Technical requirement and test specification of New...

dsoy dk;Zky; iz;ksx gsrq

FOR OFFICIAL USE ONLY

Hkkjr ljdkj

jsy ea=kky;

GOVERNMENT OF INDIA MINISTRY OF RAILWAYS

Technical requirement and test specification of New Generation Water Cooled Air Compressor for HHP Diesel locomotives

Specification No. MP. x.xx.xx.xx (Revision – .00)

July-2017

vuqla/kku vfHkdYi ,oa~~ ekud laxBu y[kuÅ & 226 011

RESEARCH DESIGNS & STANDARDS ORGANISATION MANAK NAGAR, LUCKNOW-226011.

INDEX

S. No. Topic Page 1 Scope 1

2 References. 1

3 Terminology. 1

4 System description (working priciple). 2

5 Design features. 2-5

6 Requirements (Common, Performance, Environmental, Service, Reliability).

5 -7

7 Inspection & testing. 7

8 Category of test: 7-12

Preliminary testing(Continuous improvement, Developmental testing, Relibility Growth Testing , Capability Testing, Relibility Verification testing, Prototype testing and Field Trial/ Testing.

7-12

Quality acceptence / routine test. 12-13

Quality control testing. 13-14

Prototype, Quality assurance and Quality control condition. 14

Additional testing. 14

9 Approval. 14-15

10 Installation & fitment. 15

11 Technical documents and drawings. 15-16

12 Spares and tool kit. 16

13 Maintenace manuals. 16-17

14 Perforamnce & service warranty. 17

15 General conditions for inspection and tests. 17-18

16 Training. 18

17 Technical clarifications. 18

Spec.no. MP-0.xx.00.xx (Rev.00), July’ 2017

1

1.0 Scope 1.1 This specification covers the general system description, design features, standard

technical requirements and schedule of testing & inspection of New Generation reciprocating water-cooled air compressors for HHP diesel electric locomotives on the Indian Railways. These locomotives, which are being manufactured in India consequent to transfer of technology from EMD (USA), were originally provided with Gardner & Denver (USA) compressor model WLNA9BB.).

1.2 This specification also stipulates reliability growth, reliability verification quality assurance and quality acceptance tests for New Generation water-cooled air compressor for HHP diesel locomotives.

1.3 This specification has been prepared for the guidance of locomotive production units and Zonal Railways in procurement of New Generation water-cooled compressor to be fitted on HHP diesel electric locomotive. This is a general technical specification and does not cover all the necessary provisions of contract.

2.0 References 2.1 In preparing this specification, references have been taken from the following

specification and manuals. 2.2 I. S. 10431 - 1994 (Reaffirmed 1999) - Measurement of airflow. 2.3 I.S. 5727 - 1981 (Reaffirmed 2001) - Glossary of terms relating to compressors. 2.4 I.S. 5456-1985 (Reaffirmed 2001) - Code for practice for testing of positive

displacements type air compressor and exhausters. 2.5 ISO-8573 – 2001 (E) - Compressed air for general use. 2.6 EDPS-164 – General Motors Electromotive Division’s engineering design and

performance specification for reciprocating air compressors and air compressors – exhausters (First issued date 12/23/70).

2.7 RDSO specification no. MP.0.0700.14, (Rev-00 June 2007) - specification of water cooled air compressor for diesel electric locomotive.

2.8 Gardner & Denver air compressor operating & service manuals No 13-3-618, 2nd Edition December 2016 and parts list of water-cooled Air compressor, WLNA9CQ (7-7/8 & 5-3/4 x 5), 213-3-511 version 03 December 2016.

2.9 I.E.C. - 61373 –1991-01 – Railway applications – Shock and vibration tests 3.0 Terminology 3.1 The terms and definition given in IS 5727 –1981 (Reaffirmed 2001) ‘Glossary of

terms relating to compressors and exhausters shall generally apply to this specification.

3.2 The other abbreviations used in this specification are as under: 3.2.1 R D S O – Research, Designs, and Standards Organization, Manak Nagar, Lucknow -

226 011. 3.2.2 IS - Indian Standards 3.2.3 I R – Indian Railways 3.2.4 I SO – International Organization for Standardisation. 3.2.5 FAD – Free air delivery 3.2.6 M.R.- Main Reservoir 3.2.7 Definitions of the different terms used in this specification are as under: 3.2.8 Purchaser–President of the Republic of India (acting through Railway Board or

General Manager DLW/ DMW/ Zonal Railway, as the case may be).


2

3.2.9 Inspecting Officer – Person/persons nominated by the purchaser/IR for inspection and testing of compressor.

3.2.10 Vendor – Firm involved in design, manufacturing and supply of water-cooled air compressors conforming to this specification.

4.0 System description (Working principle) 4.1 The air compressor shall compress the available air taken at atmospheric pressure to

the pre-determined gauge pressure i.e 10.0 kg/cm² (approx.140 PSI) and also to maintain the pressure of that compressed air between 8 .0 & 10.0 kg/cm² (approx.120 & 140 PSI) in the main reservoirs of locomotive, to be used for train braking and auxiliary equipment operation

4.2 The air compressor shall be positive displacement, two-stage, water-cooled type. The compressor shall have its own rotary/gear type lube oil pump providing a constant pressurized lubricating system.

4.3 This compressor shall have two low-pressure cylinders and one high-pressure cylinder. The low-pressure cylinders are to be set at an angle of 60º to its vertical line of high-pressure cylinder. All the pistons are reciprocated through their individual connecting rods. The connecting rods are oscillated on a common crankshaft, which is directly driven by diesel engine of locomotive through a steel shaft/ coupling arrangement.

4.4 As compressor starts, air at atmospheric pressure is drawn through separate intake air filters, one for each LP cylinder. Then through each intake valves into the low-pressure cylinders during the downward stroke of the LP piston travel. As air is compressed on upward stroke, due to pressure difference inside the cylinder and the atmosphere, inlet valve is closed and then compressed air is forcing through the cylinder discharge valve into the intercooler. Filters are not in scope of supply of compressor.

4.5 After passing through the intercooler, compressed air is cooled and enters the high pressure cylinder through intake valve and is again compressed in high pressure cylinder and comes out through discharge valve and connecting pipe for storing the compressed air in the main reservoirs up to 10.0 kg/cm².

4.6 When MR pressure reaches the pre-determined value of 10.0 kg/cm2, the compressor magnet valve control (MV-CC) provides a pilot signal of compressed air pressure to each suction valve unloader assembly. This pilot signal actuates a piston in each of the concentric valve clamps that in turn restrains the suction valve plates by holding them in the open position. This then allows the intake air to escape through each of the cylinder assembly inlets, resulting in the elimination of process air compression.

4.7 When MR pressure falls below the predetermined value of 8.0 kg/cm², the compressor magnet valve control (MV-CC) cuts out compressed air from MR and closes the intake valve for normal loading of the compressor and storing of compressed air to MR between 8.0 to 10.0 kg/cm².

4.8 The inter cooler contains passages for engine cooling water and compressed air to remove heat from compressed air, making the air more dense and improving its efficiency.

5.0 Design features


3

5.1 The air compressor shall be positive displacement, two - stage, water - cooled reciprocating W-type of compact and light weight design, yet it should be able to withstand the service conditions encountered in stationary and running condition of locomotives. The pressure ratio shall be approximately equal during first and second stage of compression of air.

5.2 The compressor shall be directly driven by the locomotive diesel engine and must be

capable of being run satisfactorily over a speed range of 200 - 1100 rpm. The drive to compressor shall be from the front (accessory) end of diesel engine directly from engine crankshaft through a drive shaft and flexible coupling or compressor clutch. Opposite end of crankshaft will be free and referred as non-drive/driven end.

5.3 Compressor suction and discharge valves shall have liberal air flow passages to avoid airflow restrictions and to prevent excessive heating and choking of ports with carbon deposits due to thermal decomposition of lubricating oil. The Low Pressure Valves are to be a concentric type, where the Suction / Discharge Valve Seats, including all mechanical valve components are to be common to one assembly. The concentric type valve is to be centrally located within the cylinder head, and have a clamp that facilitates the retainment of the valve assembly as well as provide directional flow of the process air. The valve function (suction / discharge) are to be separated by a seal at the valve clamp. The valve clamp design shall be such that to minimize thermal transfer occurring between the discharge to the suction side of the valve. The valve clamp shall also incorporate the mechanism for facilitating the valve / compressor unloading action. See Section5.10 for details of unloader system.

Similar to the Low Pressure Valve, the High Pressure Valve is to be a concentric type, where the Suction / Discharge Valve Seats, including all mechanical valve components are to be common to one assembly. The concentric type valve is to be centrally located within the cylinder-head, and have a clamp that facilitates the retainment of the valve assembly as well as provide directional flow of the process air. The valve function (suction / discharge) are to be separated by a seal at the valve clamp. The valve clamp design shall be such that to minimize thermal transfer occurring between the discharge to the suction side of the valve. The valve clamp shall also incorporate the mechanism for facilitating the valve / compressor unloading action, as well as providing a lifting boss for facilitating lifting the compressor assembly. See Section 5.10 for details of unloader system.

5.4 Suitable crankcase breather valve shall be provided to vent the piston ring blow-by air from the compressor crankcase. While operating, the breather should preferably maintain the crankcase volume at a negative pressure.

5.5 Mounting bolts and valve clamp bolts shall be properly torque to avoid loosening during normal compressor operation.

5.6 If aluminium alloy is used for threaded connections (in aluminium portion) for fastening of components, suitable helical steel inserts shall be used to avoid frequent wear and tear of thread.

5.7 Accessories, if any shall be attached securely to compressor crankcase.

5.8 Water cooled intercooler and their circuitry system shall have adequate thermal capacity with large heat dissipating area and shall be of robust design between the two pressure stages of compression. The inter-cooler system is to be designed to minimize compressor profile, reduce compressor assembly weight. It shall be a welded plate construction, and oriented to minimize fouling due to cooling system contaminant.


4

In addition, the inter-cooling system shall provide ports for inter-stage pressure measurement, over-pressure protection (safety valve) and condensate drainage. The condensate drain valve shall be at the lowest point downstream of the heat exchanger, and be pilot activated whenever the unloading piping system is pressurized. Inter-stage drain valve discharge size and location shall be located on the compressor outline drawing. The safety valve should lift at a static pressure between 4.6-4.8 kg/cm². The arrangement for the cooling piping system and loading unloading piping system shall be such that it does not fail during the service of the locomotives due to vibration.

5.9 A proven compact design of water jacketed cylinder, water jacketed cylinder head and water pipe circuitry system shall be used to sustain the flow of an adequate amount of cooling water at various speeds of locomotive engine. A proven compact design of water jacketed cylinder with integral water jacketed cylinder head may also be considered. The cooling water received from radiator shall cool the different components of the compressor (cylinders, cylinder-heads, inter-stage process / compressed air, etc. where by compressed air passes).

5.10 The compressor shall have inbuilt un-loader arrangement with the combined concentric suction & discharge valve to load and unload the compressor at 8.0/10.0 kg/cm² of main reservoir air pressure. Each unloader piston assembly shall be designed to minimize maintenance and provide service life to the valve reconditioning point. Each concentric valve clamp shall provide a centralized ¼ inch NPT pilot connection point to be used by the locomotive designer as desired. Connection points shall be identified on the outline drawing.

5.11 General arrangement of air compressor to be designed in such a way that it remains in horizontal position and not in tilted position while lifting the whole compressor assembly. Centre of gravity should pass through the center line of the crankshaft and HP cylinder head. Threaded lifting hole should also be provided at C.G of the compressor arrangement.

5.12 The lubricating oil and lubrication system: 5.12.1 The crankcase shall have provision for easy cleaning/draining of lubricating oil. At

least one drain plug in the bottom shall be provided to remove the ferrous particle from the lube oil.

5.12.2 Lubricating oil system- Forced feed lubrication system of reliable and proven design comprising of rotary/gear type positive displacement type of lube oil pump shall be provided. The system shall have fool proof lube oil level (maximum, minimum & working) and pressure indicator & relief valve.

5.12.3 Lubricant must be premium quality of low detergent reciprocating compressor oil made from a well refined stable base oil to which oxidation and rust inhibitor and anti additive is added. Recommended brand of lubricating oil is SAE-30 /IOC SERVO-100 RR.

5.12.4 Maximum weight (dry) –775 kg (excluding air suction filters, and drive coupling) 5.13 Maximum space –

Space Length along locomotive

Width across the locomotive

Height

Maximum envelop dimension for compressor general arrangement

675 ± 5 mm 1368 ± 5 mm 1065 ± 5 mm


5

5.13.1 Mounting and interfacing dimensions should be suitable for HHP diesel locomotive and should also conform to RDSO drawing SK.DP NO.-3842, (annexure –I).

5.14 Vibrations and shocks - The compressor shall be designed to withstand vibrations and shocks encountered in locomotive operation as per international specification IEC- 61373, category- I class A.

OR The compressor shall be designed to withstand vibrations and shocks encountered in locomotive operation as per acceptable band for displacement and velocity for vibration testing at different places of compressor i.e. ten locations designated as A, B, etc. in both ascending as per graphs given in annexure - XI of this specification.

6 Requirements

6.1 Common: 6.1.1 The compressor must be capable of being driven by diesel engine over a speed of

200-1100 rpm and maximum service speed of 950 rpm.

6.1.2 Duty cycle - The compressors are subjected to run for 22 hours a day. The compressor must be able to give satisfactory performance at 100 % load of 10 kg/cm² (approx. 142 PSI).

6.1.3 Loading / unloading - The compressor should be loaded at 8.00 ±0.1 kg/cm² (approximately 114 PSI) and get unloaded at 10.0 ± 0.1 kg/cm² (approximately 140 PSI). The compressed air system Pressure relief valve set at 10.7 ± 0.1 kg/cm² (approximately 152 PSI) to safeguard the main reservoir of locomotive and compressor if loading/unloading mechanism fails.

6.1.4 Operation in multiple locomotive - The signal from main reservoir signal transducer (MRPT), MR pressure is sent to EM2000. If pressure of main reservoirs are below approximately 9.1 kg/cm² (130 PSI) in lead, approximately 9.5 kg/cm² (135 PSI) in trail loco, EM 2000 drop out MVCC (Magnet valve compressor control) activate the compressor, when MR pressure reads 9.8 kg/cm² (approx 140 PSI) in lead 10.2 kg/cm² (approx 145 PSI) in trail EM 2000 will shut off the output signal for compressor synchronisation.

6.1.5 Pouring point of lube oil should not be below the anticipated minimum crankcase temperature i.e. -5º C.

6.1.6 Cooling of compressor - The compressor shall be provided with the cooling water received from radiator of locomotives during running of engine at following conditions.

a) Minimum water flow-amount of cooling water flow will be of 68 lit/min (approximately 15 GPM) to 122 lit/min (approx. 27 GPM) at 950 rpm in compressor system.

b) Minimum water flow-amount of cooling water flow will be of 18 lit/min (approx. 4 GPM) at 200 rpm in compressor system.

6.2 Performance: 6.2.1 FAD should not less be less than 5677 LPM and 990 LPM at maximum speed of 950

rpm and idle speed 200 rpm of drive of compressor respectively. FAD of compressor at different speeds should conform to graph placed at annexure-II.


6

6.2.2 Discharge compressed air temperature at HP outlet may be allowed up to 200 degree centigrade maximum.

6.2.3 Quality of compressed air shall be 4-4 at outlet of air compressor as per ISO specification No. 8573-1 second edition.

6.2.4 Minimum lubricating oil pressure of 1.1 kg/cm² (approximately 15 PSI) at 200 rpm. It should be maintained between 1.8 and 3.5 kg/cm² (approx. 25 and 50 PSI) at maximum service speed of 950 rpm. Lube oil consumption should not be more than 2.2 ml/hour

6.2.5 Power consumption should conform to following table and graph placed at annexure-III.

Sr. No.

Speed, rpm

Loaded/Unloaded condition Minimum consumable

Horse Power, HP (indicative)

Maximum consumable

Horse Power, HP

1 200 Unloaded condition 1.8 2.2 2 200 Loaded condition(140PSI disch) 10 22 3 950 Unloaded condition 10 23 4 950 Loaded condition(140PSI disch) 58 70

6.3 Environmental: 6.3.1 The compressor shall be capable of working satisfactorily under the service

conditions indicated below. Altitude - An altitude between 0 and 1000 meters above mean sea level. Relative Humidity - Up to 100 % in rainy season. Temperature (Ambient air) -5 to 80 deg C.

6.3.2 Ambient conditions - The compressor externally shall be capable of operating efficiently in spite of dust, dirt, mist, torrential rain, salt taken in coastal area, heavy sand or snow storms, presence of oil vapours and radiant heat etc. to which rolling stock is normally exposed in service.

6.3.3 The ambient temperature around the compressor and inlet air temperature to the air filters can vary between -5º C and 70º C with a maximum of 80º C for approximately 9 minutes

6.4 Service: 6.4.1 An oil level-indicating device should be provided to show the working, maximum and

minimum level of oil clearly. Oil top up and refill period should be of 92 days and 6 months of operation under duty cycle and environmental conditions given in this specification.

6.4.2 Oil filter – An efficient oil filter is to be provided to assure compressor service life. Cleaning period of oil filter strainer (primary) / element (secondary if provided, spin on filter) should be minimum six months within service.

6.4.3 Lubricating oil should conform to SAE-30 / IOC SERVO-100 RR approved as lubricant for this compressor.

6.4.4 Reconditioning of Valves and Unloader Assemblies – Cleaning / de-carbonization of valves should occur every 6 years. Actual date is to align with normal railroad maintenance schedule. Replacement of breather valve will be every 3 years.


7

6.4.5 Overhauling Period – Overhauling period of the complete compressor shall be after Nine years of service. It means that the compressor should work satisfactory in the field without failure/dismantling of any component except reconditioning of valves & unloaders, changing of air and oil filters and top-up & change of lubricating oil.

6.4.6 Complete overhaul means removal of compressor from locomotive, disassembly of complete compressor, inspection and re-conditioning of worn components, replacement of consumed components, re-assembly & testing of compressor.

6.5 Reliability: 6.5.1 Air compressor shall be designed as per IR spec for reliability of 99.4 %. This

assumes that constant failure rate of compressor is 0.3 % per year.

6.5.2 Above criteria shall imply for an understanding of minimum level of reliability of compressor. Therefore it is used to guide in choice of material, design of components and assembly of air compressor, quality control testing level, service life and endurance testing and maintainability.

6.5.3 A failure is defined as failed item/items for which it must be removed for its repair or replacement. This does not include item/items for normal servicing.

6.5.4 Failure Mode and effect analysis (FMEA) will be conducted for new design or major changes in existing design.

6.5.5 FMEA is to be identified all possible failure modes of the components determine the effect of those failure modes on locomotives and assign the possibilities of occurrence related to design and manufacturing based on past information in similar applications.

6.5.6 FMEA assures that the design is thoroughly analysed and failure modes are quantified before proposal to prototype testing.

7 Inspection and testing 7.1 The objectives of these tests and inspection are to ascertain the reliability,

performance potential and quality requirement of the complete compressor in respect to different category of tests.

7.2 Testing shall be in accordance with IS 5456:1985 unless otherwise specified in this specification.

7.3 Whenever new design compressor is developed within mounting dimensions stated in RDSO drawing No. SK.DP-3842. At least 03 new units shall be assembled/manufactured and subjected to series of testing as reliability growth test to establish the 99.4 % reliability and performance and quality of the compressor.

7.4 Whenever a major change in same existing design of compressor is developed within mounting dimensions stated in RDSO drawing No. SK.DP-3842. At least 03 units shall be assembled/manufactured and subjected to series of testing as reliability growth test to establish the 99.4 % reliability, performance and quality of the compressor.

8 Category of tests 8.1 Preliminary testing- The vendor shall carry out the following tests at locomotive

operating conditions mentioned as given in this specification at his works under design development.


8

8.1.1 Continuous improvement - The vendor should be engaged in a continuous test program designed to improve the reliability, performance, maintainability and cost of this compressors and its wearing components/maintenance kit.

8.1.2 Developmental testing – The vendor shall develop test programs (subject to approval from RDSO) in order to meet the reliability goals of 99.4 % for the compressor. It is supplier’s own responsibility to develop the test programs in consultation with RDSO and test the compressors at the locomotive conditions mentioned are given in this specification.

8.1.2.1 Minimum testing data to be collected by vendor and submitted to RDSO before the starting of proto-type testing of compressor by the testing authority. • Displacement and FAD in LPM at both the speeds of 200 and 950 rpm. • Lube oil consumption, ml/per hour • Lube oil temperature in deg. C • Inlet air temperatures at suction filters, LP & HP cylinders, intercooler • Outlet air temperatures at LP & HP cylinders, after cooler if used • Power consumption at both the speeds for loading and unloading condition

8.1.3 Reliability Growth Testing (RGT) – The purpose of RGT is to find out design flaws before a design reaches the purchaser. RGT should be carried out on compressor to stress their weak links in the operating conditions. Failures are expected in this test phase and corrections may be required in design to check the failures by supplier at their own end before starting the prototype test by inspecting officer.

8.1.3.1 For new compressor designs: 8.1.3.1.1 Minimum of 3 compressors are to be run for 3000 hours each. 8.1.3.1.2 Manufacturer to develop a test sequence/programme in consultation with RDSO

for operating the compressors at all relevant conditions as given in this specification and test data has to be collected as in development testing and submitted to RDSO for approval of proto type testing.

8.1.3.1.3 All the three compressors to be tested at same testing conditions as in prototype testing mentioned in clause 8.4.

8.1.3.1.4 All the three compressors are to be tested for the same length of time and start simultaneously.

8.1.3.1.5 All the data obtained should be submitted to RDSO for approval before the starting prototype testing by inspector.

8.1.3.2 For major changes in existing design: 8.1.3.1.1 Minimum of 3 compressors run for 1500 hours simultaneously. 8.1.3.1.2 Manufacturer to develop a test sequence/programme in consultation with RDSO

for operating the compressors at locomotive conditions given in this specification and test data has to be collected as in development testing.

8.1.3.1.3 All the three compressors to be tested at same testing conditions as in prototype testing mentioned in clause 8.4.

8.1.3.1.4 All the three compressors to be tested for the same length of time and start simultaneously.

8.1.3.1.5 All the data obtained should be submitted to RDSO for their consent before the starting prototype testing by inspector.

8.1.3.2 Failures (during RGT testing) - All the failures occurred in must be fully documented and submitted to RDSO. Time to failure Cause of failure


9

Corrective action taken

8.1.4 Capability Testing 8.1.4.1 In addition to the tests conducted in RGT, the vendor should also subject to run the

compressor to adverse condition or overload at speed of 1100 and other conditions outlined in clause 5.2 of this specification.

8.1.4.2 Testing procedure and collection of data should be followed as directed in development testing as per clause 8.1.2.1.

8.1.5 Reliability Verification Testing (RVT) -This test is to be carried out when failure

are not occurred in RGT carried out at supplier’s own premises. RVT may not start until all failure modes found during RGT have been addressed and corrective actions taken.

8.1.5.1 Prototype testing 8.1.5.1.1 The inspector will inspect and carry out prototype testing on 03 compressors to

verify its performance and reliability and quality claimed by the vendor. 8.1.5.1.2 The inspecting officer will adapt any means or methods for inspection and testing

of compressor to verify the performance and reliability and quality and fitment on locomotive. All the testing shall be carried out at the vendor’s premises and government approved laboratory.

8.1.5.1.3 The prototype testing shall constitute the following test parameters and values obtained/measured in this testing should conform as per graphs, sketches and drawings and also the values mentioned in different clauses of this specification or otherwise. Dimensional measurement of components and overall compressor.

8.1.5.1.3.2 Weight measurement of valves and valve plugs for determining the carbon deposit

8.1.5.1.3.3 Mechanical tests as per clause 8.1.5.1.4 of this specification. 8.1.5.1.3.4 Capacity (FAD) test at 200, 600, 950 and 1000 rpm 0, 8.0 and 10.0 kg/cm² gauge

pressure (as per IS-10431 on test rig placed at annexure-V) as per clause 6.2.1 & 8.1.5.1.5 of this specification and graph at annexure – II.

8.1.5.1.3.5 Power consumption at 200, 600, 950 and 1000 rpm for compressor loaded and unloaded conditions i.e. zero and 10.0 kg/cm2 gauge pressure as per clause 6.2.5 of this specification and graph at annexure - III.

8.1.5.1.3.6 Volumetric efficiency 8.1.5.1.3.7 Lube oil consumption in ml/hour 8.1.5.1.3.8 Orifice tests as per graph at annexure –IV and 8.1.5.1.7 of this specification. 8.1.5.1.3.9 Testing of loading and unloading mechanism at speed of 200 and 950 rpm (Cut-

in and cut-out pressure of main reservoir) to fulfil the requirement as per clause 6.1.3 of this specification.

8.1.5.1.3.10 Charging time test at speed of 200, 600, 950, 1000 and 1100 rpm up to gauge pressure of 10.0 kg/cm² for main reservoir and per clause 8.1.5.1.8 of this specification.

8.1.5.1.3.11 Endurance test/continuous running at 10 kg/cm² of 3000 hours without stop as per clause 8.1.5.1.9.

8.1.5.1.3.12 High Environmental/temperature test at (80º C) for 48 hours as per clause 8.1.5.1.10.

8.1.5.1.3.13 Vibration testing as per clause 5.14 of this specification.


10

8.1.5.1.3.14 Water leak test as per clause 8.1.5.1.6 of this specification 8.1.5.1.3.15 Quality of compressed air as per clause 8.1.5.1.12 of this specification. 8.1.5.1.3.16 Quality of lube oil as per clause 6.4.3 and 8.1.5.1.11 of this specification. 8.1.5.1.3.17 Weight measurement of complete compressor excluding air suction filter as per

clause 5.12.4 of this specification. 8.1.5.1.4 Mechanical tests are intended to ascertain the reliability of the compressor and its

accessories. Before starting prototype testing, performance of all the assemblies/sub-assemblies / parts of compressor and its accessories shall be checked for their adequacy. All the mechanical parts shall also be checked for proper functioning in their individual assembled condition and as a whole of compressor. The duration of various stages of mechanical tests is given in table-1 below.

TABLE-1 S. No. Operation Speed in

rpm Period in hrs

1. Mechanical tests a) Run the compressor as indicated below i) Against the atmospheric pressure (check for

undue heating, crankcase and joints leakages) 200 to 300 2

ii) Slowly increase the pressure to 10.0 kg/cm² 200 to 300 2 b) Increase speed to max. service speed 950 rpm

and adjust pressure to 0 kg/cm² 950 2

c) Increase speed to max. and adjust pressure to 10.0 kg/cm² (approximately 140 PSI)

950 2

8.1.5.1.5 Capacity (FAD) testing/Air flow measurement shall be carried out in accordance

with I.S specification No.-10431-1994 and a test rig as per RDSO drawing No. SKDP 3841 as per Annexure –V). The readings will be recorded in proforma given (as per Annexure – VI).

8.1.5.1.6 It should be ensured that there should be no leakage of water and air through any joint in water circuit system of compressor. For this test, the cooling water is feed at static pressure of 75 PSI and check for leakage.

8.1.5.1.7 For the orifice testing, fit the plate of 1.5875 mm (1/16’’) thickness having an orifice dia of 7.14 mm in the orifice holder. Close the globe valves on nozzle side. Run the compressor at four speeds levels between 200 to 1000 rpm. When the pressure stabilises in the reservoir, observe and record the readings at speeds of 200, 600, 950 and 1000 rpm.

8.1.5.1.8 The compressor shall be subjected FAD, power consumption, volumetric efficiency and charging time test. Reading of the testing parameters will be recorded in given proforma at per annexure VI.

8.1.5.1.9 Endurance test- After completing all the tests except high temperature and vibration Test mentioned in clause 8.1.4.1.3.12 and 8.1.4.1.3.13 drain & re-fill the 03 no of water-cooled air compressors with pouring of calculated amount of lubricating oil. Run one compressor for 3000 hours at 10.0 kg/cm² with stop at every 500 hours for dismantling for evaluation of wear trend & lube oil consumption as per testing conditions mentioned in clause 8.4 of this specification and load/time cycles given in tables 2 & 3 below. Two more compressors shall also run 3000 hours continuously at 10.0 kg/cm² pressure and 950 rpm without


11

interruption with one hour at 10% overload condition (i.e 11.0 kg/cm² & 950 rpm) at interval of 10 hours normal loading, uniformly distributed over span of 3000 hours. Readings of parameters such as temperatures, pressures water flow rate etc. shall be recorded in pro-forma given at annexure - VII at interval of two hour for the first ten readings and at interval of 5 hrs there after at every speed. After running of 3000 hours, drain the compressors and calculate the lube oil consumption for all the three compressors. Normally interruptions are not allowed, however for some interruption condition please refer at annexure – X. All the compressors shall start simultaneously at same altitude.

TABLE-2 (First cycle comprising from 0 to 1500 hrs) Notch

position Compressor speed

rpm % of 1500

hrs Running

hours Time interval

(hrs) Idle 200 8 % 120 0-120

1 269 8 % 120 120-240 2 343 8 % 120 240-360 3 490 8 % 120 360-480 4 568 8 % 120 480-600 5 651 8 % 120 600-720 6 729 8 % 120 720-840 8 820 8 % 120 840-960 9 900 8 % 120 960-1080 10 950 28 % 420 1080-1500

TABLE-3 (Second cycle comprising from 1500 to 3000 hrs)

Notch position

Compressor speed rpm

% of 1500 hrs

Running hours

Time interval (hrs)

Idle 200 8 % 120 1500-1620 1 269 8 % 120 1620-1740 2 343 8 % 120 1740-1860 3 490 8 % 120 1860-1980 4 568 8 % 120 1980-2100 5 651 8 % 120 2100-2220 6 729 8 % 120 2220-2340 8 820 8 % 120 2340-2460 9 900 8 % 120 2460-2580 10 950 28 % 420 2580-3000

8.1.5.1.10 High temperature test- After completing all the tests excluding vibration test

mentioned in clause 8.1.5.1.3.13 of this specification, run the air compressor for 48 hours by putting it into an enclosure of high temperature about 80 deg. C at 10.0 kg/cm² pressure and maximum rated speed of 950 rpm. The air compressor will be run for 8 hours and stopped for 30 minutes for cooling off at prevailing atmospheric conditions at 80 deg. C. Such six running cycles shall be performed. During this test, readings shall be recorded in pro-forma given at annexure – VIII.

8.1.5.1.11 Samples of new and used lube oils, drawn from sump after completion of endurance and high environmental test, shall be subjected to following tests.

1. Physical – chemical characteristics. 2. Elemental analysis for additives (new oil only)


12

3. Spectrographic analysis (of used oil) for all elements including additives.

8.1.5.1.12 Sample of compressed air should be collected and tested its quality/purity for solid particle, humidity and total oil (aerosol, liquid and vapour) as per ISO specification Nos ISO 8573-4, 8573-3 and 8573-2 respectively. The quality of compressed air shall confirm to ISO: 8573-1, 4 - 4 in accordance with ISO specifications No.- 8573-1:2001(E), where A, B and C, refer to class of solid, water and oil respectively.

8.1.5.1.13 Capacity (FAD), power consumption, volumetric efficiency, orifice and charging time tests will be carried out before and after endurance test and high temperature test.

8.1.5.1.14 Before and after the tests mentioned in clause 8.1.5.1.13 and 8.1.5.1.3.12 of this specification, weight of each valve assembly shall be recorded to determine the amount of carbon deposits on valve parts and valve plugs.

8.1.5.1.15 After completion of all the testings, when the performances are conforming satisfactory within standards given in this specification, the compressor will cleared for fitment and vibration testing by inspecting officer.

8.1.5.1.16 After installation of compressor on HHP diesel locomotives under manufacturing and testing at DLW, the vibration measurement will be carried out as per international specification No. IEC-61373 and clause 5.14 of this specification.

OR Vibration measurement will be carried out as per acceptable band for displacement and velocity for vibration testing at different places of compressor (placed at annexure-XI of this specification).

8.1.5.2 Field Trial / Testing 8.1.5.2.1 On satisfactory completion of prototype tests, at least 10 nos of compressor shall

be subjected to field tests/services/trials for a minimum period 24 months or more as decided by purchaser / RDSO. During the field trial period following parameters will be monitored.

Lube oil consumption Valve overhauling period Maintaining of main reservoir pressure Maintenance schedule conforming to prescribed schedules of respective of locomotive.

8.1.5.2.2 Any assembly / component including wearing/consumable items which fails during field trial shall be replaced free of cost by the vendor. Design improvement of failed items should be considered if found necessary.

8.1.5.2.3 All the compressors in this test shall have put on service in the field under supervision of inspecting officer and some compressors may be dis-assembled for inspection and dimensional measurements for wear of the components to conclude the particular design on the basis of field monitoring.

8.2 Quality acceptance / routine tests: 8.2.1 Each and every compressor will be tested for following tests to ascertain its

performance, quality and reliability before accepted by the purchaser. The vendor shall also submit a copy of routine test report of each and every compressor in approved proforma by inspecting officer to RDSO/MP.


13

8.2.2 Results of performance parameters should be submitted to purchaser along with dispatch of each and every compressor.

8.2.3 The quality acceptance testing shall constitute the following test parameters and results obtained/measured in this testing should be conformed as per graphs, sketches and drawings and also the values mentioned in different clauses of this specification or otherwise.

8.2.3.1 Dimensional measurement of G.A. of compressor.

8.2.3.2 Capacity (FAD) test at 200 and 950 rpm 10.0 kg/cm² gauge pressure (as per IS-10431on test rig placed at annexure-V) as per clause 6.2.1 of this specification and graph at annexure –II.

8.2.3.3 Power consumption at 200 and 950 rpm for compressor unloaded and loaded conditions i.e. zero and 10.0 kg/cm2 gauge pressure as per clause 6.2.5 of this specification and graph at annexure -III.

8.2.3.4 Volumetric efficiency at 200 and 950 for 0 and 10.0 kg/cm² gauge pressure

8.2.3.5 Orifice tests at speed of 200, and 950 rpm as per graph at annexure –IV

8.2.3.6 Continuous running / endurance testing of 8 hours at 10 kg/cm² and 200 and 950 rpm respectively (4 hours at each speed). Internal testing will be carried out by vendor for 4 hours and witness by inspecting by purchaser by 4 hours.

8.2.3.7 Water leak test as per clause 8.1.4.1.6

8.3 Quality control testing 8.3.1 One or two percent of each and every supply of compressors should be selected at

random for this testing, if quantity exists more than 50 nos.

8.3.2 Testing conditions and procedures should be followed as in prototype testing as clause 8.1.5.1.

8.3.3 The quality control testing shall constitute the following test parameters. Values obtained/measured in this testing should conform as per graphs, sketches and drawings and the also values mentioned in different clauses of this specification or otherwise measured during the testing.

8.3.3.1 Dimensional measurement of various wearing components and overall compressor. 8.3.3.2 Mechanical tests. 8.3.3.3 Capacity (FAD) test at 200, 600, 950 and 1000 rpm 0, 8.0, 10.0 kg/cm² gauge

pressure (as per I.S.-10431 on test rig placed at annexure-V) as per clause 6.2.1 of this specification and graph at annexure-II.

8.3.3.4 Power consumption at 200, 600, 950 and 1000 rpm for compressor loaded and unloaded conditions i.e zero and 10.0 kg/cm2 gauge pressure as per clause 6.2.5 of this specification and graph at annexure no.-III.

8.3.3.5 Volumetric efficiency. 8.3.3.6 Lube oil consumption in ml/hour. 8.3.3.7 Orifice tests at speed of 200, 600, 950 and 1000 rpm as per graph at annexure-IV and

8.1.5.1.7 of this specification. 8.3.3.8 Testing of loading and unloading mechanism at speed of 200 and 950 rpm as per

clause 6.1.3 of this specification (Cut-in and cut-out pressure of main reservoir). 8.3.3.9 Charging time test at speed of 200, 600, 950, 1000 and 1100 rpm up to gauge

pressure of 10.0 kg/cm².


14

8.3.3.10 Continuous running at 10.0 kg/cm² and speed of 950 for 100 hours without stop with 10% over loading at 11.0 kg/cm2 for one hour at interval of 10 hours.

8.3.3.11 Water leak test as per clause 8.1.5.1.6 of this specification. 8.3.4 The duration of various stages of mechanical tests is given as per table-1 of this

specification.

8.4 Prototype, Quality assurance and Quality control condition 8.4.1 Water flow of 122 LPM and 18 LPM min. at maximum and minimum service speed

respectively. At other speeds, water flow should be adjusted accordingly. Temperature of water should be maintained within 80± (-12° C).

8.4.2 Lubricating oil temperature of 60°C minimum. 8.4.3 Lube oil pressure of 1.1 kg/cm² minimum at 200 rpm and 1.8 kg/cm² to 3.5 kg/cm² at

maximum service speed of 950 rpm. 8.4.4 Discharge compressed air temperature from compressor may be allowed up to 205° C

max. 8.4.5 Load cycle and time in endurance testing as per clause 8.1.5.1.9 of this specification. 8.4.6 Load cycle and time in high temperature endurance testing as per clause 8.1.5.1.10.

8.5 Additional Testing 8.5.1 Vendor should submit all the test certificate to inspecting officer at time of prototype

testing for the following components and inspecting officer will examine all the test certificate of these sub assemblies.

8.5.1.1 Lube oil pump. 8.5.1.2 Unloading device 8.5.1.3 Oil pressure relief valve 8.5.1.4 Intercooler 8.5.1.5 After cooler if used 8.5.1.6 Oil strainer/spin on filter element if provided. 8.5.1.7 Safety valve 8.5.1.8 Cylinders 8.5.1.9 Crankcase 8.5.1.10 Crankshaft 8.5.1.11 Connecting rods 8.5.1.12 Oil seal 8.5.2 Testing being carried out for components mentioned in clause 8.5.1 should be

submitted before starting prototype testing to inspecting officer.

9 Approval 9.1 After completion of all the tests mentioned in RGT and prototype testing excluding

vibration testing and extended field trial, the compressor will be disassembled, cleaned for wearing components detailed below. These following components will be finally inspected visually for scratches on wearing surfaces to determine their conditions, wear trends after testings and extended field trial to reach on conclusion of the particular design or improvement in design.

Lube oil pump Cylinders Crankshaft Connecting rods Oil seals Gasket joints “O” ring joints


15

Valves for carbon deposit Pistons Piston rings Wrist pin bearings/bushes Crankshaft main bearings Cylinders

9.2 Analysis of a worn component will be carried out onthe basis of performance, carbon deposit lube oil consumption etc. The vendor will have to re-assemble in to a new unit, and the same compressor will then be provisionally cleared by inspecting officer for vibration test.

9.3 On the basis of vibration results being within acceptable limits, the inspecting officer will clear some appropriate nos. of compressor for extended field trial.

9.4 On the basis of satisfactory performance in the field, final approval of design of water-cooled air compressor will be considered when field trial has been successfully completed.

10.0 Installation and fitment 10.1 After completion of all the tests mentioned in clause 8.1.5.1.3 of this specification

except vibration testing and performance values within acceptable limit mentioned in this specification, the compressor will cleared for fitment and vibration testing by inspecting officer.

10.2 Installation and fitment of prototype water-cooled air compressor on HHP diesel electric locomotive, shall be the responsibility of vendor under supervision of inspecting officer and purchaser. Vibration measurement shall be carried out by inspecting officer at DLW (in case vibration testing is not done as per IEC–61373 category-I class A).

10.3 The vendor shall supply adequate no. of instructions bulletin and installation procedure at least two months before the dispatch of the equipment to purchaser in consultation with inspecting officer.

11.0 Technical Documents and Drawings 11.1 The vendor shall apply for supply of water cooled compressor along with the offer

and two copies of general arrangement drawing of complete compressor layout/arrangement, operating instructions, maintenance instructions, spare parts catalogue, and trouble shooting instructions and testing instructions of the complete assembly. The vendor shall also submit drawings for individual assembly and sub assembly. The drawing of compressor arrangement should have following minimum information.

11.1.1 Locating dimensions and type of mounting hole as per RDSO drawing no. SKDP-3842 (annexure-I)

11.1.2 Locating dimensions and type of mounting holes for external air filters and loading and unloading device.

11.1.3 Locating dimensions, and type of mounting hole for external oil pressure gauge. 11.1.4 Locating dimensions, and type of mounting hole for oil strainer. 11.1.5 Axis height and length of crank-shaft and crankpin and key fitment details. 11.1.6 Water inlet and outlet details. 11.1.7 Height of crankcase at which hp cylinder fitted. 11.1.8 Height of cylinder and heads.


16

11.1.9 Up to date drawings of whole compressors and serviceable parts.

11.2 The vendor shall provide up to date performance data of compressor and graphs to inspecting officer for all compressors including this compressor supplied to their customers. This data includes.

11.2.1 Loaded horsepower Vs – RPM. 11.2.2 Unloaded horsepower Vs – RPM. 11.2.3 Displacement volume Vs – RPM 11.2.4 FAD Vs – RPM. 11.2.5 Lube oil temperature Vs – RPM. 11.2.6 Oil consumption in compressor unit of (ml/hour). 11.2.7 Torque effect Vs – crank angle.

11.3 Offer should include the requirement of spares for a period of 09 years. The quotation for spares shall indicate the cost of individual components, assembly and sub-assemblies etc.

11.4 Technical data and detail of water-cooled air compressor to purchaser and inspecting officer before submission of proposal for development in prescribed pro-forma of this specification at annexure-IX.

11.5 The vendor shall indicate the maintenance schedule of various parts/ components to keep the compressor in proper working condition / service on locomotive.

11.6 The vendor shall indicate the periods after which the components of the water-cooled air compressor must be make serviceable and complete overhauled. These information’s should be certified by customers in support documents.

11.7 The vendor shall indicate details of marketing/manufacturing arrangements, if any, with other firms in India and abroad. The vendor shall also indicate the indigenous item and detailed programme for indigenous manufacture giving lists of specific items and their prices.

11.8 The vendor shall indicate particulars of maintenance facilities, which he recommends, for being set up in diesel sheds/POH shops.

12.0 Spares and Tool Kit 12.1 Along with the quotation for supply of the water-cooled air compressor the vendor

shall also furnish recommended list of spares for the intervals specified above. The vendor shall also agree to hold the price of spares for a period of one year from date of the supply of the compressors.

12.2 For every 20 compressor units or part thereof, one complete set of tool kit shall be supplied.

12.3 The price for tool kit, when procured independent of the order, shall be indicated for information along with the quotations for the compressor.

13.0 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 in pro-forma at annexure -IX.

13.1.1 Description, general arrangement and mounting dimensions. 13.1.2 Detailed dimensional drawings indicating mounting arrangement layout, sub

assemblies.


17

13.1.3 Technical data. 13.1.4 Manual shall contain information pertaining to working principal of operation of

compressor. 13.1.5 Details of special tools if required, parts catalogue and testing procedure of the

equipment being supplied. 13.1.6 Updated position of modifications will also be incorporated. 13.1.7 Periodical maintenance schedules and instructions. 13.1.8 Testing procedure for the equipment and auxiliaries mentioned as in clause 10.7 of

this specification. 13.1.9 Wear limits and life of wearing components. 13.1.10 Clearance data for fitment and running of wearing component. 13.1.11 Instructions for reclamation of worn out components. 13.1.12 List of instructions for use special tools. 13.1.13 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 compressor.

14.0 Performance and Service warranty 14.1 The vendor should give in writing for guarantee of Nine years minimum for the

satisfactory service/ working of water-cooled air compressor without failure of any assembly/component except valves/components which are to be attended during reconditioning at minimum Six years.

14.2 However, any assembly/component except consumable/wearing items which fails during guarantee/warranty period shall be replaced free of cost by the supplier. The replaced components shall be under a further warranty for same time as mentioned above from the date of their commissioning.

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

14.4 The vendor should collect the failed components 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 component if some flaws have been found during failure mode investigation.

15.0 General conditions for inspection and tests

15.1 The tests shall be carried out at vendor premises and government approved laboratories as directed by inspecting agency.

15.2 Labour and appliances required to the inspecting officer shall be provided by vendor for inspection and testing of the whole unit and its components, if required. The appliances include erection of suitable test stand and provision of a variable speed motor with multiple speed gearbox or suitable pulley ratios to drive the compressor at any speed. The speed range of the drive shall be 200 – 1100 rpm.

15.3 Stand by power supply shall be provided by the vendor to ensure the endurance test are not interrupted due to failure of electrical power supply. The circumstances and


18

limits of permitted interruptions are indicated in annexure – X. An hour meter shall be connected between the drive motor and the supply to record the actual hours of run.

15.4 The inspecting officer shall have right to adopt any means to satisfy himself that all the proper materials and parts specified are actually used during the manufacturing of the compressors.

15.5 The vendor shall have to make available the detailed drawings of components for inspection purposes, and also furnish the condemning limits for wearing components.

15.6 The inspecting officer shall have to access, at all reasonable items for stage inspection, to those portions of the vendor’s works in which the production of compressor or its components is being carried out and where the testing take place. This also applies to items procured from their sub- vendors.

15.7 Should have any part of the compressor unit require alteration or any defect appears, during prototype and other tests, the vendor shall change without any extra charge, make such alteration or rectify the defects to the satisfaction of the inspecting officer. Inspecting officer may be subjected to tests if considered necessary.

15.8 If the performance results obtained during the tests are found unsatisfactory the vendor may carryout minor modifications to enable unit to satisfy the requirements, at his own cost, within a period mutually agreed between the inspecting officer and the vendor.

15.9 Any modifications or alterations to the components during regular supply of compressor shall be made only after the approval of RDSO/MP. The compressor after such modifications or alterations may be subjected to performance tests if, considered necessary.

16.0 Training

16.1 Training of purchaser’s personnel for operation and maintenance of compressor shall be given by the vendor free-of-charge. Demonstration of the working of the compressor on locomotive shall be given by the vendor free-of-charge.

17.0 Technical clarifications 17.1 Any other technical clarifications with regard to this specification may be obtained

from Director General (Motive Power), RDSO, Manak Nagar, Lucknow -226 011

Annexure -I

GRAPH OF SPEED Vs FREE AIR DELIVERY ANNEXURE-II

Page 1 of 1

5677

990

0

500

1000

1500

2000

2500

3000

3500

4000

4500

5000

5500

6000

150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000

Compressor speed in rpm

Free

air

deliv

ery

in lp

m

ANNEXURE.III

75

70

65

60

55

50(Lr5ouoE=p oooo

ItuotL

30

25

20

15

10

5

0

Compressorspeed in RpM

70

tM* lir"it<-Max. limit

**-Min. timit \

7

58,

[/lin li' nit:ive)(indical

J

22

10

150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 loOO

GRAPH OF POWER CONSUMPTTON (UNLOADED COND|TION) page 1 of 2

ANNEXURE-III

23

<-HP (max)

--o*HP (min)

Ma x lim

1\

v

10

{

\Z.z

/f-"-T--

*rl--T-

1.8

(LI.=EoEf@cooLq)

=o(L

150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 9501000Compressor speed in rpm

3RAPH OF POWER CONSUMPTION (LOADED CONDITION) Page 2 of 2

GRAPH OF ORIFICE TEST ANNEXURE - IV

1.17

3.20

4.26

5.35

7.46

9.44

1.78

7.46

8.52

2.13

9

6.39

10.65

8.52

6.25

5.11

4.05

9.59

2.98

10.12

0

1

2

3

4

5

6

7

8

9

10

11

200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 950 1000

Compressor speed in rpm

Res

ervo

ir pr

essu

re in

kg/

cm2

Passing limit

Condeming limit

Annexure -V

Spec.no.-MP-0.xx.00.xx (Rev.00), July’20107

Annexure - VI

PRO-FORMA FOR (FAD) CAPACITY TESTING

Compressor model: Altitude: Compressor no: Date: Sheet no.:-

S. No.

Parameter Measuring equipment

Units used

Date and time

1. Barometric pressure Barometer mm of hg 2. Air outlet pressure P2 Gauge Kg/cm² 3. Dry bulb temp (LP1/LP2 inlet air temp) Thermometer º C 4. Wet bulb temp (LP1/LP2 inlet air temp) Thermometer º C 5. Compressor speed (RPM) Digital

tachometer rpm

6. Water flow rate Flow meter LPM 7. Nozzle inlet pressure (H2O) P3 Manometer mm 8. Nozzle outlet pressure (H2O) P4 Manometer mm 9. Nozzle air temp T3 Thermometer º C 10. Actual free air delivery Calculation LPM 11. Free air delivery corrected to ------ RPM Calculation lpM 12. Volumetric efficiency Calculation % 13. Energy input to motor for 10 minutes Energy meter kwh 14. Power (motor input) Calculation HP 15. Water outlet temp (finally at HP cylinder) Thermometer/CH º C 16. LP1outlet temp (left side cylinder viewed from

non drive end) / inter cooler inlet temp Thermometer/CH º C

17. LP2 outlet / inter cooler inlet air temp Thermometer/CH º C 18. HP inlet / intercooler outlet air temp Thermometer/CH º C 19. HP outlet air temp Thermometer/CH º C 20. Water inlet temp (LP1/LP2/HP/intercooler) Thermometer/CH º C 21. Lube oil pressure Gauge Kg/cm²

Any remarks if any:-


Annexure -VII

PRO-FORMA FOR ENDURANCE TESTING Compressor model: Altitude: Compressor no: Date: Sheet no.:-

S. No.


Units used

Date and time

1. Hour meter reading Hour meter hrs 2. Atmospheric pressure Manometer mm of Hg 3. Air outlet pressure Pressure gauge kg/cm² 4. Ambient temp Thermometer º C 5. Compressor speed (LPM) Digital

tachometer LPM

6. Water flow rate Flow meter LPM 7. Water tube temp Thermometer º C 8. Suction air temp (LP1) Thermometer º C 9. Suction air temp (LP2) Thermometer º C 10. LP1outlet temp (left side cylinder viewed from

non drive end) / inter cooler inlet air temp Thermometer º C

11. LP2 outlet / inter cooler air inlet temp Thermometer º C 12. HP inlet / intercooler air outlet temp Thermometer º C 13. HP outlet air temp Thermometer º C 14. Water inlet temp (LP1/LP2/HP/intercooler) Thermometer º C 15. Water outlet temp (finally at HP cylinder) Thermometer º C 16. LP1 cylinder water temp Thermometer º C 17. Lube oil temp Thermometer º C 18. Lube oil pressure Pressure gauge kg/cm² 19. Inter cooler air pressure Pressure gauge kg/cm² 20. LP1 cylinder head temp / Valve temp Laser

thermometer º C

21. LP2 cylinder head temp / Valve temp Laser thermometer

º C

22. HP cylinder head temp / Valve temp Laser thermometer

º C

23. Power (for 10 minutes) once in day Energy meter Kwh Any remarks if any:-


Annexure -VIII

PRO-FORMA FOR HIGH TEMPERATURE TESTING

Compressor model: Altitude: Compressor no: Date: Sheet no.:-

S. No.


Units used

Date and time

1. Hour meter reading Hour meter hrs 2. Atmospheric pressure Manometer mm of Hg 3. Air outlet pressure Pressure gauge kg/cm² 4. Ambient temp (inside enclosure) Thermometer º C 5. Compressor speed (RPM) Digital

tachometer RPM

6. Water flow rate Flow meter LPM 7. Water tube temp Thermometer º C 8. Suction air temp (LP1) Thermometer º C 9. Suction air temp (LP2) Thermometer º C 10. LP1outlet temp (left side cylinder viewed from

non drive end) / inter cooler inlet air temp Thermometer º C

11. LP2 outlet / inter cooler air inlet temp Thermometer º C 12. HP inlet / intercooler air outlet temp Thermometer º C 13. HP outlet air temp Thermometer º C 14. Water inlet temp (LP1/LP2/HP/intercooler) Thermometer º C 15. Water outlet temp (finally at HP cylinder) Thermometer º C 16. LP1 cylinder water temp Thermometer º C 17. Lube oil temp Thermometer º C 18. Lube oil pressure Pressure gauge kg/cm² 19. Inter cooler air pressure Pressure gauge kg/cm² 20. LP1 cylinder head temp / Valve temp Laser

thermometer º C

21. LP2 cylinder head temp / Valve temp Laser thermometer

º C

22. HP cylinder head temp / Valve temp Laser thermometer

º C

23. Power (for 10 minutes) once in day Energy meter Kwh Any remarks if any:-


Annexure - IX

General Technical data of Water Cooled air compressor

01 Type Reciprocating ‘W’ type, water cooled and forced feed lubrication

02 Normal working pressure 10.0 Kg/cm² 140 PSI approximately

03 Free air delivery at 200 rpm at 950 rpm

Not less than 35 CFM (990 LPM) 200.5 CFM (5677 LPM)

04 Displacement volume per revolution 7.96 litres 05 Direction of rotation Clockwise viewed from non drive end 06 Rated speed 950 RPM 07 Speed range 200 to 1100 RPM 08 Compression stages 02 nos. 09

Low pressure cylinders, nos. Bore dia Total height Heads height

02 200.025 mm (7.87”) 289±0.05 mm 156+0.1, -0.0 mm

10

High pressure cylinder, nos. Bore Dia Height Heads height

01 146.025 mm (5.748”) 273±0.05 mm 156+0.1, -0.0 mm

11 Piston stroke length 127 mm (5”) 12 Type & nos. of piston rings (On both LP

& HP) 01 No. -Taper compression ring 01 No. - Nose scraper ring 02 Nos. - Cross bevelled oil control ring

13 Ring gap (both LP and HP) 0.2 – 0.45 mm 14 Crank shaft, crank pin, dia

Crank pin length Bearing seat dia

92.02 – 92.049 mm 114.5+0.1, -0.0 mm 85.725+0.076, + 0.051 mm

15 Low pressure piston, skirt dia Total height Hole for gudgeon pin dia

199.77-199.82 mm 168.5±0.05 mm 44.45 – 44.46 mm

16 High pressure piston, skirt dia Total height Hole for gudgeon pin dia

145.80 -145.825 mm 140.5±0.25 mm 44.45 – 44.46 mm

17 Eccentric dia for pump plunger (if provided)

106.929 / 106.964 mm

18 Centre distance between big end to small end for connecting rod

350+0, -0.1 mm

19 Power consumption at rated speed of 950 RPM

63.33±10 % HP

20 Crankcase oil capacity Minimum 6 litres Maximum 11.2 litres

21 Lube oil pressure at 200 rpm at 950 rpm

0.7 Kg/cm² minimum 1.76 – 4 kg/cm2

22 Intercooler safety valve set pressure 4.6 – 4.8 kg/cm² 23 Envelope dimension (L X B X H) 675±5 mm X 1368±5 mm X 1060±5 mm 24 Net Weight (Dry) Maximum 775 Kg


Annexure - X

General conditions of endurance test

Endurance test is a continuous test and shall be carried out by running the compressor with compressor delivery pressure at 10.0 Kg/cm² running at load cycle maximum rated speed. The test shall be of 3000 hours duration. Normally, no interruptions are permitted during the testing, except under following circumstances:-

1. Interruptions are permitted if any adjustment is required to be carried out during the course of testing, which warrants stopping of compressor or drive motor. Under these circumstances, the period of interruptions should not exceed 3 minutes. The aggregate total of such interruptions should be totalled at the end the period of endurance testing prolonged by this aggregate amount.

2. During endurance test, maximum of 8 interruptions shall be tolerated when they

are required for attending defects in the equipments but in such case more than 20 minutes shall not be allowed to lapse between the interruptions and restart. In all such cases consent of RDSO or its representative should be obtained before recommencing the test. The aggregate total of such interruptions should be totalled at the end and the period of endurance testing prolonged by this aggregate amount. In case of more than 8 interruptions, the endurance testing should be done afresh.

If endurance testing is interrupted for reasons unconnected with compressor such as due to defect in drive motor and coupling, the test should be started within 24 hours, after the interruption will be allowed and in case the testing is interrupted by more than one interruption, RDSO or its representatives shall decide whether endurance test must be recommended from beginning or merely prolonged for the period equal to that of interruption. In case of such interruption should be entered in the column provided immediately after data prior to interruption.

Max. displacement in microns at position A (crank case bottom) in ascending speed of compressor

Acceptable vibration band Annexure - XI A1

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0.035

0.040

0.045

0.050

0.055

0.060

Notch positions

Dis

pale

men

t in

mic

orns

(Mean+STDEVP)comp1 2,3,

(Mean-STDEVP)comp1,2,3

(Mean+STDEVP) comp1 2,3, 0.026 0.028 0.039 0.024 0.022 0.024 0.027 0.043 0.058(Mean-STDEVP) comp1,2,3 0.012 0.011 0.015 0.014 0.018 0.016 0.020 0.027 0.024

0 1 2 3 4 5 6 7 8

Max. displacement in microns at position B (Non drive end cover) in ascending speed of compressor

Acceptable vibration band Annexure - XI B1

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0.035

0.040

0.045

0.050

0.055

0.060

Notch positions

Dis

pale

men

t in

mic

orns




0 1 2 3 4 5 6 7 8

Max. displacement in microns at position C (LP cylinder view from non drive end) in ascending speed of compressor

Acceptable vibration band Annexure - XI C1

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0.035

0.040

0.045

0.050

0.055

0.060

Notch positions

Dis

pale

men

t in

mic

orns

(Mean+STDEVP) comp1 2,3,



0 1 2 3 4 5 6 7 8

Max. dispalcement in microns at position D (LP cylinder right head view from non drive end) in ascending speed of compressor

Acceptable vibration band Annexure - XI D1

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0.035

0.040

0.045

0.050

0.055

0.060

Notch positions

Dis

pale

men

t in

mic

orns




0 1 2 3 4 5 6 7 8

Max. displacement in microns at positions E (HP cylinder head) in ascending speed of compressor

Acceptable vibration band Annexure - XI E1

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0.035

0.040

0.045

0.050

0.055

0.060

Notch positions

Dis

pale

men

t in

mic

orns




0 1 2 3 4 5 6 7 8

Max. displacement in microns at position F (inter cooler) in ascending speed of compressor

Acceptable vibration band Annexure - XI F1

0.000

0.100

0.200

0.300

0.400

0.500

0.600

0.700

0.800

0.900

Notch positions

Dis

pale

cem

ents

in m

icro

ns




0 1 2 3 4 5 6 7 8

Max. displacement in microns at position G (right LP manifold to inter cooler view from drive end) in ascending speed of compressor

Acceptable vibration band Annxeure - XI G1

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0.035

0.040

0.045

0.050

0.055

0.060

Notch positions

Dis

pale

men

t in

mic

orns




0 1 2 3 4 5 6 7 8

Max. displacement in microns at position H (HP manifold to inter cooler) in ascending speed of compressor

Acceptable vibration band Annexure - XI H1

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0.035

0.040

0.045

0.050

0.055

0.060

Notch positionsDis

pale

men

t in

mic

orns




0 1 2 3 4 5 6 7 8

Max. displacement in microns at position I (water pipe left LP to HP) in ascending speed of compressor

Acceptable vibration band Annexure - XI I1

0.000

0.050

0.100

0.150

0.200

0.250

0.300

0.350

Notch positions

Dis

pale

cem

ents

in m

icro

ns




0 1 2 3 4 5 6 7 8

Max. displacement in microns at position J (unloader pipe left side view from non drive end) in ascending speed of compressor

Acceptable vibration band Annexure - XI J1

0.000

0.200

0.400

0.600

0.800

1.000

1.200

1.400

1.600

1.800

2.000

Notch positions

Dis

pale

cem

ents

in m

icro

ns




0 1 2 3 4 5 6 7 8

Max. displacement in microns at position A (crank case bottom) in decending speed of compressor

Acceptable vibration band Annexure - XI A2

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0.035

0.040

0.045

0.050

0.055

0.060

Notch positions

Dis

pale

men

t in

mic

orns



(Mean+STDEVP) comp1 2,3, 0.019 0.023 0.022 0.026 0.023 0.042 0.058(Mean-STDEVP) comp1,2,3 0.011 0.014 0.014 0.018 0.019 0.025 0.024

2 3 4 5 6 7 8

Max. displacement in microns at position B (Non drive end cover) in descending speed of compressor

Acceptable vibration band Annexure - XI B2

0.000

0.050

0.100

0.150

0.200

0.250

0.300

Notch positionsDis

pale

men

t in

mic

orns




2 3 4 5 6 7 8

Max. displacement in microns at position C (LP cylinder view from non drive end) in descending speed of compressor

Acceptable vibration band Annexure - XI C2

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0.035

0.040

0.045

0.050

0.055

0.060

Notch positions

Dis

pale

men

t in

mic

orns




2 3 4 5 6 7 8

Max. dispalement in microns at position D (LP cylinder right head view from non drive end) in descending speed of compressor

Acceptable vibration band Annexure - XI D2

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0.035

0.040

0.045

0.050

0.055

0.060

Notch positions

Dis

pale

men

t in

mic

orns




2 3 4 5 6 7 8

Max. displacement in microns at position E (HP cylinder head) in descending speed of compressor

Accepatble vibration band Annexure - XI E2

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0.035

0.040

0.045

0.050

0.055

0.060

Notch positions

Dis

pale

men

t in

mic

orns




2 3 4 5 6 7 8

Max. dispalcement in microns at position F (inter cooler) in descending speed of compressor

Acceptable vibration band Annexure - XI F2

0.000

0.100

0.200

0.300

0.400

0.500

0.600

0.700

0.800

0.900

Notch positions

Dis

pale

cem

ents

in m

icro

ns




2 3 4 5 6 7 8

Max. dispalcement in microns at position G (right manifold to inter cooler view from drive end) in descending speed of compressor

Acceptable vibration band Annexure - XI G2

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0.035

0.040

0.045

0.050

0.055

0.060

Notch positions

Dis

pale

men

t in

mic

orns




2 3 4 5 6 7 8

Max. displacement in microns at position H (HP manifold to inter cooler) in descending speed of compressor

Acceptable vibration band Annexure- XI H2

0.000

0.005

0.010

0.015

0.020

0.025

0.030

0.035

0.040

0.045

0.050

0.055

0.060

Notch positionsDis

pale

men

t in

mic

orns




2 3 4 5 6 7 8

Max. displacement in microns at position I (water pipe left LP to HP) in descending speed of compressor

Acceptable vibration band Annexure - XI I2

0.000

0.050

0.100

0.150

0.200

0.250

0.300

0.350

Notch positions

Dis

pale

cem

ents

in m

icro

ns




2 3 4 5 6 7 8

Max. dispalcement in microns at position J (Unloader pipe left side view from non drive end) in descending speed of compressor

Acceptable vibration band Annexure- XI J2

0.000

0.200

0.400

0.600

0.800

1.000

1.200

1.400

1.600

1.800

2.000

Notch positions

Dis

pale

cem

ents

in m

icro

ns




2 3 4 5 6 7 8

Technical requirement and test specification of New...

Documents

Transcript of Technical requirement and test specification of New...