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GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS

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Specification for 10"x30"Long Life Lube oil and
Fuel oil Filter Elements (Two Piece) for EMD
Locomotives
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SPECIFICATION No. MP.0.2600-26
SEPTEMBER 2009
(REVISION .00)

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RESEARCH DESIGNS & STANDARDS ORGANISATION
MANAK NAGAR, LUCKNOW-226 011

SPECIFICATION FOR 10x30 LONG LIFE LUBE OIL AND FUEL OIL FILTER ELEMENTS
(TWO PIECE) FOR EMD LOCOMOTIVES
(DRAWING No. SKDP-3948)
1.

Scope
This specification covers a two-stage lube oil and primary fuel oil filter element. The
purpose of this element is to remove particulate matter from the fuel oil and engine lube
oil prior to delivery to the engine. The filter element must be having useful life of 180
days.

2.

General Requirements

2.1

Environmental Fuel Temperatures

2.1.1 Ambient temperature design range is -5C to 55C.
2.1.2 Operating temperature extremes can range from -12C to 77C.
2.1.3 Normal operating temperatures range between 21C and 43C.

2.2

Lube Oil Temperature

2.2.1 Normal lube oil temperatures will range from 0C to 105C.
2.2.2 Under adverse operating conditions the oil temperature can be as high as 149C
in tunnel operation for short periods of time.

2.3

Fluids handled by filter elements

2.3.1 Fuel to IS:1460 is specified for the fuel system. (essentially, ASTM #2 diesel
fuel).
2.3.2 Poorer grades of fuel may also be encountered in normal service depending on
individual customer specifications, fuel handling techniques, and wayside filtration
practices.
2.3.3 The filter must be able to handle water present in the fuel in amounts up to 1%.
2.3.4 Lubricating oil is of the SAE 20W-40 heavy duty additive type.
2.3.5 Oil viscosity can range between 70 and 85 SUS (Saybolt universal seconds) or
12.9 16.8 cs (centistokes) at 99C.

3.

Specification and Design

3.1

Filter Specifications
3.1.1 The corrugated filter paper is impregnated with suitable resin on both side and
cured .
3.1.2 Filter paper mean pore size shall be 10-14 microns and maximum pore size 45
microns.
3.1.3 Open area of centre tubes should be 25% minimum.

3.1.4 All pleats must be stablized by appropriate means to maintain spacing and
prevent pleat-to-pleat collapse.
3.1.5 The perforated outer wrapper shall be made from a high density paper with a
minimum bursting strength of 3.5 Kg/cm. It shall be perforated with round/square
holes as indicated in drg. No. SKDP- 3948, the area of perforations being
between 25 to 30 % 0f the area of the paper. The outer wrapper shall firmly
enclose the pleated paper, the ends of the wrapper forming a lap joint of at least
12 mm, suitably bonded together.
3.1.6 The Inner centre tube thickness is 1.02 mm & outer centre tube thickness is 1.5
mm shall be made from cold rolled steel sheet to IS: 513 Grade O. These shall be
suitably tin, cadmium or zinc plated on both sides. The joint shall be spot welded
with a minimum pitch of 25 mm. The centre tube shall be suitably perforated so as
to provide an area of flow around 25-30 % of the unperforated tube area. The
centre tube of secondary stage shall be reinforced with 3.5 mm dia (min.) hard
drawn steel spring wire to IS : 4454 ( Pt. I ), grade 2.
3.1.7 Alternatively, centre tubes made out of perforated steel tubes of adequate
thickness with spiral grooves may be used without reinforcing spring.
3.1.8 The end caps shall be made from min. 0.7 mm thick steel sheet to IS : 513 Grade
D. All metallic items shall have the same plating material as indicated in clause
3.1.9.
3.1.9 The end caps shall be bonded by a suitable adhesive to the pleated paper. The
bonding material shall fill the end caps to a minimum depth of 5 mm.
3.1.10The bonding material and other material used in construction of the filter shall
neither affect nor be affected by hot engine oil in locomotive service at operating
temperatures upto service life of 190 days.
3.1.11Changes to the filter element design or construction that effect performance or life
cannot be made without notifying RDSO of the proposed change and obtaining
written authorisation of such changes.
4.

Testing

4.1

Efficiency Testing of Filter Paper

4.1.1

Laboratory Method
Testing of filter paper is covered in RDSOs test programme No. MP.TP-23. The
efficiency of the paper is determined by using graduated imported test dust to ISO
12103 Pt2 standard. The results of the testing are plotted on graph paper as
efficiency versus nominal micron size (the midpoint of the micron particle range
being tested is used).
The micron rating is determined by drawing a curve through the test points, and
the rating of the filter paper is the micron size at which the curve crosses the 90%
efficiency point.

4.2

Filter Paper Extrusion Test

In some instances it has been determined that filter elements can plug when the
paper media extrudes into the centre tube holes (as opposed to plugging by
particulate matter). This situation causes excessive pressure drop across the
element and results in short filter life. A test procedure has been developed and is
required for checking resistance to extrusion.
4.2.1 Run a flow versus pressure drop curve on the element up to 360 lpm utilising
min.200 ltrs of an engine lubricating oil and additive package, which is approved
by RDSO for EMD engines. Commercial designation of these SAE 20W-40 test oil
is available on request.
4.2.2

Reduce oil temperature to 70C and add 2 ltrs of water to the 200 ltrs of
lubricating oil. Note: Circulate a portion of the oil-water emulsion through the
element for a minimum of 15 minutes taking care to regulate the flow so that the
filter pressure drop during this period does not exceed 2.8 kg/cm.

4.2.3 Reduce oil temperature to 32C and increase flow rate through the element until
the pressure drop across the element is 2.8 kg/cm. Operate at 2.8 kg/cm for a
minimum of 15 minutes.
4.2.4 Heat oil to 93C and repeat the flow versus pressure drop curve. This curve
should show no more than at 0.14 kg/cm increase in pressure drop at a flow of
360 lpm.
4.2.5 Reduce oil temperature to 32C and increase flow through the element until the
pressure drop is 4.2 kg/cm. Circulate the oil through the element at this condition
for a minimum of 15 minutes.
4.2.6 Heat the oil to 93C and repeat the flow versus pressure drop curve. This curve
should show no more than a 0.21 kg/cm increase in pressure drop from the
original curve at 360 lpm without water added.
4.2.7 If the element fail to pass this test they can be expected to have filter paper
extrusion problems in field service.

4.3

Performance Requirments
4.3.1 End load Test
A tensile load of 20 kg applied at the end caps of the filter element for 5 minutes
shall not cause any damage.
4.3.2

Fabrication Integrity
Fabrication integrity of the filter element shall be verified as per test method
described in IS:8383 or ISO:2942. The test fluid for this test shall be clean and
filtered HSD oil at room temperature between 15 to 40C. No evidence of

persistant stream of bubbles shall be visible 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 guage (min.).
4.3.3

High temperature test

The filter element shall be soaked in engine oil maintained at a constant
temperature of 1305C for a period of 24 hours. The filter shall be subjected to
end load test before it cools down below 70C.

4..3.4

Pressure Drop Vs Flow Rate

The filter element Shall be tested for determining its pressure drop Vs. flow rate
characteristics on a standard lubricating oil filter test rig approved by RDSO. The
test oil shall be a SAE 20W-40 engine oil of approved brand by RDSO for use on
Alco type 251 engines. With clean oil at a temperature of 802C, the pressure
drop across the filter element shall not exceeding 0.5 kg/cm for a flow rate of 300
l/ min. The pressure drop Vs. flow rate characteristics shall be determined upto a
flow rate of 400 l/ min. , readings being taken both in ascending and descending
order of flow.

4.3.5

Filtering Efficiency and Rig Life

The filter shall be subjected to a filtering efficiency and rig life test on the same test
rig as used for pressure drop Vs. Flow rate test using the same test oil. The flow
rate shall be maintained at 2705 l/ min. throughout the test. The test dust shall
confirm to SAE J726 Fine (Imported).The test dust slurry additions shall be made
with 11.96 gms of dust in 50 cc of test oil and added to the sump at intervals 30
minutes. The test shall be continued till a pressure differential of 2.1 kg/cm is built
up across the filter element. Rig life shall be the number of additions of
contaminant required to build 2.1 kg/cm pressure differential. The commulative
filtering efficiency during the test and rig life shall not be less than those indicated
below:

.1)

.2

Commulative filtering efficiency (min.) -

Rig life ( min.)

40%

after 4th addition of dust.

65%

after 16th addition of dust.

75%

after 32th addition of dust.

90%

at the end of rig life.

90

addition of test dust.

5.

Procedure for Accepting New Element Sources

5.1

Testing of filter paper using RDSOs test programme No. MP.TP-23 to determine the
efficiency characteristics.

5.2

Filter paper extrusion testing.

5.3

End load,fabrication integrity and high temperature testing.

5.4

Filtering efficiency, rig life test.

5.5

Upon satisfactory completion of the laboratory tests given above, the following field
testing is required for qualification and acceptance.
5.5.1 Field trial shall be conducted with filters manufactured in presence of RDSO
representative. Field test on a minimum of three locomotives for a period of 190
days. The field test would be arranged and conducted by the consignee shed. He
would submit timely reports to RDSO summarizing the test results and progress
including pressure drop versus time data, filter change-outs versus time, incidents
of premature plugging of engine mounted spin-on filters, and maintenance and / or
removal records related to fuel system components (primarily injectors). The
supplier shall actively associate with the trial shed and persue timely preperation
and despatch of reports to RDSO. The field test will consist of monitoring filter
pressure drop at a frequency not less than once per month (and just prior to
removal whenever possible), and recording service life between change-outs.
5.5.2 At the end of the field test, a report summarizing comparative filter performance, life,
and fuel system related maintenance events shall be submitted by the consignee
shed for review and disposition by RDSO as to acceptability.

6.

Inspection

6.1

Filter elements will conform to the engineering drawing No. SKDP-3948 or

manufacturers drawing approved by RDSO, in so far as physical details are specified.

6.2

The filter elements shall be free of corrosion or defects which will affect life
performance, or appearance.

6.3

The cured filter paper used in the construction of the element shall be
mean & max pore sizes at an approved laboratory, at the cost of supplier.

tested for

6.4 The method of regular inspection and sample size shall be as per given below:
The filter elements offered for inspection shall be subjected to 1% check in respect of
visual and dimensonal checks.
If filter lot is 1000 & below, then only end load, fabrication integrity & pressure drop v/s
flow rate tests will be carried out.
If filter lot is more than1000, then all the tests specified under clause 4 shall be carried
out.

7.

Marking
Name of the manufacturer, month and year of manufacture, batch number and serial
number shall be marked on the end caps.

8.

Packing
To avoid damage of filters during transit and storage, each filter element shall be
separately packed in poly bag and after that filter shall be placed in a pack made out of 5
ply corrugated paper board.

9.

Warranty
The supplier shall furnish a warranty that if the service life obtained during normal use on
the locomotives is less than 180 days, all filter elements belonging to that particular
batch will be replaced by him free of cost.
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