REVISION OF SPECIFICATION Item Name

REVISION OF SPECIFICATION

Item Name:

S.N. Name of

parts/assembly

Part nos. / Vendor

name

RDSO drg no./Spec

no.

Unified PL

No.

1. Piston – Diameter 140

mm

ELGI part no.

00021858C

KPC part no.

0960150250

Spec. No.

MP.0.0700. 03

(Revised July’ 97)

11489157

2. Piston -Diameter 197

mm

ELGI part no.

000112040, KPC part

no. 0950140150

Spec. No.

MP.0.0700. 03

(Revised July’ 97)

11489170

Specification: MP.0.0700. 03 (Final Draft)

1. RDSO is reviewing the specification to cater to the latest technological developments in the field, modify clauses not relevant in the present context and making them more enabling with focus on functional requirements.

2. It is requested that your comments / suggestions with regard to improvements / modifications in

specification of the above mentioned item may be submitted in the following format along with the

justification for the changes required.

Part A: Basic Information

SN Particulars Information

1. Name

2. Designation

3. Professional Qualification

4. Organization / Firm’s Name

5. Address for correspondence

6. Email ID

7. Whether firm is registered with RDSO for the subject item. If yes, details like date of registration, current status etc. If no, firm’s experience in manufacturing of subject item or similar item.

8. Whether any technical document/ Report/ Study to support suggested changes in available/ enclosed for better appreciation.

Part B: Comments / suggestions on the specification

SN Clause No. of RDSO STR/ Spec

Clause, as it exists in RDSO STR/ Spec

Clause, as it should read after incorporation of comments/ suggestions in RDSO Spec / STR

Justification for changes

Comments may be sent to following address within one month from the date of publication on

rdso.indianrailways.gov.in

Jt. Director/ Brake Research Designs and Standards Organization Manak Nagar, Lucknow – 226011

Email: [email protected]

mailto:[email protected]

dsoy dk;Zky; iz;ksx gsrq

FOR OFFICIAL USE ONLY

GOVERNMENT OF INDIA

MINISTRY OF RAILWAYS

TECHNICAL SPECIFICATION OF PISTONS FOR COMPRESSOR AND

EXPRESSOR FOR MAIN LINE DIESEL LOCOMOTIVE

fof'kf"V la[a;k pk-'k- 0.07.00.03 (la'kkss/ku- 02

ekpZ & 2021

Specification no. MP.0.07.00-03

(Revised July’97)

(Rev-02), March 2021

RESEARCH DESIGNS & STANDARDS ORGANISATION

MANAK NAGAR, LUCKNOW-226011.

Specification no. MP.0.0700-03, Rev-0102, July 1997March 2021 2

LIST OF AMENDMENTS

Amendment

Date

Version Revised Para Remarks

March‟ 2021 02 Para 6.1.1, 7.1.1.1,

7.1.2.1, 7.1.3.3,

7.1.3.4 and 7.3.3

Revision of Para‟s to incorporate

Equivalent Indian Standards

Para 9 Addition of Para 9 as per ISO

document no-QM-RF-7.1.3 Ver-2.0

Para 10 Addition of Para no. 10 (Preference

to Make In India) in compliance of

directives issued by GOI for

promotion of Make in India policy.

Para 11 Addition of Para no. 11 (Vendor

Changes in Approved Status) in

compliance to Vigilance cell note

no. 13/Vig/Policy dated

08.09.2016.

Para 12 Addition of Para no. 12, Field trial

Quantity & field trial period are

defined as per MP-M-8.1-1 (Latest)

& Field trial performance feedback

format added in compliance of

MOM of the VC meeting on

Specification/ STRs held on

29.08.2020.

Para 13 Addition of Para no. 13, Maintenance Manuals

Para 14 Addition of Para no. 14, Performance and Service warranty

Para 15 Addition of Para no. 15, Technical clarifications


INDEX

S. No. Topic Page 1. Scope

4

2. Designation

4

3. Dimensions

4

4. Surface finish and treatment

4

5. Weight

4

6. Material Specification

5

7. Inspection and Tests

5-7

8. Marking and Packing

8

9. Quality Assurance Programme

8

10. Preference to make in India

8

11. Vendor changes in approved status

8

12. Field Trial / Testing

8

13. Maintenance Manuals

9

14. Performance and Service warranty

9

15. Technical clarifications

10

TECHNICAL SPECIFICATION OF PISTONS FOR COMPRESSOR AND EXPRESSOR

FOR MAIN LINE DIESEL LOCOMOTIVE


1. SCOPE :

This specification covers the technical requirements and supply conditions for

pistons of following make/type of compressors and expressors used on main line

diesel locomotives of Indian Railways.

Compressors : LG-3CDB, KCW-623 and KCW-523

Expressors : 6CD.4UC, 6CD.3UC and KE-6

2. DESIGNATION : The pistons shall be designated as under:

1. “L.P. Piston”: for low pressure cylinder of compressors, compressor portion of

expressor, and exhauster cylinders of expressor.

2. “H.P. Piston”: for high pressure cylinder of compressor and compressor portion

of expressor.

3. DIMENSIONS :

3.1 Nominal dimensions and tolerances for L.P. and H.P. Pistons shall be as per

drawing Nos. SK.DP. 1889, 1888 and 3445 respectively.

3.2 Dimensions of L.P. Piston skirt at different angles with respect to major axis shall

confirm to drg. No. SK.DP 2042.

3.3 The respective oversize Pistons shall be used. If the cylinders are bored

oversize. Over sizes shall be graduated in steps of 0.25 mm. The first oversize

being 0.25 mm higher than the standard nominal diameter. Dimensions of

standard and over size pistons are indicated in the Piston drgs. mentioned

above.

4. SURFACE FINISH AND TREATMENT :

4.1 The outer surface of the piston shall be finished to surface finish specified in the

drawing for different parts of the piston.

4.2 LP Pistons shall be tin plated to uniform thickness of 0.0025-0.0075 mm on entire

surface except the wrist pin bore.

5. WEIGHT :

Weight of standard Piston (without wrist pin & Piston rings) shall be :

LP Piston (SKDP-1889) – 3.75 – 3.80 Kg

HP Piston (SKDP-1888) – 4.60 – 4.65 Kg

HP Piston (SKDP-3445) – 5.50 – 5.55 Kg

6. MATERIAL SPECIFICATION :


6.1 Materials used for the manufacture of LP and HP Pistons and their mechanical

properties shall be as indicated in Table - 1, below :

Table - 1

S. No. Piston Designation

Material Mechanical Properties

Tensile Strength (min) N/mm2 (Kgf/mm2)

Brinell Hardness (HB)

1. LP Piston Aluminium alloy 4525-px to IS: 617-1975 (with 0.5-1.0 % Ni)(with Nickel 1.0%)

4525 T5 to IS: 617-1994*

215 (21.9) 210 (21.4)

100 - 130

2. HP Piston Grey cast iron Gr. FG-300 to IS: 210-1978

294 (30) 180 - 230

Note: 1 N/mm2 = 0.102 Kgf/mm2

6.2 The micro structure of HP Piston shall show pearlitic matrix with type „A‟ graphite

of size 5 or finer.

7. INSPECTION AND TESTS :

7.1. Tests for chemical composition and mechanical properties:

7.1.1 Chemical analysis:

1. LP Piston: One test for chemical analysis shall be carried out in accordance

with IS: 504-1963 IS: 504 (Parts 1 to12) : 2002 ,** /

Spectrographic Analysis on each lot of 1000 kg or part thereof. For

preparation of samples for chemical analysis, reference may be

made to IS: 1817-1961.***

---------------------------------------------------------------------------------------------------------------------------

* P- Temper designation to IS: 5052-1969. IS 5052:1993(Reaffirmed 2003)

** Method of chemical analysis of aluminium and its alloy. Methods of chemical

analysis of Aluminium and its alloys [ MTD 7 : Light method and their Alloys]

*** Method of sampling of non-ferrous metals for chemical analysis.

2. HP piston: One test for chemical analysis shall be carried out in accordance

with IS: 228-1959 + on each lot of 500 kg or part thereof. The


percentage content of all important elements, particularly carbon,

nickel, sulphar and phosphorus shall be reported.

7.1.2 Tensile test:

.1 LP Piston: Tensile tests for aluminium alloy of LP Piston shall be carried out on

at least one Piston from every batch of Pistons heat treated together to achieve

the required mechanical properties. Test sample shall be taken from the crown

portion of the Piston and tested as per IS: 1816-1979 ++. Test bars ( Ref. IS

1816-1979 ++.) shall be cast separately by pouring the metal at the same time

and from the same ladle as the casting they represent. The Test bars shall be

heat treated to T5 (Ref IS 5052:1993(R 2003)

.2 HP Piston: Tensile test on Grey Iron castings for HP Pistons shall be carried out

in accordance with IS: 2073-1970 +++. On a test bar of 30 mm dia as cast. Test

bars shall be cast. Separately by pouring the metal at the same time and from

the same ladle as the castings they represent. The test bar shall be heat treated

(for stress relieving) simultaneously under the same conditions as the castings.

At least one tensile test shall be made on each lot of 500 kg of castings or part

thereof.

7.1.3 Hardness Test:

.1 For the purpose of these tests at least one Piston shall be selected from

every batch of Pistons heat treated together to achieve the desired

mechanical properties.

.2 The Brinell hardness shall be measured on four equi-spaced points on the

circumference of the Piston as cast and heat treated. The mean of the four

values, thus obtained shall be within the range indicated in Table 1.

.3 Hardness tests on aluminium alloy castings of LP Piston shall be carried out

in accordance with IS: 1500-19832005.*

.4 Hardness test for Grey Iron castings of HP Piston shall be carried out in

accordance with IS: 1500-19832005.*

----------------------------------------------------------------------------------------------------------------

+ Method of chemical analysis of pig iron, cast iron and plain carbon and low alloy

steels.

++ Method of tensile test for light metals and their alloys.

+++ Specification for carbon steel black bars for production of machined parts for

general engineering purposes.

* Method of Brinell hardness test for metallic materials.

7.2 Repeat tests:


7.2.1 If a sample selected fails to meet the requirements of mechanical tests

mentioned in Para 7.1, two further test pieces which represent the same

batch/cast may be selected and tested in the same manner. If both of these test

pieces meet the requirements the material represented thereby shall be

acceptable.

7.2.2 Alternatively, the supplier may reheat treat the batch once only before the two

further samples are selected.

7.3 Tests and inspection for Dimensional accuracies and workmanship

Following inspections shall be carried out on finished Pistons –

7.3.1 Visual examination: All Pistons shall be examined visually for any defects of

material and workmanship. Voids, cracks, cavities or other linear discontinuities

on or under the surface of the Piston body shall be cause for rejection.

7.3.2 Dimensions: All dimensions indicated on drawing Nos. SKDP- 1888, 1889 and

3445 are required to be adhered to. Each Piston shall be subjected to the

following minimum dimensional checks.

.1 Piston Ring Groove: Following dimensional checks on ring grooves shall be

performed at three equi-spaced points on the periphery of the Piston.

Width : The width of each ring groove shall be measured by suitable “Go-No Go”

gauge.

Depth: Depth of the ring grooves shall be measured with suitable depth gauge.

.2 Piston skirt : Diameter of the Piston skirt shall be measured at points indicated on

the respective drawings. Refer SKDP 2042 for detail profile of LP Piston skirt.

.3 Wrist pin housing: The dia of wrist pin housing shall be measured in each boss

along two perpendicular directions, vertical and horizontal.

.4 Wrist pin retaining ring groove: Depth and width of wrist pin retaining ring groove

shall be measured. No variation in these dimensions shall be accepted.

7.3.3 Surface finish: The surface finish of ring grooves the skirt and the wrist pin

housing shall be assessed in accordance with IS:3073-19672006. No machining

marks doents or erosion shall be acceptable on the skirt Piston ring grooves wrist

pin housing and retaining ring grooves.

7.3.4 Surface cracks: Each Piston shall be checked for surface cracks. These cracks

shall be performed by Zyglo testing ultrasonic method and by examination using

magnifying glass over the entire surface (inner and outer) of the Piston including

the head. Particular care shall be exercised when examining the Piston ring


grooves, oil holes, wrist pin bore and supporting ribs and parting lines. Cracks of

any type/size present any where on the Piston shall not be acceptable.

7.3.5 Weight: Each Piston shall be weighted. The weight of the Piston shall be within

the limits specified in clause 5.

8. MARKING AND PACKING

8.1 Identification mark of the manufacturer, batch number and date of manufacture

shall be stamped on each Piston as indicated in drawing No. SKDP-1888, 1889

and 3445.

8.2 Pistons shall be coated with a suitable anti-corrosive sub-stance and packed in

non- Moisture absorbent paper. Each set of Pistons shall then be securely packed

in a suitable carton. Cartons may be further packed in wooden crates, if required.

8.3 The carton containing pistons shall indicate the type of Piston, nominal size/DLW

part number, number of Pistons, batch number, month and year of manufacture

and the manufacturer‟s name and trade mark.

9. QUALITY ASSURANCE PROGRAMME:

9.1 Supplier shall submit their internal quality assurance program in accordance with RDSO ISO procedures.

9.2 Supplier shall, on demand by RDSO/ Purchaser/ Inspecting authority nominated by RDSO/ Purchaser, make the records of checks carried out during internal quality assurance available for scrutiny.

10. PREFERENCE TO MAKE IN INDIA :

The Government of India policy on “make in India” shall apply.

11. VENDOR CHANGES IN APPROVED STATUS:

All the provisions contained RDSO‟s ISO procedures laid down in Document No. QO-D-8.1-11, dated 01.07.2020 (Titled “Vendor- changes in approved status”) and subsequent version/amendment thereof, shall be binding and applicable on the successful vendor/vendors in the contract floated by Railways to maintain of products supplied to Railways.

12. Field Trial / Testing:

12.1. On satisfactory completion of prototype tests, Pistons shall be subjected to field trial. Quantity of Pistons to be subjected to field trial and field trial period shall be as per RDSO document no- MP-M-8.1-1 (Latest).

Field performance feedback format is as under:

S. Shed/ Loco Date of Date of

failure, if

Reason of Remarks


No. Rly. No. fitment any failure

The acceptance criteria of field trial shall be the satisfactory field performance of equipment.

13. Maintenance Manuals

13.1 The vendor shall arrange to supply a copy of maintenance manual covering the following vital details including fully illustrated pictures for all items, to the purchaser and RDSO at the time of submission of tender to purchaser:

13.1.1 Detailed dimensional drawings as per SKDP-2042, 1888, 1889 and 3445.

13.1.2 Technical data.

13.1.3 Manual shall contain information pertaining to working principle of operation of Pistons.

13.1.4 Details of special tools if required, parts catalogue and testing procedure of

the Pistons being supplied.

13.1.5 Updated position of modifications will also be incorporated.

13.1.6 Periodical maintenance schedules and instructions.

13.1.7 Wear limits and life of Pistons.

13.1.8 List of instructions for use special tools.

13.1.9 Trouble shooting – symptoms, causes and remedies.

13.2 Two copies of the maintenance manual shall be supplied with the quotation.

13.3 One copy of the maintenance manual shall be supplied with every Pistons.

14. Performance and Service warranty

14.1 The vendor should give in writing for warranty of 36 months from date of

commissioning or 42 months from date of dispatch which is earlier for the

satisfactory service / working of Pistons without failure.

14.2 However any Pistons fails during warranty period shall be replaced free of cost by the vendor. The replaced Pistons shall be under a further warranty for 36 months from the date of their commissioning.

14.3 If the replaced Pistons also prove unsatisfactory performance in service, they shall be replaced by the modified and improved Pistons by the vendor at their own cost.

14.4 The vendor should collect the failed Piston and study & investigate the failure mode occurred in service and whatever the results found in investigation should be furnished to RDSO.


14.5 Accordingly vendor may re-consider the process of their quality control, design and manufacturing of that Piston if some flaws have been found during failure

mode investigation.

15.0 Technical clarifications

15.1 Any other technical clarifications with regard to this specification may be

obtained from Director General (Motive Power), RDSO, Manak Nagar,

Lucknow -226 011.

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