RR 80 10 1

( LG3CDB Upgradation)
 CUSTOMER
CUSTOMERREQUIREMENT
REQUIREMENT

Based on letter no. dlw.m.65.10 dt. 7.10.2005 from D.L.W ,

Varanasi

Require a High Reliable and Less Maintenance

Product
 PRODUCT DEVELOPMENT PROCESS

Q.F.D
Customer Multiple Revise
Requirements C.T.Q Concepts DFMEA & CTQ

D.F.M.E.A

Prepare Purchase Identify Critical Analysis Design

Spec. Components Identification Calculation

Prepare models / Prepare Validation Characteristics

Drawings P.F.M.E.A
Process Flow Matrix Plan Control Plan

Analysis Vendor Tools dies & Release P.O Vendor

Validation fixtures Education

Score Card Testing Assembly Validation Receipt of Parts

Top Management Review Customer Review

 DATA COLLECTION

Present Maintenance Practice collected from

Diesel Loco Sheds - New Katni Tuglakabad,
Vishakapatnam, Gooty,
Erode, Trichy
 List of Parts for RR80101

New Parts Parts from RR100101EC

1. Crank Shaft 1. L.P & H.P Cylinders

2. Crank Case 2. Cylinder Heads

3. Coolers
3. Bi metal Bearings
4. Manifolds
5. Pump Assy. Parts 4. Needle Roller Bearings

6. Fan shroud 5. Piston Rings

7. Oil Level Indicator
6. Air Intake Filter

7. Oil strainer

8. Unloader pipes
 CRANKCASE

Existing
Upgraded
Machining to be done here
to accommodate pump mounting
 CRANKSHAFT

EXISTING UPGRADED
EN8 to EN19 to reduce wear

 Counter Weight mounting face taper angle provided to eliminate

counter weigh falling down

 Eccentric diameter & taper in counterweight face for pump mounting

 LG3CDB COMPRESSOR

Present Design

Intercooler position restricts the fan air flow to the

LP1 cylinder which will result in more carbonization & less
life of parts
 COOLERS

CONCEPT - 1 EXISTING CONFIGURATION

CONCEPT - 2 CONCEPT - 3

PROPOSAL -2 IS RECOMMENDED CONSIDERING 2 FACTORS

1. Air flow velocity 2. Air flow to Cylinder & Cylinder Head
 INTERCOOLER

EXISTING UPGRADED
Copper Cooler Aluminum cooler
 RECIPROCATING TYPE LUBE OIL PUMP

Plunger

Cartridge assembly

Pump mounting

Pump housing
LUBE OIL PATH

Oil path shown in red color

 CATRIDGE ASSEMBLY

Delivery Valve

Oil inlet into cartridge Oil pressure

assy. from crankcase Suction Valve relief valve
thro’ oil filter
LUBE OIL PATH THROUGH
CATRIDGE ASSEMBLY
 FAN GUARD

Angular profile provided to divert the air to the cylinders to

utilize
the cooling fan air flow completely.
 FLOAT TYPE OIL LEVEL INDICATOR

PRESENTLY WE HAVE SIGHT GLASS FOR OIL LEVEL INDICATION

BECAUSE OF DECOLOURIZATION OF OIL TO BLACK OVER A PERIOD OF TIME

THE OIL LEVEL THRU THE GAUGE BECOMES DIFFICULT

SO WE HAVE GONE FOR FLOAT TYPE OIL LEVEL INDICATOR WHEREIN THE OIL DOESN’T
HAVE ANY CONTACT WITH THE LEVEL INDICATOR
 CYLINDER

EXISTING UPGRADED
 CYLINDER
PROPOSAL - 1

AIR FLOW
DIRECTION

Hexagonal Fins

PROPOSAL - 2

AIR FLOW
DIRECTION

Denser Fins for the

Stroke length
POSITION OF CYLINDER FINS w.r.t
AIR FLOW
PROPOSAL- 1 IS RECOMMENDED
BASED OF THE AIR FLOW PATTERN

5 % MORE HEAT TRANSFER IN THIS CYLINDER

CYLINDER
 CYLINDER HEAD

EXISTING MODIFIED

Air flow from fan Air flow from fan

In Existing Cylinder Head Air flow from the fan In the Modified Cylinder Head Air flow from is
is useful only for half of the cylinder head, taken to other side also.
since the flange blocks the other half In addition to that even the vacuum cylinder heads
will have air flow from the fan
CYLINDER HEAD
 BIG END BEARING

Sl. Existing New

No.
1. Material : F770 Material : F820

Sl. Why the Changes Expected Results

No.
1 F770 is lead dominant and F820 is Increases the crankshaft
Alu.tin dominant and has good overhaul from 18 months
embeddability to 36 months
 SMALL END BEARING - Needle Roller
Bearing

Sl. Existing New

No.
1. Bush Needle Roller Bearing

Sl. Why the Changes Expected Results

No.
1 Better life and Load carrying capacity Increase in Bearing life of 36 months from
18 months

EXISTING UPGRADED
 PISTON RINGS

100% light tight rings to reduce oil consumption

 Taper faced compression ring

 Nose Scraper oil control ring
 Cross bevelled oil control ring
 AIR INTAKE FILTER

 Non- woven media

 Micron Rating : 15 microns
 Safety element provided to withstand the oil traces during unloading
 Mounting of filter tilted towards Expressor side due to increase in
diameter & length
 OIL SUCTION STRAINER

Sl.N Existing New

o.
1. 275 micron oil suction strainer 150 micron oil suction strainer
 UNLOADER PIPES

UNLOADER PIPE LAYOUT MODIFIED :

1. To withstand vibration and avoid failure of the pipes

2. Removal of Delivery Valve for cleaning without disturbing

the Unloader pipes

3. Unloader pipes are placed in the middle to avoid damage to

the pipes while removing the Valves.
 BREATHER

EXISTING UPGRADED

Ease of assembly, serviceability & improved performance

 CRANKCASE OIL CAPACITY

Increase in usable oil capacity & less oil consumption rate

increases the oil topping up period twice that of present.
 VALVE PLUGS

EXISTING UPGRADED

8 round holes have been changed to 4 elliptical slots with

equal area.

This is done for ease of air flow and cleaning of carbon

deposits
 OIL

Oil has been changed from

Servo Press 150

to
Servo Press 150 RR

to reduce carbonization
 Other Features

Complete RR80101 compressor can be

lifted by using an eyebolt, using the hole
provided on the H.P cylinder head
This will be useful during compressor
maintenance.

LG3CDB RR80101
Weight (Kg) 828 747

Reduction in unit weight by 81 kgs. will reduce the loco

power consumption
NOMENCLATURE
3D Model of the Product
 Side View

Breather
Assembly

Oil Level Indicator

 Rear view

Intercooler
Aftercooler

Plunger Pump
Mounting
 Top View

Safety
Valve

Aftercooler
Outlet

Compressor lifting hole

 Product Improvements done for
LG3CDB Up gradation
Sl. Part description Modification done in Upgraded Unit
No.
1 Crank Shaft Material Changed from En8 to En 19C to reduce Wear
Positive locking for Counter Weight in Crankshaft, counter weight &
crankshaft angle changed from 0o to 2o and dynamically balanced

2 Coolers Aluminum coolers instead of copper coolers, Redesigned and relocated

the coolers and its manifolds for better cooling of compressed air.

3 Cylinder Hexagonal Fins instead of Round Fins for better heat dissipation
Denser Fins on the Top (in stroke area) & Course fins at bottom for better
cooling
Plateau honing introduced for better lubrication by increasing the oil
retention volume
4 Cylinder Head Vertical fins instead of Horizontal Fins for better cooling

5 Piston Rings 100% light tight rings to reduce oil consumption

6 Big End Bearing Material changed from F770 to F 820 to reduce wear and increased life.

7 Small End Bearing Changed from Bush bearing in Low pressure side to Needle roller
bearing to reduce wear
8 Lube Oil Pump Plunger type pump introduced instead of gear pump for ease of
serviceability & reliability (Number of wear components reduced)
 Product Improvements done for
LG3CDB Up gradation

9 Oil Level Indicator Float type oil level indicator introduced instead of Sight glass, better
visibility of needle due to non contact of glass with oil.
10 Air intake Filter Non Oven media used with 15 micron filtration of air to reduce wear of
components, better filtering efficiency
11 Oil Suction strainer Fine mesh oil filtration changed from 300 to 150 micron to reduce wear

12 Unloader pipes Pipes layout modified to withstand vibration, ease of serviceability of

discharge valves by redesigning and relocating.
13 Fan Shroud Angular profile made to divert the fan air for better cooling
14 Oil Oil has been changed from Servo Press 150 to Servo Press 150 RR
to reduce carbonization
15 Valve Plug Eight round holes have been changed to 4 elliptical slots with equal area.

16 Oil Capacity Minimum oil level has been reduced to 10 liters from 14 liters by
lowering the oil strainer body so that usable capacity of oil is 10 liters.
17 Breather Valve Compact breather in size and the breathing ports are like louver type so
that foreign particle entry into the breather is restricted
 BRIEF NOTE ON TYPE TEST

 Type Test was conducted based on the RDSO

Specification : MP.0.0700-10, April 1995.

 Type Test was conducted in the presence of M/s

RDSO Representatives.

 Type Test was conducted during the period of

16.05.06 to 17.06.06 at M/s ELGI Equipments Ltd.,
 LIST OF TEST CONDUCTED FOR TYPE TEST

1. Orifice Test Compressor ( Orifice Diameter 8.7 mm)

2. Compressor Capacity Test (Test Speeds rpm: 400 ,750,1000, 1100)

3. Dimension Inspection of Critical components before & after Type Test

4. Endurance Test was conducted for 400 hrs

5. High Environment Test was conducted for about 50 hrs at 80oC

 Type test results

Comparison between Earlier Type Test Results of LG3CDB

Compressor (10.02.93 to 27.02.93) and Present Type Test
Results of LG3CDB Upgraded Unit.

1. Lube Oil Consumption

Earlier Type Test : a. 11.2 ml / hour (Total run 428 hours)

b. 7.9 ml /hour (Total run 50 hrs.-Jul’1999)

Present Type Test: 2.1 ml / hour (Total run 473 hours)

2. Carbonization in Delivery Valves (6 Nos.):

Earlier Type Test (After 428 hours) : No data available

Present Type Test (After 473 hours): 06 grams

 Type Test Results

3. Wear in Components:

Sl. Component Earlier – Present –

No Type Test Type Test
. Results Results
1. Crank Shaft
Crank pin Diameter 0.024 0.001
Pump Seat Diameter 0.020 0.002
For Gear type For Plunger type
2 LP Cylinders 0.010 0.002
3 HP Cylinder 0.010 0.001
4. Lube Oil Pump – Mounting 0.020 0.005
bore to Crankshaft For Gear type For Plunger type
5. LP Piston O.D 0.015 0.005
6. HP Piston O.D 0.007 0.002
7. LP Piston Rings Closed Gap 0.15 0.05
8. HP Piston Rings Closed Gap 0.15 0.05
9. Wrist Pins 0.002 0.001
10. Connecting Rod with Bearing 0.025 0.004
Type Test Results
 Type Test Results

Observation :

Overall Performance of Upgraded LG3CDB

Compressor is good and major improvements are
observed in the following aspects:
1. Less Oil Consumption
2. Less Wear on Parts
3. Less Carbonization
4. Better cooling.
 Advantages to the Customer

With all these features already upgraded expressor has

successfully completed one year of field trails with the
following advantages to the customer

1. Reduced the frequency of compressor maintenance

2. Reduction in downtime of the locomotives
3. Reduction in manpower for servicing the Compressor
4. Reduced oil consumption by the Compressor
5. Reduction in compressor spare cost per year.
6. Reduction in failure of parts
 Enhancement in Maintenance Schedule

Sl.
Maintenance Practice LG 3CDB RR80101
No.

1 Check oil level and top up, if required T1 M4

2 Intake air filter / Oil strainer - Inspect & Clean T2 M4

3 Discharge Valve cleaning & Inspection M2 M4

4 Reconditioning of Unloader Valve assembly M4 M8

5 Drain and refill oil M4 M8

6 Inlet Valve cleaning & Inspection M4 M8

7 Replace the Piston Rings M12 M24

Check the condition of Connecting rod bearings,
8 M12 M24
Oil seals, filter elements replace if required
9 Replace the oil seals M12 M24

10 Complete Overhaul M24 M48

11 Replace all the Pistons, if required M18 M48

12 Replace all the Cylinders M18 M48

13 Intercooler Overhaul M36 M48

 TYPE TEST AT ELGI

Type test result on one proto type compressor has been

completed with RDSO representative and the same compressor
is dispatched to DLW, Varanasi on 22.07.06 for Field Trials

During endurance test During high environmental test

Final Product Photograph – RR80101
Final Product Photograph (Drive end side)
LG3CDB & RR80101
 AIR INTAKE FILTER

Air Intake Filter Exploded View

Air Intake Filter Element should be

cleaned by blowing air from inner side
 BIMETAL BEARINGS

BIMETAL BEARING BIMETAL BEARING

USED IN RR80101 USED IN LG3CDB

For Identification :
RR80101 : Glossy finish
LG3CDB : Dull finish
 OIL LEVEL GAUGE

SIDE COVER WITH

OIL LEVEL INDICATOR USED IN
LG3CDB

ADAPTER PLATE AND

OIL LEVEL GAUGE
CAN BE MOUNTED
ON THE EXISTING
SIDE DOORS ITSELF.

ADAPTER PLATE OIL LEVEL GAUGE

 FITMENT DETAILS
Field Data

No of months
Loco Date of
Fab No. Loco no. completed as on
Shed Commisioning
01.02.08

001 13306 Pratatu 11.11.06 1 Year 2 Months

002 11210 Itarsi 07.10.07 4 Months

003 11217 Lucknow

004 11220 Lucknow

005 11216 Kalyan