INSPECTION & TEST PLAN

LONG LIFE LUBE AND

FUEL OIL FILTER (TWO PIECE)

Call ID & Date:-

P.O. No & Date:-

1. Specification /Drawing : : Long Life Lube and fuel oil Filter (2 Piece ) to EMD Part No.
40056007 Drg., DLW Part No. 16241198 to RDSO Spec. No.
MP.O.2600.26 rev00 sep.2009 To RDSO Drg. No. SKDP 3948 Alt. Nil
2. Date of Inspection :

3. Place of Inspection :

4. Size of lot (Offer Qty.) :

5. Size of Sample : RDSO Spec. No. MP.O.2600.26 of September 2009

. 6. Document Verification
Rev. 00) & RDSO Approved QAP.
 If filter lot is 1000 & below, then only end load,
fabrication integrity & pressure drop v/s flow rate
tests Shall be carried out
 If filter lot is more than1000, then all the tests
specified under clause 4 of RDSO Spec. (Sl. No.
5 to 12 of Check sheet) shall be carried out.
: a) Internal test and dimensional check report.
b) Calibration status of equipment used in inspection
c) RDSO/BLW approval & Approved Media Paper
d) Verification of Import documents.
e) Certificate of Material Compliance
f) Warranty Certificate/ Guarantee Certificate (180 Days)

7. Tests/Checks (to be witnessed/conducted by I.E.)

Sl. Parameter Value Specified Observation Remarks
No.
1 Visual  Visual inspection shall be carried (1% of Lot) Cl. 6.4
out to ensure that the filter of Spec.
elements shall be free of
corrosion or defects which will Cl. 6.2 of Spec.
affect life performance, or
appearance.
 The cured filter paper used in the
construction of the element shall Cl. 6.3 of Spec.
be tested for mean & max pore
sizes
 Open area of centre tubes should
be 25% minimum. Cl. 3.1.3 of Spec.
 The perforated outer wrapper
bursting strength of 3.5 Kg/cm². It
shall be perforated with Cl. 3.1.5 of Spec.
round/square holes., as indicated
in drg. No. SKDP- 3948, the area
of perforations being between 25
to 30 % of the area of the paper
 INSPECTION & TEST PLAN
LONG LIFE LUBE AND
FUEL OIL FILTER (TWO PIECE)

Sl. Parameter Value Specified Observation Remarks

No.
 The outer wrapper shall firmly Cl. 3.1.5 of Spec.
enclose the pleated paper, the
ends of the wrapper forming a lap
joint of at least 12 mm, suitably
bonded together.
 Centre tubes made out of
perforated steel tubes of
adequate thickness with spiral Cl. 3.1.7 of Spec.
grooves may be used without
reinforcing spring.
 The end caps shall be bonded by a
suitable adhesive to the pleated
paper. The bonding material shall Cl. 3.1.9 of Spec.
fill the end caps to a minimum
depth of 5 mm.
 Changes to the filter element Cl. 3.1.11 of
design or construction cannot be Spec.
made without notifying RDSO/
Approved Source
2. Dimension As per Drawing. No. EMD Part No. Cl. 6.4 of Spec.
Check 40056007 (1% of Lot)

3 Material As per Annex-1 EMD Part No.

Compo- 40056007
sition

4 Media As per approved Source given in Import

Grade : P.O Viz. Documents to
Filter Grade SK5085CW of M/s be Verified/P.O
AHLSTROM Korea Co. Ltd.,
Korea
Or HB-P1 Kit & HB-PO Kit of M/s
Clark, USA or Filter Media Kit Pt.
No. 369739 of M/s PARKER
FILTARATION CANADA,
CANADA /PHI etc.

5 Filter Paper Cl.3.1.2 of Spec.

Test  Filter paper mean pore size
Report shall be 10-14 microns and
maximum pore size 45
microns.(To be worked in the
Plot of Flow rate v/s
p(mmHg))
 INSPECTION & TEST PLAN
LONG LIFE LUBE AND
FUEL OIL FILTER (TWO PIECE)

Sl. Parameter Value Specified Observation Remarks

No.
6 End load  A tensile load of 20 kg applied at Cl. 4.3.1 of Spec.
Test the end caps of the filter
element for 5 minutes shall not
cause any damage

7 Fabrication  The test fluid for this test shall be

Integrity clean and filtered HSD oil at Cl.4.3.2 of Spec
room temperature between 15
to 40ºC. Test method
described in
 No evidence of 3 persistent IS:8383 or
stream of bubbles shall be visible ISO:2942
from the end caps area bonded
with adhesive and filter paper
area or paper pleat joint, prior to
foam coming out from the paper
pores.
 Apply air pressure till the foam
starts coming out from the
paper. The foam from filter
paper pores shall not come out
up to a pressure of 15 cms of
water gauge (min.).
8 Pressure  With clean oil at a temperature Cl.4.3.4 of Spec
Drop Vs of 80±2ºC, the pressure drop
Flow Rate across the filter element shall not  Standard
exceeding 0.5 kg/cm² for a flow lubricating
rate of 300 l/ min. oil filter test
 The pressure drop Vs. flow rate rig approved
characteristics shall be by RDSO.
determined upto a flow rate of  The test oil
400 l/ min. , readings being taken shall be a
both in ascending and SAE 20W-40
descending order of flow engine
oil/Approved
Brand
9. Efficiency  Plot graph paper as efficiency Cl.4. 1.1 of Spec
Testing of versus nominal micron size (the
Filter Paper midpoint of the micron particle RDSO’s test
range being tested is used). programme No.
 The micron rating is determined MP.TP-23
by drawing a curve through the (using graduated
test points, and the rating of the imported test
filter paper is the micron size at dust to ISO
which the curve crosses the 90% 12103 Pt2
efficiency point. standard)
 INSPECTION & TEST PLAN
LONG LIFE LUBE AND
FUEL OIL FILTER (TWO PIECE)

Sl. Parameter Value Specified Observation Remarks

No.
10. Filter Paper  Run a flow versus pressure drop Cl.4. 2 of Spec
Extrusion curve on the element up to 360
Test lpm utilising min.200 ltrs of an SAE 20W-40 test
engine lubricating oil and oil/Approved
additive package Note:
 Reduce oil temperature to 70°C  Circulate a
and add 2 ltrs of water to the portion of the
200 ltrs of lubricating oil.. oil-water
 Reduce oil temperature to 32°C emulsion
and increase flow rate through through the
the element until the pressure element for a
drop across the element is 2.8 minimum of
kg/cm². Operate at 2.8 kg/cm² 15 minutes
for a minimum of 15 minutes. taking care to
 Heat oil to 93°C and repeat the regulate the
flow versus pressure drop curve. flow so that
This curve should show no more the filter
than at 0.14 kg/cm² increase in pressure drop
pressure drop at a flow of 360 during this
lpm. period does
 Reduce oil temperature to 32°C not exceed
and increase flow through the 2.8 kg/cm².
element until the pressure drop
is 4.2 kg/cm². Circulate the oil  If the
through the element at this element fail
condition for a minimum of 15 to pass this
minutes. test they can
 Heat the oil to 93°C and repeat be expected
the flow versus pressure drop to have filter
curve. This curve should show no paper
more than a 0.21 kg/cm² extrusion
increase in pressure drop from problems in
the original curve at 360 lpm field service
without water added.

11 High  The filter element shall be Cl.4.3.3 of Spec

temperatur soaked in engine oil maintained
e test at a constant temperature of
130±5ºC for a period of 24
hours. The filter shall be
subjected to end load test
before it cools down below
70ºC.
 INSPECTION & TEST PLAN
LONG LIFE LUBE AND
FUEL OIL FILTER (TWO PIECE)

Sl. Parameter Value Specified Observation Remarks

No.
12. Filtering  The flow rate shall be maintained Cl.4.3.5 of Spec
Efficiency at 270±5 l/ min. throughout the
and Rig Life test. The test dust shall confirm to Cumulative
SAE J726 Fine (Imported). filtering
 The test dust slurry additions shall efficiency (min.)
be made with 11.96 gms of dust  40% after 4th
in 50 cc of test oil and added to addition of
the sump at intervals 30 minutes. dust
 The test shall be continued till a  65% after
pressure differential of 2.1 kg/cm² 16th addition
is built up across the filter of dust.
element. Rig life shall be the  75% after
number of additions of 32th addition
contaminant required to build 2.1 of dust.
kg/cm² pressure differential.  90% at the
end of rig life.
Remarks- Same test rig as used for  Rig life ( min.)
pressure drop Vs. Flow rate test using 90 addition of
the same test oil. test dust

13 Packing Material shall be packed properly to Cl. 8 of Spec

avoid transit damage during
transportation or as specified in PO.

Filter shall be placed in a pack made

out of 5 ply corrugated paper board.

14 Marking Manufacturer’s Name Cl. 7 of Spec

Mfg. Month & Year

Batch No.

Sl. No.
( On top of the Cap)

Name & signature of IE

 INSPECTION & TEST PLAN
LONG LIFE LUBE AND
FUEL OIL FILTER (TWO PIECE)

BILL OF MATERIAL (ANNEXURE-1)

REF DESCRIPTION NO. OFF MATERIAL AND SPECIFICATIONS
NO.
1 HANDLE 1 M.S Wire Dia 5
2 REINFORCING SPRING 1 Spring Steel Wire IS 4454 Pt. 1 Gr. 2
3 INNER CENTRE TUBE 1.02 TH. OD=79.5, 1 Steel Sheet to IS 513-O
HT=365
4 FILTER MEDIA PAPER(SECONDARY STAGE) 1 -
5 OUTER CENTRE TUBE 1.5 TH. OD=145, 1 Steel Sheet to IS 513-O
HT=365
6 FILTER MEDIA PAPER(PRIMARY STAGE) 1 -
7 OUTER WRAPPER (PERFORATED) 1 High density paper
8 COTTON NET WRAPPED ON FILTER MEDIA 1 -
9 ADHESIVE 1 -
10 TOP CAP NO.1 1 Steel Sheet to IS 513-D

11 BOTTOM CAP NO.1 1 Steel Sheet to IS 513-D

12 TOP CAP NO.2 1 Steel Sheet to IS 513-D

13 O RING OD=49, ID=37 2 Viton Rubber DLW SPEC. 58695

14 BOTTOM CAP NO.2 1 Steel Sheet to IS 513-D

 INSPECTION & TEST PLAN
LONG LIFE LUBE AND
FUEL OIL FILTER (TWO PIECE)

PRESSSURE DROP V/S FLOW RATE TEST

Test Oil :

Sump Volume : 200 Litres (Clean Oil)

Test Temperature : 80 ± 2 °C

Test Sample : Long Life Lube & Fuel Oil Filter (Two Piece) DLW Part No.
16241198, EMD Part No. 40056007

Test Rig : As per Approved by RDSO.

Outlet
Pressure Drop Actual
Pressure
Across the Housing Pressure Drop
Flow Rate Inlet Pressure through the
S. No. Filter with Pressure Drop Across the
(L/Min.) (psi) Filter with
Housing (psi) filter Element
Housing
(psi) (psi)
(psi)
Ascending Order
1 150 80.0 0.0
2 200 80.0 1.0
3 250 80.0 2.0
4 275 80.0 2.0
5 300 80.0 3.0
6 350 80.0 4.0
7 400 80.0 5.0
Descending Order
1 400 80.0 5.0
2 350 80.0 4.0
3 300 80.0 3.0
4 275 80.0 2.0
5 250 80.0 2.0
6 200 80.0 1.0
7 150 80.0 0.0
Remarks :
Pressure drop at flow rate of 300 LPM was observed as ____ PSI against specified 7.1PSI (0.5kg/cm²)
maximum.

Name & signature of IE

 INSPECTION & TEST PLAN
LONG LIFE LUBE AND
FUEL OIL FILTER (TWO PIECE)

Primary Stage Filter Paper

Observation
S.
Parameters Value Specified
No. S-1 S-2 S-3

1 Pleat Depth*
47 ±0.8
2 Pack Height*
367±1.2 mm
3 No. of Pleats*
187 ± 2 Nos.

Secondary Stage Filter Paper

Observation
S.
Parameters Value Specified
No. S-1 S-2 S-3

1 Pleat Depth*
30.5 ±0.8 mm
2 Pack Height*
367±1.2 mm
3 No. of Pleats*
94±2 Nos.

Remarks- * Dimension as per Approved QAP

 Tolerance as per IS 2102 (Coarse)

Name & signature of IE

 INSPECTION & TEST PLAN
LONG LIFE LUBE AND
FUEL OIL FILTER (TWO PIECE)

Dimension EMD Part No. 40056007

Observation
S.
Parameters Value Specified
No. S-1 S-2 S-3

Overall Height
1 746± 2.0mm.
Single Height
2 370 ± 1 mm
End Cap out side Dia
3 Ø245±1.2 mm
End Cap Height
4 10±1.0 mm
End Cap Collar Outer Dia.
5 Ø250±1.2mm
Handle Wire Dia.
6 Ø5± 0.2 mm
Top cap 2/Bottom cap 2 inside
7 40 ± 0.8 mm
dia (Hole)
Blank distance between two
8 6 mm± 0.8 mm
elements
‘O’ Ring inside dia
9 Ø37±0.8mm
‘O’ Ring outer dia
10 Ø49±0.8mm
Spring Outer Dia
11 80±0.8 mm
Spring Wire Dia
12 Ø3.5± 0.3 mm
Spring Coil Pitch
13 45 ± 0.8 mm
Inner Tube Outer Dia
14 79.5±0.8 mm
Outer Tube Outer Dia
15 145±1.2 mm
Height of Inner/ Outer Tube
16 365/365 ± 1.2 mm
Inner Tube Thickness
17 1.02± 0.2 mm
Outer Tube Thickness
18 1.5± 0.2 mm
 Tolerance as per IS 2102 (Coarse)

Name & signature of IE