Reasoned Document for Draft Specification of Oil ... Revised... · Reasoned Document for Draft Specification of Oil Lubricated Reciprocating Compressor Cl. No. Description in Specification

Reasoned Document for Draft Specification of Oil Lubricated Reciprocating Compressor

Cl. No.

Description in Specification Comments from Manufacturers & Railways RDSO Comments

1.0 SCOPE:

1.1 This is a general technical specification for motor driven oil lubricated compressor of 1750 LPM (FAD) capacity for three phase & WAP-4 class of electric locomotive application fitted with 180 KVA SIV. There is an additional load on the locomotive air supply system circuit (FP circuit) with introduction of LHB rakes provided with air suspension springs and Controlled Toilet Discharge System (CTDS), hence it is felt necessary to enhance the air supply capacity of conventional passenger locomotives hauling longer and modern rakes configured trains.

FTRTIL RDSO has already floated WAP-4 Loco requirement with Oil free Compressor, Specification No: RDSO/2008/EL/SPEC/0076, Rev. ‘2’ which also has the capacity of 1750 lpm. Clarification would help to understand the difference between the proposed spec to the spec already available.

The Firm seeks clarification.

The specification referred is for oil free compressors of 1750 lpm capacity. This specification is for lubricated compressors as lubricated reciprocating compressors which are still in service.

ELGI Accepted Noted

AIML No comments Noted

KBIL No comments Noted

River Noted & Understood Noted

Saberdais Acceptable Noted

Railways No comments Noted

1.2 The compressor shall be mounted in the under frame of the existing three phase electric locomotives on-board in WAP-4 class of electric locomotives fitted with 180 KVA SIV, modified driver’s cabin and tri-plate mounted Panel Mounted Brake System (PMBS) as well as underslung mounted in the existing 3-phase electric locomotives.

FTRTIL FT takes note of the information, which is not a requirement per definition. This information does not need any commitment from FT side (NOTED)

Noted

ELGI Accepted Noted



River Noted & Understood Noted



1.3 The mounting arrangement in 3-phase electric locomotives shall be as per CLW drawing No. 1209.02.127.084 revised dated Sept 2008. The overall dimensions for

FTRTIL FT takes note of the information, which is not a requirement per definition. This information does not need any commitment from FT side (NOTED)

Noted

mounting of 1750 lpm capacity compressor may differ for 3-phase electric locomotives & WAP-4 electric locomotives due to space constraints. The overall envelop space for mounting of 1750 LPM oil lubricated motor-compressor unit in 3-phase locomotives & conventional passenger electric locomotives have been specified separately in clause 7.4 & 7.5. The purchaser shall specify the requirements of high capacity (1750 LPM) compressor for three phase & conventional passenger electric locomotives clearly in the Tender documents.

ELGI Accepted. Need CLW drawing No. 1209.02.127.084 revised dated Sept 2008) Comments provided in Clause 7.4 Accepted.

Noted


KBIL CLW drawing No. 1209.02.1270.84 revised dated Sept.2008 to be provided by RDSO.

Agreed.

RIVER Noted and Understood .However please refer our comments on clause 7.4 & 7.5

Noted



1.4

The inlet air for the compressor shall be filtered air at ambient temperature available in the machine room of the conventional passenger electric locomotives and shall be unfiltered in underslung mounting arrangement for 3- phase electric locomotives.

FTRTIL FT proposal is compliant with the requirement. ( compliant)

Noted

ELGI Accepted Noted

AIML No comments. Noted


RIVER Noted and Understood unfiltered air quality may please be defined.

Noted


Railways No comments. Noted

1.5 The tenderers/ suppliers are required to familiarize themselves with the layout of the equipment of the locomotives, including the pneumatic circuit and pipe layout before quoting for their products. Adequate clearance from adjacent equipment of the locomotives shall be maintained for other maintenance purposes.

FTRTIL Noted Noted

ELGI Noted Noted

AIML Noted Noted


RIVER Noted & Understood Noted


RAILWAYS No comments Noted

1.6

This specification covers clauses which call for agreements between the Indian Railway and the supplier and supply of certain technical information by the manufacturer / supplier at the time of submitting tenders for the equipment.

FTRTIL Noted Noted

ELGI Noted Noted

AIML Noted Noted


RIVER We understand that the reference is being made for the data asked in Annexure I & II.

Noted



1.7 Any deviations from this specification, with a view to improving the performance may be given due consideration, provided, full particulars with justification, thereof are furnished. It may however be noted that due to limited availability of space in locomotive and the necessity to ensure inter changeability with existing equipment increase in the overall size and mounting dimensions shall not be allowed normally.

FTRTIL Noted Noted

ELGI Noted Noted




Saberdais Unacceptable No change is warranted.


2.0 TERMINOLOGY:

2.1 For the purpose of this standard, the following definitions in addition to these given in Indian Standard “Glossary of Terms Relating to Compressors and Exhausters” IS 5727:1981, Reaffirmed 2001 shall apply.

FTRTIL Noted Noted

ELGI Noted Noted






2.2 Manufacturer: The party manufacturing the machine. The manufacturer may or may not be the supplier.

FTRTIL Noted Noted

ELGI Noted Noted




Saberdais Both Manufacturer & Supplier No change in status is warranted


2.3 Engineers: The term ‘Engineers’ shall apply to the Director General, Research Designs and Standards Organization, Ministry of Railways, Lucknow – 226011, Dy. Chief Electrical Engineer (D), CLW / Chittaranjan and person to persons authorized by them.

FTRTIL Noted Noted

ELGI Noted Noted






2.4 Sub-Contractors: Sub-Contractor means person to persons from whom the manufacturer buys parts / assembles for fitment to the equipment to be supplied.

FTRTIL Noted Noted

ELGI Noted Noted






2.5 Supplier: The party supplying the machine.

FTRTIL Noted Noted

ELGI Noted Noted





3.0 STANDARDS:

3.1 1. IS 5456 : 2006 2. IS 11461- 1985 3. IEC 60072-1/1991 4. IEC 85 5. IS10431 : 1994 Reaffirmed 2008 6. IS11465-1985 7. ISO-2151 2004 8. IS 5727:1970Reaffirmed 2001 9. SPEC.NO.SPEC/E-10/3/09(Motor)

FTRTIL 3.1.1,3.1.7,3.1.8,3.1.9 is Accepted and 3.1.2,3.1.3,3.1.4,3.1.10 3.1.11 has been Noted

Noted

ELGI Noted.

Noted

AIML No comments

Noted


RIVER

Noted & Understood Noted

With Amendment 1 & 2 of June 2003 10. ISO 8573-1: 2010(E) Compressed air – Part 1 Contaminants and purity classes. 11. Standard IEC 61373, Category-1 Class –A edition 2.0, 2010-05 Railway applications -Rolling stock equipment – Shock and vibration tests.



3.2 Latest version/revision of the standards and specifications etc shall be followed, unless specifically mentioned otherwise.

FTRTIL Noted Noted

ELGI Accepted Noted



RIVER Noted & understood Noted



4.0 DESIGN FEATURES:

4.1 The equipment offered shall preferably be of – - Simple in design -Good workmanship - Easy for maintenance and operation - Robust and rugged in construction, suitable for traction duty application. - Preferably the compressor should be oil splashed/ forced lubricated type

FTRTIL Noted Noted

ELGI Accepted Noted



RIVER Noted and Understood .Best engineering practices will be applied

Noted

Saberdais Acceptable Oil splashed Noted


4.2 Inter Cooling and After Cooling of air shall be provided with the compressor so as to limit the final delivery temperature of air shall not be more than 30 °C above ambient when working at a pressure of 10.5 kg/cm2.

FTRTIL Delivery Air temperature to 30°C above ambient is not advisable and reasons as follows: 1) Air dryer, RDSO Specification no-RDSO/2008/EL/SPEC/0076, Rev.’1’, Clause no: 14.1 calls fir ambient temperature - 5 to 55 °C and Maximum temperature of air at inlet port Up to 60°C. As per this draft spec, Compressor ambient temp is +60 deg C. This means, the outlet temperature will be + 90°C (60°C+30°C). This is not acceptable to Air dryer since the

It was decided in the meeting and minutes of meeting issued vide letter no. EL/3.2.15/3-phase dated 21.11.2017. After detailed deliberations it was decided to keep it 230 C above ambient temperature.

performance of the air dryer will have adverse impact on its performance dew point depression and reliability. This will also impact on periodicity of overhauling of Air dryer. Additionally, the temperature of the inlet air affects the moisture, additional loading on desiccant of Air dryers. Example, for every 20 degrees C drop in temperature, the moisture content roughly reduces by half. 2) Higher outlet temperature of Compressor contains higher water mass and it tends to more loss in system. Water vapour saturation capacity of air at selected atmospheric temperatures Temperature -10 0 5 10 15 20 30 50 70 90 Water vapour, gr 2.1 4.9 7 9.5 13 17 30 83 198 424 Example, Compressed air will still contain 17 grams of moisture @20°C. Same, the Inlet temperature increases Water vapour also increases. FT strongly suggest to keep Compressor outlet temperature should be Ambient +20°C Complaint. The details Annexure-I

ELGI Working pressure should be 10.2 kg/cm² as per CLW Spec.

.

AIML In our current prototype model we have achieved temperature approx. 22 degree Celsius and we believe that maximum limit for temperature at final delivery should not be higher than 26 degree Celsius above ambient. In the meanwhile this also needs to be determined considering the effects of hanging

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position, stone protection mechanism provided in the system.

KBIL Till date, requirement of ‘final delivery temperature of air’ was ‘not more than 200C above ambient’, mentioned in other specifications of compressor also. Hence it will be better to keep it as 200C, else with increase in air temperature, condensation will increase as well as life of sealing parts in down line may affected by temperature increase.

RIVER Noted and Understood .Outlet air temperature rise being critical, our principal’s are reviewing this requirement. We will get back to you with our on this clause soon.

Saberdais Below 200C be maintained.

Railways No comments

4.3 The Free Air Delivery (FAD) of the compressor should not be less than 1750 LPM at 1000 meters altitude above sea level at 200C with relative humidity of 95% at 10.5 Kg/cm2 air pressure.

FTRTIL Noted Noted

ELGI The Free Air Delivery (FAD) of the compressor should be 1750 LPM at 200 C with relative humidity of 95% at 10.2 Kg/cm2 air pressure. Tolerance as per IS 5456 will be applicable

It was decided in the meeting and minutes of meeting issued vide letter no. EL/3.2.15/3-phase dated 21.11.2017.That to keep the Free Air Delivery (FAD) of the compressor should not be less than 1750 LPM. AIML point Represent that the least

requirement is @10.5Kg/cm2, 1750LPM so according to our experience, compressor FAD depend on several factor like atmosphere condition and on machine mating parts tolerances those put the impact from 50 to 80 LPM at 20 HP machine from a mean value that we target during design. So to attain minimum 1750 LPM for all machine for that we require to target a design mean value nearly 1800 to 1830 LPM that directly put the impact nearly 1HP on shaft brake horse power. Practically a compressor took nearly 20 hp

for 1750LPM which have tolerances on FAD. So to attaining this value at minimum side it can raise power requirement. And we also have constrains for power generation unit (Motor) availability according to HP rating. Conclusion: - To achieving minimum 1750 LPM in that case if power requirement increase for that we need to run the motor in design safety factor zone.(Above rated current)

KBIL Normally, FAD is defined & measured at standard condition and the de-rated value can be calculated.

This is the de-rated calculated value of 1750 LPM at 1000 m altitude above sea level.

RIVER Noted and Understood Noted



5.0 NORMAL DUTY:

5.1 The compressor motor set shall be suitable for continuous operation at pressure of 10.5 kg/cm2 without causing higher temperature, damage and unusual wear to the components

FTRTIL Noted Noted

ELGI Accepted Noted



RIVER Noted & understod Noted



5.2 The compressor will work continuously but after building up a pressure of 9.5 kg/cm2 in the main reservoir. Compressor motor supply will be cut off by the pressure governor setting and will restart at 8.0 Kg/cm².

FTRTIL Noted. Compressor ON / OFF is managed by customer. Compressor is capable to work from 8.0 Kg/cm² to 9.5 Kg/cm²

Agreed.

ELGI Accepted. Cut off pressure to be mentioned as 10.2 kg/cm2

Working pressure remains 10.2 Kg/cm2. 10.5 Kg/cm2 is test pressure.


KBIL Building up pressure of 9.5 10.5 Kg/cm2 9.5 Kg/cm2 is the RGCP valve pressure setting by the user railways, which can be changed as per requirement.

RIVER Noted and Understood. Compressor is capable to work from 8.0 to 9.5 kg/cm2. However we understand that pressure governor and its setting managed by the costumer and such controls are not in the scope of this specification.

Agreed



6.0 DRIVE:

6.1

The compressor driven by 3 phase induction motors controlled by a 3 phase contactor of adequate rating will be started direct on line start. Class of protection is IP 55/ Terminal Box IP 65. The motor shall be as per the RDSO specification no. E-10/3/09 (Motor) with amendment 1 & 2 of June 2003 (or latest) for induction motors for driving auxiliary machines of Electric Locomotives. Motors used to drive compressor shall be of make and type approved by RDSO for the application.

FTRTIL Compliant. Noted

ELGI Noted. Noted

AIML No comments. Noted

KBIL No comments. Noted

RIVER Noted & understood. Noted


Railways Starting current of the motor should be restricted to 90 -110 Amps

Inductance variation between two phase windings should be within the limits of 5% to 6 %

Static load and (KN) and Dynamic load(KN) of the bearing has to be designed to be sustained the variations of the rolling stock of Railway and have long life

As per cl. 4.3 of RDSO specification no. E-10/3/09 (Motor) with amendment 1 & 2 of June 2003 (or latest) the maximum sataring current shall not exceed 6.5 times the normal full load for 4 pole motor, 7.0 times for 2 pole motors and 7.5 times for 6/8 pole motors for MCP applications. In three phase locomotive motor supply has soft start and in convention locomotive motor starts direct online. Therefore, the para 6.1 rewarded ,that The motor shall be as per the RDSO specification no. E-10/3/09 (Motor) with amendment 1 & 2 of June 2003 (or latest) for 3-phase induction motors for driving auxiliary

machines of Electric Locomotives. Motors used to drive compressor shall be of make and type approved by RDSO for the application. Class of protection is IP 55/ Terminal Box IP 65.

6.2 The drive to the compressor shall be either direct or through a suitable flexible coupling.

FTRTIL Compliant Noted

ELGI Accepted Noted




Saberdais Suitable flexible coupling. No change is warranted.


6.3 Flexible coupling ”preferably disk coupling” shall be selected to suit the arduous duty encountered in normal service without the necessity of renewing any wearing part within three years of its operation. However better alternate coupling arrangement may also be acepted. It shall be of simple design and shall require minimum attention during operation. It shall be possible to replace the wearing components of the coupling in situ without disturbing the machine alignment. The coupling shall be required to withstand shocks due to frequent starting and stopping up to 30 cycles per hour in cycle of 50% OFF and 50% ON time and variation of load on compressor motor set.

FTRTIL Change of Coupling element to be done in Workshop and not SITU. Generally, Coupling element to be changed during overhaul of Compressor and hence need not a problem. Hence, RDSO may please be changed accordingly.

Flexible coupling “preferably disc coupling” has been added. Better alternate coupling arrangement may also be accepted.

ELGI Accepted Noted



RIVER Noted and Understood. Change of coupling element should be done in workshop and not SITU.RDSO may please change accordingly.

Flexible coupling “preferably disc coupling” has been added. Better alternate coupling arrangement may also be accepted.

Saberdais Acceptable. But when replaced wear component alighnment must

No change is warranted.


6.4 The limits of angular, radial and axial misalignments, which the coupling is capable of withstanding, shall be

FTRTIL Noted

ELGI Accepted

AIML No comments

intimated to ‘Engineers’/ RDSO and their approval to be obtained.


RIVER Noted & understood



6.5 The coupling shall be required to withstand shocks due to frequent starting and stopping and variation of load on compressor motor set. Manufacturer shall advise technical details including breakaway torque of the coupling.

FTRTIL The Offered product is already proven design and reference list of installation will be Provided. NOT Complaint

The product model 2A320D has been failing continuously on Railway applications, therefore, no change is warranted .

ELGI Accepted Noted






7.0 MOUNTING & LIFTING ARRANGEMENT

7.1 Three point mounting arrangement with proven design damping preferably of metallic helical coil type in 3-phase locomotive and four point mounting arrangement with proven design damping in WAP-4 and conventional passenger electric locomotive fitted with 180 KVA SIV modified driver’s cabin and tri-plate mounted Panel Mounted Brake System (PMBS). The resilient mounts shall be suitable for absorbing the vibration level up to 90% of the level

FTRTIL FT's Compressor with Anti vibration mounts NOTED

Noted

ELGI Accepted. RR20100CC is using Wire rope isolator. RR20100CG(M) is using Soft and hard mount FEA is not applicable for helical coil and hard/soft mount application.The load versus deflection graph of the part will be provided


generated on the compressor and motor size. The diameter of helical coils may be kept in accordance to the motor & compressor side. The supplier shall submit Finite Element Analysis (FEA) report to the “Engineers”/ RDSO for approval.

AIML Above point Represent the resilient (mounting pad or helical coil isolator) material should require FEA simulation. This will be a dynamic simulation so result variation could be very high for smaller point variation. For performing the simulation for that some of points require restriction during system study. 1. Basic System information i.e. how much loco vibration need to be considered or took it as idle system? 2. How many degree of freedom need to provide to isolator? 3. Is any external force need to consider during study? 4. Is any constrained for vibration frequency need to consider during study?



RIVER Noted and Understood Please elaborate the input supply of the compressor. We understand 415V 3-phase 50 Hz sinusoidal input is available

Noted



7.2 The compressor and its mounting arrangement shall be of robust design for traction duty and shall withstand satisfactorily the vibration and shocks normally encountered in service. Mounting arrangement of the compressor motor set shall be suitable for mounting in the existing conventional locomotive type WAP-4 & 3-phase electric locomotives

FTRTIL Noted Noted

ELGI Accepted Noted






7.3 The supplier has to ensure that the height of the lowest part of the compressor motor unit after mounting on the locomotive underframe is not less than 176 mm

FTRTIL Noted Noted

ELGI Accepted Noted

AIML In above point we think minimum height from compressor mounting position to rail level require to be provide or

Schedule of Dimensions (SOD) is to be followed.

above rail level for new wheel conditions. The details of arrangement of bracket on the underframe of the locomotives shall be submitted along with FEM stress analysis.

constrain the maximum compressor height including all components.


RIVER Noted and Understood Height of mounting face for compressor from the rail level for new wheel may please be provided.

Schedule of Dimensions (SOD) is to be followed.


Railways No comment Noted

7.4 The overall dimensions for under slung mounting in three phase locomotives shall be preferably fall within the limits of Length = 1460 mm Width = 740 mm Height = 825 mm.

FTRTIL As per CLW Specification no: CLW-ES-3-0100 Alt E, Length = 1464 mm ; Width = 765 mm ; Height = 840 mm. New specification is not matching CLW specification. To be modified as per CLW specification. NOT COMPLIANT

The preferably overall dimensions for underslung mounting in 3-phase locomotives are given, therefore, no change is warranted.

ELGI Existing Lx B x H of RR20100CG(M) is 1450 x 871 x 768 mm and this is compatible in the 3-phase locomotives

Noted

AIML Width of the system could be possible in inline compressor design but in W-shape compressor design to achieve this width is complex for W-shape design width should be at least 820 mm to 850mm approx 100 mm margin in existing design for 1750LPM compressor. And height could be reduce from 825 to 725 that’s possible

No comments are offered on the design limitation of the product of any manufacturer. No change is warranted


RIVER Noted and Understood We request you to retain the limiting size as in existing products L= 1465 mm W+765 mm and H= 840 mm . The clause may please be modified




7.5 The overall dimensions for on board mounting in WAP-4 conventional locomotives shall be preferably fall within the limits of Length = 1400 mm Width = 640 mm Height = 600 mm.

FTRTIL As per CLW Specification no: CLW-ES-3-0100 Alt E, Length = 1464 mm ; Width = 765 mm ; Height = 840 mm. New specification is not matching CLW specification. To be modified as per CLW Specification. NOT COMPLIANT


ELGI Lx B X H of 'RR20100CG(M) OB' is 1450 x 871 x 800 mm and it has been fitted in WAP4 locomotives. Existing 'TRC 1000 MNUG' of dimension Lx B x H : 1135 x 770 x 925 mm is also running in also running

No comments are offered on the design limitation of the product of any manufacturer. No change is warranted

AIML Width of the system could be possible in inline compressor design but in W- shape compressor design to achieve this width is complex for W-shape design width should be at least 820 mm to 850mm approx in existing design for 1750LPM compressor. And height should be from 600 to 660-690.

No comments are offered on the design limitation of the product of any manufacturer. No change is warranted.

KBIL The firm has suggested increasing the width from 640 mm to 770 mm in view of adaptability of other compressor.

The preferably overall dimensions for on-board mounting in WAP4 locomotives are given, therefore, no change is warranted.

RIVER We request you to retain the limiting size as in existing products L= 1465 mm W+765 mm and H= 840 mm . The clause may please be modified. The clause therefore may be modified.This will enable Indian Railways to have a common for both 3-phase and WAP-4 Electric locomotive, with different mounting arrangement

No comments are offered on the design limitation of the product of any manufacturer. No change is warranted.

Saberdais Unacceptable No change is warranted.

Railways No comments Noted.

7.6 Adequate numbers of lifting hooks shall be provided to facilitate lifting of the compressor motor set.

FTRTIL Noted Noted

ELGI Accepted Noted

AIML No comment Noted



Railways No comment. Noted

7.7 The compressor shall also be provided with suitable safety slings to prevent it from falling down in case of failure/ breakage of the underslung mounting arrangement.

FTRTIL Noted Noted

ELGI Accepted Noted






7.8 For on-board mounting of the compressor in WAP-4 loco fitted with 180 KVA SIV, modified driver’s cabin and tri-plate mounted Panel Mounted Brake System (PMBS), mounting holes of the compressor motor unit shall be in accordance with the mounting holes provided in the machine room of the locomotive for fitment.

FTRTIL Mounting hole requirements in the machine room may please be provided as a part of specification . CLARIFICATION NEEDED

The mounting holes as provided for the on-board mounting hole arrangement of 1000 LPM capacity compressors may be followed.

ELGI Accepted Noted



RIVER Noted and Understood. Mounting holes requirement in the machine room may please be provided as a part of specification as requested in clause no. 1.2 above.

The mounting holes as provided for the on-board mounting of 1000 LPM capacity compressors may be followed.



8.0 COOLING:

8.1 The compressor shall be air cooled. A cooling fan of adequate capacity, of simple and rugged design and light weight shall be provided.


ELGI Accepted Noted






8.2 The fan shall be mounted on the shaft and shall be dynamically balanced.


ELGI Accepted Noted






8.3

Intercooler of adequate cooling capacity / shall be provided as an integral part of the compressors unit. The intercooler shall not interface with free access to other equipment of the compressor.


ELGI Accepted Noted

KBIL Intercooler is used for multi- stage compression units only. Hence, may be kept as ‘Optional’ in view of other compressor technology.

Agreed, but presently 2 stage reciprocating compressors are in service for electric locomotives. However, the specification is not product specific, therefore, does not bar adoption of alternate better compressor technology.





8.4 After cooler of radiator type / or superior design shall be provided with the compressor. Auto drain valve provided with the unit should ensure periodic drainage of condensation.

FTRTIL Auto drain valve provision to be decided based Compressor design and it will not restricted. Hence, RDSO may please be removed the Auto drain valve in specification.

It was decided in the meeting and minutes of meeting issued vide letter no. EL/3.2.15/3-phase dated 21.11.2017. “Manual drain valve may be provided.” Specification will be amended accordingly.

ELGI Manual drain valve will be provided as main reservoir already has auto drain valve Accepted

AIML point auto drain valve need to be provided in system so for that we require the spec of auto drain valve like at what frequency you wish to operate it and from where input power need to be provided.

KBIL Arrangement for drainage of condensation should be provided, but might not be auto drain valve exactly.

RIVER Noted & understood

Saberdais Acceptable


9.0 LUBRICATION SYSTEM:

9.1 The lubrication arrangement shall be reliable and capable of withstanding continuous operation under sun

FTRTIL In recent upgradation of Compressor technology, Oil free compressor is much advance technology compare to Oil

The oil lubricated reciprocating compressors are in service on electric locomotives. No change is

temperature encountered on a locomotive, without undue carbonization of the moving parts and discharge ports/valves.

Lubricated Compressor which outdated technology. I )Economical advantages in Oil free Compressor: a) No need to periodically check the oil level; b) No need to oil refill; c) No need to change oil and cartridges with consequently no need to treat the exhausts; II) Technical advantages in Oil free Compressor: a) No oil spill with consequently no pollution all along the life of the fleet; b) No oil inside the compressed air with consequent no contamination of circuit components like filter cartridges, desiccant material, rubber element

warranted.

ELGI Accepted Noted


KBIL No comments Noted.




9.2 The oil consumption shall be low and shall be specified. The capacity of oil tank should be adequate for not requiring oil topping between preventive maintenance schedule of locomotive, i.e. 90 days.

FTRTIL Refer remarks Clause no:9.1 CLARIFICATION NEEDED


ELGI Accepted Current machines work for 60 days only.

No change is warranted

AIML it’s clear that machine oil consumption need to within limit but we think some point should be took in consideration like due to atmospheric condition oil consumption could rise in running

machine and some time heavy dust in atmospheric can impact in filter due to which oil consumption increase. Based on our experience & by considering the all weather conditions. I think, Oil consumption value should be more than

1.2 ml per hour. For calculation of top up time- we are needed average running hours in 90 days.





Railways The capacity of oil tank should be adequate not requiring oil tapping for 120 days instead of 90 days.

Not agreed. For that the sump capacity of the existing compressors needs to be increased and oil consumption needs to be reduced considerably.

9.3 Metallic dip-stick/oil sight window shall be provided for checking oil level.

FTRTIL Refer remarks against Clause no: 9.1 CLARIFICATION NEEDED 9.3.1 The lubrication system shall have a filter of adequate capacity. The filter shall be easily removable for maintenance. Refer remarks Clause no:9.1 CLARIFICATION NEEDED 9.3.2 Lubricating oil sump shall be designed to permit easy drainage/cleaning. Refer remarks Clause no: 9.1 CLARIFICATION NEEDED

The provision of oil filter is required. This issue pertains to metallic dipstick. No change is warranted.

ELGI Accepted Noted




Saberdais i) Unacceptable No change is warranted.


9.4 The lubrication system shall have a FTRTIL Compliant Noted.

filter of adequate capacity. The filter shall be easily removable for maintenance.

ELGI To be mentioned that it is required for force lubrication alone

Noted.


KBIL Filter for lubrication system is not mandatory for all type of compressors.

It was decided in the meeting and minutes of meeting issued vide letter no. EL/3.2.15/3-phase dated 21.11.2017. The lubrication system shall have a stainer/filter of adequate capacity. The stainer/filter shall be easily removable for maintenance.




9.5 Lubricating oil sump shall be designed to permit easy drainage/cleaning.

FTRTIL Compliant Noted.

ELGI Accepted Noted.





9.6 Inter-connecting pipes of the lubricating system shall be so designed so that there is no possibility of damage during transit, service, storage and handling.

FTRTIL Refer remarks Clause no:9.1 CLARIFICATION NEEDED






Saberdais No pipe in lubricating system. Noted


10.0 MISCELLANEOUS:

10.1 For securing protective hoods, pipe brackets etc. foundation and cylinder head bolts shall not be utilized. If aluminium alloy is used, threaded connections in aluminium portion for fastening of components shall not be used.

FTRTIL Lifting hooks provided in compressor OGA drawing. NOTED

Noted.







10.2 Wherever bearings are grease lubricated, easily accessible grease nipples to IS 4971:2007 “Recommendations for selection of industrial floor finishes” shall be provided. Suitable vent for overflow of excess grease shall also be provided. Type of indigenously available grease to be used, shall be specified.

FTRTIL NOTED Noted.





Saberdais No Grease required. Noted


10.3 Direction plate with 50 mm arrow shall be fitted on the compressor and motor, separately to indicate the normal direction of rotation.


ELGI Either plate or embossing in casting parts with paint can be accepted

It was decided in the meeting and minutes of meeting issued vide letter no. EL/3.2.15/3-phase dated 21.11.2017. Direction plate/ embossing with 50 mm arrow shall be fitted on the compressor and motor, separately to indicate the normal direction of rotation.





Railways Since the compressor motor is driven by inverter fed supply ceramic coated bearings are to be provided in view of circulating currents.

Motor is not part of this specification

11.0 NAME PLATE: The compressor shall have indelibly marked on a nameplate at least the following information. a. Manufacturer’s name and also brand name monogram if any. b. Type and Serial no.








c. Capacity (FAD) in liters / minute. d. Effective pressure. e. Month & year of manufacture

12.0 LUBRICATION CHART: Periodical lubricating instructions shall be affixed at a convenient location indicating the type, quantity and the frequency of lubrication required for the compressor’s Bearings if required.

FTRTIL In recent upgradation of Compressor technology, Oil free compressor is much advance technology compare to Oil Lubricated Compressor which outdated technology.CLARIFICATION NEEDED





RIVER Noted and understood Noted



13.0 SERVICE CONDITION:

13.1 The compressor shall be capable of working satisfactorily under the following conditions: • Maximum Atmospheric temperature : Under Sun : 70°C : In Shade : 55°C • Ambient temperature - 5° C to 55 °C. • Maximum temperature of air at inlet port – Up to 60°C. • Relative humidity – Up to 100% saturation during rainy season - 60% Normal Maximum • Altitude – Sea level to 1000 m. • The locomotive and equipment shall be designed to work in coastal areas (humid and salt laden atmosphere possible),

FTRTIL In recent upgradation of Compressor technology, Oil free compressor is much advance technology compare to Oil Lubricated Compressor which outdated technology. NOTED



AIML No comment Noted.





13.2 Vibration: The equipment shall be designed to withstand the vibrations

FTRTIL Noted Noted.


and shock encountered in service satisfactorily as specified in IEC 61373 Category 1 edition 2.0, 2010-05 The equipment shall withstand satisfactorily the vibration and shock normally encountered in service.






14.0 ACESSORIES

14.1 The compressor unit shall be fitted with the following accessories: i. Dry type air filter for suction. ii. Intercooler Safety valve and drain cock. iii. After cooler, fitted with auto drain valve. iv. Flexible rubber hose pipe for use on the delivery side, which shall be capable of withstanding the delivery of hot air temperature.

FTRTIL (i), (iii) and (iv) are complied. (ii) Intercooler Safety valve provided and not Drain valve.

It was decided in the meeting and minutes of meeting issued vide letter no. EL/3.2.15/3-phase dated 21.11.2017.--------- “ ii. Intercooler Safety valve and condensate drain arrangement. iii) After cooler, fitted with manual drain arrangement. ”

ELGI i) Accepted ii) Accepted iii) Manual Drain Valve iv) Accepted

AIML point auto drain valve need to be provided in system so for that we require the spec of auto drain valve like at what frequency you wish to operate it and from where input power need to be provided.

KBIL Arrangement for drainage of condensation should be provided, but might not be auto drain valve exactly.

RIVER Noted and Understood However we will get back to you with our comments after our principal’s response


Railways The under slung 1750 lpm compressor have noticed lot of dust in inlet filters and this dust is causing carbonization of disc valve. The inlet filter should be two stage filters to avoid carbonization. The quality of flexible rubber hose pipe for use on the delivery side shall be of IRS 200 grade and above.

This point is not taken in specification and left with the designer to give reliable filters and hose pipe.

15.0 TESTING & INSPECTION

15.1 TYPE TESTS FTRTIL Compliant Noted.

15.2 Test Conditions: All measurements are made using with 50Hz sinusoidal voltage for 415 V 3-phase AC electric motors during type test: i) Normal Voltage ± 5% and The tests are carried out in local atmospheric conditions






Railways

No comments Noted

15.3 Type Test: Type test according to IEC 34-1 will be carried out for motor if not already approved by RDSO. RDSO/Lucknow Specification No. E-10/3/09 Motor Part II








16.0 TEST DEATAILS

16.1 The testing shall be conducted on the compressor unit and testing shall generally conform to IS 5456: 2006 or relevant BS specification. The motor for compressor shall be procured from RDSO/CLW approved sources only. If, however, the motor is procured from any other sources not approved by RDSO/CLW, it shall also be subjected to type tests separately.








16.2 Whenever a new series of compressor is manufactured, a unit shall be subjected to a series of tests to establish the reliability and performance of the compressor.


ELGI Accepted Noted






16.3 The type tests shall be witnessed by RDSO.


ELGI Accepted Noted






16.4 The type tests shall constitute the following tests and measurements. Mechanical tests – Cl. 17.0 FAD Test -Cl. 17.1 Starting tests - Cl. 17.2 Endurance test -Cl. 17.3 High environment test - Cl. 18.0 -Tilted Condition Test - Cl. 19.0 Air quality test - Cl.20.0 Noise level test Cl.21.0 Weight measurement Cl. 22.0


ELGI Accepted Noted





Railways

No comments Noted

17.0 MECHANICAL TESTS: Tests Duration Running of compressor on discharge pressure of i. 8 kg/cm² -5 Hours ii. 9 kg/cm² -7 Hours iii. 10.5 kg/cm² -10 Hours The supply shall be of 415 V, unbalanced 3 phase at 50 C/s.


ELGI Working pressure is 10.2Kg/cm2 as per CLW specification


AIML No comments

Noted

KBIL OK, except measuring of ‘Bearing temp.” which is difficult to measure in compressor. However, bearing housing/ body surface temperature can be measured for reference.

Agreed, as per cl. 5.8 of IS 12802: 1989 the measurement of bearing temperature is to be done either by ETD method which is very complicated. Presently bearing housing/ body surface temperature is measured.




17.1 During the above tests arrange to measure Air flow when the compressor is working against pressure of 8 kg/cm2, 9 kg/cm2& 10.5 kg/cm2, after all parts have attained the maximum temperature, should not be less than 1750 LPM. Repeat measurements of Air flow when the unit is operating at rated pressure of 10.5 kg/cm2 and when the motor is supplied with 373 volt unbalance at 50 c/s. Record the method of test and measurement. Calculate value of free air delivery (FAD) volumetric efficiency and record it. Note: At frequent intervals during the testing of the compressor, listen carefully in the vicinity of each roller bearing, should there be any excessive noise then the compressor must be stopped. Measure the temperature rise for each stator winding by resistance method with 415V, 373V & 457 V unbalanced at 50 c/s supply, when the unit is operating at the rated pressure of 10.5 Kg/cm².


ELGI Working pressure is 10.2Kg/cm2 as per CLW specification


AIML Practically a compressor took nearly 20hp for 1750LPM which have tolerances on FAD. So to attaining this value at minimum side it can raise power requirement. And we also have constrains for power generation unit (Motor) availability according to HP rating. Conclusion: - To achieving minimum 1750LPM in that case if power requirement increase for that we need to run the motor in design safety factor zone.(Above rated current)

No change is warranted, The capacity of the compressor as 1750 ± 5% LPM. However it was decided to keep the Free Air Delivery (FAD) of the compressor should not be less than 1750 LPM.





17.2 Immediately after completion of the tests under clause 16.1 always operating against the pressure 10.5 kg/cm2, the compressor motor unit shall be run successfully as follows. • 10 minutes under 75% rated voltage. 1 minute stop • 5 minutes under 125% rated voltage 1 minute stop

FTRTIL Noted Noted

ELGI Accepted Noted


KBIL Nowadays, converters are being used with supply voltage tolerance ±5%. Hence Motor’s performance should be maintained at 415±10%

It was decided in the meeting and minutes of meeting issued vide letter no. EL/3.2.15/3-phase dated 21.11.2017. The compressor motor unit shall be run successfully as follows. • 10 minutes under 90% rated voltage.

• 10 minutes under 110% rated voltage 1 minute stop • 10 minutes under 125% rated voltage 1 minute stop • 10 minutes under 75% rated voltage

1 minute stop • 5 minutes under 110% rated voltage 1 minute stop • 10 minutes under 90% rated voltage 1 minute stop • 10 minutes under 110% rated voltage 1 minute stop • 10 minutes under 90% rated voltage




17.3 Endurance test is a continuous test and shall be carried out by running the compressor with compressor delivery pressure at 10.2 kg/cm2 running at rated speed. The test shall be of 400 hours duration. Following measurements shall be made during the of endurance tests at intervals one hour: (i) Ambient temperature. (ii) Suction air temperature (iii) Inter stage pressure (iv) Temperature of air at inlet to compressor. (v) After cooler outlet air temperature. (vi) LP-1 in let air temperature (vii) LP-2 in let air temperature (viii) LP-1 out let air temperature (ix) LP-2 out let air temperature (x) HP air in let air temperature (xi) HP air out let air temperature (xii) Intercooler inlet air temperature (xiii) Intercooler outlet air

FTRTIL Noted .During proto type test, temperature measurement to be carried out by Laser Thermo meter

The temperature measurement system must be accurate and digital.

ELGI Accepted Noted

AIML No comment. Noted

KBIL Few requirements may not be applicable. Example, in case of single stage compression, there wiil not be intercoolers & others.

Agreed, but presently 2 stage reciprocating compressors are in service for electric locomotives. However, the specification is not product specific, therefore, does not bar adoption of alternate better compressor technology.

RIVER Noted and Understood During prototype test, temperature measurement shall be carried out by suitable technique like laser thermometer

The temperature measurement system must be accurate and digital.



temperature. (xiv) Temperature of cylinder heads (L.P & H.P) & Valve caps, where fitted. (xv) Temperature of crank case. (xvi) Motor body temperature (xvii) Lube oil pressure, in case of pressure lubrication. (xviii) Lube oil consumption (after completion of the tests)

17.3.1 Before and after completion of the endurance tests, the compressor shall be opened and dimensions of all wearing parts shall be recorded.

FTRTIL NOT COMPLIANT Only type test to conducted as per RDSO requirement. No endurance test will be performed, since the product is already proven in India applications


ELGI Accepted Noted






17.3.2

Before and after Endurance test Free Air Delivery (FAD) test shall be done. Before and after completion of the endurance tests, the oil filled and oil extracted shall be measured and oil consumption ml per hour shall be calculated. The oil consumption should not be more than 1.2 ml per hour.

FTRTIL NOT COMPLIANT

Only type test to conducted as per RDSO requirement. No endurance test will be performed, since the product is already proven in India applications

The product model 2A320D has been failing continuously on Railway applications, therefore, no change is warranted .

ELGI Accepted Noted






17.3.3 The endurance tests of 400 hours shall also be applicable to the existing design of compressors, in case of changes in operating requirements such as increase in speed of operation, working pressure etc.


The product model 2A320D has been failing continuously on Railway applications, therefore, no change is warranted.

ELGI Accepted Noted






17.3.4 Running of the compressor on load at 10.5 kg/cm2 pressure. The compressor shall run of full load for a minimum period of 8 hours at a stretch. At least for half and hour in the 8 hours running, the compressor shall be loaded and unloaded at frequent intervals to check the performance of the unloading mechanism. In addition, the compressor shall be run at 10% over load for 10% of the time disturbed over the entire run of endurance tests.


The product model 2A320D has been failing continuously on Railway applications, therefore, no change is warranted.

ELGI Accepted Noted



RIVER Noted and understood. Noted



18.0 TESTS AT HIGHER ENVIRONMENTAL TEMPERATURE: A test run of 48 hours shall be conducted at inlet temperature of 60°C. The compressor shall run at 10.5 kg/cm² pressure for 8.00 hours and will be stopped for half and hour for cooling under prevailing atmospheric conditions. Six such cycles shall be performed. During these tests measurements as for endurance tests (17.3) shall be made.


ELGI Working pressure is 10.2 kg/cm² as per CLW Spec




RIVER Noted and understood. Noted



19.0 RUN IN TILTED POSITION TEST: With the oil filled up to the minimum level of oil sump, the unit shall be mounted on a platform of 1 in 20 inclination with the compressor raised. The platform shall also have a

FTRTIL In recent upgradation of Compressor technology, Oil free compressor is much advance technology compare to Oil Lubricated Compressor which outdated technology.


ELGI Accepted Noted

side tilt of 1 in 10. The compressor shall be worked at the rated capacity and 10 kg/cm2 pressure for 12 hours in this position. At the end of the test, the parts shall be examined for any starvation of oil etc.






20.0

AIR QUALITY TEST: The air quality of pneumatic system will be checked as per ISO-8573-1: 2010 class 1.The delivered air quality class will be as under: Class 1- for Solid particles Class 3 - for Water pressure Dew point Class 1 - for Oil including Vapour

FTRTIL There is no Air treatment unit inbuilt with Compressor. The Compressor out let Air quality to ISO-8573-1 ; 4 - # -4 Class 4 - for Solid particles for Compressor outlet air Class # -Not applicable for Water pressure Dew point Class 4 - for Oil including Vapour for Compressor outlet air

It was decided in minute of meeting vide letter no. EL/3.2.15/3-phase dated 21.11.2017. It has decided to incorporate following changes in the spec. The air quality of pneumatic system will be checked as per ISO-8573-1: 2010 class 1.The delivered air quality class will be as under: Class 4- for Solid particles Class 4 - for Oil including Vapour .

ELGI for Solid particles - noted for Water pressure Dew point - noted for Oil including Vapour - measured as 0.18mg/m3. It falls in Class 3 (<1mg/m3)

The air quality of pneumatic system will be checked as per ISO-8573-1: 2010 class 1.The delivered air quality class will be as under: Class 4- for Solid particles Class 4 - for Oil including Vapour .

KBIL The air quality classes are not applicable for compressor alone. Suitable air dryer and oil filter (Micromesh) should be used in the pneumatic system to achive the class as per ISO 8573-1: 2010.

The air quality of pneumatic system will be checked as per ISO-8573-1: 2010 class 1.The delivered air quality class will be as under: Class 4- for Solid particles Class 4 - for Oil including Vapour .


RIVER Noted and Understood Compressor air outlet quality will depend on quality of air available to it at inlet.

Noted


Railways No comment.

21.0 NOICE LEVEL TEST: Measure Noise level in all the eight Directions at a distance of 1 m, 4.6m & 7m from motor – compressor set as per ISO-2151 Edition 2.0 2004-02-01 The free field noise emission of the unit at the nominal rotation speed and at a distance of 4.6 m should not be More than 66 dB.

FTRTIL The offered Compressor can comply Sound pressure @ 4.5 meter, 78 dBA and value to be confirmed during type test.

It was decided in the meeting and minutes of meeting issued vide letter no. EL/3.2.15/3-phase dated 21.11.2017. It has decided to incorporate following changes in the spec NOICE LEVEL TEST: Measure Noise level in all the eight Directions at a distance of 1 m, 4.6m & 7m from motor – compressor set as per ISO-2151 Edition 2.0 2004-02-01 After detailed discussion it was decided to keep noise levels 90 dB(A) at a distance of 4.6 m.

ELGI Noise at 4.6m was measured to be 72dB in RR20100CG(M)

AIML No comment

KBIL No comment

RIVER Noted and Understood However we will be back to you with our comments after our principal’s response.


Railways No comment

22.0 WEIGHT MEASUREMENT TEST: The weight of the complete set, bare compressor and Motor shall be taken separately. Design should ensure minimum weight of the compressor motor set.

FTRTIL Noted Noted

ELGI Accepted Noted

AIML Noted Noted





23.0 ROUTINE TESTS: These tests shall be carried out on all the compressors before acceptance by the purchaser. The supplier shall also supply a copy of the internal test report with every machine. Following tests shall be conducted.


ELGI Accepted Noted

AIML Noted Noted




23.1 Run the compressor at maximum rated speed at 10.5 kg/cm² pressure for two hours and check the general mechanical and electrical test results and with values recorded during type tests with 415 V supply at 50 c/s. The discharge air temperature shall be recorded at half an hour’s interval.

FTRTIL Compliant

ELGI Working pressure is 10.2 kg/cm² as per CLW Spec.







23.2 Assure the capacity (output) of the compressors at the rated maximum speed and 10.5 kg/cm² pressure. This will be done in one compressor unit of a batch of fifteen.


ELGI Working pressure is 10.2 kg/cm² as per CLW Spec.







23.3 At least 10% of the total lot of compressor on order, selected at random, shall be subjected to a run of 48 hours with 30 minutes shut off at 8 hours interval, at the maximum rated speed and 10.5 kg/cm² pressure.

FTRTIL NOT COMPLIANT : During proto type test, all the requirements are tested. After completion of type test requirements, Compressor released for Serial production. Hence, additional tests of 10% of the total lot of compressor on order, selected at random.


ELGI Working pressure is 10.2 kg/cm² as per CLW Spec


AIML No comment. Noted


RIVER Noted and Understood. During prototype test. All the requirements are tested. After completion of type test compressor serial production is done. Hence again additional test on 10% of the total lot at random may not be necessary.




24.0 TESTING OF ACCESSORIES

24.1 The supplier shall indicate the test specification for the following accessories components.


ELGI Accepted Noted


i. Inter cooler & after cooler. ii. Filter – Air suction. iii. Inter cooler safety valve. iv. Oil pump for forced lubrication and any other accessory not included above.




24.2 The test specification of the accessories shall have RDSO’s approval prior to the commencementof the type tests.


ELGI Accepted Noted






25.0 GENERAL CONDITIONS FOR INSPECTION & TESTS

25.1 The manufacturer should arrange all tests at places where facilities are available in consultation with RDSO. RDSO official will inspect all type tests required for approval of prototype


ELGI Accepted Noted






25.2 Any additional tests trials, if considered necessary by the Engineers/ RDSO, shall also be arranged the manufactures free of cost

FTRTIL NOTED. Apart from type test in Proto compressor and serial test specification, other tests are to be carried out with mutual agreement with FT & RDSO.

Noted

ELGI Accepted Noted






25.3 The Purchaser / Engineer/RDSO or their representative shall have access for stage inspection, to those portions of the manufacturer’s works in which production is being carried

FTRTIL NOTED Noted

ELGI Accepted Noted



out and where the testing is taking place. This also applies to the items procured from Sub Contractors by the suppliers.




25.4

The inspecting officer shall have the power to adopt any means he may consider necessary to satisfy him that proper materials and parts specified are actually used during the manufacture of the unit.

FTRTIL NOTED Noted

ELGI Accepted Noted






25.5 The supplier / manufacturer shall provide labor or appliances required by the inspecting officer, free of charge, or inspection and testing of the whole unit and its components, if required.

FTRTIL NOTED Noted

ELGI Accepted Noted






25.6 Should any part of the compressor unit require alteration or any defect appear during the tests or trials, the supplier shall, without any extra charge, make such alterations or rectify the defects to the satisfaction of the purchaser / engineer/RDSO officials.

FTRTIL NOTED Noted

ELGI Accepted Noted






25.7 Any modification or alteration to the components during the supply of the order shall be made only after the approval of the purchaser. The unit after such modifications / alterations shall be subjected to such tests as

FTRTIL NOTED Noted

ELGI Accepted Noted





considered necessary by the purchaser / engineer.


25.8 Zinc yellow passivation /Blackening shall be done on all hardware’s.

FTRTIL Noted It was decided in the meeting and minutes of meeting issued vide letter no. EL/3.2.15/3-phase dated 21.11.2017. It was decided to remove ‘YELLOW”

as it is not environmental friendly

ELGI Accepted

AIML No comments

KBIL No comments

RIVER Noted and understood



26.0 INFORMATION TO BE FURNISHED BY TENDERER

26.1 Data as per Annexure I & II shall be furnished by the tenderer along with their QAP for this item.

FTRTIL NOTED Noted

ELGI Accepted Noted





RAilways No comments Noted

27.0 MAINTENANCE MANUAL

27.1 The supplier/manufacturer shall supply copies of exhaustive, fully illustrated maintanance manuals covering among other items, the following vital details, to the “Purchaser”. The maintenance

FTRTIL Accepted Noted

ELGI No comments Noted

AIML Noted and understood Noted


RIVER No comments Noted


periods should conferm to maintanance scheduled of electric locomotive. • Description and arrangement. • Technical data. • Dismantling and assembly instructions. • Commissioning instructions • Particulars of indigenously available recommended lubricants. • Periodical inspection schedules. • Periodical maintenance instructions along with trouble shooting instructions. • Testing procedure for the equipment and other auxiliaries like oil pump etc, if applicable. • Wear limits for vital components. • Detailed parts catalogue with description of items. The parts shall be detailed by sketches to facilitate ordering. • Instructions for reclamation of worn out components. • List of special tools with instruction for use. • List of components with their average life . • Preventive maintenance procedure and overhauling kits with list of components and manhours required for various activites. • Average life of overall equipment


27.2 Two copies of the above Maintenance Manual shall be supplied to RDSO with the quotation.

FTRTIL Noted Noted

ELGI Accepted Noted






27.3

One copy of the manual shall be supplied with every 10 compressor sets or a part thereof to the purchaser.

FTRTIL Noted Noted

ELGI Accepted Noted






28.0 TRAINING: The supplier shall provide facilities for free training of the Railway maintenance staff at their works on aspects of maintenance, overhaul and testing of the equipment.

FTRTIL Noted Noted

ELGI Accepted Noted






29.0 SPECIAL CONDITIONS Para has been included, that

supplier have not to submit LCC

during prototype test. It is only

during procurement as the part of

tender document , that LCC can be

considered . Following para added:-

“The manufacture/supplier shall

furnish life cycle cost and spare cost

to the purchasers and shall confirm

to the purchasers that the spares

availability must be for a minimum

period of 18 years .The purchaser

should ensure to include this

condition in the tender document.”

29.1

At the time of approval of the prototype unit the manufacturer / supplier shall furnish the list of names and addresses of their vendors/Sub supplier of the main items of the equipment and important raw materials which they have used in the prototype unit and shall not make any departure in the sources of supply without prior approval of RDSO. For example sources of supply for motors, couplings, bearings, insulating varnishes, enamelled wires etc.

FTRTIL Noted

ELGI Accepted

AIML No comments

KBIL No comments

RIVER Noted and understood


Railways No comment.

29.2

Field Trial: After successful completion of the type test the compressor shall be subjected to extended field trial for a minimum period of six months before according the prototype approval

FTRTIL Noted Noted

ELGI Accepted Noted





Railways At the time of approval of prototype unit the life cycle cost and spare cost has to be evaluated and the manufacturer /supplier shall confirm that the spares availability must be for a minimum period of 18 years.

Agreed. However, cost implications are to be dealt during procurement . Hence, this condition is added in Para 29.1.

29.3

Consistency test: In case of large scale failures being reported from the zonal railway/CLW and/or in case of major design change, one unit of compressor motor set selected at random to be offered for consistency test to be witnessed by RDSO. Consistency tests shall generally cover those type tests which provide valuable information on the reasons of failures and/or can establish the efficacy of the design changes. The periodicity and scope of such a test shall be decided by RDSO prior to undertaking such a test.In case running successfully then consistency should be done at 5 years intervals.

FTRTIL PARTIAL COMPLIANT: Apart from Type test in Proto Compressor and Serial test specification, other tests to be carried out with mutual agreement with FIRM & RDSO.

It was decided in the meeting and minutes of meeting issued vide letter no. EL/3.2.15/3-phase dated 21.11.2017. Para has amended . Consistency tests shall generally cover those type tests which provide valuable information on the reasons of failures and/or can establish the efficacy of the design changes. The periodicity and scope of such a test shall be decided by RDSO prior to undertaking such a test. In case running successfully then consistency should be done at 5 years intervals.

ELGI Accepted Noted






29.4

Identification of manufacturer: The compressor manufacturer should clearly emboss the following details a) Year and month of manufacturing b) Sl. no. c) Name of manufacturer at suitable places on various parts viz. crank-case, cylinder head, crank-shaft etc. to assess the performance of various makes of machines and to determine their codal life for replacement.

FTRTIL NOT COMPLIANT

Compressor name plate contains Year of manufacturing and Serial number will be provided. Other subparts are FT's internal process and there is no name plates / details mentioned on those sub parts

No change is warranted. However the same may be taken up for discussion in the meeting with OEM and Railways.

ELGI Accepted Noted





Railways No comments Noted.

30.0

FINISH: The compressor motor set shall be suitably treated to remove rust and should be coated with antirust primer and finished with two coats of light grey or black paint as per IS 5:1994. Compressor cylinders are required to be painted by special black heat resisting enamelled formulated on a modified silicon resin to withstand temperature up to 3500 C.

FTRTIL NOT COMPLIANT: Motor is procured from RDSO approved source. Compressor cylinder painting as per FIRM’S standard procedure.

Noted. However the same may be taken up for discussion in the meeting with OEM and Railways.

ELGI Accepted Noted


KBIL Proper surface treatment will be taken care considering of temperature increase based on design & actual test. Requirement of 3500C may not be valid for all design.

Noted, the specification is not product specific, therefore, does not bar adoption of alternate better compressor technology.




31.0 ISO CERTIFICATION: Indian Railway reserves the right to procure the item from ISO certified manufacturers only

FTRTIL Noted Noted

ELGI Accepted Noted






32.0 HARDWARE: FTRTIL NOT COMPLIANT: No change is warranted. However

Hardware should be of high tensile fasteners including spring washer shall be of either from RDSO’s or CLW’s approved sources only. Prior approval shall be taken from RDSO or CLW , if any other makes are proposed to be used.

Hardware requirements may please be removed in the specification. It should be left to supplier to decide for type of fasteners requirement based Compressor performance

the same may be taken up for discussion in the meeting with OEM and Railways.

ELGI Accepted Noted

AIML No Comments Noted





Annex-I

BROAD TECHNICAL FEATURES OF THE COMPRESSORS

FTRTIL Noted Noted

ELGI Can be provided Noted

AIML Point 4. HP consumption at rated capacity and speed against 8, 9 and 10.5 Kg/cm2

Noted





Annex-II

GENERAL DATA OF COMPRESSORS

FTRTIL Noted Noted

ELGI Can be provided Noted






Documents

Reasoned Document for Draft Specification of Oil ... Revised... · Reasoned Document for Draft Specification of Oil Lubricated Reciprocating Compressor Cl. No. Description in Specification