for development of STR for Dampers for LHB coaches

Reasoned Document for development of STR for Dampers for LHB coaches

o. Description of para as per draft STR uploaded on RDSO website for comments Comments received from M/s Knnor

Comments received from M/s Gabriel India Limited

Comments received from M/s ITT Holdings through PAN India Consultants Pvt. Ltd.

Comments recd from M/s Sequoia Safety products pvt. ltd

Remarks/ Reason

1. GENERAL

1.1 SCOPE

This specification covers the requirements of all types Dampers currently used in LHB coaches. Scope of this specification is related to following types of hydraulic Dampers for LHB coaches

• Primary Vertical Dampers • Secondary Vertical Damper • Secondary Lateral Damper • Yaw Damper • Secondary Lateral Damper for Air Spring Bogie` • Secondary Vertical Damper for Non AC LHB

This specification is to define :

• Performance, envelop, qualification and inspection requirement • Maintenance requirement • Any other technical and quality assurance requirements

in association to other technical documents (drawings, other specification etc.) Hereafter, this part will be referred to as dampers for LHB coaches and attachment elements. The terms shock absorbers and damper can be interchangeably used in this specification. The Specification covers the supply of damping unit with end fitting/mounting as an assembly termed as Dampers for LHB coaches. Technical details of the dampers are given in Appendix-I.

‐‐‐‐‐‐

1.2 Applicability This specification applies when recalled by the purchaser orders and/ or by the associated drawings issued by RCF/RDSO or any other agency authorized by IR for the purpose. When conflict arises between the requirements of this specification and the associated drawings, the drawing requirements shall apply. When conflict arises between the requirements of this specification and those of other specification, discrepancies shall be solved by mutual agreement between the purchaser and supplier. . Departures from this specification will be possible only following a written agreement between the supplier and purchaser.

‐‐‐‐‐‐

1.3 DRAWINGS

1.3.1 The damper shall generally conform to RDSO drawing(s) or the manufacturer’s/ purchaser’s drawing(s) duly approved by the RDSO. RCF reference drawings are as under- i) Primary Vertical Dampers - RCF drawing no. LW05102 ii) Secondary Vertical Damper - RCF drawing no. LW05101 iii) Secondary Lateral Damper - RCF drawing no. LW05100 iv) Yaw Damper - RCF drawing no. LW05103 v) Secondary Lateral Damper - RCF drawing no. LW05122 vi) Secondary Vertical Damper - RCF drawing no. LG05102

The damper shall generally conform to RCF drawing(s) as drawings are from RCF 1.3.1 i) The drawing no. should read as LW05102

The damper shall generally confirm to RDSO/RCF drawing(s) or the manufacturer's /purchasers drawing(s) duly approved by the RDSO/RCF. RCF reference drawings are as under Remark‐Since all LHB Damper drawings released by RCF i) Primary Vertical Dampers ‐ RCF drawing no. LW05102 Remark‐Seems to be Typographical error

Accepted‐ Typographical error corrected in 1.3.1 i) and RCF drawing no. corrected as LW05102 M/s Gabriel comments “The damper shall generally confirm to RDSO/RCF drawing(s) or the manufacturer's /purchasers drawing(s) duly approved by the RDSO/RCF “ can not be accepted because dampers drawings for LHB coaches have been prepared by RCF.

1.3.2 The manufacturers desirous of being considered for RDSO’s approval for manufacture & supply of damper shall submit, application in prescribed form along with assembly drawings and sectional drawings with installation dimensions.

Clause should address already approved suppliers also

The manufacturers desirous of being considered for RDSO's/RCF's approval for manufacture……… Remark‐ As initially LHB Dampers approved by RCF

No change

1.4 End mountings and methods of dampers attachment

1.4.1 End mountings shall be of a type and construction specified or approved by RDSO. The design shall allow the maximum angular misalignments specified by RDSO without imposing such forces on the dampers which would prevent it meeting the requirements of this specification.

Dimensions, orientation and performance of end mountings are to be as per RCF/RDSO drawings. Any change in this will require RDSO approval

The end mounting requirements (i.e. dimensions, orientation and performance are to be as per RCF drawings. Any change in this will require RDSO approval The recommended clause by RDSO is relevant only in case where the end mounts are not part of the dampers. And the user wants to procure the same independent of Damper Manufacturers It is an old concept British railways for defining end mounting requirements

End mountings shall be of a type and construction specified or approved by RDSO/RCF. The design shall allow the maximum angular misalignments specified by RDSO/RCF without…… Remark‐ As initially LHB Dampers approved by RCF

In the view of recommendations Para modified

1.4.2 Drawings of damper submitted by manufacturer shall also indicate the maximum misalignment of end mountings as attached to the damper and get the same approved from RDSO/Purchaser

1.5 Definition

1.5.1 Dampers for LHB coaches

a) Dampers with adjustable valves on the bottom of the damper. The damper has to be dismounted for the adjustment.

b) Dampers with adjustable valves with cylindrical helical spring. The adjustment of the damper can be done from the outside without dismounted of the whole damper.

c) Or otherwise specified by the drawing.

Dampers should be with adjustable valves. Adjustment should be possible on test equipment without fully dismantling the damper. The Dampers need to be dismounted for verifying the forces after adjustment. Forces can't be measured on the bogie.

Point not applicable Remark‐The dampers are of NON ADJUSTABLE valving type. Hence, this point is not applicable

a) There is no technical advantage of providing adjustable valve on the bottom of the damper for calibration. The damper will have to be put on testing machine for calibration, as no one can guarantee the damping force without measurement.

b) With adjustable valve on outside, the damper can be easily misaligned. The cost will also go up without offering any clear technical advantage over a non‐adjustable design. The production procedure will also be costly to design because each damper will have to be adjusted one by one.

In the view of recommendations Para deleted

1.6 Applicable standards/Reference Standards

i) ISO 23277/ EN 1289 ii) ISO 23278/ EN 1291 iii) ISO 17638/ EN 1290 iv) ISO 5817/ EN 25817 v) ISO 2409 vi) ISO 9227

Applicable standards/Reference Standards i) ISO 23277 ii) ISO 23278 iii) ISO 17638 iv) ISO 5817/ EN 25817 v) ISO 2409 vi) ISO 9227 EN 1289, EN1290 and EN1291 are obsolete standards

Agreed

2. Performance specification and Instructions for Construction

2.1 Conditions of use

The dampers for LHB coaches are likely to be exposed to the following operating conditions:

• Change in temperature from -400C to +700C • Relative humidity from 30% to 100% • Both acidic and basic cleaning product

Relative humidity up to 100% At sub zero temperatures the humidity will be Zero

a) The operation

temperature should be ‐20˚C to +70˚C

b) Top speed should be: 250 km/hr

Relative humidity up to 100% may be accepted and remaining para stand good same.

• Urine, feces, and kitchen waste (restaurant cars) • Rain, snow, ice • Sand, brake and ferric oxide dust (abrasion of wheel and tracks) • Damage from flying stones raised from the ballast track bed. • Flying pieces of ice • Salty air (coastal area)

Bogies with operating speeds of upto 330 km/h can be used where in part extreme climate conditions may be found.

The conditions of use appear normally in any conceivable combination (independent of weather conditions, speed, etc.)

2.1.1 Installation

The dampers must be designed for trouble-free operation in the assembly positions on LHB coaches.

In particular, for anti-yaw dampers, the supplier shall take into account each of the operation positions specified in the relative assembly drawing and anti-yaw connection to the body for a maximum negative angle and with the end shield at highest connection.

-------

2.2 Cleaning of the bogie

The bogies and superstructure are washed following varying periods, at the most every 2-5 days. As a result the dampers come into contact with acidic and alkaline cleaning products, against which it must be resistant for the foreseen defined service life. The appearance of under layer rust, material out breaks, leaks, changes in rigidity etc. is not allowed.

Cleaning of the bogie The bogies and superstructure are washed following varying periods, at the most every 2-5 days. As a result the dampers come into contact with acidic and alkaline cleaning products, against which it must be resistant for the defined service life. The appearance of under layer rust, material out breaks, leaks, changes in rigidity etc. is not allowed. The life of damper has already been defined inn the specification

In the view of recommendations minor correction done

2.3 Endurance

2.3.1 Load

The dampers shall be able to resist the forces listed below (unless otherwise specified). Appearance of fractures or leakage of oil as well as reduction of life time of the dampers is not permitted. This includes the dampers and also the attachment elements.

The complete installed dampers should resist the following static forces along the longitudinal axis.

In the compressed position 20kN (unless otherwise specified)

In expanded position 20kN (unless otherwise specified)

‐‐‐‐‐‐

2.3.2 Acceleration

Dampers and their attachment can be temporarily exposed to very great accelerations, which affect the longitudinal axis of the shock absorber at a 900 angle.

During type test qualification the supplier has to conduct the vibration test for 1 no. of each type damper as per vibration level given in table 1.

The dampers along with end mountings have to be mounted in vibration shaker in as installed condition on vehicle.

The damper shall be subjected to a total conditioning time of 15 hrs. This shall be divided into periods of 5 hrs testing in each of the three axis i.e. in X, Y & Z axis.

The dampers should have no loss of functionality at the end of test.

Table 1:

dynamic

Primary dampers +25g vertical

Acceleration Dampers and their attachment can be temporarily exposed to very great accelerations, which affect the longitudinal axis of the shock absorber at a900C angle. During type test qualification the supplier has to conduct the vibration test for 1 no. of each type damper as per vibration level given in table 1.

Primary dampers ± 3g Lateral direction Remark‐ Add letter "g" (typographical error)

A clear procedure for the test need to be specified as the measurement which needs to be done after testing is not mentioned. The draft says the damper after test should have no loss in functionality. The functionalities need to be mentioned clearly or any supporting EN or ISO document. Moreover, from the value’s given in table 1; the dynamic value for primary vertical damper in lateral direction should be ±3g instead of ±3. Similarly, the dynamic value for vertical

‐‐‐‐‐‐ In the view of recommendations minor correction done

+3g Longitudinal

+3g Lateral direction

Vertical dampers +10g Vertical

+0.5g Longitudinal direction

+1.5g Lateral direction

Lateral dampers +10g Vertical



Anti-yaw dampers +10g Vertical



The dampers along with end mountings have to be mounted in vibration shaker in as installed condition on vehicle. The damper shall be subjected to a total conditioning time of 15 hrs. This shall be divided into periods of 5 hrs testing in each of the three axis i.e. in X, Y & Z axis. Table-1- Primary Damper ±3g Lateral direction Vertical Damper ±0.5g Longitudinal Direction

Vertical dampers ±0.5g Longitudinal direction Remark‐ Add letter "g" (typographical error)

damper in longitudinal direction should be ±0.5g instead of ±0.5.

+3 corrected as +3g and +0.5 corrected as +0.5g. No other change except above.

2.3.3 Service life

The shock absorbers must be designed for a service life of at least 1.2 million kilometers. The manufacturer defines the necessary inspection and maintenance tasks and intervals.

The intervals for maintenance task must account to:

-at least 1.2 million kilometers for all dampers

The characteristics may not deviate from the nominal value by more than +30% (unless otherwise specified) during the entire service life

The shock absorbers must be designed for a service life of at least 1.2 million kilometers or 4 years from date of supply, whichever is earlier

The shock absorbers must be designed for a service life of at least 0.4 million kilometers. Remark‐ Considering Indian track conditions which is different than Germany.

During the meeting held on 28.03.2018 at RDSO Carriage Directorate, it was discussed that the service period will be reduced suitably. It is requested to review the same. Moreover, the characteristics deviations should be as under: a) In case of Primary Vertical

Damper, the deviate of nominate value should be ±40%. The loading of this damper is very high.

b) In case of other dampers, the ±30% is good.

No change

2.3.4 Adjustability

The dampers may not shift during operation and must be easily adjustable when required. Any required special tools and devices are to be indicated.

Point not applicable Remark‐ The dampers are of NON ADJUSTABLE valving type. Hence, this point is not applicable

Not required

May be accepted

2.3.5 Range of adjustment

The range of adjustment of the dampers force is to be indicated by the manufacturer.

Point not applicable Remark‐ The dampers are of NON ADJUSTABLE valving type. Hence, this point is not applicable

May be accepted

2.3.6 Mass

The weight of the dampers with clamping elements (including surface protection) must be measured and recorded. A low tare weight is of great importance.

The mass value shall be indicated on the supplier drawing.

The weight of the dampers with clamping elements (including surface protection) must be measured and recorded. The mass value shall be indicated on the supplier drawing.

Not necessary to mention mass value in drawing Remark‐ Not applicable

No change

2.4 STORAGE AND TRANSPORT

The dampers must be packaged in a way that damaging of the paint coating is not possible.

• The dampers attachment points are preserved.

On the Packaging the following indication shall be present as a minimum:

• Identification of the supplier • Contract number or purchase order number

‐‐‐‐‐‐

• Quantity of articles in the package • Description of the articles.

2.5 Materials

In making the choice of material for the dampers components, it must be noted that at the end of their service life it must be possible to recycle or dispose of them without need for any particular measures. Should materials be used which, according to valid instructions, require special disposal, these materials together with their weight proportion must be communicated in written form to the RDSO.

‐‐‐‐‐‐

2.6 Hydraulic Liquid

The type of oil and viscosity of the dampers oil is to be specified on suppliers drawing in the form of technical data sheet stating the characteristics of the oil contained in the dampers. Compliance to environmental and other statuary requirements should be mentioned in data sheet.

The oil data sheet shall be agreed and approved by the RDSO.

At the type-approval stage, the manufacturer shall deposit a technical data sheet stating the characteristics and the quantities of the fluid contained in the dampers, which the RDSO reserves the right to approve.

Hydraulic LiquidThe type of oil and viscosity of the dampers oil is to be specified on suppliers drawing in the form of technical data sheet stating the characteristics of the oil contained in the dampers.At the type-approval stage, the manufacturer shall deposit a technical data sheet stating the characteristics and the quantities of the fluid contained in the dampers.Since the Damper Manufacturer is responsible for achieving the overall performance requirements, including life, therefore selection of oil should be supplier's discretion. Data sheet is being provided to take care of Environmental and other statuary requirements

Minor correction

2.7 Marking

The following data is to be punched on number plate and this number plate is to be riveted properly on bottom side of dust cover in recognizable way:

• Name of the manufacturer • Month and year of manufacturing • Manufacturer part number • Serial number of the damper • Nominal force and nominal velocity • Name/Type of damper & drawing no.

The marking should remain legible with\ the naked eye for the entire service life of the dampers.

Besides above, the whole information has to be engraved/ punched on the dust cover on the opposite side of the number plate. Alternatively the same can be marked on the main body (Casing tube sub assembly).

For Lateral, Anti-Yaw dampers clear mounting indications need to be fixed on the main body (Casing tube sub assembly) to indicate the side to face the ground.

NCName of manufacter, manufacterer part number, manufactering date and serial number are marked in the reservoir tube. Other information will be indicated on a sticker type plate.

Engraving is accepted. However, instead of punched number plate, stickers should be allowed.

No change

2.8 Surface protection/varnishing

2.8.1 Dampers finishing

Non-polluting lacquer/ paint should be used for the dampers finishing. All support surfaces of the screws must be unlacquered/ unpainted have a galvanic coating. Any lacquer/ paint on the rubber bearings will be not accepted.

All parts of the dampers which are exposed to ambient air must be protected against corrosion.

The Manufacturer shall describe, and suitably document, the painting process it intends to apply for all

Dampers finishing Non‐polluting paint should be used for the shock absorber finishing. All support surfaces meant for mounting bolts must be un‐lacquered and have a

No change

visible parts of the dampers in question.

All these details shall be included in QAP which shall be submitted with RDSO for approval.

galvanic coating/plating. Any lacquer / paint on the rubber bearings is not allowed. Dust cover should be of Stainless steel Grade 304 or equivalent grade. All other metallic mounting elements i.e. Washers, bushes, Mounting pins (Bar Pins), Nuts etc. are to be plated. Piston rod to be Hard Chrome plated. All other parts / surfaces of the shock absorber (other than Dust cover) which are exposed to ambient air, whether visible or not visible, must be protected against corrosion by special plating#. The outer surfaces of Main body Sub assembly (tube welded with Bottom Eye / mounting) and End mount of Piston rod (Top Eye) of the damper are to be plated#. Welding is not allowed after plating$. The top coat is to be painted in Basalt Grey Color to RAL 7042. The tube thickness of Main body tube of the damper (Casing Tube sub assembly) is to be 5 mm and made out of carbon steel. No welding allowed after assembly$ of Damper. The dust cover is to be affixed by direct tightening (threaded joint) or by using screws. #Coating to be Zinc Nickel base Chromium free in 3 layers in sequence: Zinc‐Nickel Base coating (8 microns min), Transparent Passivation (500 Nano microns) and Transparent Siliceous Coating (2 micron). The total coating thickness10‐15 microns. Corrosion resistance should be more than 720 Hrs. of Neutral Salt spray. $ The welding after plating or assembly will damage the hidden surfaces and prone to corrosion Based on Field analysis of Dampers for LHB cars, The major cause of failure of all dampers (including imported ones) is corrosion Due to stone hits / handling during installation the paint gets damaged and corrosion starts.

In India the temperatures are generally around 35°C and the RH is also >35% for major portion of time leading to accelerated corrosion. Dust covers are normally thin tubes of less than 2 mm thickness therefore probability of premature failure is high. SS tube is recommended as a countermeasure as stone hits will have no effect on it. Painting / plating on the inner surface of cover will not arrest corrosion from outer surface. Casing tube (Body tube) with high thickness is recommended (5mm) as smaller thicknesses (~2mm) have shown to prematurily fail based on field analysis. Plating followed by painting and higher thickness tubes wll increase the life considerably. Welding after plating/ assembly is not recommended since the invisible surfaces, exposed to air, will become highly prone to corrosion. Fitting of Dust cover after assembly by Rivets or Screws or direct tiggtening (Threade joint) is recommended. This is an standard practice followed internationally

2.8.2 Resistance of the paint

To be performed at the type approval stage:

Check bond according to ISO 2409: the paint must not come off any of the squares.

‐‐‐‐‐‐

2.8.3 Resistance to salt environment

The manufacturer demonstrate the aging stability of the surface protection by a salt spray test according to ISO 9227.

The testing time for all dampers must not remain under:

720 hours

The specimen shouldn’t have any “Red Rust” on the outside as well as internal surfaces exposed to air.

Resistance to salt environment The manufacturer has to demonstrate the aging stability of the surface protection by a salt spray test according to ISO 9227. The testing time for all dampers must not remain under 720 hours. The specimen shouldn’t have any “Red Rust” on the outside as well as internal surfaces exposed to air.

NC The proposed dampers are paitned according Koni KN0040‐A1 with a NSS of 480 hours

Minor correction done in the view of recommendations

2.8.4 Colour

The colour of the coating lacquer is stated in the text of the order or on the specification drawing. The top coat is to be painted in paint shade to RAL 7012, (BASALT GREY)

‐‐‐‐‐

2.8.5 Thickness of the layer

Thickness of the paint layer shall be a minimum of 50 microns (DFT)

Clause not required As the supplier has to ensure

No change

3. DE3.1 Dem

3.2 Dem

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Where Q must be smaller than or equal to the following values (Table 2):

Table 2:

Dampers for primary suspension

{N}

Dampers for secondary suspension

{N}

Anti-yaw damper

{N}

100 100 300

4. QUALIFICATION AND INSPECTION REQUIREMENTS 4.1 Test Method Each test has to fulfill the following conditions

‐‐‐‐‐‐

4.1.1 Test Machine

• The test machine should be computer controlled capable of storing and receiving data with facility to take printouts.

• The test machine is integrated in the quality system concerning calibration • The stiffness of the test machine must not influence the measurement conditions. • The test machine is able to measure both the compression and the tension forces. • The test velocity is showing the following formula:

V(t) = V.sin (ωt)

‐‐‐‐‐‐

4.1.2 Test Temperature • All tests should be proceeded at room temperature (20 to 280 C) • Keep the dampers with this temperature for a period of 24h before testing. • The dampers to be assembled at this temperature OR soaked at this temperature for a period of 24h before testing.

Test Temperature • All tests should be proceeded at room temperature (20°C to 28° C) • The dampers to be assembled at this temperature OR soaked at this temperature for a period of 24h before testing.

Point not applicable Remarks‐ No need to keep dampers in soaking for 24 h

Para modified in the view of recommendations

4.2 Design conditions

4.2.1 Dimension of the geometry The manufacturer confirms at the first article testing, that the minimum and maximum lengths of the dampers are kept as specified.

Overall dimensions:

The dimensions showed in the drawings must be recorded by the manufacturer and compared with the specified dimensions.

The following dimensions must be measured:

Maximum and minimum length of the dampers Length and diameter of the dust tube Dimension and position of the external housing if existing Diameter of the dampers body Dimensions of the dampers bearing and its attachment elements

‐‐‐‐‐‐

4.2.2 Welding seams at dampers

Only those welding seams which are visible from outside are considered.

The quality of welding seam has to be according to EN25817/ ISO 5817 class B with the following exception:

No. 11 : Undercutting is not allowed.

At the type approval stage, the manufacturer shall hand over to RDSO necessary documentation for approval

4.2.3 Testing of welding seams

The welding seams have to be checked by non-destructive methods via PT (Penetrant Test) or MT (Magnetic Particle Test)

PT as per EN 1289 or ISO 23277

MT as per EN 1290 and EN 1291 or ISO 17638 and ISO 23278

The test has to be done with two samples per each type of dampers. The test results have to be recorded and sent to RDSO.

'Testing of welding seams

The welding seams have to be checked by non‐destructive methods via PT (Penetrant Test) or MT (Magnetic Particle Test)

PT as per ISO 23277 MT as per ISO 17638 and ISO 23278

The test has to be done with two samples per each type of dampers. The test results have to be recorded and sent to RDSO.

EN1289, EN1290 and EN1291 are obsolete, hence should not be referenced

Accepted

4.3 Testing of dampers 4.3.1 Production tests

Production test shall be carried out on every damper and recorded.

The test will be carried out at a stroke of 50mm (unless is otherwise specified in drawing or purchase order) and at two different frequencies.

‐‐‐‐‐‐

4.3.2 Visual Check

All the dampers must undergo visual inspection before they are dispatched to make sure there are no signs of:

• Failure • Indentations • Damages on the coating or damper itself • Paint on Rubber bearings and support surfaces of the screws • Detachment of laceration (deep cut or tear) of the rubber parts of the articulated joints and elastic

blocks • Fluid/oil leakages

‐‐‐‐‐‐

4.3.3 Routine Testing

This measurement serves for drawing up the graph described in section 3.1

Table 3: Force velocity characteristics test

General conditions The test method described in section 4.1 is to apply

Test position The dampers must be tested in the position according to the real position in the bogie.

Test length Installation length of the damper in the bogie/ mid position

Test amplitude At specified length and travel. Default travel =+/-25mm

Test velocity According to table 4

Test conditions - Measurement with and without attachment elements - Two pieces per each type of dampers

Number of cycles before measuring

10 complete cycles

Measurement The eleventh cycle is used in order to ascertain for each velocity

• The maximum extension force • The maximum compression force

Test length = Installation length of the damper in the bogie or mid position Installation lengths not defined in RCF drawing

Test Length : Installation length of the damper in the bogie/ Mid position Remarks‐ Installation length not mentioned in drawing nor in specification

“/Mid position” added in the view of recommendations

Diagram • A diagram (force/ displacement) must be recorded for each measurement.

• According to this force/ displacement diagram a force/velocity diagram should be draw up

• All relevant data must be obvious on the diagram i.e. velocity, force, stroke (amplitude) axis etc.

Analysis The diagram will be in compliance with section 3.1 and 3.2

Table 4: Velocity’s for the force/velocity characteristics test

V (m/s) Primary dampers 0.05 0.1 0.15 0.2 0.25 0.3 Vertical dampers 0.05 0.1 0.15 0.2 0.25 0.3Lateral dampers 0.05 0.1 0.15 0.2 0.25 0.3Yaw damper 0.005 0.01 0.02 0.05 0.1 0.15

4.3.4 Measurement of the dynamic stiffness

Table 5: Dynamical Stiffness test

General conditions The test method described in section 4.1 is to apply


Test Length Installation length of the damper in the bogie

Test amplitude According to table 6-9

Test velocity According to table 6-9

Test conditions - Measurement with and without attachment elements - 5 pieces per each type of dampers

Number of cycles before measuring

10 complete cycles

Measurement The eleventh cycle is used in order to ascertain for each velocity

• The maximum extension force • The maximum compression force

Diagram • A diagram (force/ displacement) must be recorded for each measurement.

• According to this force/ displacement diagram a force/velocity diagram should be drawn

• All relevant data must be obvious on the diagram i.e. velocity, force, stroke (amplitude) axis etc.

Analysis The diagram will be in compliance with section 3.1 and 3.2

Table : 6

Primary dampers :

Frequency {Hz} at vdamper {m/s}

Amplitude

(mm)

0.02 m/s 0.03

m/s

0.05

m/s

0.07

m/s

0.1

m/s

0.15

m/s

0.2

m/s

0.3

m/s

2 1.59 2.39 3.98 5.57 7.96 11.94 15.92 23.87

4 0.80 1.19 1.99 2.79 3.98 5.97 7.96 11.93

6 0.53 0.80 1.33 1.86 2.65 3.98 5.31 7.95

Table 7:

Vertical dampers :


Amplitude 0.02 m/s 0.03 0.05 0.07 0.1 0.15 0.2 0.3

‐‐‐‐‐‐

(mm) m/s m/s m/s m/s m/s m/s m/s

2 1.59 2.39 3.98 5.57 7.96 11.94 15.92 23.87

4 0.80 1.19 1.99 2.79 3.98 5.97 7.96 11.93

8 0.40 0.60 1.00 1.39 1.99 2.99 3.98 5.96

12 0.27 0.40 0.66 0.93 1.33 1.99 2.65 3.97

16 0.20 0.30 0.50 0.70 1.00 1.49 1.99 2.98

Table 8:

Lateral dampers :


Amplitude

(mm)

0.02 m/s 0.03

m/s

0.05

m/s

0.07

m/s

0.1

m/s

0.15

m/s

0.2

m/s

0.3

m/s

2 1.59 2.39 3.98 5.57 7.96 11.94 15.92 23.87

4 0.80 1.19 1.99 2.79 3.98 5.97 7.96 11.93

8 0.40 0.60 1.00 1.39 1.99 2.99 3.98 5.96

12 0.27 0.40 0.66 0.93 1.33 1.99 2.65 3.97

16 0.20 0.30 0.50 0.70 1.00 1.49 1.99 2.98

Table 9:

Side motion dampers :


Amplitude

(mm)

0.005 m/s

0.01

m/s

0.02

m/s

0.03

m/s

0.05

m/s

0.07

m/s

0.1

m/s

0.15

m/s

2 0.39 0.80 1.59 2.39 3.98 5.57 7.96 11.94

4 0.20 0.40 0.80 1.19 1.99 2.79 3.98 5.97

6 0.13 0.27 0.53 0.80 1.33 1.86 2.65 3.98

20 0.04 0.08 0.16 0.24 0.40 0.56 0.80 1.19

30 0.026 0.05 0.11 0.16 0.27 0.37 0.53 0.80

4.3.5 Measurement of Series stiffness and Damping coefficient

At the type-approval stage the manufacturer shall calculate and ensure the value of series stiffness and the damping coefficient of the damper –articulated joint system or of the dampers alone in the case of particularly flexible articulated joints.

The dampers must be tested in its working position (see assembly drawing) and over the range of displacements and frequencies specified in the table 11.

Table 10

Type Frequency {Hz}

Amplitude {Hz} (mm)

Primary suspension From 4 to 12 + 2.5

Secondary suspension From 0.5 to 2 + 10

Anti-yaw From 0 to 9 + 2.6

Amplitude {mm}

Amplitude {mm} Remark‐ The unit of Amplitude is mm

Accepted Typographical error corrected (mm added with amplitude)

The dampers must be activated by means of sinusoidal displacements of constant amplitude (see table) and of variable frequency over the entire specified range.

The activation displacement u(t) must be measured in a suitable manner in order to correct it for the components, such as Deformation of the supporting structures and the like, if any, which might alter its value.

At the same time, measure the force delivered by the dampers F(t).

Both quantities, u(t) and F(t) must then be subjected to a Fourier analysis in order to determine the frequency components.

For each frequency, determine the u/F ratio as imaginary number. From the real part of this ratio, determine the value of series stiffness, and from the imaginary part, determine the damping coefficient according to “receptance” theory.

The value of the damping coefficient over the entire frequency range specified must not deteriorate beyond 20% of the nominal value which must be observed at the lowest frequency values (1 to 2 Hz).

4.3.6 Measurement at extreme temperature

Table 11

General conditions The test method described in section 4.1 is to apply.


Test length Medium installation length

Test amplitude According to table 13 12

Test velocity According to table 1312

Test conditions - Test of two dampers per each type of dampers - Measurement with attachment elements

Measurement 1. Measure the dampers at room temperature according to 4.3.3. 2. Cool the complete dampers to the specified temperature (-40˚C)

and keep it in this condition for 24h then measure the characteristic according to the table below (Table 12).

3. Fit immediately the dampers onto the testing machine prepared for the execution of the test according to the stroke listed in the table 6 12 and a frequency corresponding to ¼ the value given in the table 612. Carry on the test until you reach a temperature of -20° C as measured on the body in the proximity of the sealing gasket.

4. Measure the characteristic on these temperature with the value given in the table 13 4.

5. Start the test again as per s. no. 3 above until they have reached the temperature of 0° C. The cycle must be carried on at the frequency given in the table below until a temperature of 40° C is reached. The dampers have to be measured again at this temperature as per table 13 4.

6. Start the test again until a temperature of 80° C is reached or until the temperature becomes stable, if lower than 80° C

7. Let the dampers cool down to the room temperature 8. Measure the dampers at the room temperature.

Diagram • A diagram (force/displacement) must be recorded for each measurement.

• According to this force/ displacement diagram a force/velocity diagram should be drawn

• All relevant data must be obvious on the diagram velocity, force, stroke (amplitude) axis etc.

Test Amplitude ‐ According to Table 12 Test Velocity ‐ According to Table 12 Cool the complete dampers to the specified temperature (‐40˚C) and keep it in this condition for 24h then measure the characteristic according to the table below (Table 12) Fit immediately the dampers onto the testing machine prepared for the execution of the test according to the stroke listed in the table 12 and a frequency corresponding to ¼ the value given in the table 12. Carry on the test until you reach a temperature of ‐20° C as measured on the body in the proximity of the sealing gasket. These are priming cycles to increase temperature from ‐40°C to ‐20°C > In original LHB specs there is a Typo error (Table 7 mentioned against Table 13) Measure the characteristic on these temperature with the value given in the table 4 Table 4 is for Force Velocity Characteristic test. The change in same characteristics needs to be mapped here for different temperatures. In original LHB specs there is a Typo error (Table 7 mentioned against

In measurement at extreme temperature, the test amplitude and test velocity column refers to table 13, which is a discrepancy. Instead of Table 13, it should be table 12. Similarly, point no. 4 and point no. 5 of measurements column refers to table 13 which is also a discrepancy. Instead of table 13, it should be table 6.

Accepted (Test Amplitude ‐ According to Table 12) Accepted (Test Velocity ‐ According to Table 12) Accepted and added (table 12) with below at s. no. 2.

Analysis • The diagram will be in compliance with section 3.1 and 3.2 • There should be no oil leakage at the dampers • There shall be no damages at the rubber bearings (collar, skin) • The diagrams (force/ displacement) of point 1 and point 8 above of

the measurement vary only in a range of 5% • The diagrams (force/ displacement of point 3 and point 5 above of

the measurement vary only in a range of 30%

Table 12

Type Frequency

{Hz}

Amplitude

{mm}

Temperature { ° C}

T Min T Max

Primary suspension 7 2.5 -40 80

Secondary suspension 1.6 10 -40 80

Anti-yaw 6 2 -40 80

Table 4) Start the test again as per s. no. 3 above until they have reached the temperature of 0° C. The cycle must be carried on at the frequency given in the table below until a temperature of 40° C is reached. The dampers have to be measured again at this temperature as per table 4. Table 4 is for Force Velocity Characteristic test. The change in same characteristics needs to be mapped here for different temperatures. In original LHB specs there is a Typo error (Table 7 mentioned against Table 4)

4.3.7 Fatigue Test

During the Type Test approval stage following tests shall be done-

• Static test • Dynamic test

The test specification shall be approved by RDSO.

4.3.7.1 Static test The damper has to be loaded (compressed and expanded) with a static force of 20KN according to section 2.3.1. No damage on the dampers and its attachment elements is allowed after this test.

4.3.7.2 Dynamic Testing

The supplier has to prove the specified service life in section 2.3.2 with a long-time test.

The following general conditions should be specified in the test specification and considered :

• Measuring of the dampers according to section 4.3.3 • Number of cycles specified to the whole life of the damper (minimum 2 1x107 cycles) • The table 14 13 shows the offset between the dampers and the eyelet’s as a example. • The damper is tested according to the real positioning in the bogie. • All performance specifications according to section 2 should be implemented in the test. • The test is proceeded according to the practical service conditions in section 2.1 • At the end of the tests the damper has to be measured according to section 4.3.3.

The characteristics have to be still in the specified figures. The full functionality is still guaranteed. Only replacement parts could be changed which would be like a regular revision interval. No replacements of any parts allowed during the test.

Table 13

Type of dampers Offset Dx {mm}

Offset Dy {mm}

Primary suspension dampers 3 3

Secondary suspension dampers 13 38

Anti-yaw dampers (if fitted with ball joints) 0 0

Number of cycles specified to the whole life of the damper (minimum 1x107 cycles) As per original Alstom LHB specs. This, in any case, is the most stringent requirement in the world The table 13 shows the offset between the dampers and the eyelet’s as a example. 4.3.7.2, Bullet pt 3 It is a typographical error. Table 14 is for Final Acceptance 4.3.7.2, Bullet pt 6 'Not Required

Conditions in 2.1 are general guidelines. These requirements to be monitored during field trials. Practically not possible in the labs No replacements of any parts allowed during the test. The purpose of the test is defeated by allowing replacement of any part during the test. 10^7 cycles simulate 1.2 million kms of service life.

Number of cycles specified to the whole life of the damper (minimum 1×10⁷ cycles) Remark‐ Actually in Fiat specifications no. of cycles mentioned as 1×10⁷ and these dampers are developed accordingly

In point no. 3 of general conditions, table 13 should be used instead of table 14

” Accepted “minimum 1x107 cycles Table 14 corrected as table 13 Added “No replacements of any parts allowed during the test”.

4.3.8 Specifications for the Final Acceptance

Table 14

Clause First Article Testing

Homologation

Acceptance Testing (Purchase inspection)

Remarks

Weight 2.3.56 Yes Yes 3% or min. 2 samples

Surface protection 2.8 Yes Yes 3% or min. 2 samples

Thickness of the paint layer (DFT)

2.8.5 Yes Yes 3% or min. 2 samples

Dimension of the geometry 4.2.1 Yes Yes 3% or min. 2 samples

Welding seams 4.2.2

4.2.3

Yes Yes Welding Certificate

Visual for 2 nos.

Production tests 4.3.1 ---- Yes 3% or min. 2 samples

Visual check 4.3.2 Yes Yes 3% or min. 2 samples

Routine testing 4.3.3 Yes Yes 3% or min. 2 samples

Dynamical stiffness 4.3.4 Yes ---- 2 nos. chosen at random in a lot upto lot size of 500 nos. and 3 nos. for 500 <Lot size <1000 and 4 nos. for 1000 <Lot size <2000 and 5 nos. beyond that.(Except First Article Testing, test only it is especially noted in the order).

Series stiffness and Damping coefficient

4.3.5 Yes ----

Extreme temperature 4.3.6 Yes ----

Fatigue test 4.3.7 Yes ----

Vibrational Qualification 2.3.1 & 2.3.2

Yes ----

NOTE: The quantity and other details on first article testing are given under para 8.

2% or min 2 It is in First Article Testing (Homologation) hence remarks are not relevant Vibrational Qualification Clause 2.3.1 Needs to be added to the table. To be done during First Article Testing (Homologation). It is a critical requirement

Weight ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2% or min. Surface protection ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐2% or min. 2 Thickness of the paint layer (D‐‐‐‐‐‐ 2% or min. 2 Dimenion of the deometry ‐‐‐‐‐‐‐‐ 2% or min. 2 Remarks‐ Already QAP's are approved for 2% or min.2 Content in Remarks column todeleted Remarks‐ This is only applicable during first article test

No change in sample quantity. “Yes” also to be added in visual check during First Article Testing (Homologation) in Table 14 Vibrational Qualification as per clause 2.3.2 may be added in First Article test

5. QUALITY ASSURANCE, TESTING, FINAL ACCEPTANCE

5.1 Acceptability testing As indicated in clause 4.3.8

‐‐‐‐‐‐

5.2 Product Audit The manufacturer undertakes to ensure that the manufacturing process produces a series part which corresponds to the type-tested part. Particular attention is given to the conformity with the test criteria.

‐‐‐‐‐‐

5.2.1 Quality Records All testing carried out is to be certified by the manufacturer with an acceptance Certificate according to EN 10204 3. 1B and delivered with the product.

The recorded individual test results will be kept by the manufacturer/supplier for a period of 15 7 years following delivery and can be viewed upon demand.

Instead of keeping the test results by supplier for a period of 15 years following delivery, it should be for maximum 4 years as life is estimated from date of supply.

15 years is proposed to be modified as 7 years.

5.2.2 Qualification of the lots For each lot of dampers, the supplier, working in Quality Assurance conditions, shall supply:

‐‐‐‐‐‐

• The declaration of the conformity • The safe data sheets for the materials • A statement signed by the suppliers quality control manager

and whatever else is necessary, according to the instructions of the customer as per tender.

5.3 Auditing

RDSO is authorized, following prior notification or otherwise, to audit the final testing by the manufacturer.

‐‐‐‐‐‐

6. Warranty The supplier shall ensure the efficiency at least of the dampers over mileage of 1.2 million kilometers from supply or 4 years whichever is earlier.

During the warranty period if the dampers display any inefficiency they shall be replaced/attended at the expenses of the supplier.

By inefficiency of the dampers it is meant:

• A problem detected in service conditions • A defect undermining its functionality • Oil leak or infiltration in the sealing gaskets. • The rubber of the elastic joints undergoes a deterioration process that undermines its functionality. • The values of the characteristic do not remain within the tolerance limits specified in section 3.2

4,00,000 kms or 2 years from date of fitment or 3 years from date of supply ‐ whichever is earlier Remarks‐ Considering Indian track conditions which is different than Germany. Also there is no provision to track KM running in field.

This warranty period need to be reviewed as it is too long.

No change

7. ORGANISATIONAL AND ADMINISTRATIVE PROVISIONS

7.1 Maintenance instructions Service and maintenance instructions, together with a list of replacement parts, are to be included in delivery by the manufacturer, containing all data necessary for service and maintenance of the dampers. Do/ not do and probable failures along with their reasons and remedial action/ trouble shooting during the train service/ maintenance also to be mentioned in manual. Each Zonal Railway shall be supplied with soft copy of these manual where dampers are supplied by a manufacturer of damper.

‐‐‐‐‐‐

7.2 Modifications Modifications which result in the loss of ability to replace the dampers or replacement parts may be carried out only after authorization by IR/RDSO.

‐‐‐‐‐‐

8. PROCEDURE FOR TESTING OF PROTOTYPE DAMPERS.

The vendor shall offer a lot of min. 10 dampers of a particular type for prototype testing at the time of registration. The inspector shall select at random 3 dampers from this lot for prototype testing as per para 4.3.8.

‐‐‐‐‐‐

9. Regular Procedure for Inspection and Testing of Production Dampers

‐‐‐‐‐‐

9.1 Purchase inspection shall be carried out at the premises of manufacturer who are cleared for the regular manufacture of production damper. The following procedure shall be followed for the purchase inspection.

‐‐‐‐‐‐

9.1.1 The inspecting authority shall make audit checks of the manufacturing procedure/Internal Quality Assurance System to ensure that the lot offered for inspection is manufactured strictly as per Internal Quality Assurance System and the manufacturer has carried out all tests/inspection during manufacturing stage to ensure that damper offered are strictly to the specification. During such audit checks, the inspecting authority shall also see from the records of ‘Internal Quality Assurance’ that the raw materials used for the manufacturer of damper is as per approved QAP.

‐‐‐‐‐‐

9.1.2 The inspecting authority shall conduct the checks from the offered lot of dampers as per para 4.3.8.

‐‐‐‐‐‐

9.1.3 In case any of the samples picked up fail in any of the tests indicated in para 4.3.8, manufacturer shall find out the reason for such failure to the satisfaction of inspecting authority. In case inspecting authority is convinced that the failure was on account of non-implementation of ‘Internal Quality Assurance System’, the entire lot of dampers shall be rejected. In case, the failure is on account of reasons other than non-implementation or Internal Quality Assurance System, the manufacturer may re-offer the lot after rectifying the defects. However, in such cases double the quantity of sample shall be picked up and tests/checks conducted as per para 4.3.8. In case any of the samples again fails in any of the tests/checks, the entire lot shall be rejected.

‐‐‐‐‐‐

9.1.4 In the event of a dispute between the inspecting authority and the manufacturer, the decision of purchaser/RDSO shall be final and binding.

‐‐‐‐‐‐

9.1.5 In normal course, testing of production damper offered by the manufacturer shall form part of the ‘Internal Quality Assurance System’ for which proper record shall be maintained and presented to the inspecting authority on demand. The following system of testing as a minimum shall be followed by manufacturers for fatigue testing as

‐‐‐‐‐‐

per para 4.3.7. 9.1.5.1 One damper out of every 2000 Nos produced. 3000 Nos. produced or once in 6 month whichever in later shall

be subjected to fatigue tests by the manufacturers as part of the quality assurance programme and documents maintained. The result of these tests shall be monitored by the inspector to ensure the quality.

One damper out of every 2000 Nos. produced or once every year , whichever is later, shall be subjected to fatigue tests by the manufacturers as part of the quality assurance programme and documents maintained. The result of these tests shall be monitored by the inspector to ensure the quality. The volumes are very high. 2,000 nos mean every month, which is not practical. The test itself is very time consuming.

once in 2 years or 2,000 coach sets ‐ whichever is ealier Remarks‐ Vibration test to be done during validation and re‐validation testing only. 1. Quantity will be produced in a one month only. 2. Also it is time consumming activity

In place of 2000 nos., the sample size should be increased to 4000 nos. in accordance with the following clause 9.1.5.2

May be modified for “3000 Nos. produced or once in 6 month whichever in later”

9.1.5.2 Dampers shall be tested for Fatigue tests in the presence of Inspector, at the rate of one per 4000 dampers produced 4000 Nos. produced or once in 2 years whichever in later. For this purpose, sample shall be drawn at random from a batch of not less than 50 dampers. The tests can be conducted and witnessed by the Inspector at the firm’s premises or at RDSO at his discretion.

Dampers shall be tested for Fatigue tests in the presence of Inspector, at the rate of one per 4000 dampers produced or once in 2 years, whichever is later. For this purpose, sample shall be drawn at random from a batch of not less than 50 dampers. The tests can be conducted and witnessed by the Inspector at the firm’s premises or at RDSO at his discretion. The volumes are very high. 4,000 nos mean every month, which is not practical. The test itself is very time consuming.

once in 2 years or 2,000 coach sets ‐ whichever is ealier Remarks‐ Vibration test to be done during validation and re‐validation testing only. 1. Quantity will be produced in a one month only. 2. Also it is time consumming activity

May be modified for “ 4000 Nos. produced or once in 2 years whichever in later”

9.1.5.3 At the discretion of inspecting authority, these tests may be carried out at any time in addition to the frequency specified in clauses 9.1.5.1 to 9.1.5.2 inclusive.

Clause to be deleted in view of 9.1.5.1 and 9.1.5.2 above

Content to be deleted Remarks‐ Point not required

Deleted

9.1.6 Notwithstanding what has been written in clause 9.8.1, for the purpose of purchase inspection, inspecting authority, at his discretion may ask for testing of one damper out of 5% selected as per clause 9.1.4 for strength, endurance and end mounting tests. Should any of the samples fail during such tests entire lot of dampers offered shall be rejected.

Clause to be deleted. There is no clause 9.8.1. Clause 9.1.4 is not for Sampling

Content to be deleted Remarks‐ Clause 9.8.1 no where appears.

This clause takes reference to clause no. 9.8.1 whereas such a clause no. hasn’t been mentioned anywhere in the entire specification.

Deleted

10. PARTICULAR REQUIREMENTS

‐‐‐

10.1 Manufacturer willing to supply damper for the use of Indian Railways shall register themselves with RDSO.

‐‐‐‐

10.2 The manufacturer shall have adequate facilities for the manufacture and testing of damper conforming to this specification.

‐‐‐‐

10.3 The manufacturers shall have a well-documented ‘Internal Quality Assurance System’ to ensure sustained quality of product being manufactured and shall submit his internal Q.A.P in triplicate. ‘Quality Assurance System’ Shall generally cover the following: -

‐‐‐‐

10.3.1 System to ensure that correct raw material is being used. 10.3.2 System to ensure that components having manufacturing defects are identified and destroyed so that such

components are not used during assembly.

‐‐‐

10.3.3 System to ensure that bought out components are strict as per requirements laid down in the specification / drawing.

‐‐‐‐

2.8.6 System to maintain strict control of dimensions and workmanship of components and assembled products.

‐‐‐‐

10.3.4 System to test and establish that the damper manufactured by the firm meets all the requirements laid down is the specification/drawings.

‐‐‐‐

10.3.5 System of periodical calibration of equipment/gauges to ensure accuracy of product.

‐‐‐‐

10.3.6 System to ensure that the quality of bought out hardware items are as per the relevant specifications. ‐‐‐‐

10.4 Manufacturers should have the ISO 9001-2000 ISO 9001-2015 or latest Certificate for manufacture of dampers.

Manufacturers should have the ISO 9001‐2015 or latest Certificate for manufacture of dampers. IRIS certified suppliers will be preferred as it is Railway specific Quality standard

Manufacturers should have the ISO 9001‐2015 or latest Certificate for manufacture of the dampers. Remark‐ ISO 9001 verison get changed periodically

Changed as “ ISO 9001‐2015 or latest”

11. GUARANTEE / WARRANTY 11.1 The manufacturer shall furnish a guarantee that each new damper supplied, shall function satisfactorily without

attention and in accordance with the requirements of this specification for 1.2 million kms of service running on a vehicle or for 4 years from the date of supply, whichever is earlier. A format of the certificate is given at Appendix-III

………..of this specification for 4,00,000 kms or 2 years from date of fitment or 3 years from date of supply,……………. Remarks‐ Considering Indian track conditions which is different than Germany. Also there is no provision to track KM running in field.

The warranty period need to be reviewed as it is too long.

No change

11.2 The warranty shall survive inspection, payment for and acceptance of the goods, but shall expire 60 months after placement in service or 1.2 million kms of service running of a vehicle, whichever is earlier, except in respect of complaints, defects and/or claims, notified to the contractor within 3 months of such date. Any approval or acceptance by the purchaser of the stores of the material incorporated herein shall not in any way limit the contractor’s liability.

4,00,000 kms or 2 years from date of fitment or 3 years from date of supply,……………. Remarks‐ Considering Indian track conditions which is different than Germany. Also there is no provision to track KM running in field.

The warranty period need to be reviewed as it is too long.

No change

12 GENERAL 12.1 All welded joints of the damper shall be free from welding defects and shall be sufficiently strong to withstand the

loads..

12.2 The damper shall be assembled in such a manner that the damping shall be uniform throughout the stroke.

12.3 The external dimensions, design, construction, characteristics or materials used in the manufacture of the damper

shall not be altered by the manufacturer without the prior written consent of RDSO. Unless otherwise specified in the respective drawing, the tolerance in compressed and extended length of all types of dampers shall be within ±3 mm of the specified dimension.

12.4 The hydraulic fluid used in dampers shall be a type and grade which has been specified in QAP and approved in

writing by RDSO.

12.5 The damper shall be manufactured and assembled at the manufacturer’s own works.

12.6 Damper found to be defective after delivery within the warranty period will be returned to the manufacturer for replacement at his own expenses, not with standing that they may have passed the tests required by this specification and have been accepted by the Inspector.

12.7 Damper shall not be dispatched from the manufacturers works before dispatch memo certificate has been obtained

from the Inspector and this certificate shall be forwarded to the office from which the order was issued attached to the invoice as evidence that the dampers have been duly inspected.

‐‐‐‐‐‐‐‐‐‐

13 GENERAL INSPECTION 13.1 All the materials or fittings used in dampers shall be subjected to inspection by the Inspecting Authority and shall be

to his entire satisfaction.

13.2 The manufacturer shall supply the necessary man power and appliances for testing and inspection of the dampers and mountings and shall supply to inspector a copy of the test results signed by manufacturer or his representative.

13.3 The Inspecting Authority shall have right to: -

13.4 Adopt any means he may think advisable to satisfy himself that the materials or fittings as per the specifications are

actually used in the construction.

13.5 Take samples of components/parts for such tests, as he may consider necessary by an approved metallurgist selected by him whose report shall be final and binding on the manufacturer.

13.6 Visit at any reasonable time and without previous notice, the manufacturer’s works to inspect progress and the

quality of the work and the manufacturer shall provide free of the charge all equipments, gauges and other facilities required by him for the purpose.

Not Applicable, Design is propritory of the manufacturer and he is responsible for the performance of the product

Not applicable Remarks‐ All internal parts are proprietary items

Clause 13.6 may be deleted however other clauses may stand good.

13.7 Reject any material or fittings, which do not conform the relevant specifications or good practice. These shall be

marked in a distinguishable manner and shall be disposed of in such a manner as the inspecting authority directs. Such rejected parts shall be replaced by the manufacturer without extra charges.

13.8 In the event of a dispute between the inspecting authority and the manufacturer the decision of the purchaser shall

be final and binding.

14 TRAINING AND INFRASTRUCTURAL FACILITIES. The manufacturer shall provide the requisite training to the staff of purchaser to use, repair and overhaul the dampers. He shall also supply set of maintenance/instruction manuals in soft and hard copy for each order indicating dimension of critical items and its permissible wear, specification and quantity of oil etc. to the user Railways. The manual shall be vetted by RDSO before issue to Railways.

.

‐‐‐‐‐‐

15 PACKING The manufacturer shall ensure that dampers are suitably packed in polyethylene covers polyethylene covers/ bubble sheet using suitable cartons to prevent ingress of foreign matter and damage during handling and storage.

The manufacturer shall ensure that dampers are suitably packed in cartons (as polybags are not enviroment friendly) to prevent ingress of foreign matter and damage during handling and storage

The manufacturer shall ensure that dampers are suitably packed in polyethylene covers/ bubble sheet using ……… Remarks‐ Option of Bubble sheet added

polyethylene covers may be modified as polyethylene covers/ bubble sheet

16 SPECIAL CONDITIONS:

a) Vendors of Dampers for LHB Coaches shall be recognized on the basis of their design. Company shall have the facilities for designing the Dampers for LHB Coaches and the necessary infrastructure to carry out detailed type tests at their own facility.

b) Since Dampers for LHB Coaches are a safety related item, in-service trials shall be necessary for each design before full clearance is given for vendor registration as “Vendors for Developmental Order” status for manufacture and supply of Dampers for LHB coaches.

c) The Dampers for LHB Coaches of a particular design shall be subjected to field trials on a minimum of

ten coach sets on IR’s system for vendor registration as “Vendors for Developmental Order” status for manufacture and supply of Dampers for LHB coaches for 12 months from date of fitment or 15 months from date of last IC issued whichever is earlier.

d) In case of any failure during field trials attributable to poor design or material, the field trials shall be

repeated.

e) After completion of service trial period, two samples of the Dampers for LHB Coaches shall be subjected to the tests to verify the properties laid down in Appendix-I of this STR/ Approved drawing. In case these values are beyond permissible limits, the design of that type of Dampers for LHB coaches shall be deemed to have failed the service trials.

f) A Vendor shall be considered eligible for upgradation to Part-I “Approved Vendors” status on

completing successful supply of a minimum of 250 coach sets of the particular type of Dampers for LHB Coaches as a ‘list of RDSO vendors for developmental order’ and the dampers of these 250 coaches should have completed minimum for 12 months from date of fitment or 15 months from date of last IC issued whichever is earlier.

g) A vendor considered eligible for upgradation to Part-I “Approved Vendors” status shall undertake manufacturing facilities and process of manufacturing.

h) After type tests of a particular design are approved by RDSO, vendors shall ensure that Dampers for

LHB Coaches to the particular specification are supplied with components manufactured from the sources as indicated at the time of design approval and included in QAP. However, in case of change of sub vendor or source of supply for manufacturing of Dampers for LHB Coaches components, the firm shall get approval of their modified QAP from RDSO before manufacturing and supply of Dampers for LHB coaches. .

i) The type test shall be witnessed by authorized representative of RDSO at the time of design approval of the vendor at their own test facility. Any additional tests if considered necessary shall also be arranged by vendor free of cost. All necessary arrangements for witnessing the type test of Dampers for LHB Coaches at firm’s premises shall be done by the vendor. RDSO reserves the right to witness the type test again if changes in approved design/drawings are carried out which are likely to alter design / performance characteristics of the Dampers for LHB Coaches.

A Vendor shall be considered eligible for upgradation to Part‐I status on completing successful supply of a minimum of 250 coach sets of the particular type of Dampers for LHB Coaches as a ‘list of RDSO vendors for developmental order’ and the dampers of these 1000 coaches (250 coach set is a very small population) should have completed minimum for 12 months from date of fitment or 15 months from date of IC issued whichever is earlier.

f) ………………status on completing successful supply of a minimum of 100 coach sets of the particular……. Remarks‐ 250 Coach set is huge quantity and also requires more time.

Since this product is just added to R.D.S.O. vendor directory, this clause should be waived for initial 6 months in order to qualify more Indian vendors and support “Make in India”.

Part‐I changed as “Approved Vendors”

j) In case design of critical component is changed, fresh type test and service trial shall be required.

However service trials can be dispensed with by RDSO considering the reasons for change and extent of modification.

k) In case, source of any component of Dampers for LHB Coaches is changed or any additional new source is introduced, the firm shall get approval of modified QAP form RDSO before manufacturing and supply of Dampers for LHB coaches. The vendor should provide the detailed information of the source changed/ additional source introduced along with the documentary evidences for the record of this office. Firm shall validate the source in all respects i.e. material, manufacturing process, quality control and inspection & testing etc. to conform to originally approved design and process. Compliance to all obligations including guarantee/warrantee shall remain the responsibility of vendor.

17 SUBMISSION OF OFFER:

17.1 Vendors desirous of seeking approval from RDSO for supply of dampers for LHB coaches as per this STR, shall apply online and submit their proposal as per ISO guidelines and also accompanied by the documents containing the following information to RDSO :-

1) Dimensional drawing of Dampers for LHB Coaches. 2) Weight of one Dampers for LHB Coaches. 3) Whether proposed Dampers for LHB Coaches is being used by any other rail-road system? If yes,

details regarding quantity, type of stock, max. operating speed, type of service, average annual running kilometers, life cycle obtained by the user rail-road and maintenance cycle followed by them shall be furnished.

4) Details of deviation from the STR. 5) Content of indigenous and imported items in offered Dampers for LHB Coaches. 6) Expected life cycle in operating and environmental conditions enumerated in this STR. 7) A write-up giving broadly the maintenance requirements on time/distance basis along with the facilities

that would be needed for proper maintenance/upkeep of the offered Dampers for LHB Coaches. 8) A detailed write-up giving the details of "Quality Assurance System" being followed for manufacture of

the offered items; and 9) Details of manufacturing and testing facilities available with the manufacturer.

‐‐‐‐‐

17.2 The information as received above shall be used for preliminary evaluation of the firm's capability in meeting with the requirements of this STR.

‐‐‐‐

17.3 The firm shall be required to submit a internal Type Test Report of a proposed design after the preliminary evaluation carried out found satisfactory.

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17.4 The premises of the firm shall be visited by RDSO's officials for on-the-spot assessment of the firm's capacity/ capability after the internal Type Test Report is accepted by RDSO

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17.5 RDSO reserves complete right in granting approval or otherwise to a firm.

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Appendix-ITECHNICAL REQUIREMENTS OF DAMPERS FOR LHB COACHES- A) Technical requirements of dampers for LHB coaches are as under-

The value for Axial stiffness at End connections is given a fixed value which can’t be achieved. This value should be provided with sufficient tolerance. Moreover, the value of Force in Secondary Vertical Damper is mentioned as 400 ± 60 N whereas in RCF drawing no. LG5102, it is mentioned as 400 ± 60 kg. On converting Kg to N, we multiply both base value and tolerance with 9.81~10. Hence the new value for Force in Secondary Vertical Damper should be 4000 ± 600 N.

corrected

i) Primary Vertical Dampers Technical requirements of Primary Vertical Dampers are tabulated below-

NC Refer to Koni 99A 2729 Outline drawing OFF

No change

I. Drawing No. As per RCF drawing no. LW05102

II. Compressed Length 294+3 mm

III. Stroke 140 mm

IV. Extended Length 434+3 mm

V. Damper testing at 200+20C

VI. Stroke 50 mm

VII. No. of revolutions 115 min

VIII. Velocity 0.3 m/s

IX. Force 4250+640 N

X. Cardanic Angle +8 Deg

XI. Axial Stiffness at End Connections 4500 N/mm

15062 Characteristic drawing 0100 27 79 04 Compressed length: 293 ±3mm Stroke: 141mm Extended length: 434 ±3mm Radial stiffness at end connection: 4kN/mm ±20%

ii) Secondary Vertical Damper Technical requirements of Secondary Vertical Damper are tabulated below-



III. Stroke 240 mm


V. Damper testing at 200 +20C

VI. Stroke 50 mm

VII. No. of revolutions 76 min-1


IX. Force 3500+520 N

X. Torsional Angle +22 Deg

XI. Cardanic Angle +10 Deg

XII. Radial Stiffness at End Connections 8500 N/mm

NC Refer to Koni 99V 3297 Outline drawing OFF 15043 Characteristic drawing 0100 27 78 89 Compressed length: 397 ±3mm Stroke: 238mm Extended length: 635 ±3mm Nominal damping force: 3350N ±15% Radial stiffness at end connection: 20kN/mm ±20% Torsional angle: 19°

No change

iii) Secondary Lateral Damper Technical requirements of Secondary Lateral Damper are tabulated below-

I. Drawing No. As per RCF drawing

no.LW05100


III. Stroke 240 mm



VI. Stroke 50 mm

NC Refer to Koni 99H 3298 Outline drawing OFF 15044 Characteristic drawing 0100 27 78 91 Compressed length: 395 ±3mm Stroke: 237mm Extended length: 632 ±3mm Nominal dampiing force: 8100N ±15% Radial stiffness at end connections: 20kN/mm ±20% Torsional angle: 19°

No change



IX. Force 8000+1200 N




iv) Yaw Damper

Technical requirements of Yaw Damper are tabulated below-

2. as per RCF drawing no.LW05103 I. Drawing No. As per RCF drawing no. LW05103


III. Stroke 380 mm



VI. Stroke 25 mm



IX. Force 11000+1650 N

X. Torsional Angle +9.5 Deg


XII. Radial Stiffness at End Connections 70 KN/mm

XIII. Max. compressive force on Rubber part 20 KN (Approx.)

NC Refer to Koni 02R 1849 001 Outline drawing OFF 11587 Characteristic drawing 0100 27 53 19 Compressed length: 700 +2/-3mm Stroke: 382mm Extended length: 1082 +3/-2mm Radial stiffness at end connections: 75kN/mm ±20%

No change

v) Secondary Lateral Damper Technical requirements of Secondary Lateral Damper are tabulated below-



III. Stroke 185 mm



VI. Stroke 50 mm



IX. Force 8000+1200 N


NC Refer to Koni 99H 3299 Outline drawing OFF 15045 Characteristic drawing 0100 27 78 92 Compressed length: 355 ±3mm Stroke: 197mm Extended length: 552 ±3mm Nominal damping force: 8100N ±15% Radial stiffness at end connections: 20kN/mm ±20% Torsional angle: 19°

No change



XIII. Damper is mounted in horizontal position

vi) Secondary Vertical Damper

Technical requirements of Secondary Vertical Damper are tabulated below-

I. Drawing No. As per RCF drawing no. LG05102


III. Stroke 240 mm



VI. Stroke 50 mm



IX. Force 400+ 60 N Kg




NC Refer to Koni 99V 3297 001 Outline drawing OFF 15043 Characteristic drawing 0100 27 78 90 Compressed length: 397 ±3mm Stroke: 238mm Extended length: 635 ±3mm Nominal damping force: 4200N ±15% Radial stiffness at end connection: 20kN/mm ±20% Torsional angle: 19°

Typographical error of unit i.e. “N” corrected as “Kg” at s. no. IX

FIRM NAME Quality Assurance and Testing Scheme

FIRST ARTICLE/TYPE TEST PLAN Model No. I Description:

Doc. No.: DAMPERS / QAP Date

S. No.

Test Parameters Specifications Mode of Inspection Acceptance

Criteria Remarks

1 Dynamic Stiffness

Measurement as per clause 4.3.4 of

this STR

Computer Controlled machine

As per Specification

2 Series Stiffness & Damping Co-Efficient

Measurement of series stiffness and damping coefficient as per clause 4.3.5

of this STR

Actuator Testing Machine As per Specification

3 Extreme temperature

Measurement of extreme

temperature as per clause 4.3.6 of this

STR for velocity specified on drawings.

Force denoted as

Force measured at

F(-20˚C) At -20°C for test parameters specified on drawing

F(+40˚C) At +40°C for test parameters

`

specified on drawing

F(+20˚C), before

At +20°C for test parameters specified on drawing, before starting the test process

F(+20˚C), after

At +20°C for test parameters specified on drawing, after completion of test

4 Fatigue test Static Load test-20KN in

compression & extension as per clause 4.3.7.1 of

this STR

Computer Controlled Testing Machine

No Structural Damage. No major change in Damping

forces

Vibration Testing as per clause 2.3.1 of

this STR

Computerized Vibration Shaker

No Structural Damage. No major change in Damping

forces

Dynamic/endurance test as per clause 4.3.7.2 of this STR

for ten million cycles

Computer Controlled Testing Machine

As per Specification

Frequency to be selected as per Table 7-10 and Appendix-I

5 Coating Paint adhesion test as per ISO2409

Standard tape test No peel off

Resistance to salt environment as IS0:9227 for 720

hrs

Salt spray testing machine No red rust after 720 hrs.

Note: Sample quantity shall be as per clause 4.3.8 of this STR FIRM NAME Quality Assurance and Testing Scheme

ROUTINE TESTING PLAN Model No/ Description:

Doc No.: DAMPERS / QAP Date

S. No.

Test Parameters Specifications Mode of Inspection Acceptance

Criteria Remarks

1 Appearance No Dents ,Cracks, Pitting, Sharp Edges, Leakage of Oil, uniform coating & no damage on coating etc.

Visual As per specification

2 Production Testing

Damping Force to be recorded at two different frequencies as per spec.

Damper Testing Machine

Force to be within specified

values

No change

3 Routine Testing

Measurement as per clause 4.3.3 of this STR

Damper Testing Machine

As per specification

4 Dimension As per approved drawing Steel scale/ vernier To be within tolerance

5 Welding Welding seam non-destructive test

EN 25817 Class B/ ISO 5817

With the exception of Clause 11:

"Under cutting is not allowed"

EN 1289/ ISO 23277, EN 1290/ ISO 17638 & EN 1291/ ISO 23278

WPS/ PQR Records for the

lot

Weld specs provided are obsolete.

• New specs are- EN 25817 class B replaced by ISO 5817.

• PT EN 1289 replace dby DIN EN ISO 23277.

• MT EN 1290 replaced by DIN EN ISO 17638.

• EN 1291 replaced by DIN EN ISO 23278

6 Coating DFT of paint as per QAP approved by RDSO

DFT tester Should confirm

Colour shade to RAL7012 (Ba salt grey)

Visual Should confirm

7 Marking of Damper

Serial No., Name of manufacturer, Month & year of manufacture, manufacturer part no.

Nominal force and nominal velocity Type of damper

Visual Should confirm

Note: Sample quantity shall be as per clause 4.3.8 of this STR

FIRM NAME Quality Assurance and Testing Scheme

ROUTINE TESTING PLAN Model NoI Description:

Doc No.: DAMPERS / QAP Date

S.No. Test Parameters Specifications Mode of

Inspection Acceptance

Criteria Remarks

1 Weight Weight of complete damper

Electronic weighing machine

As per drawing/ QAP approved

2 Hydraulic Oil Type and viscosity of hydraulic oil to be

informed As per drawing & Approved QAP

---------- As per QAP

3 Packing Packing to ensure no damage during transit

visual As per clause 2.4 & 15 of this

STR

No change

APPENDIX-III

QUALITY ASSURANCE & GUARANTEE CERTIFICATE (Reference – Clause 11 of specification)

No :. ……………………… Dated ……………

Railway : ……………………………..

P.O. No. : …………………………… Dated …………

Quantity : ………………………… Consignee ………………

Damper Description

THIS IS TO CERTIFY THAT THE DAMPERS INDICATED IN THIS PURCHASE ORDER HAVE BEEN SUBJECTED TO OUR INSPECTION AND TEST PROCEDURES AND ARE FOUND TO CONFORM TO THE ORDER/ DRAWING/ SPECIFICATION REQUIREMENTS.

i) THE QUALITY CONTROL PROCEDURES IN RESPECT OF THIS SUPPLY ARE IN ACCORDANCE WITH

OUR QUALITY MANUAL.

ii) THIS IS TO CERTIFY THAT EACH DAMPER SUPPLIED AGAINST THIS PURCHASE ORDER SHALL FUNCTION SATISFACTORILY AS PER CLAUSE 11 OF SPECIFICATION NO……………. (LATEST ISSUE).

Q.C. INCHARGE

DATED: (SIGNATURE & SEAL OF THE MANUFACTURER)

DATED:

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for development of STR for Dampers for LHB coaches

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Transcript of for development of STR for Dampers for LHB coaches