Method of detecting a water leak in a locomotive

• US 7,165,442 B2
• Filed: 12/07/2004
• Issued: 01/23/2007
• Est. Priority Date: 12/08/2003
• Status: Active Grant

• Current Assignee: GE Global Sourcing LLC (Westinghouse Air Brake Technologies Corporation)
• Original Assignee: General Electric Company
• Inventors: Cryer, Robert Douglas, Kumar, Manoj P., McAndrew, Dennis William, Sonney, Thomas Charle, Ruprecht, William Joseph III, Swedberg, Matthew Lee, Mayle, John Albert, Waugaman, Charles Joseph
• Primary Examiner(s): Williams; Hezron
• Assistant Examiner(s): FRANK, RODNEY T
• Application Number:
  US11/006,357
• Publication Number:
  US 20050120777A1
• Time in Patent Office: 777 Days
• Field of Search: 73/40, 73/497, 73/37
• US Class Current: 73/40
• CPC Class Codes: G01M 3/04 by detecting the presence of fluid at the leakage point

Abstract

Disclosed herein are methods for detecting a water leak in a locomotive engine cooling system comprising numerous components, each being a potential source of leakage of water. The method typically comprises performing at least one inspection providing an indication of a water leak from an engine cooling system of the locomotive. The step of performing at least one inspection may comprise at least one of several steps including performing a visual inspection to determine if water is leaking from a portion of the cooling system external to the engine; performing a visual inspection of exhaust of the engine to detect an indication of water vapor in the exhaust; performing a visual inspection to detect an indication of water leaking into an intake air manifold 30 of the engine; performing an engine oil analysis to detect water in the engine lubricant; reviewing a fault log history for the locomotive; and checking a level of a cooling system sight glass. The method allows for the isolation of potential sources of the water leak from one another so as to prevent false positive leak identification caused by transient water flow between the potential sources. If an engine cylinder assembly is a component identified as a potential source of the water leak during the water pressurization test, the method enables further testing to confirm leakage at such cylinder assembly, before undertaking the costly and time-consuming process of removing the cylinder assembly from the engine. Cylinder assemblies can be tested for leaks by performing an air leak test disclosed herein.

Claims

1. A method of detecting a water leak in a locomotive engine cooling system comprising numerous components, each being a potential source of leakage of water, the method comprising:

performing at least one inspection providing an indication of a water leak from an engine cooling system of a locomotive;

isolating potential sources of the water leak from one another so as to prevent transient water flow between the potential sources;

performing a visual inspection while performing a water pressurization test on the engine cooling system to identify the source of the water leak;

identifying an engine cylinder assembly as a potential source of the water leak during the water pressurization test; and

performing an air leak test of the cylinder assembly to confirm that the cylinder assembly is leaking prior to removal of the cylinder assembly from the engine.

6. The method of claim 1, wherein the air leak test further comprises:

installing a blank flange on a first of the group of a water inlet port and a water outlet port of the cylinder assembly;

installing test fixture on a second of the group of the water inlet port and the water outlet port of the cylinder assembly;

applying pressure to a water jacket of the cylinder assembly through the test fixture; and

determining that the cylinder assembly is leaking if a sealed pressure within the water jacket decays at greater than a predetermined rate.

2. A method of detecting a water leak in a locomotive engine cooling system comprising numerous components, each being a potential source of leakage of water, the method comprising:

performing at least one inspection providing an indication of a water leak from an engine cooling system of a locomotive;

isolating potential sources of the water leak from one another so as to prevent transient water flow between the potential sources;

performing a visual inspection while performing a water pressurization test on the engine cooling system to identify the source of the water leak;

wherein the step of performing at least one inspection comprises at least one of the group consisting of;

performing a visual inspection to determine if water is leaking from a portion of the cooling system external to the engine;

performing a visual inspection of exhaust of the engine to detect an indication of water vapor in the exhaust;

performing a visual inspection to detect an indication of water leaking into an intake air manifold of the engine;

performing an engine oil analysis to detect water in engine oil;

reviewing a fault log history for the locomotive; and

checking a level of coolant in a cooling system sight glass.

3. A method of detecting a water leak in a locomotive engine cooling system comprising numerous components, each being a potential source of leakage of water, the method comprising:

performing at least one inspection providing an indication of a water leak from an engine cooling system of a locomotive;

isolating potential sources of the water leak from one another so as to prevent transient water flow between the potential sources;

performing a visual inspection while performing a water pressurization test on the engine cooling system to identify the source of the water leak; and

removing an exhaust bellows to prevent transient water flowing between a cylinder assembly and a turbocharger of the engine.

4. A method of detecting a water leak in a locomotive engine cooling system comprising numerous components, each being a potential source of leakage of water, the method comprising:

performing at least one inspection providing an indication of a water leak from an engine cooling system of a locomotive;

isolating potential sources of the water leak from one another so as to prevent transient water flow between the potential sources;

performing a visual inspection while performing a water pressurization test on the engine cooling system to identify the source of the water leak; and

displacing a component between an intercooler and a turbocharger of the engine to prevent transient water flowing there between.

5. A method of detecting a water leak in a locomotive engine cooling system comprising numerous components, each being a potential source of leakage of water, the method comprising:

performing at least one inspection providing an indication of a water leak from an engine cooling system of a locomotive;

isolating potential sources of the water leak from one another so as to prevent transient water flow between the potential sources;

performing a visual inspection while performing a water pressurization test on the engine cooling system to identify the source of the water leak; and

opening a crankcase door of the engine to provide visual access for identifying water leaking from a turbocharger drain line or from a cylinder assembly of the engine during the water pressurization test.

7. A method of detecting a water leak in a locomotive engine cooling system comprising numerous components, each being a potential source of leakage of water, the method comprising:

performing at least one inspection providing an indication of a water leak from an engine cooling system of the locomotive, wherein the step of performing at least one inspection comprises at least one of the group consisting of;

(i) performing a visual inspection to determine if water is leaking from a portion of the cooling system external to the engine;

(ii) performing a visual inspection of exhaust of the engine to detect an indication of water vapor in the exhaust;

(iii) performing a visual inspection to detect an indication of water leaking into an intake air manifold of the engine;

(iv) performing an engine oil analysis to detect water in the engine lubricant;

(v) reviewing a fault log history for the locomotive; and

(vi) checking a level of a cooling system sight glass;

isolating potential sources of the water leak from one another so as to prevent transient water flow between the potential sources;

performing a visual inspection while performing a water pressurization test on the engine cooling system to identify the source of the water leak; and

provided that an engine cylinder assembly is a component identified as a potential source of the water leak during the water pressurization test, the method further comprises performing an air leak test of the cylinder assembly to confirm that the cylinder assembly is leaking prior to removal of the cylinder assembly from the engine.

8. The method of claim 7, wherein performing a visual inspection to determine if water is leaking from a portion of the cooling system external to the engine is conducted a first time while the engine is running and a second time when the engine is stopped and cooled.

9. The method of claim 7, wherein said performing a visual inspection to detect an indication of water leaking into an intake air manifold of the engine comprises removing at least one end cap provided on said intake air manifold.

10. A method of detecting a water leak in a locomotive engine cooling system comprising numerous components, each being a potential source of leakage of water, the method comprising:

performing at least one inspection providing an indication of a water leak from an engine cooling system of the locomotive, wherein the step of performing at least one inspection comprises at least one of the group consisting of;

(i) performing a visual inspection to determine if water is leaking from a portion of the cooling system external to the engine;

(ii) performing a visual inspection of exhaust of the engine to detect an indication of water vapor in the exhaust;

(iii) performing a visual inspection to detect an indication of water leaking into an intake air manifold of the engine;

(iv) performing an engine oil analysis to detect water in the engine lubricant;

(v) reviewing a fault log history for the locomotive; and

(vi) checking a level of a cooling system sight glass;

isolating potential sources of the water leak from one another so as to prevent transient water flow between the potential sources;

performing a visual inspection while performing a water pressurization test on the engine cooling system to identify the source of the water leak; and

provided that an engine cylinder assembly is a component identified as a potential source of the water leak during the water pressurization test, the method further comprises performing an air leak test of the cylinder assembly to confirm that the cylinder assembly is leaking prior to removal of the cylinder assembly from the engine;

wherein said air leak test comprises;

(i) installing a blank flange on a first of the group of a water inlet port and a water outlet port of the cylinder assembly;

(ii) installing test fixture on a second of the group of the water inlet port and the water outlet port of the cylinder assembly;

(iii) applying pressure to a water jacket of the cylinder assembly through the test fixture; and

(iv) determining that the cylinder assembly is leaking if a sealed pressure within the water jacket decays at greater than a predetermined rate.