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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
TECHNICAL REQUIREMENTS
FOR
HYDRAULIC DAMPERS
OF
WDG4 & WDP4 LOCOMOTIVES
No. MP.0.40.99.03
(Revision - 01)
December 2007
R.D.S.O
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
TECHNICAL REQUIREMENTS
FOR
HYDRAULIC DAMPERS
OF
WDG4 & WDP4 LOCOMOTIVES
No. MP.0.40.99.03
(Revision - 01)
December 2007
Prepared By
S.P.Govil
Asstt. Design Engineer (MP)
Checked By
Approved By
Naresh Kumar
Director (MP/VDG)
S.Mani
Executive Director(MP)
CONTENTS
Sr. No.
Description
Page No.
Scope
Definitions
Deviation(s)
Drawings
Test Results
Guarantee / Warranty
General
10
General Inspection
11
12
Marking
13
Packing
14
Field Trials
Appendix - I
Enclosure
2.
SCOPE
1.1
This document covers the technical requirements relating to design and performance
characteristics for lateral, vertical & yaw hydraulic dampers for use in WDG4 & WDP4
locomotive bogies. However, this it does not include all the necessary provisions required
for a supply contract.
1.2
The document covers the supply of damping unit with end fittings /mountings as an
assembly termed as hydraulic dampers.
DEFINITIONS
i.
ii.
iii.
iv.
v.
vi.
3.
Overall damping characteristic shall, for all type of Hydraulic Dampers, refer to the
damping forces and corresponding relative velocities between the attachment points of the
Hydraulic Damper to the vehicle.
Hydraulic Damper Temperature shall refer to the temperature of the oil in the Hydraulic
Dampers. For measurement purpose, the temperature of the outside surface of bottom
side of the main body of the Hydraulic Damper shall be taken.
Compressed length between the mounting eyes i.e. center-to-center distance (in case of
stem/ eye type) or mounting faces (in case of stem-type) of a Hydraulic Damper when it is
compressed to the maximum of stroke.
Extended length between the mounting eyes i.e., center to center distance (in case of
stem/ eye type) or mounting faces (in case of stem type) of a Hydraulic Damper when it is
pulled out to the maximum of stroke.
Stroke is the difference between the extended length and the compressed length (effective
maximum travel of the Hydraulic Damper).
Wherever Inspecting Agency has been mentioned in this document, it shall be taken as
Authorised Inspecting Agency mentioned in the purchase order.
DEVIATION(s)
If deviations from original design, dimensions, etc. are desired by the tenderer, specific proposals
with reasons shall be submitted to the purchaser. Commencement of manufacture shall not be
done till the purchaser grants clear authorization for acceptance of the deviation(s).
4.
DRAWINGS
The Hydraulic Damper shall conform to RDSO Drawing No. SK.VL- 484 or recommended EMDs/
OEM's drawing(s).
5.
The firm shall have acquired ISO: 9000 series certification for manufacturing of Hydraulic
Dampers.
5.2
The manufacturer shall have adequate infrastructure, manufacturing and testing facilities for
the manufacture and testing of Hydraulic Dampers.
Page No. 1
5.3
The firm shall have a system of easy traceability of the product from raw material stage to
finished product stage. Stamped Identification marking with serial number of Hydraulic
Damper should be used for this purpose.
5.4
The firm shall have a Quality Assurance Plan (QAP) for the product detailing various
manufacturing aspects. The QAP shall include the following:
.1
Organization chart
.2
.3
.4
.5
.6
Identification Marking
5.5
The firm shall maintain a record of implementation of QAP for documentary evidence.
5.6
Firm shall have a Quality Manual indicating the extent of control over production.
5.7
The firm shall have a system of documentation in respect of rejection at customer end,
warranty replacement and failure of items supplied by them during service.
5.8
Calibration of the Testing / Measuring Equipments should be done at least once in a year
unless stated otherwise.
5.9
The firm shall have a system of recording the plant, machinery and control equipments
remaining out of service, nature of repairs done etc.
5.10 Training needs for all personnel shall be identified & organized by the firm on regular basis.
The Inspection staff conducting testing shall be adequately qualified, trained & having
adequate experience.
6.
OPERATIONAL REQUIREMENTS
6.1.1 Service Conditions
.1
Service Interval
The service interval of the damper, the maximum admissible percent
deterioration of damping characteristics at the end of service interval in
comparison to the nominal damping characteristic and the maximum admissible
rate of failure shall be as follows:
S.No. Conditions
Requirements
1.
2.
3.
0.05/ MKm
or
0.05/4 years
Page No. 2
.2
projection of ballast
exposure to oil or petroleum
exposure to organic waste
Wind, rain, snow, cold dust, sand storms
sand, brake and ferric oxide dust (abrasion of wheels, brake blocks and
tracks)
saline spray
washing plant agent (both acids and alkalis)
100% humidity
.3
Conditions
Requirements
1.
- 20 C
2.
+ 70 C
After operating to these extremes, the damper shall be required to fully recover
its functionality. Furthermore, the damper shall not display any fluid leaks and
any signs of failure or cracking in the damper components.
6.1.2 Storage Temperatures ( Ts,min - Ts,max )
The damper shall withstand the following temperature range during transport or
storage:
Sl.
Conditions
Requirements
1.
- 20 C
2.
Maximum temperature to
transport or storage Ts, max
+ 70 C
withstand
during
Page No. 3
6.2
PHYSICAL REQUIREMENTS
6.2.1 Strength
The construction of Hydraulic Damper shall be such as to withstand the static
compressive axial load of 3 tonnes when fully closed and a tensile load of 3 tonnes
when fully extended respectively without any failure, damage or permanent change in
damping characteristic or reduction in service interval.
6.2.2 Dimensional Parameters
Various dimensional parameters of the damper shall be as per RDSO Drawing No.
SK.VL - 484 or recommended EMDs/ OEM's drawing(s).
6.2.3 Adjustability
The damper capacity shall be adjustable and the adjustment shall be easy to perform. It
shall be clearly indicated if any special tools and devices are required. The maintenance
instructions for the damper shall cover the procedure to perform such adjustments.
6.2.4 Surface Protection
All the parts of the damper in contact with the ambient air shall be protected from
corrosion. The protection can be ensured either by the nature of materials used or by
suitable painting / surface treatments.
The following requirements for the damper painting and other anti-corrosion surface
protections (in particular, the stem surface treatment or plating) shall be maintained:
Painting Parameters
Requirements
RAL 7012
120
Adhesion
<5%
Rubber parts shall not be painted. Otherwise, the Supplier has to produce test results
or return from service experience data demonstrating that painting process doesnt
alter rubber mechanical characteristics for the whole damper service life.
6.2.5 Damper Oil
The details of damper oil including type, viscosity and amount of the damper oil shall be
provided by the supplier.
6.2.6 Leakage
The damper shall operate without excessive loss of oil throughout its operating life. Oil
loss is excessive when there is visible evidence of accumulation of oil in the form of
drip on the body of the damper.
Once leakage seems to be present in service, the damper has to be cleaned from oil &
dust and shall be checked after one week or 1000 km. If oil is again present on the
damper and/ or oil is bonded in an area of 100 cm2 of dust, the damper is classified as
leaking.
6.2.7 Noise
When determined as being necessary, the damper shall provide no noise during
work.
Motive Power Directorate (VDG), RDSO, Lucknow
Page No. 4
Loco Type
Extension
5600 20%
5600 20%
Primary (Vertical)
Secondary (Yaw)
WDG4
12200 20%
12200 20%
Secondary (Yaw)
WDP4
6000 20%
6000 20%
The Hydraulic Damper shall be assembled in such a manner that the damping shall
be uniform throughout the stroke i.e the damping characteristics shall not have any
sudden deviation or changes throughout the stroke.
The stipulated tolerances and requirements shall apply at all points within the required
working stroke of the Hydraulic Damper.
6.3.3 Force - Displacement Characteristic
The Force - Displacement characteristic is the variation in damper Force as a function
of damper displacement under harmonic motion of established strokes and frequencies
depending on the type of application. Moreover, it is also referred to a given damper
length and operating temperature.
The shape of the Force - Displacement curve or Hysteresis Cycle (see above figure),
shall turn out to be regular and symmetrical, in particular shall be free from:
flex as shown in above figure with letter A, B and C
local vibrational phenomena
jumps and sudden change in the shape of the curve
6.3.4 Priming
The damper must not loose priming during service or after storage or transport.
Page No. 5
7.
TEST RESULTS
The manufacturer shall submit internal test results in support of various performance
characteristics as laid down in this document, duly signed by manufacturer or his authorized
representative.
8.
GUARANTEE / WARRANTY
The manufacturer shall furnish a guarantee that each new Hydraulic Damper supplied, shall
function satisfactorily without attention and in accordance with the requirements of this document
for 10,00,000 kms of service running on a vehicle or for 4 years from the date of fitting to a
vehicle, whichever is earlier. A format of the certificate is given at Appendix - I.
9.
10.
GENERAL
9.1
All welded joints of the Hydraulic Damper shall be free from welding defects and shall be
sufficiently strong to withstand the loads intended.
9.2
The external dimensions & characteristics of the Hydraulic Dampers shall not be altered by
the manufacturer without the prior written consent of RDSO. Unless otherwise specified in
the respective drawing, the tolerance in compressed and extended length of all types of
Hydraulic Dampers shall be within 3mm of the specified dimension.
9.3
After suitable pretreatment, Hydraulic Damper shall be painted with primer under coat and
finishing coat. The Hydraulic Dampers shall be painted as specified. Paint must not be
permitted to adhere to the working portion of the piston rods.
9.4
The Hydraulic Damper shall be manufactured, assembled and tested at the manufacturers
own works.
9.5
Hydraulic Damper found to be defective after delivery within the warranty period will be
returned to the manufacturer for replacement at his own expenses, not withstanding that
they may have passed the relevant tests and have been accepted by the Inspecting
Agency.
GENERAL INSPECTION
10.1 Records of all the materials or fittings used in Hydraulic Dampers shall be scrutinized by the
Inspecting Authority and shall be to his entire satisfaction.
10.2 The manufacturer shall supply the necessary labour and appliances for testing and
inspection of the Hydraulic Dampers, if felt necessary by the inspecting authority.
10.3 The Inspecting Authority shall have right to:
10.3.1 Adopt any means he may think advisable to satisfy himself that the materials or
fittings as per the specifications are actually used in the manufacture.
10.3.2 Take samples of components/parts for such tests, as he may consider necessary
by an approved metallurgist selected by him whose report shall be final and binding
on the manufacturer.
10.3.3 Visit at any reasonable time and without previous notice, the manufacturers works
to inspect progress & the quality of the work and the manufacturer shall provide all
equipments, gauges and other facilities required by him for the purpose, free of
charge.
10.3.4 Reject any material or fittings, which do not conform the relevant specifications or
good practice. These shall be marked in a distinguishable manner and shall be
Page No. 6
IR
Page No. 7
APPENDIX I
QUALITY ASSURANCE & GUARANTEE CERTIFICATE
(Reference Clause 8 of Specification No. MP.0.40.99.03)
No.
..
Dated:.
Railway :
..
P.O. No. :
..
Dated:.
Quantity :
..
Consignee:
i.
ii.
iii.
Dated:
Q.C. INCHARGE
(SIGNATURE & SEAL OF THE MANUFACTURER)
Page No. i