Escolar Documentos
Profissional Documentos
Cultura Documentos
Made by G4P6-
1. Sh. Chirag Malik
2. Gulshan Pawar
3. Nishant
4. Dhruv Sharma
5. Shrom Dubey
TABLE OF CONTENTS
1. INTRODUCTION TO TKD
2. SUMMARY
3. INTRODUCTION TO PREDICTIVEMAINTENANCE
4. SECTIONWISE MAINTENANCEANALYSIS
I. TURBOCHARGER
II. COMPRESSOR
III. BOGIEAND TRACK
IV. POWERASSEMBLY
5. CONCLUSION
ACKNOWLEDGEMENT
Every project big or small is successful largely due to the effort of a number
of wonderful people who have always given their valuable advice or have
given a helping hand. We sincerely appreciate the inspiration, support and
guidance of all those people who have been there in making this project and
our training a successful one.
At this juncture we feel deeply honored in expressing our sincere thanks to
Senior DME Devendra Kumar, Chief Instructor Ajay Kumar Sharma &
Principal Anil Kumar Sharma, SSE Om Kant & SSE S P Kalra for making
the resource available at right time and providing the valuable insights
leading to the successful completion of our project.
We are extremely grateful to the “Diesel Locomotive Shed, NR,
Tughlakabad, New Delhi” For the confidence bestowed in us and allowing
us to held the summer training in the duration June 2018 to July 2018.
In particular, we are grateful to Mr. S.K. Jain who scheduled our training in
the various departments and cells of the shed handed out this project to us.
We would like to thank all those people who directly or indirectly helped and
guided us to complete our training and project in the Diesel Training Centre
and various sections.
DIESEL LOCOMOTIVE SHED
TUGHLAKABAD HISTORY
Diesel Shed, Tughlakabad of Northern Railway is located in NEW DELHI.
The shed was established on 22nd April 1970. It was initially planned to
home 75 locomotives but now this shed has more than 150 locomotives.
The shed cater the needs of Northern railway. This shed mainly provides
locomotive to run the
mail, goods and
passenger services. No
doubt the reliability,
safety through
preventive and
predictive maintenance
is high priority of the
shed. To meet out the
quality standard shed
has taken various steps
and obtaining of the
ISO-9001-200O& ISO
14001 OHSAS
CERTIFICATION is
among of them. The Diesel Shed is equipped with modern machines and
plant required for Maintenance of Diesel Locomotives and has an attached
store depot. To provide pollution free atmosphere, Diesel Shed has
constructed Effluent Treatment Plant. The morale of supervisors and staff
of the shed is very high and whole shed works like a well-knit team.
SUMMARY
The statement of purpose of the report is “To analyze
scope of predictive maintenance in diesel locos.”
To satisfy the purpose the report is structured into different
sections as we saw while training at TKD diesel shed ,
there current maintenance schedules and how predictive
maintenance can be used and incorporated in those
sections. From there it can reach to whole railway
maintenance system.
The sections we chose are turbo, air compressor, bogie
and power assembly section.
The report constantly will try to showcase the scope and
benefits of predictive maintenance over the current
maintenance schedule and various technologies that can
be used in predictive maintenance of that section related
issues.
Report will conclude with overall benefit and scope of
predictive maintenance of diesel locos.
INTRODUCTION TO PREDICTIVE
MAINTENANCE
Predictive maintenance (PdM) techniques are designed to help determine
the condition of in-service equipment in order to predict when maintenance
should be performed. This approach promises cost savings over routine or
time-based preventive maintenance, because tasks are performed only
when warranted.
The main promise of predictive maintenance is to allow convenient
scheduling of corrective maintenance, and to prevent unexpected
equipment failures. The key is "the right information in the right time". By
knowing which equipment needs maintenance, maintenance work can be
better planned (spare parts, people, etc.) and what would have been
"unplanned stops" are transformed to shorter and fewer "planned stops",
thus increasing plant availability. Other potential advantages include
increased equipment lifetime, increased plant safety, fewer accidents with
negative impact on environment, and optimized spare parts handling.
Predictive maintenance differs from preventive maintenance because it
relies on the actual condition of equipment, rather than average or
expected life statistics, to predict when maintenance will be required.
Some of the main components that are necessary for implementing
predictive maintenance are data collection and preprocessing, early fault
detection, fault detection, time to failure prediction, maintenance scheduling
and resource optimization.[1] Predictive maintenance has also been
considered to be one of the driving forces for improving productivity and
one of the ways to achieve "just-in-time" in manufacturing.
Predictive maintenance evaluates the condition of equipment by performing
periodic (offline) or continuous (online) equipment condition monitoring.
The ultimate goal of the approach is to perform maintenance at a
scheduled point in time when the maintenance activity is most cost-
effective and before the equipment loses performance within a threshold.
This results in a reduction in unplanned downtime costs because of failure
where for instance costs can be in the hundreds of thousands per day
depending on industry.[3] In energy production in addition to loss of revenue
and component costs, fines can be levied for non-delivery increasing costs
even further. This is in contrast to time- and/or operation count-based
maintenance, where a piece of equipment gets maintained whether it
needs it or not. Time-based maintenance is labor intensive, ineffective in
identifying problems that develop between scheduled inspections, and so is
not cost-effective.
The "predictive" component of predictive maintenance stems from the goal
of predicting the future trend of the equipment's condition. This approach
uses principles of statistical process control to determine at what point in
the future maintenance activities will be appropriate.
Most predictive inspections are performed while equipment is in service,
thereby minimizing disruption of normal system operations. Adoption of
PdM can result in substantial cost savings and higher system reliability.
SECTION WISE
MAINTENANCE
ANALYSIS
TURBO SUPERCHARGER
INTRODUCTION
The diesel engine produces mechanical energy by converting heat energy
derived from burning of fuel inside the cylinder. For efficient burning of fuel,
availability of sufficient air in
proper ratio is a prerequisite. In
a naturally aspirated engine,
during the suction stroke, air is
being sucked into the cylinder
from the atmosphere. The
volume of air thus drawn into
the cylinder through restricted
inlet valve passage, within a
limited time would also be
limited and at a pressure slightly
less than the atmosphere. The availability of less quantity of air of low
density inside the cylinder would limit the scope of burning of fuel. Hence,
mechanical power produced in the cylinder is also limited. An improvement
in the naturally aspirated engines is the super-charged or pressure charged
engines. During the suction stroke, pressurized stroke of high-density is
being charged into the cylinder through the open suction valve. Air of higher
density containing more oxygen will make it possible to inject more fuel into
the same size of cylinders and produce more power, by effectively burning it.
A turbo supercharger, or turbo, is a gas compressor that is used for forced-
induction of an internal combustion engine. It increases the density of air
entering the engine to create more power. A turbo supercharger has the
compressor powered by a turbine, driven by the engine’s own exhaust
gases. The turbine and compressor are mounted on a shared shaft. The
turbine converts exhaust heat and pressure to rotational force, which is in
turn used to drive the compressor. The compressor draws in ambient air
and pumps it in to the intake manifold at increased pressure, resulting in a
greater mass of air entering the cylinders on each intake stroke. Turbo
supercharging dramatically improves the engine's specific power, power-to-
weight ratio and performance characteristics, which are normally poor in
non-turbo supercharged diesel engines.
TURBOS USED IN DIESEL LOCOMOTIVE
In diesel locomotives, different turbo are used for different engines based on
their horsepower and make. Still, their general function remains the same
i.e.to provide compressed air to the engine by employing the energy of
exhaust gases. The exhaust manifold is connected to the inlet of the
turbocharger. The exhaust gases enter the gas inlet casing where they are
directed towards the nozzle
ring. The function of the
nozzle ring is to guide the
exhaust gases and reduce
shock on the turbine blades.
The exhaust gases impinge
on the turbine blades and
cause the turbine to rotate
on their way out to the
atmosphere through the chimney. The rotating turbine causes the impeller of
the compressor to rotate along with it since they are mounted on the same
shaft. The compressor starts sucking air through the air inlet casing and
compresses it due to the centrifugal action of the impeller. After leaving the
impeller, the air is compressed further in the diffuser vanes. From here, the
compressed air is passed into the blower casing, which guides the air to an
after cooler. The function of the after cooler is to cool the compressed air
and consequently reduce its specific volume. The pressure of this
compressed air is in the range of 1.2-1.8 kg/cm2, and this is known as
BOOSTER AIR PRESSURE (BAP). This compressed air is then introduced
into the air gallery, which is connected to the intake valves of all the
cylinders.
Preventive maintenance
PREVENTATIVE MAINTAINCE
Preventative maintenance is a precautionary approach. Maintenance is
scheduled in advance on a per-facility, per-system, or per-component
basis. During these scheduled maintenance sessions, held at fixed
intervals, consumable parts are replaced and any issues that may have
come up are remedied.
Typically, a preventative maintenance plan for an air compressor consists
of:
Oil sampling
Filter and oil changing
System walkthrough and evaluation
And so on
PREDICTIVE MAINTENANCE
(A bogie at TKD)
In diesel locos bogie consists of mainly:
Traction motor
Wheel base
Bearings and springs
Gears
Oil impregnated cases
Bogie frame
In TKD there is a whole bogey section that follows the procedures
of bogie maintenance according to the maintenance schedule.
Maintenance of bogie at TKD
The bogie section at TKD is further divided in sections to focus on
particular part of maintenance. The different sections are:
Gear overhauling
Spare part storage
Spring testing
Oiling section, etc.
Current maintenance
schedule of bogies of
diesel locos is preventive
maintenance i.e., when
the loco arrives on its fixed
schedule all parts are
disassembled and checked according to maintenance sheet
instructions. Checking is widely physical and observational and
some are machine testing. These processes takes time and not
economical as locos are there for longer period of time, in which
they can run. Also this maintenance process lacks accuracy as
some parts are changed before life and some after failure so no
exact information before the failures is known.
Preventive maintenance has easy structure to follow but with
more advancements in technology of co relation of internet and
physical world i.e., internet of things (IoT) this process is
becoming obsolete slowly.
F PIPE
S PIPE
CAMSHAFT
CRANKSHAFT
CYLINDER HEAD
FUEL INJECTION PUMP
CROSS PIPE
FIP COVER
FUEL OIL BENZO
LUBE OIL SUMP
GEARCASE
CYLINDER HEAD
INLET & EXHAUST VALVE
TURBO SUPERCHARGER
AFTER COOLING CORE
OVER SPEED TRIP
HOUSING
OIL SLEEVE RING
WATER PUMP
LUBE OIL PUMP
OIL SLEEVE
DRAINE PIPE
FUEL CONTROLLING SHAFT
CROSSHEAD
The cylinder head is held on to the cylinder liner by seven hold
down studs or bolts provided on the cylinder block. It is subjected
to high shock stress and combustion temperature at the lower
face which forms a part of combustion chamber. It is a
complicated casting where cooling passages are cored for holding
water for cooling the cylinder head. In addition to this provision is
made for providing pas sage of inlet air and exhaust gas. Further
space has been provided for holding fuel injection nozzles, valve
guides and valve seat inserts also.
BENEFITS