hyd damper

8/18/2019 Hyd Damper

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R.D.S.O

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GOVERNMENT OF INDIAMINISTRY OF RAILWAYS

TECHNICAL REQUIREMENTS

FOR

HYDRAULIC DAMPERS

OF

WDG4 & WDP4 LOCOMOTIVES

No. MP.0.40.99.03

(Revision - 01)


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R.D.S.O

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GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

TECHNICAL REQUIREMENTS

FOR

HYDRAULIC DAMPERS

OF

WDG4 & WDP4 LOCOMOTIVES

No. MP.0.40.99.03

(Revision - 01)

December 2007


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Technical Requirements for Hydraulic Dampers of WDG4 & WDP4 Locomotives

CONTENTS

Sr. No. Description Page No.

1 Scope 1

2 Definitions 1

3 Deviation(s) 1

4 Drawings 1

5 Minimum General Requirements of the Firm 1

6 Damper Performance Description 2

7 Test Results 6

8 Guarantee / Warranty 6

9 General 6

10 General Inspection 6

11 Training and Infrastructural Facilities 7

12 Marking 7

13 Packing 7

14 Field Trials 7

Appendix - I Quality Assurance & Guarantee Certificate i

Enclosure RDSO Drawing No. SK.VL - 484 -


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TECHNICAL REQUIREMENTS FOR HYDRAULIC DAMPERS

OFWDG4 & WDP4 LOCOMOTIVES

1. SCOPE

1.1 This document covers the technical requirements relating to design and performancecharacteristics for lateral, vertical & yaw hydraulic dampers for use in WDG4 & WDP4

locomotive bogies. However, this it does not include all the necessary provisions requiredfor a supply contract.

1.2 The document covers the supply of damping unit with end fittings /mountings as anassembly termed as hydraulic dampers.

2. DEFINITIONS

i. Overall damping characteristic shall, for all type of Hydraulic Dampers, refer to the

damping forces and corresponding relative velocities between the attachment points of theHydraulic Damper to the vehicle.

ii. Hydraulic Damper Temperature shall refer to the temperature of the oil in the HydraulicDampers. For measurement purpose, the temperature of the outside surface of bottomside of the main body of the Hydraulic Damper shall be taken.

iii. Compressed length between the mounting eyes i.e. center-to-center distance (in case ofstem/ eye type) or mounting faces (in case of stem-type) of a Hydraulic Damper when it is

compressed to the maximum of stroke.iv. Extended length between the mounting eyes i.e., center to center distance (in case of

stem/ eye type) or mounting faces (in case of stem type) of a Hydraulic Damper when it ispulled out to the maximum of stroke.

v. Stroke is the difference between the extended length and the compressed length (effectivemaximum travel of the Hydraulic Damper).

vi. Wherever “Inspecting Agency” has been mentioned in this document, it shall be taken as

“Authorised Inspecting Agency” mentioned in the purchase order.

3. DEVIATION(s)

If deviations from original design, dimensions, etc. are desired by the tenderer, specific proposalswith reasons shall be submitted to the purchaser. Commencement of manufacture shall not bed till th h t l th i ti f t f th d i ti ( )


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5.3 The firm shall have a system of easy traceability of the product from raw material stage tofinished product stage. Stamped Identification marking with serial number of HydraulicDamper should be used for this purpose.

5.4 The firm shall have a Quality Assurance Plan (QAP) for the product detailing variousmanufacturing aspects. The QAP shall include the following:

.1 Organization chart

.2 Process flow chart

.3 Stage Inspection details

.4 Record of finished product

.5 Policy of disposal of rejected product

.6 Identification Marking

5.5 The firm shall maintain a record of implementation of QAP for documentary evidence.

5.6 Firm shall have a Quality Manual indicating the extent of control over production.

5.7 The firm shall have a system of documentation in respect of rejection at customer end,warranty replacement and failure of items supplied by them during service.

5.8 Calibration of the Testing / Measuring Equipments should be done at least once in a yearunless stated otherwise.

5.9 The firm shall have a system of recording the plant, machinery and control equipmentsremaining out of service, nature of repairs done etc.

5.10 Training needs for all personnel shall be identified & organized by the firm on regular basis.

The Inspection staff conducting testing shall be adequately qualified, trained & havingadequate experience.

6. DAMPER PERFORMANCE DESCRIPTION

6.1 OPERATIONAL REQUIREMENTS

6.1.1 Service Condit ions

.1 Service Interval The service interval of the damper, the maximum admissible percentdeterioration of damping characteristics at the end of service interval incomparison to the nominal damping characteristic and the maximum admissiblerate of failure shall be as follows:


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.2 Operational Environment Conditions

The damper shall be resistant to the following operating environmental

conditions to which it may be exposed during service:

− projection of ballast

− exposure to oil or petroleum

− exposure to organic waste

− Wind, rain, snow, cold dust, sand storms

− sand, brake and ferric oxide dust (abrasion of wheels, brake blocks and

tracks)− saline spray

− washing plant agent (both acids and alkalis)

− 100% humidity

.3 Operating Temperatures ( To,min - To,max )

The damper is required to function safely at minimum operating temperature To,min and maximum operating temperature To, max as follows:

Sl. Conditions Requirements

1. Minimum Operating Temperature To, min - 20º C

2. Maximum Operating Temperature To, max + 70º C

After operating to these extremes, the damper shall be required to fully recover

its functionality. Furthermore, the damper shall not display any fluid leaks andany signs of failure or cracking in the damper components.

6.1.2 Storage Temperatures ( Ts,min - Ts,max )

The damper shall withstand the following temperature range during transport orstorage:

Sl. Conditions Requirements

1. Minimum temperature to withstand during transportor storage Ts, min

- 20º C

2. Maximum temperature to withstand duringtransport or storage Ts max

+ 70º C


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6.2 PHYSICAL REQUIREMENTS

6.2.1 Strength

The construction of Hydraulic Damper shall be such as to withstand the staticcompressive axial load of 3 tonnes when fully closed and a tensile load of 3 tonneswhen fully extended respectively without any failure, damage or permanent change indamping characteristic or reduction in service interval.

6.2.2 Dimensional Parameters

Various dimensional parameters of the damper shall be as per RDSO Drawing No.

SK.VL - 484 or recommended EMD’s/ OEM's drawing(s).

6.2.3 Adjustability

The damper capacity shall be adjustable and the adjustment shall be easy to perform. Itshall be clearly indicated if any special tools and devices are required. The maintenanceinstructions for the damper shall cover the procedure to perform such adjustments.

6.2.4 Surface Protection

All the parts of the damper in contact with the ambient air shall be protected fromcorrosion. The protection can be ensured either by the nature of materials used or bysuitable painting / surface treatments.

The following requirements for the damper painting and other anti-corrosion surfaceprotections (in particular, the stem surface treatment or plating) shall be maintained:

Painting Parameters Requirements

Colour: RAL number RAL 7012

Minimum dry film thickness according to ISO 2808 ≥ 120 μ

Adhesion ISO 2409 or EN 24624

Gloss to ISO 2813 (Angle of incidence: 60°) < 5 %

Rubber parts shall not be painted. Otherwise, the Supplier has to produce test resultsor return from service experience data demonstrating that painting process doesn’talter rubber mechanical characteristics for the whole damper service life.

6.2.5 Damper Oil

The details of damper oil including type, viscosity and amount of the damper oil shall beprovided by the supplier


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6.3. FUNCTIONAL REQUIREMENTS

6.3.1 Orientation

The range of various damper angular positions during fitment and operation shall be asper RDSO Drawing No. SK.VL- 484 or recommended EMD’s/ OEM's drawing(s).

6.3.2 Overall Damping Characterist ics

The overall damping forces on the compression and extension strokes of the damper,taken separately, shall be within the following tolerances at dampers temperature range

of 20 ± 2 ºC inclusive:

Damper Capacity (N at 0.1 m/sec)Hydraulic DamperType

Loco TypeCompression Extension

Primary (Vertical) WDG4 & WDP4 5600 ± 20% 5600 ± 20%

Secondary (Yaw) WDG4 12200 ± 20% 12200 ± 20%

Secondary (Yaw) WDP4 6000 ± 20% 6000 ± 20%

The Hydraulic Damper shall be assembled in such a manner that the damping shallbe uniform throughout the stroke i.e the damping characteristics shall not have anysudden deviation or changes throughout the stroke.

The stipulated tolerances and requirements shall apply at all points within the requiredworking stroke of the Hydraulic Damper.

6.3.3 Force - Displacement Characteristic

The Force - Displacement characteristic is the variation in damper Force as a functionof damper displacement under harmonic motion of established strokes and frequenciesdepending on the type of application. Moreover, it is also referred to a given damperlength and operating temperature.


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7. TEST RESULTS

The manufacturer shall submit internal test results in support of various performancecharacteristics as laid down in this document, duly signed by manufacturer or his authorizedrepresentative.

8. GUARANTEE / WARRANTY

The manufacturer shall furnish a guarantee that each new Hydraulic Damper supplied, shallfunction satisfactorily without attention and in accordance with the requirements of this documentfor 10,00,000 kms of service running on a vehicle or for 4 years from the date of fitting to a

vehicle, whichever is earlier. A format of the certificate is given at Appendix - I.

9. GENERAL

9.1 All welded joints of the Hydraulic Damper shall be free from welding defects and shall besufficiently strong to withstand the loads intended.

9.2 The external dimensions & characteristics of the Hydraulic Dampers shall not be altered bythe manufacturer without the prior written consent of RDSO. Unless otherwise specified inthe respective drawing, the tolerance in compressed and extended length of all types of

Hydraulic Dampers shall be within ± 3mm of the specified dimension.

9.3 After suitable pretreatment, Hydraulic Damper shall be painted with primer under coat andfinishing coat. The Hydraulic Dampers shall be painted as specified. Paint must not bepermitted to adhere to the working portion of the piston rods.

9.4 The Hydraulic Damper shall be manufactured, assembled and tested at the manufacturer’s

own works.9.5 Hydraulic Damper found to be defective after delivery within the warranty period will be

returned to the manufacturer for replacement at his own expenses, not withstanding thatthey may have passed the relevant tests and have been accepted by the Inspecting

Agency.

10. GENERAL INSPECTION

10.1 Records of all the materials or fittings used in Hydraulic Dampers shall be scrutinized by theInspecting Authority and shall be to his entire satisfaction.

10.2 The manufacturer shall supply the necessary labour and appliances for testing andinspection of the Hydraulic Dampers, if felt necessary by the inspecting authority.

10.3 The Inspecting Authority shall have right to:


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disposed of in such a manner as the inspecting authority directs. Such rejectedparts shall be replaced by the manufacturer without extra charges.

10.3.5 In the event of a dispute between the inspecting authority and the manufacturer,the decision of RDSO shall be final and binding.

11. TRAINING AND INFRASTRUCTURAL FACILITIES

The manufacturer shall provide the requisite training to the staff of purchaser to use, repair andoverhaul the Hydraulic Dampers. He shall also supply 10 sets of maintenance/instruction manualsfor each order, indicating dimension of critical items and its permissible wear, specification, quantityof oil etc to the user Railways.

12. MARKING

Marking identification plate should be of ‘Aluminium’ and should be fixed by ‘Aluminium’ rivets. TheHydraulic Dampers shall be marked with:

a. Manufacturer’s name or Code

b. Serial No.

c. Type of Damper

d. Rated Capacity

e. Month & Year of manufacture

f. “IR”

g. RDSO drawing No.

In addition to marking plate, the manufacturers name or code, rated capacity, serial number andmonth & year of manufacture shall also be marked in 10 mm height letters by punch mark withminimum depth of 0.25mm on outer surface at bottom side of the damper.

13. PACKING

The manufacturer shall ensure that Hydraulic Dampers are suitably packed in polyethylene coversusing suitable cartons to prevent ingress of foreign matter and damage during handling andstorage.

14. FIELD TRIALS

Before approval in Part II in RDSO vendor directory, the field performance for a period of one yearshall be monitored.


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APPENDIX – I

QUALITY ASSURANCE & GUARANTEE CERTIFICATE

(Reference – Clause 8 of Specification No. MP.0.40.99.03)

No. …………………………….. Dated:………………………….

Railway : ……………………………..

P.O. No. : …………………………….. Dated:………………………….

Quantity : …………………………….. Consignee:……………………Hydraulic Damper Description: ………………………………………………………………………………….

………………………………………………………………………………….

i. THIS IS TO CERTIFY THAT THE HYDRAULIC DAMPERS INDICATED IN THIS PURCHASEORDER HAVE BEEN SUBJECTED TO OUR INSPECTION AND TEST PROCEDURES AND AREFOUND TO CONFORM TO THE ORDER/DRAWING/SPECIFICATION REQUIREMENTS.

ii. THE QUALITY CONTROL PROCEDURES IN RESPECT OF THIS SUPPLY ARE IN ACCORDANCE WITH OUR QUALITY MANUAL AND AS PER APPROVED QUALITY ASSURANCE PLAN.

iii. THIS IS TO CERTIFY THAT EACH HYDRAULIC DAMPER SUPPLIED AGAINST THISPURCHASE ORDER SHALL FUNCTION SATISFACTORILY FOR THE INTENDED

APPLICATION

Dated: Q.C. INCHARGE(SIGNATURE & SEAL OF THE MANUFACTURER)


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