Exhaust gas extraction systems are an essential requirement to ensure operator health and safety. But what happens when working conditions become extreme, with large engines and operating temperatures far above standard levels? In such scenarios, conventional solutions are insufficient, and it becomes necessary to rely on specialized technologies and expertise.
This was precisely the case in a recent project requiring the extraction of exhaust gases generated by powerful diesel locomotives inside a railway maintenance facility. A complex challenge we successfully turned into a practical solution, thanks to tailor-made systems and high-temperature exhaust extraction arms.
High-Temperature Exhaust Gases: Why a Dedicated Solution Is Needed
When dealing with large-displacement diesel engines, such as those used in locomotives, exhaust gas temperatures can reach extremely high peaks. Using a high-temperature exhaust extractor is not an option but a critical requirement to ensure:
- Durability and resistance: Standard materials would quickly degrade, compromising system performance and safety. High-temperature flexible hoses are specifically designed to withstand extreme conditions.
- Extraction efficiency: A high-temperature fume extractor is sized to manage not only the heat but also the large volumes of gas produced by high-power engines, ensuring a safe working environment.
- Operational safety: Preventing the risk of fire or equipment damage is crucial. Dedicated solutions eliminate these hazards at the source.
Case Study: Exhaust Extraction on Locomotives — A Challenge of Obstacles and Custom Solutions
The request came through our local distributor: a railway maintenance workshop required a system to extract exhaust gases from two different diesel locomotives used to service electric trains.
From the beginning, the project presented several technical challenges that ruled out conventional solutions. The distributor’s efficiency clearly emerged in managing two crucial phases simultaneously:
- identifying and selecting the most suitable materials
- coordinating an on-site inspection promptly
Challenges to Address
The technical inspection by our area manager was essential to define the scope of work and assess the critical aspects. The situation presented several major obstacles:
- Different exhaust locations: the two locomotives featured different exhaust configurations—one vertical, the other lateral and located under the chassis.
- System sizing: the engine power required dedicated calculations to ensure effective extraction capacity.
- High temperatures: the use of high-temperature components and flexible hoses was indispensable.
- Variable vehicle positioning: the locomotives could enter the track from either direction, resulting in a constantly changing exhaust outlet location.
- Structural constraints: the overhead electrification line, located only 1.5 meters above the locomotives, made it impossible to use the ceiling for system anchoring.
The WORKY Solution: Engineering and Military Technology
Faced with such a complex scenario, the ingenuity and experience of WORKY’s technicians made the difference. Each issue was analyzed in detail to design a unique, efficient, and cost-optimized solution using proven components and military-derived technologies.
The key to success was the implementation of a system based on:
- Two independent articulated arms: anchored directly to the sturdy steel pillars alongside the tracks, solving the ceiling-mounting limitation and ensuring maximum stability.
- Controlled footprint: the arms were engineered not to exceed one and a half meters above the trains, fully complying with the clearance required by the electrification line.
- Magnetic coupling nozzle: for the locomotive with the under-chassis exhaust, one arm was equipped with a magnetic nozzle ensuring fast, safe, and stable connection.
- High-temperature strip-curtain hood: for the vertical exhaust, the second arm featured a special hood with heat-resistant strips. This smart design enabled effective fume capture without requiring the hood to be manually positioned over the exhaust stack.
In addition, the entire installation was carried out inside the service station, avoiding complex and costly external mounting on the building façade, which would have required rail traffic interruption.
Complete Product Range: Beyond Exhaust Gas Extraction
WORKY collaborates with specialized professionals in consulting, design, installation, and maintenance. Beyond exhaust gas extraction, the product range extends across multiple sectors, offering fully integrated solutions:
- oil, power, and compressed-air distribution
- welding fume extraction and filtration
- sanding dust extraction and filtration
Collaboration and Expertise: The Formula for an Excellent Result
This project, initially marked by significant technical constraints, evolved into a successful case study. Credit goes to the synergy between the highly cooperative end customer—proactive and precise in providing data—the valuable support of our regional distributor, and the expertise of WORKY’s technicians, who delivered a flawless installation.
Once again, WORKY has demonstrated its ability to turn the most complex challenges into efficient and innovative solutions, always guaranteeing maximum quality and safety.
