 The first letter (Gauge)

W= Broad Gauge
Y= Meter Gauge
Z= Narrow Gauge
The second letter (Power)
D=Diesel
C=DC traction
A= AC traction
B =Battery electric
The third letter (Load)
M= Mixed traffic
P= Passenger
G=Goods
U=Multi-unit

WDM3

YDM3

ZDM3

Diesel Engine
The concept of diesel engine is given by Rudolf
Diesel in 1892.

Fig.2.1: Diesel Engine

Four stroke Engine

Fig.2.3 Working of Four Stroke Engine

Locomotive
A locomotive or engine is a rail transport vehicle that
provides the motive power for a train.

Fig 3.1: YDM4 Locomotive

Loco Specification Of YDM4

Engine Model: YDM4

Engine Company: ALCO
No. of cylinder:
6
Cylinder arrangement: Inline
Cylinder Shape: I Shape
Engine BHP : 1200
Max. weight:
72 tone
Starting speed: 100-150rpm
continue.

Compression ratio: 12 : 1
Full speed:100-1100 rpm
Fuel tank capacity:3000 liters.
Radiator fan:41HP
Firing order: 1-4-2-6-3-5
Diameter of wheel : 965mm
Compressor :1100rpm
Battery connection: Series

Locomotive Compartments

Short hood
Driver cabin
Generator room
Engine room
Accessories room
Expressor room
Radiator room

Locomotive main components

1.Main generator:
The diesel engine drive the main generator which
provide the power to move the train. It produce DC
electricity which is use to provide power to traction
motor.

Fig .4.1: Generator

2.Auxiliary Generator:
This provide DC power for lighting, air
conditioning, dining facilities etc, on train.
3.Motor Blower:
Motor blower provides air which is blown over the
traction motor to keep them cool during period of
heavy work.

4.Air Intake:
The air for cooling the locomotives motor is drawn
from outside. It has to be filter to remove dust and
other impurities.

5.Batteries:
The diesel engine need a battery to start it and to
provide electric power for lights.

6.Traction Motor:
The are six traction motors on the two bogies for one
Loco. The are use to give final drive to the wheel.

Fig.4.2:Traction Motor

7.Fuel tank:
The fuel tank is normally under the frame of loco tank.
It has a capacity of 3000 liters.

8.Air Reservoirs:
Air reservoirs containing compressed air at high pressure
which is required for train braking.

9.Drive Shaft:
The main output from the diesel engine is transmitted by
the drive shaft to the generator , radiator and fan and
compressor

10.Radiator and Radiator Fan:

Water is circulated around the engine block to keep the
temperature within the most efficient range.

Power Transmission
Battery

Generator

work as motor

Crank Shaft

firing at approx 150 rpm

Batter & generator Disconnect

Generator

current

Traction Motor

Bull & Pinion gear

mesh

wheels

Turbo Supercharger
It is invented By Alfred J. Buchi in 1905 and in
locomotive began in 1920.
It is a turbine-driven forced induction device that
increase power output of engine by forcing extra air
into the combustion chamber.
It increase the density of air supplied to the engine.

Fig.5.1: Turbo Supercharger

continue

Main parts of Turbo Supercharger

Fig.5.2: Parts of turbo Supercharger

Working Principle
A turbo supercharger consist of a turbine wheel and
compressor wheel on shared shaft.
The turbine convert exhaust to rotational force, which
in turn use to drive the compressor wheel.
The compressor wheel draws air and pump it in to the
intake manifold at increase pressure.
It then passes through intercooler, which increase the
density of air.
Then it is drawn into cylinder.
continue

Fig 5.3: Turbo cycle

Advantages
Provide better air -fuel mixture to the locomotive
engine.
No extra driving power requirement as it is driven by
the exhaust gases of the locomotive engine.
It increase the volumetric efficiency
It give each intake cycle of engine more oxygen,
letting it burn more fuel and do more work, thus
increase power.

Fuel Oil System

All locomotive have individual fuel oil system
This system introduce fuel oil into the cylinder:
-At correct time
-At correct pressure
-Correctly atomized.
The fuel feed system maintain steady supply of fuel to
the injection pumps .
Fuel pump meter and deliver the oil into the cylinder at
correct time and pressure.

continue.

Parts of Fuel feed system

Fuel oil tank

Fuel primary filter
Booster pump
Fuel relief valve
Fuel secondary filter
Fuel regulating valve

Fig.6.1:Fuel Injection Pump

continue.

Fig .6.2: Fuel Oil System

Fuel Injection Nozzle

The fuel injection nozzle is fitted in the cylinder head
Its tip projected inside the combustion chamber.
It is connected to the fuel injection pump with a
high pressure line.
It has multi-hole needle type valve.
High-pressure oil is injected into the combustion
chamber through these holes.

Fig. 6.3: Fuel Injector

Water Cooling System

The Locomotives have a closed non-pressurized
water cooling system .
The water circuit has two storage tanks known as
expansion tanks.
The expansion tank is filled with 1210 liters of
distilled water. (pH value 8.5 - 9.5)
A centrifugal pump driven by the engine crankshaft
through which water is circulated to keep the engine
cool.
continue

Main parts of Water Cooling System

Centrifugal pump
Two radiator
One fan
Sensor
T1 Temperature switch
T2 Temperature switch
Engine temperature switch ( ETS3 )
Engine temperature switch ( ETS4 )
Warning system.

Working of water cooling system

T1 is for starting the movement of radiator fan at
600C temperature of water.
When water temperature reach at 640C, T2
accelerates the radiator fan to full speed.
When temp. reach at 900C , ETS3 gives bell alarm
and red lamp indication.
When temperature become 950C,ETS4 brings the
engine to the idle speed.

Fig 7.1: Water Cooling System

Lube Oil System

The lubricating system in a diesel engine is of vital

importance.
This system serves the following purposes:
Cooling of different rubbing parts.
Protection of metal surfaces from corrosion, rust,
surface damages and wear.
Keep the components clean.
Prevent damage due to deposits foreign particles

Components of Lube Oil system

Gear type lube oil pump

Spring loaded relief valve
Lube oil filter tank.
Differential bypass valve
Lube oil cooler
Regulating valve
Lube oil strainer
Oil pressure switch (OPS)
Oil pressure gauge
Oil sump

Air Brake System

The air brake is the standard, fail-safe, train brake used by
railways all over the world.
It is based on the simple physical properties of compressed
air.

Fig .8.1: Air brake system

Main parts of Air Brake System

1.
2.
3.
4.
5.
6.
7.
8.

Compressor
Main reservoir tank
Drivers Brake valve
Feed valve
Brake pipe
Angle cocks
Brake cylinder
Auxiliary reservoir

9. Brake block
10. Brake rigging
11. Triple valve

SA-9 Brake Valve:

This is independent brake valve.
It is applied only in train not loco.
This valve has three position:
i. Release position: Running loco is in release position.
ii. Application position: Stopped pressure of 3.5kg/cm
sq.
iii. Quick release : 5 kg/cm sq. pressure is drop.

A-9 Brake Valve

For loco and train brake system
To apply brake in train and loco by co-action,
It has five position:
i. Release Position: Pressure to 5 kg/cm sq.
ii. Minimum Position: brake pipe pressure 3.5kg/cm sq.
iii. Service application:brake pipe pressure 3.5 kg/cm sq
iv. Over reduction: brake pipe pressure 2.5kg/cm sq.
v. Emergency : brake pipe pressure 0.0

Dynamic brake system

Dynamic braking lowers the wear of friction-based
braking components.
Dynamic brake is applied only when train is running
at some slope.
During dynamic braking, the traction motors are
acting as generators
The generator current is send to grid resistance where
it is loaded down.
Due to which speed of loco is slow down.

Expressor
Expressor is the combination of Exhauster and
Compressor.
It is located at the free end of engine block.
It is driven through the extension shaft attached to the
engine crank shaft.
The are six cylinder which are arranged in W type,
4 Exhauster and 2 compressor.
continue.

Fig.9.1 : Expressor

Components of Expressor

Crank Case
Cylinder And Cylinder Head
Inlet And Discharge Valve
Air Intake And Strainer Assembly
Piston And Connecting Rod
Crank Shaft
Intercooler
Unloaded Valve
Safety Valve
Crank Case Vacuum Maintaining Valve

Demineralization
It is the process of removing mineral salts from water by using
the ion exchange process.
Dematerialized water is water completely free of dissolved
minerals.
The following ions are widely found in raw waters :
Cations
Anions
Calcium (Ca2+)
Chloride ( Cl-)
Magnesium (Mg2+)
Bicarbonate (HCO3-)
Sodium (Na+)
Nitrate (NO3-)
Potassium (K+)
Carbonate (CO32-)

Fig .10.1: Dematerialized Plant

Ion Exchange Method

.There are three ways in which ion-exchange
technology can be used in water treatment :
i. Cation-exchange resins alone can be employed to
soften water by base exchange.
ii. Anion-exchange resins alone can be used for organic
scavenging or nitrate removal.
iii. Combinations of cation-exchange and anion-exchange
resins can be used to remove virtually all the ionic
impurities present in the feed water, a process known
as deionization.

Effluent Treatment Plant

Effluent Treatment Plant (ETP) is essential to purify
the waste water
After washing the loco parts the water may contain
some chemicals, lube oil etc.
If this water is discharge into the land it may cause
land pollution.
So it become necessary for the treatment of water to
remove the hazardous chemicals.
continue.

Flow chart of ETP

Effluent from different Sewage

Primary Filtration

Cooling and Mixing

Neutralization (by acid or alkali)

Chemical Co-Agulation

Settling and Separation of Sludge

Pressure Filtration

Discharge

Fig.11.1: Effluent Treatment Plant

Any Query

Thanking You