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GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

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Specification for 10"x30"Long Life Lube oil and Fuel oil Filter Elements (Two Piece) for EMD

Locomotives

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SPECIFICATION No. MP.0.2600-26

SEPTEMBER 2009 (REVISION .00)

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RESEARCH DESIGNS & STANDARDS ORGANISATION

MANAK NAGAR, LUCKNOW-226 011

SPECIFICATION FOR 10x30 LONG LIFE LUBE OIL AND FUEL OIL FILTER ELEMENTS (TWO PIECE) FOR EMD LOCOMOTIVES

(DRAWING No. SKDP-3948) 1. Scope

This specification covers a two-stage lube oil and primary fuel oil filter element. The purpose of this element is to remove particulate matter from the fuel oil and engine lube oil prior to delivery to the engine. The filter element must be having useful life of 180 days.

2. General Requirements 2.1 Environmental Fuel Temperatures 2.1.1 Ambient temperature design range is -5C to 55C. 2.1.2 Operating temperature extremes can range from -12C to 77C. 2.1.3 Normal operating temperatures range between 21C and 43C. 2.2 Lube Oil Temperature

2.2.1 Normal lube oil temperatures will range from 0C to 105C. 2.2.2 Under adverse operating conditions the oil temperature can be as high as 149C

in tunnel operation for short periods of time. 2.3 Fluids handled by filter elements

2.3.1 Fuel to IS:1460 is specified for the fuel system. (essentially, ASTM #2 diesel fuel).

2.3.2 Poorer grades of fuel may also be encountered in normal service depending on individual customer specifications, fuel handling techniques, and wayside filtration practices.

2.3.3 The filter must be able to handle water present in the fuel in amounts up to 1%. 2.3.4 Lubricating oil is of the SAE 20W-40 heavy duty additive type. 2.3.5 Oil viscosity can range between 70 and 85 SUS (Saybolt universal seconds) or

12.9 16.8 cs (centistokes) at 99C. 3. Specification and Design 3.1 Filter Specifications

3.1.1 The corrugated filter paper is impregnated with suitable resin on both side and

cured . 3.1.2 Filter paper mean pore size shall be 10-14 microns and maximum pore size 45

microns. 3.1.3 Open area of centre tubes should be 25% minimum.

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3.1.4 All pleats must be stablized by appropriate means to maintain spacing and prevent pleat-to-pleat collapse.

3.1.5 The perforated outer wrapper shall be made from a high density paper with a

minimum bursting strength of 3.5 Kg/cm. It shall be perforated with round/square holes as indicated in drg. No. SKDP- 3948, the area of perforations being between 25 to 30 % 0f the area of the paper. The outer wrapper shall firmly enclose the pleated paper, the ends of the wrapper forming a lap joint of at least 12 mm, suitably bonded together.

3.1.6 The Inner centre tube thickness is 1.02 mm & outer centre tube thickness is 1.5

mm shall be made from cold rolled steel sheet to IS: 513 Grade O. These shall be suitably tin, cadmium or zinc plated on both sides. The joint shall be spot welded with a minimum pitch of 25 mm. The centre tube shall be suitably perforated so as to provide an area of flow around 25-30 % of the unperforated tube area. The centre tube of secondary stage shall be reinforced with 3.5 mm dia (min.) hard drawn steel spring wire to IS : 4454 ( Pt. I ), grade 2.

3.1.7 Alternatively, centre tubes made out of perforated steel tubes of adequate

thickness with spiral grooves may be used without reinforcing spring. 3.1.8 The end caps shall be made from min. 0.7 mm thick steel sheet to IS : 513 Grade

D. All metallic items shall have the same plating material as indicated in clause 3.1.9.

3.1.9 The end caps shall be bonded by a suitable adhesive to the pleated paper. The

bonding material shall fill the end caps to a minimum depth of 5 mm. 3.1.10The bonding material and other material used in construction of the filter shall

neither affect nor be affected by hot engine oil in locomotive service at operating temperatures upto service life of 190 days.

3.1.11Changes to the filter element design or construction that effect performance or life

cannot be made without notifying RDSO of the proposed change and obtaining written authorisation of such changes.

4. Testing 4.1 Efficiency Testing of Filter Paper

4.1.1 Laboratory Method Testing of filter paper is covered in RDSOs test programme No. MP.TP-23. The efficiency of the paper is determined by using graduated imported test dust to ISO 12103 Pt2 standard. The results of the testing are plotted on graph paper as efficiency versus nominal micron size (the midpoint of the micron particle range being tested is used). The micron rating is determined by drawing a curve through the test points, and the rating of the filter paper is the micron size at which the curve crosses the 90% efficiency point.

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4.2 Filter Paper Extrusion Test In some instances it has been determined that filter elements can plug when the

paper media extrudes into the centre tube holes (as opposed to plugging by particulate matter). This situation causes excessive pressure drop across the element and results in short filter life. A test procedure has been developed and is required for checking resistance to extrusion.

4.2.1 Run a flow versus pressure drop curve on the element up to 360 lpm utilising

min.200 ltrs of an engine lubricating oil and additive package, which is approved by RDSO for EMD engines. Commercial designation of these SAE 20W-40 test oil is available on request.

4.2.2 Reduce oil temperature to 70C and add 2 ltrs of water to the 200 ltrs of

lubricating oil. Note: Circulate a portion of the oil-water emulsion through the element for a minimum of 15 minutes taking care to regulate the flow so that the filter pressure drop during this period does not exceed 2.8 kg/cm.

4.2.3 Reduce oil temperature to 32C and increase flow rate through the element until

the pressure drop across the element is 2.8 kg/cm. Operate at 2.8 kg/cm for a minimum of 15 minutes.

4.2.4 Heat oil to 93C and repeat the flow versus pressure drop curve. This curve

should show no more than at 0.14 kg/cm increase in pressure drop at a flow of 360 lpm.

4.2.5 Reduce oil temperature to 32C and increase flow through the element until the

pressure drop is 4.2 kg/cm. Circulate the oil through the element at this condition for a minimum of 15 minutes.

4.2.6 Heat the oil to 93C and repeat the flow versus pressure drop curve. This curve

should show no more than a 0.21 kg/cm increase in pressure drop from the original curve at 360 lpm without water added.

4.2.7 If the element fail to pass this test they can be expected to have filter paper

extrusion problems in field service.

4.3 Performance Requirments

4.3.1 End load Test

A tensile load of 20 kg applied at the end caps of the filter element for 5 minutes shall not cause any damage.

4.3.2 Fabrication Integrity Fabrication integrity of the filter element shall be verified as per test method

described in IS:8383 or ISO:2942. The test fluid for this test shall be clean and filtered HSD oil at room temperature between 15 to 40C. No evidence of

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persistant stream of bubbles shall be visible from the end caps area bonded with adhesive and filter paper area or paper pleat joint, prior to foam coming out from the paper pores. Apply air pressure till the foam starts coming out from the paper.

The foam from filter paper pores shall not come out up to a pressure of 15 cms of

water guage (min.). 4.3.3 High temperature test The filter element shall be soaked in engine oil maintained at a constant

temperature of 1305C for a period of 24 hours. The filter shall be subjected to end load test before it cools down below 70C.

4..3.4 Pressure Drop Vs Flow Rate The filter element Shall be tested for determining its pressure drop Vs. flow rate

characteristics on a standard lubricating oil filter test rig approved by RDSO. The test oil shall be a SAE 20W-40 engine oil of approved brand by RDSO for use on Alco type 251 engines. With clean oil at a temperature of 802C, the pressure drop across the filter element shall not exceeding 0.5 kg/cm for a flow rate of 300 l/ min. The pressure drop Vs. flow rate characteristics shall be determined upto a flow rate of 400 l/ min. , readings being taken both in ascending and descending order of flow.

4.3.5 Filtering Efficiency and Rig Life

The filter shall be subjected to a filtering efficiency and rig life test on the same test

rig as used for pressure drop Vs. Flow rate test using the same test oil. The flow rate shall be maintained at 2705 l/ min. throughout the test. The test dust shall confirm to SAE J726 Fine (Imported).The test dust slurry additions shall be made with 11.96 gms of dust in 50 cc of test oil and added to the sump at intervals 30 minutes. The test shall be continued till a pressure differential of 2.1 kg/cm is built up across the filter element. Rig life shall be the number of additions of contaminant required to build 2.1 kg/cm pressure differential. The commulative filtering efficiency during the test and rig life shall not be less than those indicated below:

.1) Commulative filtering efficiency (min.) - 40% after 4th addition of dust. 65% after 16th addition of dust. 75% after 32th addition of dust. 90% at the end of rig life. .2 Rig life ( min.) 90 addition of test dust.

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5. Procedure for Accepting New Element Sources 5.1 Testing of filter paper using RDSOs test programme No. MP.TP-23 to determine the

efficiency characteristics. 5.2 Filter paper extrusion testing. 5.3 End load,fabrication integrity and high temperature testing.

5.4 Filtering efficiency, rig life test. 5.5 Upon satisfactory completion of the laboratory tests given above, the following field

testing is required for qualification and acceptance. 5.5.1 Field trial shall be conducted with filters manufactured in presence of RDSO

representative. Field test on a minimum of three locomotives for a period of 190 days. The field test would be arranged and conducted by the consignee shed. He would submit timely reports to RDSO summarizing the test results and progress including pressure drop versus time data, filter change-outs versus time, incidents of premature plugging of engine mounted spin-on filters, and maintenance and / or removal records related to fuel system components (primarily injectors). The supplier shall actively associate with the trial shed and persue timely preperation and despatch of reports to RDSO. The field test will consist of monitoring filter pressure drop at a frequency not less than once per month (and just prior to removal whenever possible), and recording service life between change-outs.

5.5.2 At the end of the field test, a report summarizing comparative filter performance, life,

and fuel system related maintenance events shall be submitted by the consignee shed for review and disposition by RDSO as to acceptability.

6. Inspection 6.1 Filter elements will conform to the engineering drawing No. SKDP-3948 or

manufacturers drawing approved by RDSO, in so far as physical details are specified. 6.2 The filter elements shall be free of corrosion or defects which will affect life

performance, or appearance. 6.3 The cured filter paper used in the construction of the element shall be tested for

mean & max pore sizes at an approved laboratory, at the cost of supplier.

6.4 The method of regular inspection and sample size shall be as per given below: The filter elements offered for inspection shall be subjected to 1% check in respect of

visual and dimensonal checks. If filter lot is 1000 & below, then only end load, fabrication integrity & pressure drop v/s

flow rate tests will be carried out. If filter lot is more than1000, then all the tests specified under clause 4 shall be carried

out.

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7. Marking Name of the manufacturer, month and year of manufacture, batch number and serial

number shall be marked on the end caps. 8. Packing

To avoid damage of filters during transit and storage, each filter element shall be separately packed in poly bag and after that filter shall be placed in a pack made out of 5 ply corrugated paper board.

9. Warranty

The supplier shall furnish a warranty that if the service life obtained during normal use on the locomotives is less than 180 days, all filter elements belonging to that particular batch will be replaced by him free of cost.

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