air compressors in diesel locomotives

8/18/2019 air compressors in diesel locomotives

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CHAPTER 1

INTRODUCTION

1.1 Introduction:

Indian Railways is an Indian state-owned enterprise, owned and operated

by the Government of India through the Ministry of Railways. It is one of the

world's largest railway networks comprising !,""" km #$,""" mi% of track over

a route of &!,""" km #",""" mi% and $,!"" stations. In ("(, IR carried over

),*"" million passengers+ annually or more than ( million passengers daily

#roughly half of which were suburban passengers% and (.) million tons of freightdaily. In ("((" Indian Railways had revenues of *)).*

million #/0* billion% which consists of &*&$!*.$ million #/0( billion% from

freight and ()&!!.( million #/0.) billion% from passengers tickets.

Railways were first introduced to India in )! from 1ombay to 2hane. In

*! the systems were nationalised as one unit, the Indian Railways, becoming

one of the largest networks in the world. IR operates both long

distance and suburban rail system on a multi-gauge net work

of broad, metre and narrow gauges. It also owns locomotive and coach production

facilities at several places in India and are assigned codes identifying their gauge,

kind of power and type of operation. Its operations cover twenty nine states and

seven union territories and also provide limited international services

to 3epal, 1angladesh and 4akistan.

Indian Railways is the world's ninth largest commercial or utility

employer , by number of employees, with over . million employees. 5s

for rolling stock , IR holds over (*,() freight wagons, !*,$ 4assenger

coaches and *,!* 6ocomotives # steam, !,*$ diesel and ,"* electric

locomotives%. 2he trains have a ! digit numbering system as the Indian Railways

runs about ",""" trains daily. 5s of March (", (,! km #,&() mi%

#&7% of the total &!,""" km #",""" mi% route length was electrified. /ince *&",

almost all electrified sections on IR use (!,""" 8olt 59 traction through overhead

catenary delivery.

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1.2 Indian Railways Ovrviw:

:6ifeline of the 3ation:

2ype 4ublic /ector ndertaking

Industry Railways

;ounded 5pril &, )! #& years ago%

elhi, India

5rea served India

/ervices 4assenger Railways freight services,

4arcel carrier, 9atering and 2ourism /ervices.

Revenue (!&.) billion #/0( billion% #("(%

3et Income ". billion #/0.$ billion% #("(%

?wner#s% Government of India #""7%

@mployees . million #("(%

4arent Ministry of Railways through Railway 1oard

#India%

>ivisions $ Railway Aones

2

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Indian Railways

Reporting Mark IR

6ocate India

>ates of operation & 5pril )!4resent

2rack Gauge ,&$& mm #! ft. & in%

,""" mm # ft. B ) in%

$&( mm #( ft. & in%

&" mm #( ft.%

6ength &!,""" kilometres #",""" mi%

elhi, India

@lectrification (,! kilometres #,&() mi%

;ig..C >iesel 6ocomotive @ngine

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1.! HI"TOR#:

2he history of rail transport in India began in the mid-nineteenth century.

2he core of the pressure for building Railways In India came from 6ondon. In

)), there was not a single kilometre of railway line in India. 5 1ritish

engineer, Robert Maitland 1rereton, was responsible for the eDpansion of the

railways from )!$ onwards. 2he 5llahabad-Eabalpur branch line of the @ast

Indian Railway had been opened in Eune )&$. 1rereton was responsible for

linking this with the Great Indian 4eninsula Railway, resulting in a combined

network of &,"" km #,""" mi%. epartment of 9ommerce

and Industry and had a government railway official serving as chairman, and a

railway manager from @ngland and an agent of one of the company railways as the

other two members. ;or the first time in its history, the Railways began to make a

profit.

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In *"$ almost all the rail companies were taken over by the government.

2he following year, the first electric locomotive made its appearance. Fith the

arrival of Forld Far I, the railways were used to meet the needs of the 1ritish

outside India. Fith the end of the war, the railways were in a state of disrepair and

collapse.

In *(", with the network having eDpanded to &,((" km #),"" mi%, a

need for central management was mooted by /ir Filliam 5cworth. 1ased on the

@ast India Railway 9ommittee chaired by 5cworth, the government took over the

management of the Railways and detached the finances of the Railways from other

governmental revenues.

2he period between *(" and *(*, was a period of economic boom there

were ,""" mi #&&,""" km% of railway lines serving the country the railways

represented a capital value of some &)$ million sterling and they carried over &("

million passengers and approDimately *" million tons of goods each

year. ;ollowing the Great >epression, the railways suffered economically for the

neDt eight years. 2he /econd Forld Far severely crippled the railways. /tarting

**, about "7 of the rolling stock including locomotives and coaches was taken

to the Middle @ast, the railways workshops were converted to ammunitionsworkshops and many railway tracks were dismantled to help the 5llies in the war.

1y *&, all rail systems had been taken over by the government.

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Production Units

Na$ A%%r.#ar

Esta%lis&d'ocation

(ain

)roducts

1harat Fagonand@ngineeringMuLaffarpur

1F@6 *$) MuLaffarpur

4assenger

9oaches#manufacturing

Nmaintenance%.

Eamalpur 6ocomotiveForkshop

E6F )&( Eamalpur >ieselO@lectric

6ocomaintenance.

Golden Rock Railway

ForkshopG?9 *() 2richy

>iesel-electric6ocomotives

9hittaranJan6ocomotive

Forks96F *$ 9hittaranJan,

5sansol@lectric

6ocomotives

>iesel6ocomotive

Forks>6F *& 8aranasi

>iesel6ocomotives

>iesel-6ocoModernisation

Forks>MF *) 4atiala

>iesel-electric6ocomotives

Integral 9oach;actory

I9; *!( 9hennai4assenger coaches

Rail 9oach;actory

R9; *)& Kapurthala 4assenger coaches

Rail /pringKarkhana

R/K *)) Gwalior 4assenger

coach springs

Rail Fheel;actory

RF; *) 1angaloreRailway

wheels andaDles

Rail Fheel;actory

RF; ("( 9hhapraRailwaywheels

Rail 9oach

;actory,Raebareli R9; ("( Raebareli

4assenger

coaches

2able no..C 4roduction nits

6

http://en.wikipedia.org/wiki/Muzaffarpurhttp://en.wikipedia.org/wiki/Jamalpur_Locomotive_Workshophttp://en.wikipedia.org/wiki/Jamalpur_Locomotive_Workshophttp://en.wikipedia.org/wiki/Jamalpur_Locomotive_Workshophttp://en.wikipedia.org/wiki/Jamalpurhttp://en.wikipedia.org/wiki/Golden_Rock_Railway_Workshophttp://en.wikipedia.org/wiki/Golden_Rock_Railway_Workshophttp://en.wikipedia.org/wiki/Golden_Rock_Railway_Workshophttp://en.wikipedia.org/wiki/Trichyhttp://en.wikipedia.org/wiki/Chittaranjan_Locomotive_Workshttp://en.wikipedia.org/wiki/Chittaranjan_Locomotive_Workshttp://en.wikipedia.org/wiki/Chittaranjan_Locomotive_Workshttp://en.wikipedia.org/wiki/Diesel_Locomotive_Workshttp://en.wikipedia.org/wiki/Diesel_Locomotive_Workshttp://en.wikipedia.org/wiki/Diesel_Locomotive_Workshttp://en.wikipedia.org/wiki/Varanasihttp://en.wikipedia.org/wiki/Diesel-Loco_Modernisation_Workshttp://en.wikipedia.org/wiki/Diesel-Loco_Modernisation_Workshttp://en.wikipedia.org/wiki/Diesel-Loco_Modernisation_Workshttp://en.wikipedia.org/wiki/Patialahttp://en.wikipedia.org/wiki/Integral_Coach_Factoryhttp://en.wikipedia.org/wiki/Integral_Coach_Factoryhttp://en.wikipedia.org/wiki/Chennaihttp://en.wikipedia.org/wiki/Rail_Coach_Factoryhttp://en.wikipedia.org/wiki/Rail_Coach_Factoryhttp://en.wikipedia.org/wiki/Kapurthalahttp://en.wikipedia.org/wiki/Rail_Spring_Karkhanahttp://en.wikipedia.org/wiki/Rail_Spring_Karkhanahttp://en.wikipedia.org/wiki/Gwaliorhttp://en.wikipedia.org/wiki/Rail_Wheel_Factoryhttp://en.wikipedia.org/wiki/Rail_Wheel_Factoryhttp://en.wikipedia.org/wiki/Bangalorehttp://en.wikipedia.org/wiki/Rail_Wheel_Factoryhttp://en.wikipedia.org/wiki/Rail_Wheel_Factoryhttp://en.wikipedia.org/wiki/Chhaprahttp://en.wikipedia.org/wiki/Rail_Coach_Factory,_Raebarelihttp://en.wikipedia.org/wiki/Rail_Coach_Factory,_Raebarelihttp://en.wikipedia.org/wiki/Rail_Coach_Factory,_Raebarelihttp://en.wikipedia.org/wiki/Raebarelihttp://en.wikipedia.org/wiki/Jamalpur_Locomotive_Workshophttp://en.wikipedia.org/wiki/Jamalpur_Locomotive_Workshophttp://en.wikipedia.org/wiki/Jamalpur_Locomotive_Workshophttp://en.wikipedia.org/wiki/Jamalpurhttp://en.wikipedia.org/wiki/Golden_Rock_Railway_Workshophttp://en.wikipedia.org/wiki/Golden_Rock_Railway_Workshophttp://en.wikipedia.org/wiki/Golden_Rock_Railway_Workshophttp://en.wikipedia.org/wiki/Trichyhttp://en.wikipedia.org/wiki/Chittaranjan_Locomotive_Workshttp://en.wikipedia.org/wiki/Chittaranjan_Locomotive_Workshttp://en.wikipedia.org/wiki/Chittaranjan_Locomotive_Workshttp://en.wikipedia.org/wiki/Diesel_Locomotive_Workshttp://en.wikipedia.org/wiki/Diesel_Locomotive_Workshttp://en.wikipedia.org/wiki/Diesel_Locomotive_Workshttp://en.wikipedia.org/wiki/Varanasihttp://en.wikipedia.org/wiki/Diesel-Loco_Modernisation_Workshttp://en.wikipedia.org/wiki/Diesel-Loco_Modernisation_Workshttp://en.wikipedia.org/wiki/Diesel-Loco_Modernisation_Workshttp://en.wikipedia.org/wiki/Patialahttp://en.wikipedia.org/wiki/Integral_Coach_Factoryhttp://en.wikipedia.org/wiki/Integral_Coach_Factoryhttp://en.wikipedia.org/wiki/Chennaihttp://en.wikipedia.org/wiki/Rail_Coach_Factoryhttp://en.wikipedia.org/wiki/Rail_Coach_Factoryhttp://en.wikipedia.org/wiki/Kapurthalahttp://en.wikipedia.org/wiki/Rail_Spring_Karkhanahttp://en.wikipedia.org/wiki/Rail_Spring_Karkhanahttp://en.wikipedia.org/wiki/Gwaliorhttp://en.wikipedia.org/wiki/Rail_Wheel_Factoryhttp://en.wikipedia.org/wiki/Rail_Wheel_Factoryhttp://en.wikipedia.org/wiki/Bangalorehttp://en.wikipedia.org/wiki/Rail_Wheel_Factoryhttp://en.wikipedia.org/wiki/Rail_Wheel_Factoryhttp://en.wikipedia.org/wiki/Chhaprahttp://en.wikipedia.org/wiki/Rail_Coach_Factory,_Raebarelihttp://en.wikipedia.org/wiki/Rail_Coach_Factory,_Raebarelihttp://en.wikipedia.org/wiki/Rail_Coach_Factory,_Raebarelihttp://en.wikipedia.org/wiki/Raebarelihttp://en.wikipedia.org/wiki/Muzaffarpur


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1.* OR+ANI"ATIONA' "TRUCTURE , "TA-- "TREN+TH:

Railway ons

Indian Railways is divided into several Lones, which are further sub-divided

into divisions. 2he number of Lones in Indian Railways increased from siD to eight in

*!, nine in *!( and siDteen in ("" and now seventeen. @ach Lonal railway is

made up of a certain number of divisions, each having a divisional head=uarters.

2here are a total of siDty-eight divisions.

@ach of the seventeen Lones is headed by a general manager who reports

directly to the Railway 1oard. 2he Lones are further divided into divisions under the

control of divisional railway managers #>RM%. 2he divisional officers of engineering,mechanical, electrical, signal and telecommunication, accounts, personnel, operating,

commercial, security and safety branches report to the respective >ivisional Manager

and are in charge of operation and maintenance of assets. ;urther down the hierarchy

tree are the station masters who control individual stations and the train movement

through the track territory under their stations administration.

Zonal Railway details

"l.No

Na$ DatEsta%lis&d

Rout/$

Had0uarts

Divisions

9entral "!-3ov-! *"! MumbaiMumbai, 1husawal, 4une,

/holapur and 3agpur

( Festern "!-3ov-! &)( Mumbai

Mumbai

9entral, Ratlam, 5hmedabad,

RaJkot, 1havnagar

Gandhidham 8adodara

/outhern -5pr-! !"*) 9hennai

9hennai, 2iruchirappalli,

Madurai and /alem, 4alakkad,

2hiruvananthapuram @astern -5pr-!( ( Kolkata

elhi

>elhi, 5mbala, ;iroLpur,

6ucknow,Moradabad and

dhampur

& 3orth

@astern-5pr-!( &&$ Gorakhpur

ILLatnagar, 6ucknow and

8aranasi

7

http://en.wikipedia.org/wiki/Central_Railway_(India)http://en.wikipedia.org/wiki/Mumbaihttp://en.wikipedia.org/wiki/Western_Railway_(India)http://en.wikipedia.org/wiki/Mumbaihttp://en.wikipedia.org/wiki/Southern_Railway_(India)http://en.wikipedia.org/wiki/Chennaihttp://en.wikipedia.org/wiki/Eastern_Railway_(India)http://en.wikipedia.org/wiki/Kolkatahttp://en.wikipedia.org/wiki/Northern_Railway_(India)http://en.wikipedia.org/wiki/Delhihttp://en.wikipedia.org/wiki/North_Eastern_Railway_(India)http://en.wikipedia.org/wiki/North_Eastern_Railway_(India)http://en.wikipedia.org/wiki/Gorakhpurhttp://en.wikipedia.org/wiki/Central_Railway_(India)http://en.wikipedia.org/wiki/Mumbaihttp://en.wikipedia.org/wiki/Western_Railway_(India)http://en.wikipedia.org/wiki/Mumbaihttp://en.wikipedia.org/wiki/Southern_Railway_(India)http://en.wikipedia.org/wiki/Chennaihttp://en.wikipedia.org/wiki/Eastern_Railway_(India)http://en.wikipedia.org/wiki/Kolkatahttp://en.wikipedia.org/wiki/Northern_Railway_(India)http://en.wikipedia.org/wiki/Delhihttp://en.wikipedia.org/wiki/North_Eastern_Railway_(India)http://en.wikipedia.org/wiki/North_Eastern_Railway_(India)http://en.wikipedia.org/wiki/Gorakhpur


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$/outh

@astern*!! (& Kolkata

5dra, 9hakradharpur,

Kharagpur and Ranchi

)/outh

9entral"(-?ct-&& !*! /ecundrabad

8iJayawada, /ecunderabad,

Guntakal, Guntur,

hanbad,

Mughasarai,/amastipur and

/onpur

3orth

Festern"-?ct-"( !!* Eaipur

Eaipur, 5Jmer, 1ikaner and

Eodhpur

(@ast

9oast"-5pr-" (&$$ 1hubaneswar

KhurdaRoad, /ambalpur

and Faltair

3orth9entral "-5pr-" ! 5llahabad 5llahabad, 5gra and Ehansi

/outh

@ast

9entral

"-5pr-" ($ 1ilaspur 1ilaspur, Raipur and

3agpur

!/outh

Festern"-5pr-" $$


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2he shed has a total berthing capacity for $ locomotives under covered bays.

2he main bays areC-

. 2he subassemblies section

(. 2he heavy repair and bogie section# berths for heavy repairs P ( lifting points%

. Mail running repair bay #& berths%.. Goods and out of course running repair bay#& berths%

2here was one old steam shed. 2his shed had a capacity for berthing

locomotives. 2his shed was used for light repairs only. 3ow days, a new construction

is being on for new locos of make F>4 locomotives.

;ig..C 6ayout 4lan of >iesel 6oco /hed

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;ig..C 2op 8iew of 6ayout 4lan of >iesel 6oco /hed

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CHAPTER 2

Air Co$)rssor

2.1 Introduction:

In this chapter the diagram of the air compressor and design aspect of

independent parts of the air compressors are considered. >iagram is shown in

figure (.C

;ig.(.C Reciprocating air compressor in 6ocomotives

5n air compressor is a device that converts power #usually from an electric

motor, a diesel engine or a gasoline engine% into kinetic energy by compressing

and pressuriLing air, which, on command, can be released in =uick bursts. 2here

are numerous methods of air compression, divided into either positive-

displacement or negative-displacement types.

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2.2 Ty)s o Air Co$)rssor:

2.2.1 Accordin5 to t& Dsi5n and Princi)l o O)ration:

1. Reciprocating Compressor

2. Rotary Screw Compressor3. Turo Compressor

1. Rci)rocatin5 Co$)rssor:

5 reciprocating compressor or piston compressor is a positive-

displacement compressor that uses pistons driven by a crankshaft to deliver gases

at high pressure.

2he intake gas enters the suction manifold, then flows into the

compression cylinder where it gets compressed by a piston driven in a

reciprocating motion via a crankshaft, and is then discharged. 5pplications

include oil refineries, gas pipelines, chemical plants, natural gas processing plants

and in locomotives.

2he heat eDchangers that are used in a normal piston compressor are

removed as the heat is removed in the cylinder itself where it is generated. 5lmost

""7 of the energy going into the process is being used with little energy wasted as

reJect heat.

;ig.(.(C /ectional 8iew of Reciprocating 5ir 9ompressor

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2. Rotary "crw Co$)rssor:

5 rotary screw compressor is a type of gas compressor which uses a

rotary type positive displacement mechanism. 2hey are commonly used to

replace piston compressor where large volumes of high pressure air are needed, either

for large industrial applications or to operate high-power air tools such as

Jackhammers.

2he gas compression process of a rotary screw is a continuous

sweeping motion, so there is very little pulsation or surging of flow, as occurs with

piston compressors.

;ig.(.C Rotary /crew 9ompressor

;ig.(.C /ectional view of Rotary /crew 9ompressor

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!. Tur%o Co$)rssor:

2urbocharger compressors are generally centrifugal compressors

consisting of three essential componentsC compressor wheel, diffuser, and housing.

Fith the rotational speed of the wheel, air is drawn in aDially, accelerated to high

velocity and then eDpelled in a radial direction.

;ig.(.!C 2urbo 9ompressor

2.2.2 Positiv Dis)lac$nt Co$)rssor:

4ositive-displacement air compressors work by forcing air into a

chamber whose volume is decreased to compress the air. 4iston-type air compressors

use this principle by pumping air into an air chamber through the use of the constant

motion of pistons. 2hey use one-way valves to guide air into a chamber, where the air

is compressed. Rotary screw compressors also use positive-displacement compression

by matching two helical screws that, when turned, guide air into a chamber, whose

volume is decreased as the screws turn. 8ane compressors use a slotted rotor with

varied blade placement to guide air into a chamber and compress the volume. 5 type

of compressor that delivers a fiDed volume of air at high pressures. 9ommon types of

positive displacement compressors include piston compressors and rotary screw

compressors.

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;ig.(.&C 4ositive >isplacement 9ompressor

2.2.! Non Positiv Dis)lac$nt Co$)rssor:

3on positive displacement air compressors include centrifugal compressors.

2hese use centrifugal force generated by a spinning impeller to accelerate and then

decelerate captured air, which pressuriLes it.

;ig.(.$C 3on positive >isplacement 9ompressor

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2.! Dscri)tion Air Co$)rssor:

AIR COMPRESSOR MODELS WLN AND WLG

DESCRIPTION

2he F63 and F6G model air compressors are water cooled two stage

air compressors. @ach compressor has its own oil pump and pressure lubricating

system. >omestic models are e=uipped with a deep sump oil pan. @Dport models are

e=uipped with a shallow sump oil pan.

2he F63 #formerly F1?% compressor has two low pressure and one

high pressure cylinders and the F6G #formerly F1G% compressor has four low

pressure and two high pressure cylinders. 2he low pressure cylinders are set at an

angle to the vertical high pressure cylinder position. 2he pistons of the high and low

pressure cylinders are all driven by common shafts.

;ig.(.)C /ide 8iew of 5ir 9ompressor in 6ocomotives

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CHAPTER !

Parts o t& Co$)rssor

In this chapter we will discuss about the different parts of the compressor. 2he

following are the lists of the partsC

.9rank 9ase 1ody

(.1reather 8alve

.9ylinder or liner

.9rank /haft!.4iston with connecting rod

&.9ylinder head with 8alves

$.6ube ?il 4ump

).Inter 9oolers

*.5fter 9oolers

"./afety 8alve

.>rain 8alve

(.@4G Governor

./olenoid valve

.Indicator 8alve

!.Main Reservoir 2ank #MR 2ank%

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!.1 Cran/ Cas 6ody:

2he crankcase was employed as a sump for the lube oil, Fhich houses (

litres of lube oil, 2he side cover mounted on the crankcase Is provided with' an oilfilling pipe which prevents over filling of oil. 2his pipe is closed with a threaded type

cap and float type oil level indicator for indicating the level of oil in the crank case.

2he crankcase has four mounting holes for mounting the compressor in the

locomotive.

2he lube oil pump can be dismantled from the crankcase by removing the

mounting pump. 5 breather valve is provided at the top of the crankcase, which keeps

the crankcase in a partial vacuum condition. ?il seal were provided on both side of

crankcase along the crankshaft aDis which prevents oil leaks and dust entering the

crankcase.

;ig..C 9rank 9ase 1ody

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!.2 6rat&r 7alv:

F63 compressors are e=uipped with a crankcase breather which permits a

partial vacuum in the compressor crankcase. 2o accomplish this, the breather acts as a

check valve. Fhen pressure builds up in the crankcase as the pistons move down, the

breather valve opens. 5s the pistons start up, the breather valve closes, preventing the

admission of air into the crankcase

.

;ig..(C 1reather 8alve

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!.! Cylindr or 'inr:

T!is compressor !as two 196"875 mm #iameters $ow

%ressure Cy&in#ers an# one 139.7tiim #iameter !ig! %ressure

Cy&in#er" Cy&in#ers are ma#e up o' Grey iron Castings wit!

!e(agona& )ns 'or etter coo&ing.

;ig..C 9ylinders

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!.* Cran/ "&at:

2his converts rotary motion into reciprocating motion. It transfers

power form the engine to the piston.

;ig..C 9rank /haft

!.4 Piston wit& Connctin5 Rod:

4iston is used to compress the air inside the cylinder. 2he piston has

four rings, two rings are at the top which are known as the 9ompression Rings. 2he

other two are known as oil scrapper rings.

2he oil scrapper rings are used to scrap the oil from the cylinder walls.

2he ;ollowing ;igure will illustrate it.

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;ig..!C 4iston

;ig..&C 4iston Rings

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Connctin5 Rod:

In a reciprocating piston @ngine, the connecting rod or conrod connects

the piston to the crank or crank shaft. 2ogether with the crank, they form a simple

mechanism that converts reciprocating motion into rotating motion.

9onnecting rods may also convert rotating motion into reciprocating motion.


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!.8 Cylindr Had wit& 7alvs:

2his 9ompressor Is e=uipped with three cylinder heads the valves are

Individual disc type, loaded with springs, operated due to the differential pressure

between the upstream and downstream pressure.

5s the name indicates that it is located at the top or at the head of the cylinder.

It has two valves in the head they are

. Inlet or /uction 8alve and(. >ischarge 8alve

!.8.1 Inlt or "uction 7alv:

Inlet valves are located at the suction side on the cylinder head. 2heinlet valve is as shown in the figure below

;ig..)C Inlet 8alves

!.8.2 Disc&ar5 7alv:

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>ischarge valve is located on the discharge side of the cylinder

head. 2he >ischarge valve is as shown in the figure.

;ig..*C >ischarge 8alve

9or/in5 Princi)l o t& 7alvs:

5s we see from the figure, in the first stage i.e., low pressure side, when the

piston moves from the 2op >ead 9entre #2>9% to 1ottom >ead 9entre #1>9%

vacuum is created in the cylinder due to this vacuum, the plate on the valve

compresses the spring which is located below the plate. >ue to this spring tension the

plate comes downwards and then the air from the air strainer enters into the cylinder

and then when the piston moves from the 1>9 to 2>9 air which is entered into the

cylinder is compressed in the second stage i.e., high pressure side. 5fter the

compression the valve plate tries to compress the spring which is on the top of the

plate and then the compressed air is send to after cooler and then to the MR tank.

;ollowing figure shows the eDact working principle of the valves.

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;ig.."C Forking 4rinciple of the 8alves

• Cylindr Had wit& t& 7alvs:

2he following figure shows the figure of the 9ylinder


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like dust and other solid particles from entering into the pump and the lubricating

system. 2he filtered oil is passed through the groove to the distributing ring.

2hrough the distributing ring, the lubricating oil flows to each crank pin in the

crankshaft through the oil holes drilled in It, 2he oil lubricates the Inner bearings of the connecting rods through the groove provided and the needle roller bearing and

gudgeon pin at small end through the hole drilled in the connecting rods. 5 relief

valve fitted on the body of the oil pump maintains the oil pressure between (.( to .!

kgfOcm(. It can be adJusted to the desired oil pressure.

In case the oil line pressure eDceeds. 2he oil relief valve opens and allows the

oil pass out the pump, thus maintaining the set pressure. 5n oil pressure Indicator

valve, mounted on the side cover of crankcase helps to ensure the line pressure of the

oil system. Recommended oil pressure is minimum (.( kgO cm( at Idle and .!

kgOcm( at full speed. ?il seals fiDed at the outer position of the two bearings prevent

the oil leakage over the shaft and the atmospheric air entering into the crankcase.

?il level can be checked visibly, and by the dipstick through the transparent

oil level indicator, fitted on the side cover of the crankcase, the breather fitted on the

crankcase maintains partial vacuum inside the crankcase which ensures better

lubrication. 2he oil pump relief valve P oil pressure indicator respectively. ?il will

overflow while filling when the maDimum level is reached.

*ig.3.12+ $ue ,i& %ump

!.; Intrcoolr and Atr< coolr:

2he Intercooler reduces the temperature of the compressed air leaving the first

stage prior to entering the second stage in order to improve the overall

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thermodynamic efficiency of the system. 2he air from atmosphere is forced to flow

configuration to reduce the temperature of the compressed air.

2he inlet-cooler contains passages for engine cooling water and for air from

the low pressure cylinders. It acts to remove heat from the compressed air, making itdenser, and thereby improving the efficiency of the high pressure cylinder#s%. 2he

basic intercooler has one water inlet and one water outlet, but some intercoolers #two-

pass% have one water inlets and two outlets to obtain parallel flows and more efficient

cooling of the air- 5 two-pass intercooler is re=uired for operating speeds of *!" R4M

or greater. 5ir flow is the same through each typ. of intercooler.

;ig..C Inter - 9ooler

!.= Rli and Indicator 7alvs:

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2hese valves works on the same principle when the relief valve fitted on the

body of the oil pump maintains the oil pressure between 2.2to .! kgfOcm(. It can be

adJusted to the desired oil pressure.

In case the oil line pressure eDceeds. 2he oil relief valve opens and allows theoil pass out the pump, thus maintaining the set pressure. 5n oil pressure Indicator


oil system. Recommended oil pressure is minimum 2.2 kgO cm( at Idle and .!








;ig..C Relief and Indicator 8alve

!.1> (ain Rsrvoir Tan/ ?(R Tan/@:

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It is the main component of the air compressor in locomotives which stores the

compressed air in the cylindrical vessel of having pressure in the range of )-"

kgfOcm(. 2he air from the after cooler directly enters into the MR tank. If the pressure

reaches the maDimum range then the cylinder will damage due to fatigue.

;ig..!C MR 2ank

CHAPTER *

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9OR3IN+ PRINCIP'E

*.1 9or/in5 )rinci)l o air co$)rssor:

'1efore 5IR enters the compressor the air is cleaned by passage through a dry-

type air filter. ?n single filter units the filter is mounted on the air inlet manifold. ?n

dual filter units the filters are mounted directly onto each of the two low pressure

cylinder heads- >ual lifters are recommended for optimum compressor performance.

5ir at atmospheric pressure is drawn in through the litres and intake valves

into the low pressure cylinders during the downward strokes of the pistons- 5s the air is compressed on the upward stroke, the intake valve is closed and the air at higher

pressure is forced through the discharge valve into the intercooler. 5ir leaves the

intercooler, entering the high pressure cylinder through its intake valve. 5s the high

pressure piston moves upward, it compresses the air " a higher pressure, forcing it

out through the discharge valve and connecting piping to the main air reservoir.

;ig..C Forking 4rinciple of 5ir 9ompressor

*.2 Unloadd Princi)l:

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Fhen the M5I3 R@/@R8?IR reaches the recommended pressure, the

compressor activates the @4G # @6@92R? 43@M52I9 G?8@R3?R% when this

get activated the compressor governor senses the pressure in the MR 2ank and sends

the information to solenoid switch which help to control the admit air to the unloaded

assembly, i.e. cutting out the compressor action by holding the intake valve open.


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AIR INTA3E AND COO'IN+ "#"TE(

4.1 AIR INTA3E "#"TE(:

'1efore 5IR enters the compressor the air is cleaned by passage through a dry-

type air filter. ?n single filter units the filter is mounted on the air inlet manifold. ?n

dual filter units the filters are mounted directly onto each of the two low pressure

cylinder heads- >ual lifters are recommended for optimum compressor performance.

5ir at atmospheric pressure is drawn in through the filters and intake valves

into the low pressure cylinders during the downward strokes of the pistons- 5s the air

is compressed on the upward stroke, the intake valve is closed and the air at higher

pressure is forced through the discharge valve into the intercooler. 5ir leaves the

intercooler, entering the high pressure cylinder through its intake valve. 5s the high

pressure piston moves upward, it compresses the air " a higher pressure, forcing it

out through the discharge valve and connecting piping to the main air reservoir.

;ig.!.C 5ir Intake system

4.2 Coolin5 "yst$:

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2o cool the compressor the water pump circulates the water to low pressure

cylinders of both sides of compressor and to high pressure cylinder. Fhile water

pumping to 64 cylinder an intermediate connection will be there to intercooler. Fater

which passes through intercooler helps to cool the high pressuriLed air. In 64 cylinder

the water enters to 64 6iners to head of the cylinder and in the same the water enters

to


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'U6RICATION O- CO(PRE""OR

'u%rication o Co$)rssor:

2he compressor lubricating system is piloted by the gear drive ?il pump. 2he

oil pump circulates the oil under pressure. >rive is taken from the crankshaft. 1y

means of a /et of gears with an Idler, to pump the oil through the system. 5 primary

oil filter which faces the inner side of the crankcase bottom filters the oil to prevent

the Ingress of eDternal agents like dust and other solid particles from entering into the

pump and the lubricating system. 2he filtered oil is passed through the groove to the

distributing ring.

2hrough the distributing ring, the lubricating oil flows to each crank pin in the

crankshaft through the oil holes drilled in It, 2he oil lubricates the Inner bearings of

the connecting rods through the groove provided and the needle roller bearing and

gudgeon pin at small end through the hole drilled in the connecting rods. 5 relief

valve fitted on the body of the oil pump maintains the oil pressure between (.( to .!

kgfOcm(. It can be adJusted to the desired oil pressure.

In case the oil line pressure eDceeds. 2he oil relief valve opens and allows the

oil pass out the pump, thus maintaining the set pressure. 5n oil pressure Indicator


oil system. Recommended oil pressure is minimum (.( kgO cm( at Idle and .!








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;ig.&. 6ube ?il ;low 4ath

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CHAPTER

AIR CO(PRE""OR (AINTANCE AND

"PECI-ICATION"

.1 Air Co$)rssor (aintanc:

T!e compressor oi& &e-e& s!ou e c!ece# regu&ar&y

using t!e #ipstic" an# t!e oi& &e-e& s!ou e ept at t!e 'u&& mar.

T!e compressor oi& an# compressor oi& )&ter s!ou e c!ange# at

t!e sc!e#u&e# maintenance inter-a&s. T!e compressor air )&ters

s!ou e c!ange# out at t!e sc!e#u&e# maintenance 1inter-a&s.

Remo-e t!e )&ters y )rst remo-ing t!e nuts attac!e# to t!e c&amps

on t!e )&ter !ousing. Swing t!e c&amps to t!e si#e an# remo-e t!e

retainer screen.

T!e )&ter !ousing an# screen s!ou e c&eane#

w!ene-er t!e )&ter e&ements are c!ange#. /!en t!e app&ications o'

test gauges are reuire# 'or aintenance" ensure t!at t!e gauges

are remo-e# an# t!e proper sie p&ug is inserte# an# tig!tene#

e'ore returning t!e &ocomoti-e to ser-ice. ir compressor c!ange

out an# o-er!au& s!ou e #one at t!e sc!e#u&e# maintenance

inter-a&s. *or #etai&e# reui instructions see t!e appropriate

-en#ors instructions.

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;ig.$.C 5ir 9ompressor Maintance

.2 AIR CO(PRE""OR CONTRO':

2he standard air compressor on a G2&459 locomotive is coupled directly to

the diesel engine through a driveshaft and when the engine is running, the air

compressor is being driven. 2herefore an unloader assembly, mounted on the

compressor, is re=uired to control when the compressor is actually pumping air.

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2he intake or suction valves of the compressor contain unloaders that block

the valve open when pneumatically activated. Fith the intake valves blocked open the

compressor is incapable of compressing, whether it is rotated or not. 2hese unloaders

are controlled pneumatically, through the unloader magnet valve. 2his valve is called

the M8-99, or Magnet 8alve 9ompressor 9ontrol.

2he locomotive computer, the @M(""", controls the M8-99 in turn. Fhen

the locomotive is started, the computer picks up the M8-99, allowing main reservoir

air through to activate the unloaders. Fhen the computer, monitoring main

reservoir pressure, notes that the pressure is below the re=uired pre-programmed

maDimum pressure it drops out the M8-99. 2his releases the unloaders causing the

compressor to load.

;ig.$.(C 5ir 9ompressor

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.! ")ciications o Air Co$)rssor

;ig.$.C /pecifications of RR && " F 9ompressor

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CHAPTER ;

CONC'U"ION

2he compressor is located at the free end of the engine block and driven

through the eDtension shaft attached to the engine crank -shaft. 9ompressor is a

combined unit of 9rank case, cylinder, piston and the inlet and the eDhaust valve.

2he main function of compressor unit is to create air pressure in main

reservoir of locomotive up to "kgOcm(. 5tmospheric air is drown into the

compressor 64 cylinder through the open inlet valves during suction stroke and same

air is discharged to

air compressors in diesel locomotives

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