This document summarizes tests performed on piston and connecting rod parts removed from a diesel locomotive engine. Non-destructive and destructive tests were conducted to inspect for damage, cracks, or material failures. Bearings and piston rings were replaced. A load test was also performed using a water grid apparatus to determine the locomotive's output power rating. The load test involves placing the locomotive on a test box and measuring values like compression pressure, exhaust temperature, and generator voltage and current output to calculate power.

1. By
G. SAIVISHAL (16-310)
B. SRIKANTH (16-306)
G. SRIKANTH (15-305)

2.  Abstract
 Introduction of Diesel locomotive
• Parts of Diesel Locomotive
 Introduction Diesel engine
• Function of piston & connecting rod
• Inspection of piston & connecting rod
 Load test(or)performance test on diesel engine
• Procedure for load test
 Reference

3.  In this project the disassembly of piston & connecting rod from
the locomotive engine was performed, then several tests have
been conducted on those parts.
 to determine it's strength & hardness , also to identify any
deformation like crack's or bend's which would lead to material
failure.
 After inspection the bearings of the connecting rod is replaced
& Similarly for the Piston & the Piston rings ,oil rings are also
replaced.
 The pre-final stage of inspection involves conduct a
performance test using water grid load test apparatus , in which
the output power rating is determined

4.  Diesel locomotive is one of the electrical locomotive.
 A locomotive is a device which converts the chemical
energy of fuel into the mechanical energy of motion.
 The fuel used may be coal, water or fuel oil and the
conversion may be brought about by steam or electricity.
 The diesel locomotive has horse power ranging from
2800 - 4800

6.  Engine
 Fuel injectors
 Main alternator
 auxiliary alternator
 Air compressor
 Radiator
 Blower(or)air intakes
 Traction motor
 Turbo charger
 Governor
 Air brakes

7.  Diesel engine also known as internal combustion engine. Diesel
engines work by compressing only the air. This increases the air
temperature inside the cylinder to such a high degree that
automized diesel fuel that is injected into the combustion chamber
ignites spontaneously.
Working of 4- stroke cycle of diesel engine:
1) suction stroke 2)Compression stroke
2) Power stroke 4)Exhaust stroke

8.  Piston: A piston is a components of reciprocating engines ,
reciprocating pump , gas compressors & pneumatic cylinders
among other similar mechanisms. It is the moving component that
is contained by cylinder & is made gas-tight by piston rings.
 Connecting rod: A connecting rod is an engine component that
transfers motion from the piston to the crankshaft and functions as
a lever arm. Connecting rods are commonly made from cast
aluminum alloy and are designed to withstand dynamic stresses
from combustion and piston movement.

9.  Various Inspections done on the piston & connecting rod:
 Non destructive tests (NDT) done on piston & connecting rod to
determine the damage , cracks& leakages.
 Some Non destructive tests are
i. Visual inspection
ii. Radiography
iii. Magnetic particles
iv. Ultrasonic Inspection
 Some destructive tests done on connecting rod & piston & piston pin
to determine the strength, hardness.
i. Bend test.
ii. Break test.
iii. Tensile test.
iv. Hydraulic test

10.  Load box test: Load box examination carried out on diesel locomotive to
determine the generator / alternator out put arrived engine power.
 Procedure:
1. Place the locomotive on load box.
2. Remove the de-compressor plugs & fit adaptors to measure
compression/firing pressure during the test.
3. Fit the thermocouples before turbo super gas inlet carrying the exhaust
temperature
4. Check the water level in locomotive before start the load test on
locomotive.
5. Ensure electrical connections to titanium electrodes by electrical staff.
6. Crank the locomotive wait till mean pressure build up in the cylinder.
7. Give the supply to electrodes.
8. Note down the values from generator & engine.

11.  In this test we are mainly calculating the out put of the generator output.
 In locomotive The generator shaft is connected with engine crank shaft.
 So the engine output equals to generator output.
 So we in this test we are calculating power generated by generator /
alternator
The generator output power (P) = V*I
Where V is the voltage generated by every notch in volts
& I is the current generated in generator by every notch in Amps

12. URLS
 https://www.dieselnet.com/tech/diesel_engines.phP
 https://en.wikipedia.org/wiki/Diesel_locomotive
 https://en.wikipedia.org/wiki/Diesel_Locomotive_Works
 /www.apta.com/resources/standards/Documents/APTA-PR-E-RP-
003-98.pdf
 http://users.sussex.ac.uk/~tafb8/eti/eti_07_PerformanceTest
 https://www.slideshare.net/Lahiru_Dilshan/load-test-on-a-perkins-
diesel-engine