NCP Clinker Cooler Hydraulic Cylinder datasheet

Sr. No. Parameter Specification requirement Vendor Comments

1 Make Rexroth Bosch Advanced Hydraulic Technology
2 Model CYH1MP5/80/56/240A11/BXCSUX D4843 AHT 80 × 56 × 240 23-24
3 GA drawing Ok
4 Piston diameter 80 mm 80 mm
5 Piston rod diamter 56 mm 56 mm
6 Stroke length 240 mm 240 mm
7 operating pressure 250 bar 250 bar
8 Test pressure 375 bar 375 bar
9 Operating temperature range 5-80 Deg C 5 - 80 ° C
10 Working Media Mineral Oil (VG46) / HLP 46 Mineral oil / HLP 46 / Enklo 46
11 End connection - Base Clevis with spherical bearing Clevis with spherical bearing
12 End connection - Base Threaded M39 x 3. To be assembled with swivel clevis ( Not in vendor scope) Customer Requirement

ST 52 DIN2391/E355
Seamless, barrel diameter tolerance - H8
Barrel ID Honed & finished to 0.4 Ra.
13 Barrel Ultrasonic Tested (longitudinal as well as lateral scan) as per ASTM A388. Barrel Seamless ST52
Acceptance criteria 3 mm FBH
( Ultrasonic inspection will be witnessed by third party inspector deployed by NVCL)
Material test certificate ( chemical analysis and mechanical properties) shall be submitted for review

Forged steel- 42CrMo4

Piston Rod OD tolerance f7
Double hard Chrome Plated to a thickness of minimum 2 x 25 microns & finished 0.2 to 0.4 Ra. Material EN24 hardness 40 - 50 HRC Index Hardness
14 Piston rod Piston Rod Shall Be Quenched & Tempered.240-280 BHN. Piston Rod Shall Be Induction Hardened to 58-62 HRC to A Case Depth of minimum 3 mm. plating thickness 50 to 60 micron & Finished 0.2 to 0.4
Ultrasonic Tested (longitudinal as well as lateral scan) as per ASTM A388. Ra
Acceptance criteria 3 mm FBH
( Ultrasonic inspection will be witnessed by third party inspector deployed by NVCL)
Material test certificate ( chemical analysis and mechanical properties) shall be submitted for review

EN8 / 080M40 (BS970-3)

Ultrasonic Tested (longitudinal as well as lateral scan) as per ASTM A388.
15 Piston Acceptance criteria 3 mm FBH Material EN8 with test certificate
( Ultrasonic inspection will be witnessed by third party inspector deployed by NVCL)
Material test certificate ( chemical analysis and mechanical properties) shall be submitted for review

Piston Glyd Ring : Energiser -Viton, Antiextrusion ring - 40% Bronze+PTFE

Piston Wear Ring 1 : PTFE / Turcon
Piston O-Ring : Viton
16 Seal kit Base O-Rings: Viton Parker - Busak Shamban make suitable 450 bar OR
Head O-Rings : Viton Equivalent as per ISO standard.
Rod seal : Energiser -Viton, Antiextrusion ring - 40% Bronze+PTFE
Rod Wear Rings : PTFE / Turcon
Make : Parker/Freudenberg / O ringTrelleborg / SKF are only acceptable

17 Head S355J2G3 / ST52 EN8

18 Base S355J2G3 / ST52 EN8
19 Base clevis spherical bearing Make SKF / FAG SKF - IKO - Equivalent
20 Gland Bush C 83600 / GGG 40 Cast and machined EN8
21 Fasteners Make : UNBRAKO / TVS , Gr 12.9 UNBRAKO / TVS , Gr 12.9 (Equivalent)

22 Warranty Warrantee the performance of the cylinder for 24 months from the date of installation or 30 months from the date of supply whichever is earlier 24 months from the date of Invoice
NVCL Comment AHT Reply
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK
OK

Please confirm following

1. the witness type ultrasonic test ( ASTM A 388) for barrel with
the mentioned acceptance criteria of 3 mm FBH DGS
2. Confirm that barrel shall be made from Cold drawn Seamless
(CDS) or Drawn on Mandrel ( DOM) " ready to be honed" tube
procured from vendors as per DIN 2391 part 2 . grade St52 or
EN10305-1 E355 . The tube shall cold finished and stress relieved
. The tubes shall be honed or Skived + roller burnished to a
surface finish of 0.2-0.4 micron Ra. The applicable dimensional
tolerance shall be H7.
3. Material test certificate ( Chemical compostion and
mechanical property )shall be submitted to NVCL

Please confirm following

1. the witness type ultrasonic test ( ASTM A388) for piston with
the mentioned acceptance criteria of 3 mm FBH DGS
2. Confirm that piston rod shall be made from Forged EN19 /
42CrMo4.. The rod shall be first volume hardened ( quenched
and tampered) up to 240-280BHN. After that the samd shall be
induction hardenede to 58-62 HRC with a minimum case depth
of 3 mm. After final machining , the rod will be chrome plated
with a thickness of 2 x 25 microns = 50 microns. chrome steel bar
can pass the salt spray tested to at least 48 hours in accordance
with ASTM B-117. The surface finish shall be 0.2 micron Ra. The
applicable dimensional tolerance shall be f6.
3. Material test certificate ( Chemical compostion and
mechanical property )shall be submitted to NVCL

OK

Please confirm that

1. seals of the approved make only will be used. We prefer seals
of Parker and Trelleborg, Freuedenberg
2. Please confirm that all elastomers shall be of viton
3. Please provide the detailed seal arrnagement for piston and
piston rod which you are proposing

OK
Ok
Please consider SKF / FAG make only
OK
OK

OK
 QAP for Raw Mill Hydraulic cylinder ( 400 mm x 220 mm x 950
S. No. Inspection stage Inspection method

Review of ingot / billet

1 Ingot / Billet
making process

2 Ingot / billet Chemical compostion test

Verification of heat no. &

Material identification of
3 identification of integral
forgings
forged test piece

4 Chemical composition Chemical compostion test

Mechanical propoerties ( UTS, Tensile Test

Proof Strength , Elongation, Charpy impact test @
5
Imapct Energy, Surface room temp
hardness) Hardness test

One test piece per heat per

6 Heat treatment details h.t. batch will be tested as
per std

7 Microstructure and Grain size EN ISO 643

Ultrasonic test (longitudinal

9 as well as lateral scan) - after
ASTM A388 M
proof machining

12 Dimesional check Physical measurement

Surface finish test by

13 Surface Finish
comparator
Mill Hydraulic cylinder ( 400 mm x 220 mm x 950 mm )
NVCL inspection scope
Acceptance standard Inspection record
(Review / Witness)

The ingot / billet should be of virgin steel .

It should not be made of scrap steel. The
billet should have been procured from a
Ingot purchase
reputed steel manufacturer . The steel
documents of forging Review
ingot making process shall be verified
manufacturer .
( Electric Arc Furnace, Ladle Refining
furnace, vacuum degassed and fully
killed)

Chemical compostion for following steel.

ST 52 DIN2391/E355
42CrMo4
Material test
EN8 / 080M40 (BS970-3)
certificate by an NABL Review
S355J2G3 / ST52
approved laboratory
C 83600 / GGG 40

Witness by NVCL or third

- - party inspector deputed by
NVCL
As per agreed material grade standard Witness by NVCL or third
Test certificate as per
mentioned in apporved drawing party inspector deputed by
EN 10204 type 3.2
NVCL

Witness by NVCL or third

As per agreed material grade standards Test certificate as per
party inspector deputed by
mentioned in apporved drawing EN 10204 type 3.2
NVCL

Heat treatment report Review

Witness by NVCL or third

Austenite grain size of 5 or finer Test report party inspector deputed by
NVCL
Witness by NVCL or third
No laps, folds are allowed. No indications
UT report party inspector deputed by
more than 3 mm FBH are allowed
NVCL
Witness by NVCL or third
As per tolerances given in the approved
Measurement report party inspector deputed by
drawing.
NVCL
Barrel ID Honed & finished to 0.4 Ra. Witness by NVCL or third
Surface finish testing
Piston Rod finished 0.2 to 0.4 Ra. party inspector deputed by
report
NVCL
Vendor Comment