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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
SPECIFICATION FOR
HYDRAULIC DAMPERS OF WDG3A,
WDM3D (WITH EQUALISER & COMPENSATING MECHANISM)
AND
WDM3A (WITH A.T.H.S BOGIES) LOCOMOTIVES
No. MP.0.49.00.16
(Revision - 00)
March 2009
R.D.S.O
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
SPECIFICATION FOR
HYDRAULIC DAMPERS OF WDG3A,
WDM3D (WITH EQUALISER & COMPENSATING MECHANISM)
AND
WDM3A (WITH A.T.H.S BOGIES) LOCOMOTIVES
No. MP.0.49.00.16
(Revision - 00)
March 2009
Prepared By
S.P.Govil
Asstt. Design Engineer (MP)
Checked By
Approved By
Naresh Kumar
Director (MP/VDG)
S.Mani
Executive Director(MP)
Specification for Hydraulic Dampers of WDG3A, WDM3D (With equalizer & compensating mech.) & WDM3A (with ATHS bogies) Locomotives
CONTENTS
Sr.
Description
Page
1.
Scope
2.
Deviation(s)
3.
Drawings
4.
5.
6.
7.
Test Results
8.
Warranty
9.
Marking
10.
Packing
11.
Field Trials
viii
Specification for Hydraulic Dampers of WDG3A, WDM3D (With equalizer & compensating mech.) & WDM3A (with ATHS bogies) Locomotives
SCOPE
This document covers the technical specifications for vertical & lateral hydraulic dampers for use in
WDG3A, WDM3D (With equalizer & compensating mechanism) & WDM3A (with A.T.H.S bogies)
locomotives. However, this specification does not include all the necessary provisions required for a
supply contract.
2.
DEVIATION(s)
If deviations from original design, dimensions etc. are desired by the supplier, 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).
In case of contradiction between this specification and the relevant RDSO drawing(s) or if any special
requirements are given in these drawing(s), the stipulations in the drawing(s) shall override this
specification.
3.
DRAWINGS
The document shall be applicable to dampers to Drg No. SK.VL - 295, SK.VL - 328, SK.VL- 471 &
SK.VL - 527.
4.
End mountings / Silent blocks / Spheribloc: End mounting with better quality of rubber
(Shore hardness between 60 to 70 Shore A) should be provided. Arrangement to fit dust caps
should be such that it does not get loose or detached during locomotive operation.
4.2
Clearance between mounting bolts & damper eye: Strict adherence to specified tolerance
has been recommended between damper eye and its mounting bolt to avoid impact loading
during operation.
4.3
Installation of dampers: The nut & bolts for the fitment of damper in position should be
provided by the damper supplier along with the damper to avoid any play in the fitment which
can control the failure of silent blocks/ mounting bolts. The OEM should indicate the torque
value for tightening the damper mounting bolts (hexagonal head bolts) to mount dampers on
locomotive. Latest locking aids like disc lock washers should be supplied along with dampers to
prevent loosening of mounting bolts due to vibrations during locomotive operation.
4.4
Provision of oil seals: An oil seal along with a special sealing ring has been recommended in
lock ring (cover) should be to avoid ingress of dust inside the damper. These seals should
provide less friction, should be capable of withstanding higher pressure and should be wear
resistant should to achieve higher working life and reliability.
4.5
Improvement in dust cover and casing tube: Dust covers break from its joint with the Piston
Rod Eye. Extra strengthening of joint and use of seamless tubes for protection cover and
casing tubes has been recommended to increase the life of dampers.
Page No. 1
Specification for Hydraulic Dampers of WDG3A, WDM3D (With equalizer & compensating mech.) & WDM3A (with ATHS bogies) Locomotives
4.6
Improvement in surface finish of cylinder & piston rod: A superfine finish of these subcomponents will help controlling their excessive wear. OEMs have been recommended to
maintain a surface finish of 10 to 35 m or better for cylinder after honing and 0.1 to 0.3 m for
piston rod after hard chrome to achieve the desired results.
4.7
Positive locking of Piston and Piston rod: Due to higher forces encountered at higher
operating speeds, there is a possibility that piston could rotate and free itself from piston rod.
Therefore, positive locking of piston with piston ring has been recommended like use of circlip,
nylock nuts etc.
4.8
4.9
Improvements in damping oil: OEMs have been advised to use damping oil such that they
do not lose their viscosity during service with temperature variation to an extent, which can
affect damping characteristics of damper.
4.10 Rubber components: The rubber components being used inside the damper are exposed to
oil. Hence, the rubber being used for these components should have good resistance to oil
absorption, sufficient to sustain a minimum of 48 months life.
4.11 Internal design: The internal mechanism with a provision of discharge valve so that, in any
odd situation and hyper characteristics of the force of oil beyond a prescribed limit may
discharge automatically to prevent the failure of the damping system.
4.12 Sealing arrangement: One of the major causes of damper failures is ingress of dust along
with piston rod. Specific measures to guard against dust have been recommended like use of
sealing arrangements with better wiping properties, provision of additional dust lip etc.
4.13 Cleanliness of damper components: The cleanness of critical damper parts has to be of high
standards. Ultra-sonic cleaning of critical parts is desirable for long life of dampers. Any dust or
burrs will damage the seals, surfaces and properties of oil. Cleaning of other parts to be done
by machine wash.
4.14 Leak test of sub-assemblies: Internal leakages in the damper can deteriorate in service
leading to loss of damping forces. Hence, leak test of sub-assemblies have been introduced
before final assembly.
5.
Service Intervals
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
shall be as follows:
Sr.
Conditions
1.
2.
Requirements
Page No. 2
Specification for Hydraulic Dampers of WDG3A, WDM3D (With equalizer & compensating mech.) & WDM3A (with ATHS bogies) Locomotives
.2
The damper shall be resistant to the following operating environmental conditions to which it may
be exposed during service:
Projection of ballast
Exposure to oil or petroleum
Wind, rain, snow, cold dust, sand storms
Saline spray
Washing plant agent (both acids & alkalis)
100% humidity
Exposure to organic waste, sand, brake & ferric oxide dust (abrasion of wheels, brake blocks
and tracks)
.3 Operating Temperatures
The damper is required to function safely up to operating temperature of 70 C.
After operating to extremes, the damper shall be required to fully recover its functionality.
Furthermore, the damper shall not display any fluid leaks or any signs of failure or cracking in the
damper components.
B. Storage Temperatures ( Ts,min ; Ts,max )
The damper shall withstand the following temperature range during transport or storage:
Sr.
Conditions
Requirements
1.
- 10 C
2.
+ 70 C
Requirements
RAL 7012
120
Adhesion
Rubber parts shall not be painted. Otherwise, the supplier has to produce test results or return
Motive Power Directorate (VDG), RDSO, Lucknow
Page No. 3
Specification for Hydraulic Dampers of WDG3A, WDM3D (With equalizer & compensating mech.) & WDM3A (with ATHS bogies) Locomotives
from service experience data demonstrating that painting process doesnt alter rubber mechanical
characteristics for the whole damper service life.
E.
Damper Oil: The details of damper oil including type, viscosity and amount of the damper oil
shall be provided by the supplier.
F.
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.
G. Noise: When determined as being necessary, the damper shall provide no noise during
work.
5.3 FUNCTIONAL REQUIREMENTS
A. Orientation: The range of various damper angular positions during fitment and operation shall be
as per the relevant RDSO drawing.
.1
The overall damping forces on the compression and extension strokes of the damper, taken
separately, shall be within the 10% tolerances of capacity as specified in the drawing(s).
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.
.2
The shape of the Force - Displacement curve or Hysteresis Cycle shall be regular and symmetrical,
and in particular shall be free from flex, local Vibrational phenomena and jumps / sudden change in
the shape of the curve.
.3
Priming
The damper must not lose priming during service or after storage or transport.
6.
7.
TEST RESULTS
The supplier shall submit internal test results in support of various performance characteristics/
endurance test, duly signed by supplier or his authorized representative.
8.
WARRANTY
The supplier 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
Page No. 4
Specification for Hydraulic Dampers of WDG3A, WDM3D (With equalizer & compensating mech.) & WDM3A (with ATHS bogies) Locomotives
kms of service running on a vehicle or for 4 years from the date of fitment to a vehicle, whichever is
earlier. A format of the certificate is given at Annexure - II.
Hydraulic Damper found to be defective after delivery within the warranty period will be returned to the
manufacturer for replacement, not withstanding that they may have passed the relevant tests and
have been accepted by the Inspecting Agency.
9.
MARKING
Marking (identification) plate should be of Aluminum and should be fixed by Aluminum rivets on the
damper. It shall be legibly marked with:
a.
c.
e.
g.
10.
b. Serial No.
d. Rated Capacity
f. IR
PACKING
The manufacturer shall ensure that Hydraulic Dampers are suitably packed in polyethylene covers
using suitable cartons to prevent ingress of foreign matter and damage during handling and storage.
11.
FIELD TRIALS
Before approval in Part II in RDSO vendor directory, the field performance for a period of one year
shall be monitored.
Page No. 5
Specification for Hydraulic Dampers of WDG3A, WDM3D (With equalizer & compensating mech.) & WDM3A (with ATHS bogies) Locomotives
Annexure I
ENDURANCE TESTING PROCEDURE FOR HYDRAULIC DAMPERS OF WDG3A,
WDM3D (WITH EQUALISER & COMPENSATING MECHANISM) AND
WDM3A / WDM3C (WITH A.T.H.S BOGIES) LOCOMOTIVES
1.
BACKGROUND
The purpose of endurance testing of hydraulic damper is to check its suitability for field application
under simulated operating conditions in test laboratory in a limited time frame. It is used as a
criterion to ascertain the expected service life.
The fatigue test shall be carried out on dampers as per the procedure given below.
2.
TEST MACHINE
The hydraulic dampers can be tested as single damper or in a fixture together with other hydraulic
dampers. The fixture should be designed in such a way that both ends of the damper remain
parallel and perpendicular to the loading direction. Besides, suitable arrangements for damper
cooling during endurance testing should be available to ensure that damper oil temperature is
controlled within the specified range. The test setup should allow measuring height, load and
stroke simultaneously. The machine should be capable to apply the desired forces at specified
frequency and speed. It should also have facility to seal the Fatigue Cycle Counters and dampers
being tested. The test machine should be properly calibrated.
Pictorial view of a typical endurance testing machine is given below.
A. SAMPLE QUANTITY
Three nos. of samples manufactured as per the relevant RDSO drawing should be randomly
selected from the damper lot for strength and endurance test.
Motive Power Directorate (VDG), RDSO, Lucknow
Page No. i
Specification for Hydraulic Dampers of WDG3A, WDM3D (With equalizer & compensating mech.) & WDM3A (with ATHS bogies) Locomotives
4.
TEST PREPARATION
The inspection authority shall witness the calibration of testing machine and ascertain under test
conditions, various parameters to be measured in the sample dampers being tested.
Visually examine the test samples for soundness.
5.
DAMPER TESTING
A. STRENGTH/PERFORMANCE TEST
.1
Prior to endurance testing, each selected hydraulic damper shall be compressed to its
fully closed position and then extended to its maximum stroke (expanded) position at
damper temperature range of 20 2 C inclusive.
The construction of hydraulic damper and mountings 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.
No component of damper should suffer damage or permanent distortion. Besides, no
signs of oil leakage should be visible.
The damping force measurements should be done as per Proforma placed at Annexure
IA. The measured damping forces should lie within the permissible limits as per the
relevant RDSO drawing under various testing conditions prescribed in the Annexure I.
All the three samples should pass the strength/performance test. If any of the samples
fail this test, double the failed quantity shall be selected and subjected to this test. All of
these samples should pass the stipulated criteria failing which the whole damper lot shall
be rejected.
.2
Each hydraulic damper shall be primed prior to testing to ensure that all the air is brought
into the correct chamber of the damper and then handled in such a way that the primed
condition is maintained during testing.
Procedure
Two of the samples that have passed the tests under Para 5 shall be randomly selected
for endurance testing.
The hydraulic dampers shall preferably be tested in their normal plane of operation.
Page No. ii
Specification for Hydraulic Dampers of WDG3A, WDM3D (With equalizer & compensating mech.) & WDM3A (with ATHS bogies) Locomotives
The hydraulic damper shall be connected to the testing machine with its flexible end
mountings in the same manner as it is done on the locomotives. No additional flexible
elements shall be used for this purpose. However, in the case of hydraulic dampers
where such installation is not possible, flexible elements suitable for installing the
hydraulic damper on testing machine (having characteristics identical to that of flexible
element provided on the hydraulic damper), shall be allowed to be used provided prior
approval of RDSO has been obtained for this purpose.
The endurance testing machine shall enable keeping one end of the hydraulic damper
fixed and the other end oscillating at 1.67 Hz with amplitude of 9.5mm from mean
position corresponding to a maximum velocity of 10 cm/sec.
Hydraulic damper shall thus be subjected to a total 3 million cycles. The damper oil
temperature should not exceed 70C temperature during the endurance test.
After completion of 8 lakh, 16 lakh, 24 lakh and 30 lakh cycles each, the hydraulic
damper shall be removed from endurance testing machine and re-tested for overall
damping characteristics as mentioned above after it cools to room temperature so that
the damping characteristics test is carried out with the hydraulic damper at a temperature
between 27 C to 33 C inclusive. The necessary data should be recorded as per the
Proforma enclosed at Annexure I C. A continuous record of endurance testing shall be
maintained in the log sheet as per the Proforma placed at Annexure I D.
The cyclic working on endurance testing machine shall preferably be continuous except
for short intervals when hydraulic damper is removed for checking their capacity or when
circumstances are beyond the control of testing agency e.g. power failures etc.
.2
6.
a.
b.
Specification for Hydraulic Dampers of WDG3A, WDM3D (With equalizer & compensating mech.) & WDM3A (with ATHS bogies) Locomotives
Annexure IA
DAMPER PERFORMANCE TEST
Damper
No.
Damper Details
Capacity Type
(Kg) (Vertical/
at 10 Lateral)
cm/sec
Condition
(Before/After)
Strength Test
1.67 Hz
9.5 mm
0.83 Hz
19 mm
0.56 Hz
28.5 mm
At Piston Velocities of
At Piston Velocities of
20
(mm/sec)
60
(mm/sec)
100
(mm/sec)
20
(mm/sec)
60
(mm/sec)
100
(mm/sec)
Comp Expn Comp Expn Comp Expn Comp Expn Comp Expn Comp Expn Comp Expn Comp Expn Comp Expn
1.
Before
After
2.
Before
After
3.
Before
After
4.
Before
After
5.
Before
After
Page No. iv
Specification for Hydraulic Dampers of WDG3A, WDM3D (With equalizer & compensating mech.) & WDM3A (with ATHS bogies) Locomotives
Annexure IB
A TYPICAL FORCE - DISPLACEMENT CHARACTERISTIC LOOP OF A HYDRAULIC DAMPER
Page No. v
Specification for Hydraulic Dampers of WDG3A, WDM3D (With equalizer & compensating mech.) & WDM3A (with ATHS bogies) Locomotives
Annexure IC
DAMPER PERFORMANCE DURING / AFTER ENDURANCE TEST
Product: Vertical hydraulic damper / Lateral damper
Capacity (Kg):
Sample No:
Start:
Test Dates:
S.No.
Completion:
Endurance
Test Stage
At Piston Velocities of
At Piston Velocities of
20
(mm/sec)
Comp
1.
Initial
2.
After 8 Lakh
Cycles
3.
After 16
Lakh Cycles
4.
After 24
Lakh Cycles
5.
After 30
Lakh Cycles
Expn
60
(mm/sec)
Comp
100
(mm/sec)
Expn
Comp
Expn
20
(mm/sec)
Comp
Expn
60
(mm/sec)
Comp
Expn
100
(mm/sec)
Comp
Expn
Page No. vi
Specification for Hydraulic Dampers of WDG3A, WDM3D (With equalizer & compensating mech.) & WDM3A (with ATHS bogies) Locomotives
Annexure ID
Capacity (Kg):
Sample No:
Start:
Test Dates:
Completion:
Stroke (mm):
Sl.
No.
Date
Frequency (Hz):
Started
time
Stopped
time
Total
hours
No. of
cycles
Cumulative Temperature
no. of
of damper
cycles
(C)
completed
Velocity (cm/sec):
Remarks
Specification for Hydraulic Dampers of WDG3A, WDM3D (With equalizer & compensating mech.) & WDM3A (with ATHS bogies) Locomotives
Annexure II
QUALITY ASSURANCE & GUARANTEE CERTIFICATE
(Reference Clause 7 of Specification No. MP.0.49.00.16)
No.
..
Dated:.
Railway :
..
P.O. No. :
..
Dated:.
Quantity :
..
Consignee:
i.
ii.
iii.
THIS IS TO CERTIFY THAT EACH HYDRAULIC DAMPER SUPPLIED AGAINST THIS PURCHASE
ORDER SHALL FUNCTION SATISFACTORILY FOR THE INTENDED APPLICATION & PERIOD
SPECIFIED IN THE RELEVANT SPECIFICATION.
Dated:
Q.C. INCHARGE
(SIGNATURE & SEAL OF THE MANUFACTURER)