LOCOMOTIVE WORKSHOP

NORTHERN RAILWAY, CHARBAGH

LUCKNOW

An
INDUSTRIAL TRAINING REPORT
On
"Cylinder Head"

SUBMITTED TO:

SUBMITTED BY:

Mr. V.K. Sonkar

Devyanshu Kumar Kumar

Senior Section Engineer

B.Tech (Mechanical)
SRMCEM, LUCKNOW

ACKNOWLEDGEMENT

Industrial training is very essential for successfully completing the Bachelor of

Technology. I was very lucky that I got an opportunity to do an Industrial training in
Locomotive Workshop, Lucknow.
I am sincerely thankful and pleased to show my deep gratitude to my project head Mr.
V.K Sonkar for his cooperation during the training period. This project would not have
been possible without his kind support and able guidance.
I would also like to thank might God and my parents, without their help it would have
been very difficult for me to complete the project successfully & also to all my colleagues
& the employees of Locomotive Workshop with whom Ive developed a special bond.
(Devyanshu Kumar)

1.INTRODUCTION TO INDIAN RAILWAY

Indian Railways is the state-owned enterprise, owned and operated
by the Government of India through the Ministry of Railways. Indian Railways has
one of the largest and busiest rail networks in the world, transporting over 18
million passengers and more than 2 million tons of freight daily. Its revenue is
Rs.107.66 billion. It is the world's largest commercial employer, with more than
1.4 million employees. It operates rail transport on 6,909 stations over a total route
length of more than 63,327 kilometers(39,350 miles).The fleet of Indian railway
includes over 200,000 (freight) wagons, 50,000 coaches and 8,000 locomotives. It
also owns locomotive and coach production facilities. It was founded in 1853
under the East India Company.
Indian Railways is administered by the Railway Board. Indian
Railways is divided into 16 zones. Each zone railway is made up of a certain
number of divisions. There are a total of sixty-seven divisions. It also operates the
Kolkata metro. There are six manufacturing plants of the Indian Railways. The
total length of track used by Indian Railways is about 108,805 km (67,608 mi)
while the total route length of the network is 63,465 km (39,435 mi). About 40% of
the total track kilometer is electrified & almost all electrified sections use 25,000 V
AC. Indian railways uses four rail track gauges
Indian Railways operates about 9,000 passenger trains and transports
18 million passengers daily .Indian Railways makes 70% of its revenues and most
of its profits from the freight sector, and uses these profits to cross-subsidies the
loss-making passenger sector. The Rajdhani Express and Shatabdi Express are the
fastest trains of India.

2.DIESEL
LOCOMOTIVE
SHED
CHARBAGH,
LUCKNOW

Diesel locomotive shed is

an industrial-technical setup, where repair and maintenance works of diesel
locomotives is carried out, so as to keep the loco working properly. It contributes
to increase the operational life of diesel locomotives and tries to minimize the line
failures. The technical manpower of a shed also increases the efficiency of the loco
and remedies the failures of loco.
The shed consists of the infrastructure to berth, dismantle, repair and test the loco
and subsystems. The shed working is heavily based on the manual methods of
doing the maintenance job and very less automation processes are used in sheds,
especially in India.
The diesel shed usually has: Berths and platforms for loco maintenance.
Pits for under frame maintenance
Heavy lift cranes and lifting jacks
Fuel storage and lube oil storage, water treatment plant and testing
labs etc.
Sub-assembly overhauling and repairing sections

 Machine shop and welding facilities.

DIESEL SHED, CHARBAGH, LUCKNOW of northern railway is located in

LUCKNOW. The shed was established on 22nd April 1857. It was initially planned
to home 75 locomotives. The shed cater the needs of Northern railway. This shed
mainly provides locomotive to run the mail, goods and passenger services. No
doubt the reliability, safety through preventive and predictive maintenance is high
priority of the shed. To meet out the quality standard shed has taken various steps
and obtaining of the ISO-9001-200O& ISO 14001 OHSAS CERTIFICATION is
among of them. The Diesel Shed is equipped with modern machines and plant
required for Maintenance of Diesel Locomotives and has an attached store depot.
To provide pollution free atmosphere, Diesel Shed has constructed Effluent
Treatment Plant. The morale of supervisors and staff of the shed is very high and
whole shed works like a well-knit team.

3.DIESEL ELECTRIC LOCOMOTIVE

PARTS OF THE LOCOMOTIVE (FIG. 1)

SAND BOX
RADIATOR
RADIATOR FAN
TURBO SUPERCHARGER
BOGIE(2 SETS)(3AXLE OR 2 AXLE)
FUEL TANK
AIR RESERVOIERS
POWER PACK
DYNAMO WITH ALTRNATOR
BATTERIES
DRIVER CABIN
WHEEL ASSEMBLY
DISC
BLOWER
TRACTON MOTER
TRUCK
GEAR AND PENION ASSSEMBLY

CYLINDER HEAD
CROSS HEAD
FUEL INJECTION PUMP
BATTERIES (8 OF 8.68 VOLTS)
FUEL TANK
AFTER COOLING CORE
JUNCTION BOX

4.CYLINDER HEAD
(PROJECT STUDY)

4.1 INTRODUCTION
In an internal combustion engine, the cylinder head (often informally abbreviated
to just head) sits above the cylinders on top of the cylinder block. It closes in the
top of the cylinder, forming the combustion chamber. This joint is sealed by a head
gasket. In most engines, the head also provides space for the passages that feed air
and fuel to the cylinder, and that allow the exhaust to escape. The head can also be
a place to mount the valves, spark plugs, and fuel injectors.
Key features of Cylinder Head:
It is subjected to high shocks, stresses and combustion temperature.
Cooling passages are cored for heat rejection.
It also provides passages for inlet air, exhaust gases, fuel injection nozzles,
valve guide, valve seats etc.

4.2 Common components used in Indian Railway

Cylinder Heads

Part No.

DESCRIPTION

22200215

CYLINDER HEAD WITH VALVES

2231129

AIR VALVE

2231129

EXHAUST VALVE

2461082-1

AIR AND EXHAUST VALVE SPRING

2231231

SPRING SEAT

2231152

SPRING SEAT LOCK

22200115

CYLINDER HEAD WITH INSERTS, LESS VALVE

2221082

PLUG, SPL , FOR NOZZLE CLAMP STUD

2221092-1

NOZZLE OPENING SLEEVE

2221093-1

STUD OPENING SLEEVE

2221094-1

INJECTION TUBE OPENING SLEEVE (REQURED FOR EARLY DESIGN HEADS

ONLY

2461083

SNAP RING FOR VALVE SEAT INSERT

2241024-1

VALVE LEVER YOKE GUIDE

2221081-2

PLUG, INDICATOR CONNECTION

2151119

GASKET, INDICATOR PLUG

54021A

PLUG, THERMOCOUPLE CONNECTION, 1/2 IPS, HEX. H.

21514279-3

STUD, INJECTION TUBE TO CYLINDER HEAD

21516311

NUT. SPL., INJECTION TUBE STUD

2151313-1

LOCKWASHER,1/2

2151429-5

STUD, NOZZLE CLAMP, 5/8-11 X 5-5/16

21516310

NUT NOZZLE CLAMP 5/8-11

2241294-1

PUSH ROD SLEEVE

2153403

GROMMET, PUSHROD SLEEVE

25000286

WATER ELBOW KIT (3 PC.) HEAD TO BLOCK (LOCOMOTIVE, MARINE AND

STATIONARY)

25000288

WATER ELBOW KIT (3 PC.) HEAD TO BLOCK (DUAL FUEL)

4.3 Compulsory components to be exchanged in

Cylinder Head Section
S.NO.
1.
2.

DESCRIPTION
Valve Guide
Lock

P.L. NO.
10124639
10210477

4.4 Critical parts

S.No.
1.
2.
3.
4.
5.

Description
Exhaust Gas Valve
Inlet Valve
Lock
Valve Seat Insert 30
Spring

P.L. No.
10244334
10245807
10210477
10249254
10160115

4.5 Cylinder Head section working procedure

1.
2.
3.
4.
5.
6.
7.
8.

Opening of Head (valve, spring, valve insert seats, etc.).

Scratching the cylinder head to remove carbon.
Spring, seat, lock, flange, etc. are cleaned with diesel and surf water.
Removing carbon from old Valves.
Grinding the face of old valve with grinding machine.
Performing R.D.P. test for checking the caps of cylinder head.
Valve, spring, cage and valve locks are Zyglo Tested.
Valve guide, valve seat insert, spring, compression seat etc. are measured.
Rejected parts are red-crossed and removed.
9. Damaged valve seat insert, valve guide, nozzle, cooling sleeve etc. are
replaced by new ones.
10.Performing hydraulic testing (for internal cracks).
11.After recording each dimensions, head is tied back.
12.Performing Blow-By test for blow-by gasses.

4.6 Testing of Cylinder Head

RED-DYE PENETRATION TEST (RDP)
Dye penetrant inspection (DPI), also called liquid penetrant
inspection (LPI), is a widely applied and low-cost inspection
method used to locate surface-breaking defects in all nonporous materials (metals, plastics, or ceramics). Penetrant
may be applied to all non-ferrous materials, but for inspection
of ferrous components magnetic particle inspection is
preferred for its subsurface detection capability. LPI is used
to detect casting and forging defects, cracks, and leaks in new
products, and fatigue cracks on in-service components.
Zyglo test:
The zyglo test is a nondestructive testing (NTD) method that helps to
locate and identify surface defects in order to screen out potential
failure-producing defects. It is quick and accurate process for locating
surface flaws such as shrinkage cracks, porosity, cold shuts, fatigue
cracks, grinding cracks etc. The ZYGLO test works effectively in a
variety of porous and non-porous materials: aluminum, magnesium,
brass, copper, titanium, bronze, stainless steel, sintered carbide, nonmagnetic alloys, ceramics, plastic and glass.
Since cylinder head is quite heavy therefore cylinder head is not
dipped in zyglo solution instead of dipping in the solution it is
checked by spraying powder on the cylinder head by the following
procedure.
Clean the surface and internal areas of the cylinder head with water.

 Apply penetrant, through spray.

Now a source of light is used i.e., ultrasonic light is made to fall on the
surface of the cylinder head if there is any crack is present then a green
light will appear with a zig-zag pattern.
If it is less than 20 micron than it is repairable by surface finishing or
removal of upper layer of the defective surface.
If the intensity of the light is more than 20 micron then it is condemned.

Hydraulic test
A hydrostatic test is a way by which cylinder heads, pressure vessels
such as pipelines, plumbing, boilers and fuel tanks can be tested for
strength and leaks. The test involves filling the vessel or pipe system
with a liquid, usually water, which may be dyed to aid in visual leak
detection, and pressurization of the vessel to the specified test pressure.
Pressure tightness can be tested by shutting off the supply valve and
observing whether there is a pressure loss. The location of a leak can be
visually identified more easily if the water contains a colorant. Strength
is usually tested by measuring permanent deformation of the container.
Steps:
o Run the engine to attain normal operating temperature(650C)
o Stop running the engine after attaining its operating temperature
o Bring the piston into its compression state
o Fit the hydraulic gadget into the cylinder head close all the openings
o Flow the water into the combustion chamber

o Cut off water supply at 70 psi. Through stop cock and record the time
when it comes to zero. 7 to 10 seconds are ok.

Blow-by Test
Blow-by refers to the leakage of gas past the piston of an engine at
maximum pressure.
Cause: oversized bore, bad ring profile, dent on piston rings, more
gaps in piston ring, late opening and closing of exhaust valves, etc.
Effect: Generally, a new engine has high blow-by which reduces
considerably with running as the high points of bore honing wears away
and thus improving piston rings sealing. But if it is due to any
manufacturing defects or excessive worn parts, then it will surely reduce
engine performance. In worst case it will increase lubricating oil
consumption causing high smoke and particulate emission.
Blow-by Test: It is conducted to check the sealing
efficiency of the combustion chamber on a running
engine, as per the following procedure:
Run the engine to attain normal operating temperature
(65C)
Stop running after attaining normal operating temperature.
Bring the piston of the corresponding cylinder at TDC in
compression stroke.

 Fit blow-by gadget (Consists of compressed air line with the

provision of a pressure gauge and stopcock) removing
decompression plug.
Charge the combustion chamber with compressed air.
Cut off air supply at 70 psi. Through stop cock and record
the time when it comes down to zero.7 to 10 secs is OK.

Various important process and components to be replaced

VALVES/VALVE SEAT INSERTS AND VALVE GUIDES
Unless extreme caution is used while grinding the valve seat inserts valve
seat cracking and checking may result. A major cause for this condition is either
the use of improper strokes or the application of too much pressure by the
driver.
If it is necessary to remove a valve seat insert use a valve seat extractor tool.
MACHINING INSERT BORES
The procedure for machining bore are as follows:
1. Remove all valve guides, equalizing yoke guides and studs.
2. For standard oversized valve seat inserts machine cylinder head bore
is indicated.
3. Blow out chips.
4. Press new valve guides, using inserting sleeve tool.
5. Press new valve equalizing yoke guides.
6. Apply new nozzles studs or reapply old studs if in good condition.
APPLICATION OF VALVE GUIDES
All valve guide bores should be cleaned using 5/8 inch wire brush. The
brush has a spindle which may be attached to a hand drill or some other hand
machine.
VALVE AND VALVE SEAT GRINDING
Stellite inserts may be prone to grinding cracks. In such a case these should
be ground using a little machine solvents.

The procedure for grinding valve seat inserts and reconditioning valves are
as follows:
1. Remove glaze on valve seat by using piece of sand paper under
grinding stone and then spin it.
2. Grind the seat and use dial indicator to check the trueness.
3. Check out valve seat run out. The valve guide bore must be within
tolerance limit.
4. Check the surface of the valve seat insert for cracks.
5. If valves showing crack should be scrapped.
6. Valves should be properly faced (exhaust gas valve at 45 o, air inlet
valve at 30o).
7. To check valve with seat blue valve insert is used. Fine line must
show around entire circumference on large diameter of seat
contracting area.
COMPRESSION SEAL
Since the cylinder head liner joint is metal to metal the seating area must be
in good condition. These surfaces should be checked and if necessary, lapped
using a lapping ring. Seating surfaces must be smooth and in one plane. Using
bluing, a continuous blue mark not less than 1/16 inch wide must show
throughout the circumference.
NOZZLE HOLE SLEEVE
A sleeve is applied with Tite seal in the nozzle hole of each cylinder head to
provide a water jacket for nozzle cooling and to furnish a seat for the nozzle.

4.7 New Generation Cylinder Head

ALCO 251+ cylinder heads are the latest generation cylinder heads, used in
updated engines, with the following feature:
Fire deck thickness reduced for better heat transmission.
Middle deck modified by increasing number of ribs (supports) to increase its
mechanical strength. The flying buttress fashion of middle deck improves
the flow pattern of water eliminating water stagnation at the corners inside
cylinder head.
Water holding capacity increased by increasing number of cores (14 instead
of 11)
Use of frost core plugs instead of threaded plugs, arrest tendency of leakage.
Made lighter by 8 kgs (Al spacer is used to make good the gap between
rubber grommet and cylinder head.)
Retaining rings of valve seat inserts eliminated.
BENEFITS
Better heat dissipation
Failure reduced by reducing crack and eliminating sagging effect of fire
deck area.

5.VARIOUS OTHER COMPONENTS OF RAIL

LOCOMOTIVE
5.1
The diesel

TURBO SUPERCHARGER

engine produces mechanical energy

by

converting heat energy derived from

burning of

fuel inside the cylinder. For efficient

burning of

fuel, availability of sufficient air in

proper ratio

is a prerequisite.

turbocharger, or turbo, is a gas

compressor

used for forced-induction of an

internal combustion engine. Like a supercharger, the purpose of a turbocharger

is to increase the density of air entering the engine to create more power.
However, a turbocharger differs in that the compressor is powered by a turbine
driven by the engine's own exhaust gases.
MAIN COMPONENTS OF TURBO-SUPERCHARGER

Turbo- supercharger consists of following main components.

Gas inlet casing.

Turbine casing.
Intermediate casing
Blower casing with diffuser
Rotor assembly with turbine and rotor on the same shaft.

5.2 FUEL OIL PUMP

All locomotive have individual fuel oil system. The fuel oil system is
designed to introduce fuel oil into the engine cylinders at the correct time, at

correct pressure, at correct quantity and correctly atomized. The system injects
into the cylinder correctly metered amount of fuel in highly atomized form.
High pressure of fuel is required to lift the nozzle valve and for better
penetration of fuel into the combustion chamber. High pressure also helps in
proper atomization so that the small droplets come in better contact with the
compressed air in the combustion chamber, resulting in better combustion.
Metering of fuel quantity is important because the locomotive engine is a
variable speed and variable load engine with variable requirement of fuel. Time
of fuel injection is also important for better combustion.
5.3 BOGIE

A bogie is a wheeled wagon or trolley. In mechanics terms, a bogie is

a chassis or framework carrying wheels, attached to a vehicle. It can
be fixed in place, as on a cargo truck, mounted on a swivel, as on a
railway carriage or locomotive, or sprung as in the suspension of a
caterpillar tracked vehicle.
Bogies serve a number of purposes: To support the rail vehicle body
To run stably on both straight and curved track

 To ensure ride comfort by absorbing vibration, and

minimizing centrifugal forces when the train runs on curves
at high speed.
To minimize generation of track irregularities and rail
abrasion.
Usually two bogies are fitted to each carriage, wagon or
locomotive, one at each end.
5.4 GENERATOR
This giant engine is hooked up to an equally impressive generator.
It is about 6 feet (1.8m) in diameter and weighs about 17,700 pounds
(8029kg). At peak power this generator makes enough electricity to
power a neighborhood of about 1,000 houses.
So, where does all the power go? It goes into six, massive electric motors
located in the bogies. The engine rotates the crank shaft at up to 1000rpm and
this drives the various items need to power the locomotive. As the transmission
is electric the engine is used as the power source for the electricity generator or
alternator.
5.5 Power Pack

The work of power pack section is to do the overhauling and repairing work. They
take out the head from the engine and assembles it after necessary repair. In the
power pack section the assembly of piston and connecting rod is done. The
thorough checking of piston is done in this section. The piston is send for zyglo test
then it is checked for all the clearances. It is checked whether the piston is seizing
or not.
There are two types of piston used, modified and unmodified. In modified piston,
piston head is made up of steel, the piston skirt is made up of aluminum.
Unmodified piston is totally made up of steel only. The weight of the assembly is
of 90kg. There are generally 5 rings used in the cylinder, first 3 are compression
ring next 2 are oil rings. The first one is made up of steel and has square face. The
second one is also of steel and has tapered face. The third one is of C.I. and is fuel
efficient taper face. The fourth and fifth are also of C.I. and are called oil scrapper
rings.
PARTS OF THE POWER PACK

EXHAUST MANIFOLD
WATER CHANNEL
PGEV GOVERNOR
CRANK CASE MOTOR
CYLINDER (MAX. 16 CYLINDER)
PISTON
FUEL OIL INJECTOR
ROCKER ARM
YOKE
LUBE OIL HEADER PIPE
CAM SHAFT
CRANK SHAFT
CROSS HEAD
FUEL INJECTION PUMP
CROSS PIPE
FIP COVER

FUEL OIL BENZO

LUBE OIL SUMP
GEAR CASE
CYLINDER HEAD
INLET & EXHAUST VAULVE
TURBO SUPER CHARGER
AFTER COOLING CORE
OVER SPEED TRIP
HOUSING
OIL SLEEVE RING
WATER PUMP
LUBE OIL PUMP
OIL SLEEVE
DRAINE PIPE
FUEL CONTROOLING SHAFT

6. REFERENCE
Internal combustion Engine Fundamentals, Heywood, Tata McGraw Hills.
Internal combustion Engine, V Ganeshan, Tata McGraw Hills.
Internet sources like:
o www.wikipedia.com
o www.railwaylocoengine.com
o www.rdso.indianrailways.gov.in

Contents
1.

INTRODUCTION TO INDIAN RAILWAY....................................................................3

2.

DIESEL LOCOMOTIVE SHED CHARBAGH, LUCKNOW.............................................4

3.

DIESEL ELECTRIC LOCOMOTIVE............................................................................6

4.

CYLINDER HEAD................................................................................................... 8

5.

6.

4.1

INTRODUCTION.............................................................................................. 8

4.2

Common components used in Indian Railway Cylinder Heads.......................9

4.3

Compulsory components to be exchanged in Cylinder Head Section..........10

4.4

Critical parts................................................................................................ 10

4.5

Cylinder Head section working procedure....................................................11

4.6

Testing of Cylinder Head.............................................................................. 12

4.7

New Generation Cylinder Head....................................................................17

VARIOUS OTHER COMPONENTS OF RAIL LOCOMOTIVE......................................18

5.1

TURBO SUPERCHARGER...............................................................................18

5.2

FUEL OIL PUMP............................................................................................. 18

5.3

BOGIE........................................................................................................... 19

5.4

GENERATOR................................................................................................. 20

5.5

Power Pack................................................................................................... 20

REFERENCE........................................................................................................ 23