FUEL OIL SYSTEM
The purpose of fuel oil system is to suck the fuel oil from the tank, filter it and supply to cylinder with adequate pressure and quantity at appropriate time. Description: A detachable fuel oil tank is provided in between two bogies of under truck. Its capacity is 6000 liters. Fuel used in this system is HSD (High Speed Diesel). Two oil filling caps are provided on both sides of the loco. Two vent pipes are provided on tank to evacuate the gasses. One drain plug is provided at bottom of the tank. There are two glass tubes with gauge on both side of loco to check fuel oil balance in the tank, gauge having marking from 600 to 6000 liters, each dot shows 25 liters. Minimum fuel oil level should be 1000 liters.
Fuel pump motor (AC single phase) is fitted on engine right side in Compressor room; its horsepower is 1/1.5. On either side of Fuel pump motor, fuel pump (engine room side) and governor pump (radiator room side) are provided. Initially it is started by battery and after starting engine by auxiliary generator. Necessary circuit breakers are required to close for starting the fuel pump motor. When fuel oil pump starts, it sucks fuel oil from the tank through cage strainer and primary filter (paper type), goes to delivery pipe, relief valve (setting 5.2 Kg/cm2). Relief valve protect the fuel pump from overloading and excess oil returned to fuel tank, then fuel oil goes to the secondary filter(paper type), provided on delivery pipe. Both the filters are provided on engine right side free end near cylinder no.R1
The filtered fuel goes to right side fuel oil gallery and through cross over pipe to left side fuel oil gallery, one copper pipe connection given to regulating valve (setting 4.2 kg/cm2 ) and fuel oil pressure gauge. From both side gallery fuel is supplied to fuel injection pumps with the help of jumper pipes.
FIP is a reciprocating pump operated by camshaft. The FIP increase the fuel oil pressure and sends to the fuel injector through a high pressure pipe. FIP fuel rake having marking from 0 to 30 mm. FIP can be dummied with help of locking device if required.
Fuel injector is fitted in the cylinder head. At the end of compression stroke the fuel oil is injected in atomized form into the cylinder to get power stroke.
Leak off gallery is provided on both side of the engine. Oil leakage of FIP and injector collected in leak off gallery and return to fuel oil tank.
The filtered fuel goes to right side fuel oil gallery and through cross over pipe to left side fuel oil gallery, one copper pipe connection given to regulating valve (setting 4.2 kg/cm2 ) and fuel oil pressure gauge. From both side gallery fuel is supplied to fuel injection pumps with the help of jumper pipes.
FIP is a reciprocating pump operated by camshaft. The FIP increase the fuel oil pressure and sends to the fuel injector through a high pressure pipe. FIP fuel rake having marking from 0 to 30 mm. FIP can be dummied with help of locking device if required.
Fuel injector is fitted in the cylinder head. At the end of compression stroke the fuel oil is injected in atomized form into the cylinder to get power stroke.
Leak off gallery is provided on both side of the engine. Oil leakage of FIP and injector collected in leak off gallery and return to fuel oil tank.
Air lock in fuel oil system - Air lock in fuel oil system is indicated by fluctuation of fuel oil pressure gauge needle OR dropping of FOP. Action to be taken - Loose delivery pipe coupler of fuel pump and allow draining till thick oil flow, further tied the coupler. Book in repair book.
High pressure pipe line burst – If high pressure pipe line is broken then isolate concern cylinder. Maximum two cylinders can be isolate at time, one from each side.
Fuel Oil Economy:-
1. Tank should not be filled fully.
2. Ensure proper handing over and taken over of fuel oil balance.
3. Poor hauling power and leakage of system should be checked and booked.
4. Ensure adequate amount of BP pressure/vacuum in loco and releasing of train brake.
5. Open throttle notch by notch and achieve maximum speed in minimum time. Observe sectional temporary /permanent caution order.
6. Always work on higher notches.
7. If black thick smoke is coming out from chimney, check the reasons.
8. Drive the train as per road and load.
9. Use maximum dynamic brakes.
10. Maximum coasting on down gradient.
11. Engine to shut down on receiving the memo from PCOR.
12. While working light load with multiple unit keep rear loco on idle.
Fuel Efficient Kit
The following changes are made in loco for saving fuel on higher notches.
1. Maximum fuel rack opening is 25-27 mm on 8th notch.
2. 15 mm dia of FIP plunger is increased to 17 mm.
3. Steel cap piston is used.
4. Over lap period of main crank shaft is increase from 1230 to 1400
5. Alco TSC is replaced by ABB/GE TSC
6. Size of After Cooler is increased.
7. Air maize oil bath filter and car body filter are replaced by cyclonic filter.
8. Size of Radiator core is increased.
9. Lube oil relief valve setting is increased to 135 psi and regulating valve 75 psi.
High pressure pipe line burst – If high pressure pipe line is broken then isolate concern cylinder. Maximum two cylinders can be isolate at time, one from each side.
Fuel Oil Economy:-
1. Tank should not be filled fully.
2. Ensure proper handing over and taken over of fuel oil balance.
3. Poor hauling power and leakage of system should be checked and booked.
4. Ensure adequate amount of BP pressure/vacuum in loco and releasing of train brake.
5. Open throttle notch by notch and achieve maximum speed in minimum time. Observe sectional temporary /permanent caution order.
6. Always work on higher notches.
7. If black thick smoke is coming out from chimney, check the reasons.
8. Drive the train as per road and load.
9. Use maximum dynamic brakes.
10. Maximum coasting on down gradient.
11. Engine to shut down on receiving the memo from PCOR.
12. While working light load with multiple unit keep rear loco on idle.
Fuel Efficient Kit
The following changes are made in loco for saving fuel on higher notches.
1. Maximum fuel rack opening is 25-27 mm on 8th notch.
2. 15 mm dia of FIP plunger is increased to 17 mm.
3. Steel cap piston is used.
4. Over lap period of main crank shaft is increase from 1230 to 1400
5. Alco TSC is replaced by ABB/GE TSC
6. Size of After Cooler is increased.
7. Air maize oil bath filter and car body filter are replaced by cyclonic filter.
8. Size of Radiator core is increased.
9. Lube oil relief valve setting is increased to 135 psi and regulating valve 75 psi.
