BMW M3 Forum (E90 E92)

BMW Garage BMW Meets Register Search Today's Posts Mark Forums Read


Go Back   M3Post - BMW M3 Forum > BIMMERPOST Universal Forums > General Automotive (non-BMW) Talk + Photos/Videos
 
GT Haus
Post Reply
 
Thread Tools Search this Thread
      07-11-2012, 12:57 PM   #1
rader1
Banned
42

 
Drives: Cobb Stage 2+ 135i
Join Date: Apr 2011
Location: Roanoke, VA


Posts: 2,197
iTrader: (0)

My Job: building 4,400hp engines

Hey guys, not exactly automotive but interesting none the less.

I work for the only non-manufacturer ran General Electric locomotive overhaul facility in North America and I figured I'd share a few pics of some of the cool stuff I get to work on.

I mainly work on GE 7FDL16 series engines. They are 10,700CID V16s rated at 4,400hp/20,000ftlbs@1055RPM. Each locomotive is rated at ~140,000 pounds of tractive effort(pulling force.) Total locomotive weight is 400,000lbs.

This is a complete engine setting next to the alternator that will bolted to rear of the engine and provides the power necessary to turn the traction motors. Combined weight is ~65,000lbs.


This is just the bare block. The holes in the top are where each Power Assembly sit. The square holes in the side provide access for inspection/ repair.


This is the crankshaft. It is ~11 feet long and weighs 4,200lbs.


The pistons are a 2 piece design where the crown and skirt are bolted together. Combined weight of crown and skirt is ~50lbs. This particular piston had a failure of the wrist pin causing damage to both the skirt and cylinder walls.


The turbochargers weigh 1,900lbs and are designed to provide 36psi of pressure in two separate 11ID intake manifolds.


Here are a couple pics of the turbo mounted. One from the front, one from the rear and one of just the exhaust manifold.

The pics from the rear is obstructed on the left by a power assembly and on the right by a water to air intercooler.

Exhaust manifold


I love working on this stuff and if you guys have any questions I'll be happy to answer them to the best of my abilities.
Appreciate 0
      07-11-2012, 01:05 PM   #2
Levi
Brigadier General
Czech_Republic
154

 
Levi's Avatar
 
Drives: Alfa Romeo
Join Date: Jul 2009
Location: Prague


Posts: 3,402
iTrader: (0)

Cool !

At Abbott I saw some huge Mercedes V12 engines. Don't know what they were for.
Appreciate 0
      07-11-2012, 01:10 PM   #3
Doctor///M
Colonel
77

 
Doctor///M's Avatar
 
Drives: F80 M3, R56 MCS
Join Date: Feb 2012
Location: USA


Posts: 2,104
iTrader: (4)

Garage List
2015 BMW M3  [4.00]
2009 BMW 335i  [0.00]
2010 MINI Cooper S  [0.00]
holy moly, this is impressive! Will have to read up more before I can make more of an educated contribution here, but how rapidly is power delivered from these engines? I assume that 4400hp supplied to the driving wheels all at once wouldn't work so well?
__________________
2015 BMW M3 (ED 03-11-14) /l\ Austin Yellow /i\ 6MT /l\ Exec Pkg /i\ HK Audio /l\ 437M
CCA Member
Appreciate 0
      07-11-2012, 01:14 PM   #4
Amir87
Gruppe Titan
Pakistan
166

 
Amir87's Avatar
 
Drives: 08 E92 SG/Coral
Join Date: Sep 2007
Location: NC


Posts: 2,839
iTrader: (37)

Garage List
2008 E92 335i  [5.00]
Hmmm...wonder if there's a JB4 for that?

Impressive pics and machinery!
__________________
Appreciate 0
      07-11-2012, 01:53 PM   #5
rader1
Banned
42

 
Drives: Cobb Stage 2+ 135i
Join Date: Apr 2011
Location: Roanoke, VA


Posts: 2,197
iTrader: (0)

Quote:
Originally Posted by S3RI35 View Post
holy moly, this is impressive! Will have to read up more before I can make more of an educated contribution here, but how rapidly is power delivered from these engines? I assume that 4400hp supplied to the driving wheels all at once wouldn't work so well?
Locomotives use a throttle lever to control power. It ranges from idle to "8th notch" with 8th notch being wide open. Normally a locomotive on its own, or when coupled to one other locomotive/empty freight cars, will start from a dead stop in 1st notch. As speed increases you begin notching up the throttle.

Really, the engine is there just to turn the alternator to power the traction motors. In 8th notch it puts out about 2,400 amps and 1,200 volts.
Appreciate 0
      07-11-2012, 02:18 PM   #6
ragingclue
One cam is enough
92

 
ragingclue's Avatar
 
Drives: VF
Join Date: Oct 2008
Location: mulletville


Posts: 6,810
iTrader: (1)

Quote:
Originally Posted by rader1 View Post
2,400 amps
Good Lord.
Appreciate 0
      07-11-2012, 02:35 PM   #7
NYC6
Banned
United_States
52

 
Drives: '10 135i PPKI/06 C6 Z51 Vette
Join Date: Aug 2009
Location: LI/NY


Posts: 2,078
iTrader: (0)

Very cool pics.
Especially that crank and turbo! Amazing but still dwarfed by a show I saw on the tube about a luxury liners piston engine. There where doors in the crank case so workers can walk inside the house sized engine!
Appreciate 0
      07-11-2012, 02:42 PM   #8
sn0pea
Captain
39

 
sn0pea's Avatar
 
Drives: Black 325i 2006
Join Date: Oct 2010
Location: OK


Posts: 841
iTrader: (1)

First ever GE 7FDL 3-series engine swap. I'll take two
__________________

2006 325i: Matte Black Grills, AG m310 19's (19X8.5et35 & 19X9.5et33 - 235/35/19 & 265/30/19), Amber Covers, Magnaflow with black tips, Blacked Emblems, M3 Replica Bumper and Vorsteiner hood!
Appreciate 0
      07-11-2012, 03:01 PM   #9
ragingclue
One cam is enough
92

 
ragingclue's Avatar
 
Drives: VF
Join Date: Oct 2008
Location: mulletville


Posts: 6,810
iTrader: (1)

Quote:
Originally Posted by NYC6 View Post
Very cool pics.
Especially that crank and turbo! Amazing but still dwarfed by a show I saw on the tube about a luxury liners piston engine. There where doors in the crank case so workers can walk inside the house sized engine!
haha yeah I saw that one too. I couldn't believe the sheer scale of things....
Appreciate 0
      07-11-2012, 07:31 PM   #10
Greenkirby21
Vrooom :)
United_States
160

 
Greenkirby21's Avatar
 
Drives: C7 Stringray
Join Date: Jun 2010
Location: Dream Land


Posts: 2,608
iTrader: (1)

Send a message via AIM to Greenkirby21
holy crap thats a huge engine
__________________
2014 C7 Corvette Stringray - Laguna Blue - NPP Exhaust - Competition Seats
Appreciate 0
      07-11-2012, 10:57 PM   #11
rader1
Banned
42

 
Drives: Cobb Stage 2+ 135i
Join Date: Apr 2011
Location: Roanoke, VA


Posts: 2,197
iTrader: (0)

Quote:
Originally Posted by ragingclue View Post
Good Lord.
Yep, its nuts. There's so much current flowing through the electrical contractors that they develop a magnetic a field so strong that it requires air pressure to assist in opening the contractors when required.
Appreciate 0
      07-11-2012, 11:50 PM   #12
MisterSkiMask
Lieutenant Colonel
57

 
Drives: I Can not say
Join Date: Nov 2005
Location: you must not know


Posts: 1,940
iTrader: (0)

Thanks for sharing, I love commercial grade stuff!
Appreciate 0
      07-12-2012, 12:27 AM   #13
jhv
Lieutenant General
No_Country
731

 
jhv's Avatar
 
Drives: Every Day
Join Date: Apr 2007
Location: Los Angeles


Posts: 17,307
iTrader: (1)

this is amazing. please post more pictures and whatnot. i love this kind of stuff
__________________
Appreciate 0
      07-12-2012, 12:37 AM   #14
DSB335d
Lieutenant
30

 
Drives: '11 335d DSB/oyster&black/navi
Join Date: Dec 2011
Location: West palm beach


Posts: 557
iTrader: (0)

Cool stuff!! Only 36psi? Needs a manual boost controller. Lol
Appreciate 0
      07-12-2012, 10:18 AM   #15
ejheverest
First Lieutenant
United_States
13

 
ejheverest's Avatar
 
Drives: E90 SG 330i
Join Date: Nov 2006
Location: Mass, NH, Maine, Virginia


Posts: 386
iTrader: (0)

Nice pics!!

We have(4) Wartsila 32 V18's and (2)V12's at my work.(320mm cylinder bore diameter) Here's a few pics of one after the connecting rod bolts loosened up while under load @ 720 RPM's

Ended up having to order a new block with all new parts...

rated at 10k HP
Attached Images
 
__________________
SOLD......E90 SG, ColdWeather Pckg, Sport Pckg, Logic7,H R Sports, Rogue Ikon, M sport shift knob/boot

Last edited by ejheverest; 07-12-2012 at 10:34 AM.
Appreciate 0
      07-12-2012, 10:41 AM   #16
positiveions
Lieutenant General
Lebanon
136

 
positiveions's Avatar
 
Drives: 09 MKV JETTA 2.5 & E90 M3 :)
Join Date: Sep 2007
Location: La Verne, CA


Posts: 10,520
iTrader: (1)

Send a message via MSN to positiveions Send a message via Yahoo to positiveions
wooo. talking about a turbo.
Thanks for sharing. A very interesting and complex engineering.
Appreciate 0
      07-12-2012, 10:42 AM   #17
ejheverest
First Lieutenant
United_States
13

 
ejheverest's Avatar
 
Drives: E90 SG 330i
Join Date: Nov 2006
Location: Mass, NH, Maine, Virginia


Posts: 386
iTrader: (0)

Notice the conn rod is bent in a circle...

The crankcase door is blown off and the block is cracked...
Attached Images
   
__________________
SOLD......E90 SG, ColdWeather Pckg, Sport Pckg, Logic7,H R Sports, Rogue Ikon, M sport shift knob/boot
Appreciate 0
      07-12-2012, 01:31 PM   #18
rader1
Banned
42

 
Drives: Cobb Stage 2+ 135i
Join Date: Apr 2011
Location: Roanoke, VA


Posts: 2,197
iTrader: (0)

Quote:
Originally Posted by ejheverest View Post
Nice pics!!

We have(4) Wartsila 32 V18's and (2)V12's at my work.(320mm cylinder bore diameter) Here's a few pics of one after the connecting rod bolts loosened up while under load @ 720 RPM's

Ended up having to order a new block with all new parts...

rated at 10k HP
That's some awesome stuff. Am I right to assume that the engines are mechanical fuel injection and at the end closest to the camera is the governor/governor drive?


Quote:
Originally Posted by ejheverest View Post
Notice the conn rod is bent in a circle...

The crankcase door is blown off and the block is cracked...
Damn, I've seen the same thing myself dozens of times. When these things go they GO lol
We actually have a means of repairing block damage like that(depending on severity, of coarse.) My shop is one of only two facilities in the world that does "stitch" repair. We machine the entire damaged section out and insert a blank casting by means of using metal stitch pins to secure new section in place. It very tedious and time consuming work but it works.

Here's a con rod of an engine that over sped and starved of oil. The piston crown seized in the bore and broke off of the piston skirt. The push rods are now bananas lol
Appreciate 0
      07-12-2012, 04:12 PM   #19
ejheverest
First Lieutenant
United_States
13

 
ejheverest's Avatar
 
Drives: E90 SG 330i
Join Date: Nov 2006
Location: Mass, NH, Maine, Virginia


Posts: 386
iTrader: (0)

Yes, they are mechanical injection, all our diesel gens. onboard are 4 strokes, V type, except for our inline 6 R 32 Emergency Diesel Gen.

Yes-governor is closest in the photo, we have diesel-electric to power our plant loads.(6 thrusters, motors, all drilling equipment, etc.) 58600 hp total.

I used to work on container ships so I've been in side a few 900 mm bore Inline 9, 2 strokes. They have ladders in the crankcase and you can walk the airbox from one end to the other. I have seen the 2 stroke technologies where they use hydraulics to open/close the exhaust valves and don't have any camshafts.

In our industry, they cut a 50' hole in the deck and remove the block, order all new parts to build up a new engine, including turbos(2). Pocket change for them, Wartsila techs would also fly out for that type of job since we still have the rest of the power plant and rig floor to take care of.
__________________
SOLD......E90 SG, ColdWeather Pckg, Sport Pckg, Logic7,H R Sports, Rogue Ikon, M sport shift knob/boot
Appreciate 0
      07-12-2012, 04:14 PM   #20
ejheverest
First Lieutenant
United_States
13

 
ejheverest's Avatar
 
Drives: E90 SG 330i
Join Date: Nov 2006
Location: Mass, NH, Maine, Virginia


Posts: 386
iTrader: (0)

Yes, they are mechanical injection, all our diesel gens. onboard are 4 strokes, V type, except for our inline 6 R 32 Emergency Diesel Gen.

Yes-governor is closest in the photo, we have diesel-electric to power our plant loads.(6 thrusters, motors, all drilling equipment, accomodations, etc.) 58600 hp total.

I used to work on container ships so I've been inside a few 900 mm bore Inline 9, 2 strokes. They have ladders in the crankcase and you can walk the airbox from one end to the other. I have seen the 2 stroke technologies where they use hydraulics to open/close the exhaust valves and don't have any camshafts.

In our industry, they cut a 50' hole in the deck and remove the block, order all new parts to build up a new engine, including turbos(2). Pocket change for them, Wartsila techs would also fly out for that type of job since we still have the rest of the power plant and rig floor to take care of.
__________________
SOLD......E90 SG, ColdWeather Pckg, Sport Pckg, Logic7,H R Sports, Rogue Ikon, M sport shift knob/boot
Appreciate 0
      07-13-2012, 03:26 PM   #21
delio13
Private
Canada
3

 
Drives: 2011 X5 35d
Join Date: Oct 2009
Location: british coumbia


Posts: 84
iTrader: (0)

This is awesome cause my job as an operator in a coal terminal is to operate the locomotives, most of the time there are two coupled together or sometimes there's three depending on the amount of coal cars. Two locis usually 112 cars three locis usually 175 cars. A load of coal cars is 105 tonnes and the car alone is I believe 40 tonnes dead weight. Yeah the sheer power of these engines are amazing. Thanks for posting the pics I am also a millwright and a welder by trade so it is so cool to see how it works
Appreciate 0
      07-18-2012, 08:46 AM   #22
GoldenMember
If you ain't first, you're last!
Singapore
6

 
GoldenMember's Avatar
 
Drives: '13 Boxster S + 10' 1198S
Join Date: Feb 2011
Location: Europe


Posts: 570
iTrader: (0)

That's one big a$$ turbocharger. Thanks for sharing, I found it interesting
Appreciate 0
Post Reply

Bookmarks

Thread Tools Search this Thread
Search this Thread:

Advanced Search

Posting Rules
You may not post new threads
You may not post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off


All times are GMT -5. The time now is 11:50 AM.




m3post
Powered by vBulletin® Version 3.7.0
Copyright ©2000 - 2014, Jelsoft Enterprises Ltd.
1Addicts.com, BIMMERPOST.com, E90Post.com, F30Post.com, M3Post.com, ZPost.com, 5Post.com, 6Post.com, 7Post.com, XBimmers.com logo and trademark are properties of BIMMERPOST