Fuel Tank Calibration
Content
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
RESEARCH DESIGNS AND STANDARDS ORGANIZATION
MANAK NAGAR, LUCKNOW– 226 011
Instruction Bulletin No. MP.IB.EC.02.08.10 (Rev.0.00),dated 25.02.10
1.0Title:
Instruction bulletin for calibration of fuel oil tank with ultrasonic fuel level sensor for
ALCo Diesel Electric Locomotives (Applicable for FOL sensor fitted MEP660,VER-3
locos).
2.0 Background:
A fuel level sensor for use on diesel electric locomotives had been developed as per
R.D.S.O specification No.MP.0.24.00.63 (Rev0.00), dated Nov’09.
In Diesel electric locomotives, the fuel oil tank shapes are not uniform. Each type of
the locomotive has its own shape. For this reason, while installing the fuel sensor for
the first time on a diesel locomotive, it needs to be calibrated.
Once it is calibrated during installation, does not require it further until sensor or tank
profile is changed.
3.0 OBJECT:
To enable shed personnel at shed level to do calibration of fuel tank of Alco diesel
locomotives fitted with ultrasonic fuel oil level sensor.
4.0 DETAILS OF STUDY/EXPERIMENTATION DONE:
4.1 During type test on this sensor at the premises of M/s Medha Servo Drives Ltd
in Hyderabad, simulated calibration was carried out on two numbers of this type of
sensors ( M/s Medha SNo.2006 and 2017).
4.2 Earlier, during manufacturing stage of the locomotive No. 13512 one no. sensor
had been fitted on this locomotive. To ascertain the performance of the sensor, foot
plating was conducted on this locomotive on 23rd February and 24th February from
Bangalore to Tumkur. The performance of the sensor was found satisfactory.
5.0 APPLICATION TO CLASS OF LOCOMOTIVES:
6. INSTRUCTION CONTENT:
6.1 FUEL LEVEL CALIBRATION:
Before starting the calibration, the fuel tank has to be drained completely and user
has to enter the fuel oil tank capacity in the configuration parameters (by default –
5000 litres).
6.2 To Select the Volume of the Fuel tank using Configuration Software
Steps to configure:
1. Connect the USB Cable to the IDL port of the MEP system and PC.
2. Run the MEP 660 version 3 configuration software
Page 1 of 4
3. Select Configuration.
4. Select Configure parameters.
5. Then select the General Block.
6. Enter the Fuel Tank Capacity in litres.
7. Click on the Send push button to send the configuration to the
system
8. Select the Read Config in the software to confirm the fuel tank
volume.
6.3 To Enable / disable Fuel tank calibration:
Fuel tank calibration has to be enabled, when ever user wishes to do calibration.
Through Test mode only fuel tank calibration can be enabled in the software.
6.4 Procedures of enabling or disabling the calibration through DID are as
follows:
Go to Main Menu then press F2 then Press 7 display should ask Pass word then
enter password and press “Enter” key. The default password is “6000”.
Then Press “F2” key 3 times and press 13 or “Enter” key to select fuel tank
calibration enabling screen.
The screen looks like:
Press “F3” key to enable the fuel tank calibration. The system enables the fuel tank
calibration and displays the confirmation message ‘Configuration’ Success.
The screen looks like:
Press “F1” to go to previous menu or “F4” key to go to default screen.
F2 F3 FF1 4
Page 2 of 4
6.5. Fuel tank calibration:
Go to Main Menu and select Maintenance mode press “Enter” key, then display
should ask Password. The default password is “12345”.
After entering password press “Enter” key, then in maintenance screen select TEST
MODE menu. In TEST MODE menu Press “F2” key 2 times and press 12 or “Enter”
key to select FUEL LEVEL CALIBRATION.
The display prompts for the conditions to be fulfilled before carrying out the ‘FUEL
LEVELCALIBRATION’. Fulfil all the conditions and then press “Enter” key. If any of
the conditions are not satisfied, then display shows that condition.
After all the conditions are satisfied, the calibration procedure is automatically
started. The display prompts to drain the fuel tank completely.
If the tank is not drained completely erroneous values will be shown on display with
in correct fuel level. Drain the existing fuel oil from the tank completely and press
“F3” key to start calibration. The display prompts the user to fill the tank with
measured quantity of 500 litres. Fill the fuel tank with 500 litres of fuel oil and then
press “F3” key under ‘OK’
The display prompts for confirmation after filling 500 litres of fuel oil and the
display looks like:
Press “F3” once again and confirm that 500 litres of oil is added.
F2 F3 FF1 4
NOTE: During Calibration progress time or at any stage, if “END TEST” (F4)
Key is pressed Calibration will get aborted with calibration fail message.
Once after confirmation button is pressed, the display shows an informative
message “FUEL TANK CALIBRATION IN PROGESS”. The display looks like:
After progress is completed once again the display prompts to add 500 litres more of
fuel oil and then press “F3” key under ‘OK’ to continue. This process is repeated until
the tank is full or filled up to the configured value. Once the calibration process is
completed, the display shows calibration results:
‘Fuel Tank Cal. Successful’ or ‘Fuel Tank Cal. Fail’.
Page 3 of 4
On this screen press “F4” key to end test. The display changes to screen shown
below.
The user can press “F1” key to go to Test Mode menu or he can press “F4” key to go
to default screen.
8. BENEFIT:
8.1 It will relieve the loco pilots from the hassle of noting down the fuel oil level
reading during handing and taking over of a diesel locomotive.
8.2 Data of fuel level can be viewed on web with the help of REMMLOT.
8.3 Better account of fuel oil filling at every fuel filling station as the volume will be
kept on being displayed on web through REMMLOT. This will also avoid the theft of
the fuel oil if any.
8.4 As the data of fuel oil level will be flowing to microprocessor control of the
locomotive, the specific fuel consumption will be easily calculated by the micro
control system of the locomotive.
9. AGENCY AND SCHEDULE OF IMLEMENTATION:
(i)
DLW, Varanasi
(ii)
DMW, Patiala
(iii)
All diesel sheds
10. DISTRIBUTION AS PER ENCLOSED LIST:
(i)
DLW, Varanasi
(ii)
DMW, Patiala-147003
(iii)
Al diesel sheds
(Anil Kumar)
for Director General/MP
Page 4 of 4
MINISTRY OF RAILWAYS
RESEARCH DESIGNS AND STANDARDS ORGANIZATION
MANAK NAGAR, LUCKNOW– 226 011
Instruction Bulletin No. MP.IB.EC.02.08.10 (Rev.0.00),dated 25.02.10
1.0Title:
Instruction bulletin for calibration of fuel oil tank with ultrasonic fuel level sensor for
ALCo Diesel Electric Locomotives (Applicable for FOL sensor fitted MEP660,VER-3
locos).
2.0 Background:
A fuel level sensor for use on diesel electric locomotives had been developed as per
R.D.S.O specification No.MP.0.24.00.63 (Rev0.00), dated Nov’09.
In Diesel electric locomotives, the fuel oil tank shapes are not uniform. Each type of
the locomotive has its own shape. For this reason, while installing the fuel sensor for
the first time on a diesel locomotive, it needs to be calibrated.
Once it is calibrated during installation, does not require it further until sensor or tank
profile is changed.
3.0 OBJECT:
To enable shed personnel at shed level to do calibration of fuel tank of Alco diesel
locomotives fitted with ultrasonic fuel oil level sensor.
4.0 DETAILS OF STUDY/EXPERIMENTATION DONE:
4.1 During type test on this sensor at the premises of M/s Medha Servo Drives Ltd
in Hyderabad, simulated calibration was carried out on two numbers of this type of
sensors ( M/s Medha SNo.2006 and 2017).
4.2 Earlier, during manufacturing stage of the locomotive No. 13512 one no. sensor
had been fitted on this locomotive. To ascertain the performance of the sensor, foot
plating was conducted on this locomotive on 23rd February and 24th February from
Bangalore to Tumkur. The performance of the sensor was found satisfactory.
5.0 APPLICATION TO CLASS OF LOCOMOTIVES:
6. INSTRUCTION CONTENT:
6.1 FUEL LEVEL CALIBRATION:
Before starting the calibration, the fuel tank has to be drained completely and user
has to enter the fuel oil tank capacity in the configuration parameters (by default –
5000 litres).
6.2 To Select the Volume of the Fuel tank using Configuration Software
Steps to configure:
1. Connect the USB Cable to the IDL port of the MEP system and PC.
2. Run the MEP 660 version 3 configuration software
Page 1 of 4
3. Select Configuration.
4. Select Configure parameters.
5. Then select the General Block.
6. Enter the Fuel Tank Capacity in litres.
7. Click on the Send push button to send the configuration to the
system
8. Select the Read Config in the software to confirm the fuel tank
volume.
6.3 To Enable / disable Fuel tank calibration:
Fuel tank calibration has to be enabled, when ever user wishes to do calibration.
Through Test mode only fuel tank calibration can be enabled in the software.
6.4 Procedures of enabling or disabling the calibration through DID are as
follows:
Go to Main Menu then press F2 then Press 7 display should ask Pass word then
enter password and press “Enter” key. The default password is “6000”.
Then Press “F2” key 3 times and press 13 or “Enter” key to select fuel tank
calibration enabling screen.
The screen looks like:
Press “F3” key to enable the fuel tank calibration. The system enables the fuel tank
calibration and displays the confirmation message ‘Configuration’ Success.
The screen looks like:
Press “F1” to go to previous menu or “F4” key to go to default screen.
F2 F3 FF1 4
Page 2 of 4
6.5. Fuel tank calibration:
Go to Main Menu and select Maintenance mode press “Enter” key, then display
should ask Password. The default password is “12345”.
After entering password press “Enter” key, then in maintenance screen select TEST
MODE menu. In TEST MODE menu Press “F2” key 2 times and press 12 or “Enter”
key to select FUEL LEVEL CALIBRATION.
The display prompts for the conditions to be fulfilled before carrying out the ‘FUEL
LEVELCALIBRATION’. Fulfil all the conditions and then press “Enter” key. If any of
the conditions are not satisfied, then display shows that condition.
After all the conditions are satisfied, the calibration procedure is automatically
started. The display prompts to drain the fuel tank completely.
If the tank is not drained completely erroneous values will be shown on display with
in correct fuel level. Drain the existing fuel oil from the tank completely and press
“F3” key to start calibration. The display prompts the user to fill the tank with
measured quantity of 500 litres. Fill the fuel tank with 500 litres of fuel oil and then
press “F3” key under ‘OK’
The display prompts for confirmation after filling 500 litres of fuel oil and the
display looks like:
Press “F3” once again and confirm that 500 litres of oil is added.
F2 F3 FF1 4
NOTE: During Calibration progress time or at any stage, if “END TEST” (F4)
Key is pressed Calibration will get aborted with calibration fail message.
Once after confirmation button is pressed, the display shows an informative
message “FUEL TANK CALIBRATION IN PROGESS”. The display looks like:
After progress is completed once again the display prompts to add 500 litres more of
fuel oil and then press “F3” key under ‘OK’ to continue. This process is repeated until
the tank is full or filled up to the configured value. Once the calibration process is
completed, the display shows calibration results:
‘Fuel Tank Cal. Successful’ or ‘Fuel Tank Cal. Fail’.
Page 3 of 4
On this screen press “F4” key to end test. The display changes to screen shown
below.
The user can press “F1” key to go to Test Mode menu or he can press “F4” key to go
to default screen.
8. BENEFIT:
8.1 It will relieve the loco pilots from the hassle of noting down the fuel oil level
reading during handing and taking over of a diesel locomotive.
8.2 Data of fuel level can be viewed on web with the help of REMMLOT.
8.3 Better account of fuel oil filling at every fuel filling station as the volume will be
kept on being displayed on web through REMMLOT. This will also avoid the theft of
the fuel oil if any.
8.4 As the data of fuel oil level will be flowing to microprocessor control of the
locomotive, the specific fuel consumption will be easily calculated by the micro
control system of the locomotive.
9. AGENCY AND SCHEDULE OF IMLEMENTATION:
(i)
DLW, Varanasi
(ii)
DMW, Patiala
(iii)
All diesel sheds
10. DISTRIBUTION AS PER ENCLOSED LIST:
(i)
DLW, Varanasi
(ii)
DMW, Patiala-147003
(iii)
Al diesel sheds
(Anil Kumar)
for Director General/MP
Page 4 of 4
