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REVISION OF SPECIFICATION
Item Name:
S.N. Name of
parts/assembly
Part nos. / Vendor
name
RDSO drg no./Spec
no.
Unified PL
No.
1. Piston – Diameter 140
mm
ELGI part no.
00021858C
KPC part no.
0960150250
Spec. No.
MP.0.0700. 03
(Revised July’ 97)
11489157
2. Piston -Diameter 197
mm
ELGI part no.
000112040, KPC part
no. 0950140150
Spec. No.
MP.0.0700. 03
(Revised July’ 97)
11489170
Specification: MP.0.0700. 03 (Revised Draft)
1. RDSO is reviewing the specification to cater to the latest technological developments in the field, modify clauses not relevant in the present context and making them more enabling with focus on functional requirements.
2. It is requested that your comments / suggestions with regard to improvements / modifications in
specification of the above mentioned item may be submitted in the following format along with the
justification for the changes required.
Part A: Basic Information
SN Particulars Information
1. Name
2. Designation
3. Professional Qualification
4. Organization / Firm’s Name
5. Address for correspondence
6. Email ID
7. Whether firm is registered with RDSO for the subject item. If yes, details like date of registration, current status etc. If no, firm’s experience in manufacturing of subject item or similar item.
8. Whether any technical document/ Report/ Study to support suggested changes in available/ enclosed for better appreciation.
Part B: Comments / suggestions on the specification
SN Clause No. of RDSO STR/ Spec
Clause, as it exists in RDSO STR/ Spec
Clause, as it should read after incorporation of comments/ suggestions in RDSO Spec / STR
Justification for changes
Comments may be sent to following address within one month from the date of publication on
rdso.indianrailways.gov.in
Jt. Director/ Brake Research Designs and Standards Organization Manak Nagar, Lucknow – 226011
Email: [email protected]
dsoy dk;Zky; iz;ksx gsrq
FOR OFFICIAL USE ONLY
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
TECHNICAL SPECIFICATION OF PISTONS FOR COMPRESSOR AND
EXPRESSOR FOR MAIN LINE DIESEL LOCOMOTIVE
fof'kf"V la[a;k pk-'k- 0.07.00.03 (la'kkss/ku- 02
Qjojh & 2021
Specification no. MP.0.07.00-03
(Revised July’97)
(Rev-02), Ferbuary 2021
RESEARCH DESIGNS & STANDARDS ORGANISATION
MANAK NAGAR, LUCKNOW-226011.
Specification no. MP.0.0700-03, Rev-0102, July 1997February 2021 2
LIST OF AMENDMENTS
Amendment
Date
Version Revised Para Remarks
February‟
2021
02 Para 6.1.1, 7.1.1.1,
7.1.2.1, 7.1.3.3,
7.1.3.4 and 7.3.3
Revision of Para‟s to incorporate
Equivalent Indian Standards in
compliance of MOM of the VC
meeting on Specification/ STRs
held on 29.08.2020
Para 9 Addition of Para 9 as per ISO
document no-QM-RF-7.1.3 Ver-2.0
Para 10 Addition of Para no. 10 (Preference
to Make In India) in compliance of
directives issued by GOI for
promotion of Make in India policy.
Para 11 Addition of Para no. 11 (Vendor
Changes in Approved Status) in
compliance to Vigilance cell note
no. 13/Vig/Policy dated
08.09.2016.
Para 12 Addition of Para no. 12, Field trial
Quantity & field trial period are
defined as per MP-M-8.1-1 (Latest)
& Field trial performance feedback
format added in compliance of
MOM of the VC meeting on
Specification/ STRs held on
29.08.2020.
Para 13 Addition of Para no. 13, Maintenance Manuals
Para 14 Addition of Para no. 14, Performance and Service warranty
Para 15 Addition of Para no. 15, Technical clarifications
Specification no. MP.0.0700-03, Rev-0102, July 1997February 2021 3
INDEX
S. No. Topic Page 1. Scope
4
2. Designation
4
3. Dimensions
4
4. Surface finish and treatment
4
5. Weight
4
6. Material Specification
5
7. Inspection and Tests
5-7
8. Marking and Packing
8
9. Quality Assurance Programme
8
10. Preference to make in India
8
11. Vendor changes in approved status
8
12. Field Trial / Testing
8
13. Maintenance Manuals
9
14. Performance and Service warranty
9
15. Technical clarifications
10
Specification no. MP.0.0700-03, Rev-0102, July 1997February 2021 4
TECHNICAL SPECIFICATION OF PISTONS FOR COMPRESSOR AND EXPRESSOR
FOR MAIN LINE DIESEL LOCOMOTIVE
1. SCOPE :
This specification covers the technical requirements and supply conditions for
pistons of following make/type of compressors and expressors used on main line
diesel locomotives of Indian Railways.
Compressors : LG-3CDB, KCW-623 and KCW-523
Expressors : 6CD.4UC, 6CD.3UC and KE-6
2. DESIGNATION : The pistons shall be designated as under:
1. “L.P. Piston”: for low pressure cylinder of compressors, compressor portion of
expressor, and exhauster cylinders of expressor.
2. “H.P. Piston”: for high pressure cylinder of compressor and compressor portion
of expressor.
3. DIMENSIONS :
3.1 Nominal dimensions and tolerances for L.P. and H.P. Pistons shall be as per
drawing Nos. SK.DP. 1889, 1888 and 3445 respectively.
3.2 Dimensions of L.P. Piston skirt at different angles with respect to major axis shall
confirm to drg. No. SK.DP 2042.
3.3 The respective oversize Pistons shall be used. If the cylinders are bored
oversize. Over sizes shall be graduated in steps of 0.25 mm. The first oversize
being 0.25 mm higher than the standard nominal diameter. Dimensions of
standard and over size pistons are indicated in the Piston drgs. mentioned
above.
4. SURFACE FINISH AND TREATMENT :
4.1 The outer surface of the piston shall be finished to surface finish specified in the
drawing for different parts of the piston.
4.2 LP Pistons shall be tin plated to uniform thickness of 0.0025-0.0075 mm on entire
surface except the wrist pin bore.
5. WEIGHT :
Weight of standard Piston (without wrist pin & Piston rings) shall be :
LP Piston (SKDP-1889) – 3.75 – 3.80 Kg
HP Piston (SKDP-1888) – 4.60 – 4.65 Kg
HP Piston (SKDP-3445) – 5.50 – 5.55 Kg
Specification no. MP.0.0700-03, Rev-0102, July 1997February 2021 5
6. MATERIAL SPECIFICATION :
6.1 Materials used for the manufacture of LP and HP Pistons and their mechanical
properties shall be as indicated in Table - 1, below :
Table - 1
S. No. Piston Designation
Material Mechanical Properties
Tensile Strength (min) N/mm2 (Kgf/mm2)
Brinell Hardness (HB)
1. LP Piston Aluminium alloy 4525-px to IS: 617-1975 (with 0.5-1.0 % Ni)(with Nickel 1.0%)
4525 T5 to IS: 617-1994*
215 (21.9) 210 (21.4)
100 - 130
2. HP Piston Grey cast iron Gr. FG-300 to IS: 210-1978
294 (30) 180 - 230
Note: 1 N/mm2 = 0.102 Kgf/mm2
6.2 The micro structure of HP Piston shall show pearlitic matrix with type „A‟ graphite
of size 5 or finer.
7. INSPECTION AND TESTS :
7.1. Tests for chemical composition and mechanical properties:
7.1.1 Chemical analysis:
1. LP Piston: One test for chemical analysis shall be carried out in accordance
with IS: 504-1963 IS: 504 (Parts 1 to12) : 2002 ,** /
Spectrographic Analysis on each lot of 1000 kg or part thereof. For
preparation of samples for chemical analysis, reference may be
made to IS: 1817-1961.***
---------------------------------------------------------------------------------------------------------------------------
* P- Temper designation to IS: 5052-1969. IS 5052:1993(Reaffirmed 2003)
** Method of chemical analysis of aluminium and its alloy. Methods of chemical
analysis of Aluminium and its alloys [ MTD 7 : Light method and their Alloys]
*** Method of sampling of non-ferrous metals for chemical analysis.
Specification no. MP.0.0700-03, Rev-0102, July 1997February 2021 6
2. HP piston: One test for chemical analysis shall be carried out in accordance
with IS: 228-1959 + on each lot of 500 kg or part thereof. The
percentage content of all important elements, particularly carbon,
nickel, sulphar and phosphorus shall be reported.
7.1.2 Tensile test:
.1 LP Piston: Tensile tests for aluminium alloy of LP Piston shall be carried out on
at least one Piston from every batch of Pistons heat treated together to achieve
the required mechanical properties. Test sample shall be taken from the crown
portion of the Piston and tested as per IS: 1816-1979 ++. Test bars ( Ref. IS
1816-1979 ++.) shall be cast separately by pouring the metal at the same time
and from the same ladle as the casting they represent. The Test bars shall be
heat treated to T5 (Ref IS 5052:1993(R 2003)
.2 HP Piston: Tensile test on Grey Iron castings for HP Pistons shall be carried out
in accordance with IS: 2073-1970 +++. On a test bar of 30 mm dia as cast. Test
bars shall be cast. Separately by pouring the metal at the same time and from
the same ladle as the castings they represent. The test bar shall be heat treated
(for stress relieving) simultaneously under the same conditions as the castings.
At least one tensile test shall be made on each lot of 500 kg of castings or part
thereof.
7.1.3 Hardness Test:
.1 For the purpose of these tests at least one Piston shall be selected from
every batch of Pistons heat treated together to achieve the desired
mechanical properties.
.2 The Brinell hardness shall be measured on four equi-spaced points on the
circumference of the Piston as cast and heat treated. The mean of the four
values, thus obtained shall be within the range indicated in Table 1.
.3 Hardness tests on aluminium alloy castings of LP Piston shall be carried out
in accordance with IS: 1500-19832005.*
.4 Hardness test for Grey Iron castings of HP Piston shall be carried out in
accordance with IS: 1500-19832005.*
----------------------------------------------------------------------------------------------------------------
+ Method of chemical analysis of pig iron, cast iron and plain carbon and low alloy
steels.
++ Method of tensile test for light metals and their alloys.
+++ Specification for carbon steel black bars for production of machined parts for
general engineering purposes.
* Method of Brinell hardness test for metallic materials.
Specification no. MP.0.0700-03, Rev-0102, July 1997February 2021 7
7.2 Repeat tests:
7.2.1 If a sample selected fails to meet the requirements of mechanical tests
mentioned in Para 7.1, two further test pieces which represent the same
batch/cast may be selected and tested in the same manner. If both of these test
pieces meet the requirements the material represented thereby shall be
acceptable.
7.2.2 Alternatively, the supplier may reheat treat the batch once only before the two
further samples are selected.
7.3 Tests and inspection for Dimensional accuracies and workmanship
Following inspections shall be carried out on finished Pistons –
7.3.1 Visual examination: All Pistons shall be examined visually for any defects of
material and workmanship. Voids, cracks, cavities or other linear discontinuities
on or under the surface of the Piston body shall be cause for rejection.
7.3.2 Dimensions: All dimensions indicated on drawing Nos. SKDP- 1888, 1889 and
3445 are required to be adhered to. Each Piston shall be subjected to the
following minimum dimensional checks.
.1 Piston Ring Groove: Following dimensional checks on ring grooves shall be
performed at three equi-spaced points on the periphery of the Piston.
Width : The width of each ring groove shall be measured by suitable “Go-No Go”
gauge.
Depth: Depth of the ring grooves shall be measured with suitable depth gauge.
.2 Piston skirt : Diameter of the Piston skirt shall be measured at points indicated on
the respective drawings. Refer SKDP 2042 for detail profile of LP Piston skirt.
.3 Wrist pin housing: The dia of wrist pin housing shall be measured in each boss
along two perpendicular directions, vertical and horizontal.
.4 Wrist pin retaining ring groove: Depth and width of wrist pin retaining ring groove
shall be measured. No variation in these dimensions shall be accepted.
7.3.3 Surface finish: The surface finish of ring grooves the skirt and the wrist pin
housing shall be assessed in accordance with IS:3073-19672006. No machining
marks doents or erosion shall be acceptable on the skirt Piston ring grooves wrist
pin housing and retaining ring grooves.
7.3.4 Surface cracks: Each Piston shall be checked for surface cracks. These cracks
shall be performed by Zyglo testing ultrasonic method and by examination using
magnifying glass over the entire surface (inner and outer) of the Piston including
Specification no. MP.0.0700-03, Rev-0102, July 1997February 2021 8
the head. Particular care shall be exercised when examining the Piston ring
grooves, oil holes, wrist pin bore and supporting ribs and parting lines. Cracks of
any type/size present any where on the Piston shall not be acceptable.
7.3.5 Weight: Each Piston shall be weighted. The weight of the Piston shall be within
the limits specified in clause 5.
8. MARKING AND PACKING
8.1 Identification mark of the manufacturer, batch number and date of manufacture
shall be stamped on each Piston as indicated in drawing No. SKDP-1888, 1889
and 3445.
8.2 Pistons shall be coated with a suitable anti-corrosive sub-stance and packed in
non- Moisture absorbent paper. Each set of Pistons shall then be securely packed
in a suitable carton. Cartons may be further packed in wooden crates, if required.
8.3 The carton containing pistons shall indicate the type of Piston, nominal size/DLW
part number, number of Pistons, batch number, month and year of manufacture
and the manufacturer‟s name and trade mark.
9. QUALITY ASSURANCE PROGRAMME:
9.1 Supplier shall submit their internal quality assurance program in accordance with RDSO ISO procedures.
9.2 Supplier shall, on demand by RDSO/ Purchaser/ Inspecting authority nominated by RDSO/ Purchaser, make the records of checks carried out during internal quality assurance available for scrutiny.
10. PREFERENCE TO MAKE IN INDIA :
The Government of India policy on “make in India” shall apply.
11. VENDOR CHANGES IN APPROVED STATUS:
All the provisions contained RDSO‟s ISO procedures laid down in Document No. QO-D-8.1-11, dated 01.07.2020 (Titled “Vendor- changes in approved status”) and subsequent version/amendment thereof, shall be binding and applicable on the successful vendor/vendors in the contract floated by Railways to maintain of products supplied to Railways.
12. Field Trial / Testing:
12.1. On satisfactory completion of prototype tests, Pistons shall be subjected to field trial. Quantity of Pistons to be subjected to field trial and field trial period shall be as per RDSO document no- MP-M-8.1-1 (Latest).
Specification no. MP.0.0700-03, Rev-0102, July 1997February 2021 9
Field performance feedback format is as under:
S.
No.
Shed/
Rly.
Loco
No.
Date of
fitment
Date of
failure, if
any
Reason of
failure
Remarks
The acceptance criteria of field trial shall be the satisfactory field performance of equipment.
13. 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:
13.1.1 Detailed dimensional drawings as per SKDP-2042, 1888, 1889 and 3445.
13.1.2 Technical data.
13.1.3 Manual shall contain information pertaining to working principle of operation
of Pistons.
13.1.4 Details of special tools if required, parts catalogue and testing procedure of the Pistons being supplied.
13.1.5 Updated position of modifications will also be incorporated.
13.1.6 Periodical maintenance schedules and instructions.
13.1.7 Wear limits and life of Pistons.
13.1.8 List of instructions for use special tools.
13.1.9 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 Pistons.
14. Performance and Service warranty
14.1 The vendor should give in writing for warranty of 24 months from date of
commissioning or 30 months from date of dispatch which is earlier for the
satisfactory service / working of Pistons without failure.
14.2 However any Pistons fails during warranty period shall be replaced free of cost by the vendor. The replaced Pistons shall be under a further warranty for 24 months from the date of their commissioning.
14.3 If the replaced Pistons also prove unsatisfactory performance in service, they shall be replaced by the modified and improved Pistons by the vendor at their own cost.
Specification no. MP.0.0700-03, Rev-0102, July 1997February 2021 10
14.4 The vendor should collect the failed Piston 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 Piston if some flaws have been found during failure
mode investigation.
15.0 Technical clarifications
15.1 Any other technical clarifications with regard to this specification may be
obtained from Director General (Motive Power), RDSO, Manak Nagar,
Lucknow -226 011.