Technical requirement and test specification of New

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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)
XXX-2017
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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
8
Inspection & testing.
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.
Prototype, Quality assurance and Quality control condition.
Additional testing.
9
7
Approval.
13-14
14
14
14-15
10
Installation & fitment.
15
11
Technical documents and drawings.
12
Spares and tool kit.
13
Maintenace manuals.
14
Perforamnce & service warranty.
15
General conditions for inspection and tests.
16
Training.
18
17
Technical clarifications.
18
15-16
16
16-17
17
17-18
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
2.9
In preparing this specification, references have been taken from the following
specification and manuals.
I. S. 10431 - 1994 (Reaffirmed 1999) - Measurement of airflow.
I.S. 5727 - 1981 (Reaffirmed 2001) - Glossary of terms relating to compressors.
I.S. 5456-1985 (Reaffirmed 2001) - Code for practice for testing of positive
displacements type air compressor and exhausters.
ISO-8573 – 2001 (E) - Compressed air for general use.
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).
RDSO specification no. MP.0.0700.14, (Rev-00 June 2007) - specification of water
cooled air compressor for diesel electric locomotive.
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.
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.
The other abbreviations used in this specification are as under:
R D S O – Research, Designs, and Standards Organization, Manak Nagar, Lucknow 226 011.
IS - Indian Standards
I R – Indian Railways
I SO – International Organization for Standardisation.
FAD – Free air delivery
M.R.- Main Reservoir
Definitions of the different terms used in this specification are as under:
Purchaser–President of the Republic of India (acting through Railway Board or
General Manager DLW/ DMW/ Zonal Railway, as the case may be).
2.2
2.3
2.4
2.5
2.6
2.7
2.8
3.2
3.2.1
3.2.2
3.2.3
3.2.4
3.2.5
3.2.6
3.2.7
3.2.8
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Spec.no. MP-0.xx.00.xx (Rev.00), XXXXX’ 2017
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 lowpressure 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
2
Spec.no. MP-0.xx.00.xx (Rev.00), XXXXX’ 2017
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.
3
Spec.no. MP-0.xx.00.xx (Rev.00), XXXXX’ 2017
5.9
5.10
5.11
5.12
5.12.1
5.12.2
5.12.3
5.12.4
5.13
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. Interstage 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.
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).
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.
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.
The lubricating oil and lubrication system:
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.
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.
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.
Maximum weight (dry) –775 kg (excluding air suction filters, and drive coupling)
Maximum space –
Space
Maximum envelop dimension for
compressor general arrangement
Length along
locomotive
675 ± 5 mm
4
Width across
Height
the locomotive
1368 ± 5 mm 1065 ± 5 mm
Spec.no. MP-0.xx.00.xx (Rev.00), XXXXX’ 2017
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
6
Vibrations and shocks - The compressor shall be designed to withstand vibrations and
shocks encountered in locomotive operation as per international specification IEC61373, 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.
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.
5
Spec.no. MP-0.xx.00.xx (Rev.00), XXXXX’ 2017
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 annexureIII.
Sr.
No.
Speed,
rpm
Loaded/Unloaded condition
1
2
3
4
200
200
950
950
Unloaded condition
Loaded condition(140PSI disch)
Unloaded condition
Loaded condition(140PSI disch)
Minimum
consumable
Horse Power, HP
(indicative)
1.8
10
10
58
Maximum
consumable
Horse Power,
HP
2.2
22
23
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.
6
Spec.no. MP-0.xx.00.xx (Rev.00), XXXXX’ 2017
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.
7
Spec.no. MP-0.xx.00.xx (Rev.00), XXXXX’ 2017
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
8
Spec.no. MP-0.xx.00.xx (Rev.00), XXXXX’ 2017
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 (Cutin 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.
9
Spec.no. MP-0.xx.00.xx (Rev.00), XXXXX’ 2017
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 Period
rpm
in hrs
1.
Mechanical tests
a) Run the compressor as indicated below
i) Against the atmospheric pressure (check for 200 to 300
2
undue heating, crankcase and joints leakages)
ii) Slowly increase the pressure to 10.0 kg/cm²
200 to 300
2
b) Increase speed to max. service speed 950 rpm
950
2
and adjust pressure to 0 kg/cm²
c) Increase speed to max. and adjust pressure to
950
2
10.0 kg/cm² (approximately 140 PSI)
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
10 Spec.no. MP-0.xx.00.xx (Rev.00), XXXXX’ 2017
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.
Notch
position
Idle
1
2
3
4
5
6
8
9
10
TABLE-2 (First cycle comprising from 0 to 1500 hrs)
Compressor speed
% of 1500
Running
Time interval
rpm
hrs
hours
(hrs)
200
8%
120
0-120
269
8%
120
120-240
343
8%
120
240-360
490
8%
120
360-480
568
8%
120
480-600
651
8%
120
600-720
729
8%
120
720-840
820
8%
120
840-960
900
8%
120
960-1080
950
28 %
420
1080-1500
TABLE-3 (Second cycle comprising from 1500 to 3000 hrs)
Notch
Compressor speed % of 1500 Running
position rpm
hrs
hours
Idle
200
8%
120
1
269
8%
120
2
343
8%
120
3
490
8%
120
4
568
8%
120
5
651
8%
120
6
729
8%
120
8
820
8%
120
9
900
8%
120
10
950
28 %
420
Time interval
(hrs)
1500-1620
1620-1740
1740-1860
1860-1980
1980-2100
2100-2220
2220-2340
2340-2460
2460-2580
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)
11 Spec.no. MP-0.xx.00.xx (Rev.00), XXXXX’ 2017
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
8.2.1
Quality acceptance / routine tests:
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.
12 Spec.no. MP-0.xx.00.xx (Rev.00), XXXXX’ 2017
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 IS10431on 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.
13 Spec.no. MP-0.xx.00.xx (Rev.00), XXXXX’ 2017
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
14 Spec.no. MP-0.xx.00.xx (Rev.00), XXXXX’ 2017
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
electric locomotive, shall be the responsibility of vendor under
inspecting officer and purchaser. Vibration measurement shall be
inspecting officer at DLW (in case vibration testing is not done as
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
11.1
Technical Documents and Drawings
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.
on HHP diesel
supervision of
carried out by
per IEC–61373
11.1.1 Locating dimensions and type of mounting hole as per RDSO drawing no. SKDP3842 (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.
15 Spec.no. MP-0.xx.00.xx (Rev.00), XXXXX’ 2017
11.1.9 Up to date drawings of whole compressors and serviceable parts.
11.2
11.2.1
11.2.2
11.2.3
11.2.4
11.2.5
11.2.6
11.2.7
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.
Loaded horsepower Vs – RPM.
Unloaded horsepower Vs – RPM.
Displacement volume Vs – RPM
FAD Vs – RPM.
Lube oil temperature Vs – RPM.
Oil consumption in compressor unit of (ml/hour).
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 proforma 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 watercooled 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.
16 Spec.no. MP-0.xx.00.xx (Rev.00), XXXXX’ 2017
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
17 Spec.no. MP-0.xx.00.xx (Rev.00), XXXXX’ 2017
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
18 Spec.no. MP-0.xx.00.xx (Rev.00), XXXXX’ 2017
Annexure -I
GRAPH OF SPEED Vs FREE AIR DELIVERY
ANNEXURE-II
6000
5677
5500
5000
Free air delivery in lpm
4500
4000
3500
3000
2500
2000
1500
990
1000
500
0
150
200
250
300
350
400
450
500
550
600
650
700
750
800
850
900
950
1000
Compressor speed in rpm
Page 1 of 1
ANNEXURE.III
75
70
70
<-Max.
65
**-Min.
60
limit
t M* lir"it
timit
7
\
58,
55
(L
r
50
5ou
o
E
=p
o
o
oo
Itu
[/lin li' nit
o
(indical :ive)
tL
J
30
25
22
20
15
10
10
5
0
150 200 250 300 350 400 450 500 550 600 650 700 750 800
850 900 950 loOO
Compressorspeed in RpM
GRAPH OF POWER CONSUMPTTON (UNLOADED
COND|TION)
page 1 of 2
ANNEXURE-III
23
<-HP
(L
Ma x lim
(max)
--o*HP (min)
I
1
\
.=
E
o
v
E
f
@
c
o
o
L
q)
o
=
(L
10
{
\
Z.z
/
*rl
f-"
-T-- --T-
1.8
150 200 250 300 350 400 450 500 550 600 650 700 750 800 850 900 9501000
Compressor speed in rpm
3RAPH OF POWER CONSUMPTION (LOADED
CONDITION)
Page 2 of 2
GRAPH OF ORIFICE TEST
ANNEXURE - IV
11
10.65
10.12
10
9.59
9.44
9
9
Passing limit
8.52
8.52
8
7.46
7.46
Reservoir pressure in kg/cm2
7
6.39
6.25
6
5.35
5.11
5
Condeming
limit
4.26
4.05
4
2.98
3.20
3
2
1.78
2.13
1.17
1
0
200
250
300
350
400
450
500
550
600
650
700
Compressor speed in rpm
750
800
850
900
950
1000
Annexure -V
Annexure - VI
PRO-FORMA FOR (FAD) CAPACITY TESTING
Compressor model:
Compressor no:
S.
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
Parameter
Altitude:
Date:
Sheet no.:-
Measuring
equipment
Barometric pressure
Barometer
Air outlet pressure P2
Gauge
Dry bulb temp (LP1/LP2 inlet air temp)
Thermometer
Wet bulb temp (LP1/LP2 inlet air temp)
Thermometer
Compressor speed (RPM)
Digital
tachometer
Water flow rate
Flow meter
Nozzle inlet pressure (H2O) P3
Manometer
Nozzle outlet pressure (H2O) P4
Manometer
Nozzle air temp T3
Thermometer
Actual free air delivery
Calculation
Free air delivery corrected to ------ RPM
Calculation
Volumetric efficiency
Calculation
Energy input to motor for 10 minutes
Energy meter
Power (motor input)
Calculation
Water outlet temp (finally at HP cylinder)
Thermometer/CH
LP1outlet temp (left side cylinder viewed from Thermometer/CH
non drive end) / inter cooler inlet temp
LP2 outlet / inter cooler inlet air temp
Thermometer/CH
HP inlet / intercooler outlet air temp
Thermometer/CH
HP outlet air temp
Thermometer/CH
Water inlet temp (LP1/LP2/HP/intercooler)
Thermometer/CH
Lube oil pressure
Gauge
Units
used
mm of hg
Kg/cm²
ºC
ºC
rpm
Date and
time
LPM
mm
mm
ºC
LPM
lpM
%
kwh
HP
ºC
ºC
ºC
ºC
ºC
ºC
Kg/cm²
Any remarks if any:-
Spec. no.-MP-0.XX.00.XX (Rev.00), XXXX2017
Annexure -VII
PRO-FORMA FOR ENDURANCE TESTING
Compressor model:
Compressor no:
S.
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Parameter
Altitude:
Date:
Sheet no.:-
Measuring
equipment
Hour meter reading
Hour meter
Atmospheric pressure
Manometer
Air outlet pressure
Pressure gauge
Ambient temp
Thermometer
Compressor speed (LPM)
Digital
tachometer
Water flow rate
Flow meter
Water tube temp
Thermometer
Suction air temp (LP1)
Thermometer
Suction air temp (LP2)
Thermometer
LP1outlet temp (left side cylinder viewed from Thermometer
non drive end) / inter cooler inlet air temp
LP2 outlet / inter cooler air inlet temp
Thermometer
HP inlet / intercooler air outlet temp
Thermometer
HP outlet air temp
Thermometer
Water inlet temp (LP1/LP2/HP/intercooler)
Thermometer
Water outlet temp (finally at HP cylinder)
Thermometer
LP1 cylinder water temp
Thermometer
Lube oil temp
Thermometer
Lube oil pressure
Pressure gauge
Inter cooler air pressure
Pressure gauge
LP1 cylinder head temp / Valve temp
Laser
thermometer
LP2 cylinder head temp / Valve temp
Laser
thermometer
HP cylinder head temp / Valve temp
Laser
thermometer
Power (for 10 minutes) once in day
Energy meter
Units
used
hrs
mm of Hg
kg/cm²
ºC
LPM
Date and
time
LPM
ºC
ºC
ºC
ºC
ºC
ºC
ºC
ºC
ºC
ºC
ºC
kg/cm²
kg/cm²
ºC
ºC
ºC
Kwh
Any remarks if any:-
Spec.no.-MP-0.XX.00.XX (Rev.00), XXX2017
Annexure -VIII
PRO-FORMA FOR HIGH TEMPERATURE TESTING
Compressor model:
Compressor no:
S.
No.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Parameter
Altitude:
Date:
Sheet no.:-
Measuring
equipment
Hour meter reading
Hour meter
Atmospheric pressure
Manometer
Air outlet pressure
Pressure gauge
Ambient temp (inside enclosure)
Thermometer
Compressor speed (RPM)
Digital
tachometer
Water flow rate
Flow meter
Water tube temp
Thermometer
Suction air temp (LP1)
Thermometer
Suction air temp (LP2)
Thermometer
LP1outlet temp (left side cylinder viewed from Thermometer
non drive end) / inter cooler inlet air temp
LP2 outlet / inter cooler air inlet temp
Thermometer
HP inlet / intercooler air outlet temp
Thermometer
HP outlet air temp
Thermometer
Water inlet temp (LP1/LP2/HP/intercooler)
Thermometer
Water outlet temp (finally at HP cylinder)
Thermometer
LP1 cylinder water temp
Thermometer
Lube oil temp
Thermometer
Lube oil pressure
Pressure gauge
Inter cooler air pressure
Pressure gauge
LP1 cylinder head temp / Valve temp
Laser
thermometer
LP2 cylinder head temp / Valve temp
Laser
thermometer
HP cylinder head temp / Valve temp
Laser
thermometer
Power (for 10 minutes) once in day
Energy meter
Units
used
hrs
mm of Hg
kg/cm²
ºC
RPM
Date and
time
LPM
ºC
ºC
ºC
ºC
ºC
ºC
ºC
ºC
ºC
ºC
ºC
kg/cm²
kg/cm²
ºC
ºC
ºC
Kwh
Any remarks if any:-
Spec.no.-MP-0.XX.00.XX (Rev.00), XXX2017
Annexure - IX
General Technical data of Water Cooled air compressor
01
Type
02
Normal working pressure
03
Free air delivery at 200 rpm
at 950 rpm
Displacement volume per revolution
Direction of rotation
Rated speed
Speed range
Compression stages
Low pressure cylinders, nos.
Bore dia
Total height
Heads height
High pressure cylinder, nos.
Bore Dia
Height
Heads height
Piston stroke length
Type & nos. of piston rings (On both LP
& HP)
04
05
06
07
08
09
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
Ring gap (both LP and HP)
Crank shaft, crank pin, dia
Crank pin length
Bearing seat dia
Low pressure piston, skirt dia
Total height
Hole for gudgeon pin dia
High pressure piston, skirt dia
Total height
Hole for gudgeon pin dia
Eccentric dia for pump plunger (if
provided)
Centre distance between big end to
small end for connecting rod
Power consumption at rated speed of
950 RPM
Crankcase oil capacity
Lube oil pressure at 200 rpm
at 950 rpm
Intercooler safety valve set pressure
Envelope dimension (L X B X H)
Net Weight
Reciprocating ‘W’ type, water cooled and
forced feed lubrication
10.0 Kg/cm²
140 PSI approximately
Not less than 35 CFM (990 LPM)
200.5 CFM (5677 LPM)
7.96 litres
Clockwise viewed from non drive end
950 RPM
200 to 1100 RPM
02 nos.
02
200.025 mm (7.87”)
289±0.05 mm
156+0.1, -0.0 mm
01
146.025 mm (5.748”)
273±0.05 mm
156+0.1, -0.0 mm
127 mm (5”)
01 No. -Taper compression ring
01 No. - Nose scraper ring
02 Nos. - Cross bevelled oil control ring
0.2 – 0.45 mm
92.02 – 92.049 mm
114.5+0.1, -0.0 mm
85.725+0.076, + 0.051 mm
199.77-199.82 mm
168.5±0.05 mm
44.45 – 44.46 mm
145.80 -145.825 mm
140.5±0.25 mm
44.45 – 44.46 mm
106.929 / 106.964 mm
350+0, -0.1 mm
63.33±10 % HP
Minimum 6 litres
Maximum 11.2 litres
0.7 Kg/cm² minimum
1.76 – 4 kg/cm2
4.6 – 4.8 kg/cm²
675±5 mm X 1368±5 mm X 1060±5 mm
Maximum 775 Kg
Spec.no.-MP-0.XX.00.XX (Rev.00), XXX2017
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.
Spec.no.-MP-0.XX.00.XX (Rev.00), XXX2017
Max. displacement in microns at position A (crank case bottom) in ascending speed of compressor
0.060
(Mean+STDEVP)
comp1 2,3,
0.055
(Mean-STDEVP)
comp1,2,3
0.050
0.045
0.040
0.035
Dispalement in micorns
0.030
0.025
0.020
0.015
0.010
Notch positions
0.005
0.000
0
1
2
3
4
5
6
7
8
(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
Acceptable vibration band
Annexure - XI A1
Max. displacement in microns at position B (Non drive end cover) in ascending speed of compressor
(Mean+STDEVP)
comp1 2,3,
0.060
(Mean-STDEVP)
comp1,2,3
0.055
0.050
0.045
0.040
0.035
Dispalement in micorns
0.030
0.025
0.020
0.015
0.010
Notch positions
0.005
0.000
0
1
2
3
4
5
6
7
8
(Mean+STDEVP) comp1 2,3,
0.024
0.034
0.022
0.032
0.026
0.049
0.060
0.037
0.042
(Mean-STDEVP) comp1,2,3
0.007
0.008
0.010
0.010
0.020
0.029
0.033
0.026
0.024
Acceptable vibration band
Annexure - XI B1
Max. displacement in microns at position C (LP cylinder view from non drive end) in ascending speed of compressor
0.060
0.055
(Mean+STDEVP
) comp1 2,3,
0.050
(Mean-STDEVP)
comp1,2,3
0.045
0.040
0.035
0.030
Dispalement in micorns
0.025
0.020
0.015
0.010
Notch positions
0.005
0.000
0
1
2
3
4
5
6
7
8
(Mean+STDEVP) comp1 2,3,
0.019
0.022
0.019
0.016
0.015
0.017
0.020
0.020
0.020
(Mean-STDEVP) comp1,2,3
0.003
0.006
0.005
0.008
0.009
0.009
0.009
0.012
0.012
Acceptable vibration band
Annexure - XI C1
Max. dispalcement in microns at position D (LP cylinder right head view from non drive end) in ascending speed of compressor
0.060
(Mean+STDEVP)
comp1 2,3,
0.055
(Mean-STDEVP)
comp1,2,3
0.050
0.045
0.040
0.035
0.030
Dispalement in micorns
0.025
0.020
0.015
0.010
0.005
0.000
Notch positions
0
1
2
3
4
5
6
7
8
(Mean+STDEVP) comp1 2,3,
0.021
0.024
0.017
0.017
0.015
0.021
0.019
0.024
0.020
(Mean-STDEVP) comp1,2,3
0.006
0.006
0.009
0.009
0.009
0.012
0.010
0.012
0.013
Acceptable vibration band
Annexure - XI D1
Max. displacement in microns at positions E (HP cylinder head) in ascending speed of compressor
0.060
(Mean+STDEVP)
comp1 2,3,
0.055
(Mean-STDEVP)
comp1,2,3
0.050
0.045
0.040
0.035
0.030
Dispalement in micorns
0.025
0.020
0.015
0.010
Notch positions
0.005
0.000
0
1
2
3
4
5
6
7
8
(Mean+STDEVP) comp1 2,3,
0.022
0.023
0.018
0.023
0.017
0.018
0.016
0.018
0.018
(Mean-STDEVP) comp1,2,3
0.002
0.003
0.003
0.005
0.009
0.007
0.006
0.009
0.011
Acceptable vibration band
Annexure - XI E1
Max. displacement in microns at position F (inter cooler) in ascending speed of compressor
0.900
(Mean+STDEVP)
comp1 2,3,
0.800
(Mean-STDEVP)
comp1,2,3
0.700
0.600
Dispalecements in microns
0.500
0.400
0.300
0.200
0.100
0.000
Notch positions
0
1
2
3
4
5
6
7
8
(Mean+STDEVP) comp1 2,3,
0.777
0.700
0.717
0.821
0.402
0.624
0.763
0.744
0.792
(Mean-STDEVP) comp1,2,3
0.170
0.101
0.160
0.288
0.230
0.289
0.230
0.288
0.191
Acceptable vibration band
Annexure - XI F1
Max. displacement in microns at position G (right LP manifold to inter cooler view from drive end) in ascending speed of
compressor
0.060
(Mean+STDEVP)
comp1 2,3,
0.055
(Mean-STDEVP)
comp1,2,3
0.050
0.045
0.040
0.035
0.030
Dispalement in micorns
0.025
0.020
0.015
0.010
0.005
0.000
Notch positions
0
1
2
3
4
5
6
7
8
(Mean+STDEVP) comp1 2,3,
0.021
0.020
0.014
0.015
0.017
0.023
0.027
0.018
0.018
(Mean-STDEVP) comp1,2,3
0.001
0.004
0.005
0.004
0.006
0.003
0.005
0.008
0.010
Acceptable vibration band
Annxeure - XI G1
Max. displacement in microns at position H (HP manifold to inter cooler) in ascending speed of compressor
0.060
0.055
(Mean+STDEVP)
comp1 2,3,
0.050
(Mean-STDEVP)
comp1,2,3
0.045
0.040
0.035
Dispalement in micorns
0.030
0.025
0.020
0.015
0.010
Notch positions
0.005
0.000
0
1
2
3
4
5
6
7
8
(Mean+STDEVP) comp1 2,3,
0.029
0.026
0.034
0.041
0.028
0.030
0.032
0.034
0.037
(Mean-STDEVP) comp1,2,3
0.027
0.023
0.024
0.029
0.025
0.022
0.019
0.030
0.028
Acceptable vibration band
Annexure - XI H1
Max. displacement in microns at position I (water pipe left LP to HP) in ascending speed of compressor
0.350
(Mean+STDEVP)
comp1 2,3,
(Mean-STDEVP)
comp1,2,3
0.300
0.250
Dispalecements in microns
0.200
0.150
0.100
0.050
Notch positions
0.000
0
1
2
3
4
5
6
7
8
(Mean+STDEVP) comp1 2,3,
0.109
0.100
0.127
0.183
0.142
0.189
0.144
0.138
0.312
(Mean-STDEVP) comp1,2,3
0.058
0.068
0.075
0.103
0.087
0.123
0.136
0.128
0.114
Acceptable vibration band
Annexure - XI I1
Max. displacement in microns at position J (unloader pipe left side view from non drive end) in ascending speed of compressor
2.000
(Mean+STDEVP)
comp1 2,3,
1.800
(Mean-STDEVP)
comp1,2,3
1.600
1.400
1.200
Dispalecements in microns
1.000
0.800
0.600
0.400
0.200
0.000
Notch positions
0
1
2
3
4
5
6
7
8
(Mean+STDEVP) comp1 2,3,
1.725
1.694
1.638
1.740
1.628
1.623
1.701
1.493
1.530
(Mean-STDEVP) comp1,2,3
0.692
0.876
0.918
0.947
0.884
0.899
0.885
0.999
1.068
Acceptable vibration band
Annexure - XI J1
Max. displacement in microns at position A (crank case bottom) in decending speed of compressor
0.060
(Mean+STDEVP)
comp1 2,3,
0.055
(Mean-STDEVP)
comp1,2,3
0.050
0.045
0.040
0.035
Dispalement in micorns
0.030
0.025
0.020
0.015
0.010
0.005
0.000
Notch positions
2
3
4
5
6
7
8
(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
Acceptable vibration band
Annexure - XI A2
Max. displacement in microns at position B (Non drive end cover) in descending speed of compressor
0.300
(Mean+STDEVP)
comp1 2,3,
(Mean-STDEVP)
comp1,2,3
0.250
0.200
Dispalement in micorns
0.150
0.100
0.050
Notch positions
0.000
2
3
4
5
6
7
8
(Mean+STDEVP) comp1 2,3,
0.023
0.029
0.025
0.029
0.168
0.184
0.038
(Mean-STDEVP) comp1,2,3
0.013
0.018
0.017
0.017
0.013
0.012
0.021
Acceptable vibration band
Annexure - XI B2
Max. displacement in microns at position C (LP cylinder view from non drive end) in descending speed of compressor
0.060
0.055
(Mean+STDEVP)
comp1 2,3,
0.050
(Mean-STDEVP)
comp1,2,3
0.045
0.040
0.035
0.030
Dispalement in micorns
0.025
0.020
0.015
0.010
Notch positions
0.005
0.000
2
3
4
5
6
7
8
(Mean+STDEVP) comp1 2,3,
0.017
0.015
0.016
0.020
0.020
0.020
0.020
(Mean-STDEVP) comp1,2,3
0.011
0.013
0.010
0.009
0.009
0.012
0.012
Acceptable vibration band
Annexure - XI C2
Max. dispalement in microns at position D (LP cylinder right head view from non drive end) in descending speed of compressor
0.060
(Mean+STDEVP)
comp1 2,3,
0.055
(Mean-STDEVP)
comp1,2,3
0.050
0.045
0.040
0.035
0.030
Dispalement in micorns
0.025
0.020
0.015
0.010
Notch positions
0.005
0.000
2
3
4
5
6
7
8
(Mean+STDEVP) comp1 2,3,
0.018
0.016
0.013
0.016
0.017
0.019
0.020
(Mean-STDEVP) comp1,2,3
0.011
0.009
0.012
0.010
0.010
0.013
0.013
Acceptable vibration band
Annexure - XI D2
Max. displacement in microns at position E (HP cylinder head) in descending speed of compressor
0.060
(Mean+STDEVP)
comp1 2,3,
0.055
(Mean-STDEVP)
comp1,2,3
0.050
0.045
0.040
0.035
0.030
Dispalement in micorns
0.025
0.020
0.015
0.010
Notch positions
0.005
0.000
2
3
4
5
6
7
8
(Mean+STDEVP) comp1 2,3,
0.016
0.014
0.016
0.014
0.015
0.017
0.018
(Mean-STDEVP) comp1,2,3
0.008
0.008
0.012
0.006
0.007
0.008
0.011
Accepatble vibration band
Annexure - XI E2
Max. dispalcement in microns at position F (inter cooler) in descending speed of compressor
0.900
(Mean+STDEVP)
comp1 2,3,
0.800
(Mean-STDEVP)
comp1,2,3
0.700
0.600
Dispalecements in microns
0.500
0.400
0.300
0.200
0.100
0.000
Notch positions
2
3
4
5
6
7
8
(Mean+STDEVP) comp1 2,3,
0.683
0.478
0.426
0.796
0.751
0.729
0.792
(Mean-STDEVP) comp1,2,3
0.102
0.182
0.220
0.230
0.211
0.274
0.191
Acceptable vibration band
Annexure - XI F2
Max. dispalcement in microns at position G (right manifold to inter cooler view from drive end) in descending speed of compressor
0.060
(Mean+STDEVP)
comp1 2,3,
0.055
(Mean-STDEVP)
comp1,2,3
0.050
0.045
0.040
0.035
0.030
Dispalement in micorns
0.025
0.020
0.015
0.010
0.005
0.000
Notch positions
2
3
4
5
6
7
8
(Mean+STDEVP) comp1 2,3,
0.014
0.019
0.014
0.018
0.018
0.019
0.018
(Mean-STDEVP) comp1,2,3
0.009
0.009
0.008
0.008
0.007
0.007
0.010
Acceptable vibration band
Annexure - XI G2
Max. displacement in microns at position H (HP manifold to inter cooler) in descending speed of compressor
0.060
(Mean+STDEVP)
comp1 2,3,
0.055
(Mean-STDEVP)
comp1,2,3
0.050
0.045
0.040
0.035
Dispalement in micorns
0.030
0.025
0.020
0.015
0.010
Notch positions
0.005
0.000
2
3
4
5
6
7
8
(Mean+STDEVP) comp1 2,3,
0.024
0.039
0.027
0.033
0.033
0.038
0.037
(Mean-STDEVP) comp1,2,3
0.020
0.029
0.018
0.026
0.023
0.026
0.028
Acceptable vibration band
Annexure- XI H2
Max. displacement in microns at position I (water pipe left LP to HP) in descending speed of compressor
0.350
(Mean+STDEVP)
comp1 2,3,
(Mean-STDEVP)
comp1,2,3
0.300
0.250
Dispalecements in microns
0.200
0.150
0.100
0.050
Notch positions
0.000
2
3
4
5
6
7
8
(Mean+STDEVP) comp1 2,3,
0.145
0.170
0.126
0.157
0.239
0.147
0.312
(Mean-STDEVP) comp1,2,3
0.065
0.103
0.065
0.131
0.121
0.122
0.114
Acceptable vibration band
Annexure - XI I2
Max. dispalcement in microns at position J (Unloader pipe left side view from non drive end) in descending speed of compressor
2.000
(Mean+STDEVP)
comp1 2,3,
1.800
(Mean-STDEVP)
comp1,2,3
1.600
1.400
1.200
Dispalecements in microns
1.000
0.800
0.600
0.400
0.200
0.000
Notch positions
2
3
4
5
6
7
8
(Mean+STDEVP) comp1 2,3,
1.246
1.796
1.620
1.616
1.479
1.485
1.530
(Mean-STDEVP) comp1,2,3
0.759
0.980
0.737
0.879
1.282
1.011
1.068
Acceptable vibration band
Annexure- XI J2