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8/2/2019 RLV SB Process Sheet
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PROCESS SHEET NO : REV.NO
CLIENT :
PART NAME : RLV-SB HEAD END MATL :
RLV-SB
OPN.NO STAGE
005# Inspection
010 CNC VTL
015 Inspection
020 CNC VTL
Without disturbing setup, clamp the job from I/S & remove O/S clamp
025 Inspection
Form a groove as per sketch-2.
Compute the depth
Hold the job on VTL, True ID & Clamp the job from out side. Face to maintain,overall height 394mm. Bore 180+0.2/+0.0 through.
Allot part Idn.No as RLV-HED-02-05.
1) 180+0.2/+0.0 I/S Micrometer
1) 25mm2) 1000+5.0 Vernier Caliper
Vernier Caliper
Turn OD 242.0 to 39.5mm depth.
Inspect for the following
Inspect & record the following
DESCRIPTION TOOLINGS
Note : The Idn shall be retained during m/cing & transferred to the job after machning.
Verify the RMC No. and the acceptance of the material in co-relation with theTC issued by VSSC.
RKE/RLV/68/PS-01 R1
SUB ASSY NAME : REF DRG. NO. REV.NO. QUANTITY : 1 No per
VSSC
HEAT TREATED FORGING
RAMAKRISHNA ENGINEERING COMPANY, CHENNAI-106.
PROCESS AND QUALITY CONTROL PLAN
RLV-SB MOTOR CASE
SHEET NO : 1 OF 5 PROJECT : RLV-SB
10.01.2009
APPLICABILITY 02- 05
Confirm H/T by verifying hardness reported in TC
Supply condition to be reported and act accordingly.
REFER SKETCH - 1
REFER SKETCH - 2
PART DRG.NO. REV. NO. 15CDV6
DOME RING RKE-RD-06-234-01 R2
HEAD END DOME PRE ASSY RD06-25-05-02-3-17-13-10-110 Sheet 1 & 2 R3 ASSY.
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3) 89mm
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OPN.NO STAGE
030 CNC VTL
035 # Inspection
040 CNC VTL
050 CNC VTL
055 # Inspection
060 CNC VTL
070 # Inspection
RKE-RO06-234-T-17
Checking template No
Dial setup
UT gaugeO/S Mic & Compute
TOOLINGSDESCRIPTION
the programme for 'Y' ring machining and merge on ODWithout disturbing the setup, remove the outside clamp and clamp on OD. Execute
Reverse the job, Load the fixture and true within 0.1mm
face turn to maintain total height 384.35mm.
RKE-RD06-234-T-03
2) 2+0.2/+0.0 UT Gauge
4) 384.35mm
program & execute I/S profile by maintaining 996.00.2mm
REFER SKETCH - 3
2. 2+0.2/+0.0
Inspect & record the following
Vernier Caliper
Load the job and Clamp on O/S. Check for runout within 0.1mm on 180
REFER SKETCH - 4
as shown in the sketch. Execute the programme for outside machining by
maintaining 2 +0.2/-0.0 wall thickness and 144.25mm height. Turn 232 through.
Checking template No.
REFER SKETCH - 6
3) 30mm
1. 9930.2
RKE-RD06-234-T-02
In the same setup machine "V" groove as per drawing.
Inspect & Record
Inspect unload the job.
Vernier Caliper
2. 2.0+0.2 thk Vernier Caliper3. 232+1.0/-0.5 UT Gauge
UT Gauge
I/S Checking template
I/S Mic
Page 2 of 5
Turn on OD to a depth of 30mm to maintain a wall thickness of 2+0.2/+0.0
Checking template No :
RKE-RD06-234-T-01
REFER SKETCH - 5
Machining Fixture No
1) 9960.2
1. 996.00.2
Execute the programme as per detail "A" by maintaining 11.5+1.0/-0.50 wall thickness.
Prepare weld edge angle 30and 0.5 to 1mm root face.
Load the machining fixture on VTL and true within 0.05mm. Reverse the job & clamp
Inspect and record the following dimensions
// 0.2 C 0.1 B0.2 A
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OPN.NO STAGE
18. 2.0 +0.2/-0.0
20. 144.25
22. DP Test all over
# Mandatory stages to be cleared by RQS/VSSC
* Dimensions to be checked in fixture condition.
21. Ovality on 996 and 180 (8 generators) I/S Mic
DP Kit
Checking Template
RKE-RD06-234-T-02
Height Gauge
Inside Micrometer
Dial setup
19. R100, R87.24,10.16 and angle11
15. 3.5+0.2/-0.0 thk
Vernier Caliper
Detail "X"
RKE-RD06-234-T-03
16. 30, 0.5 to 1mm
Height Guage7. 384.35
B. Protractor/ V. CaliperDetail "A"
Checking Template
Ball Point Mic
Ball Point Mic
13. 11.5+1.0/-0.5
12. 50.31.0
RKE-RD06-234-T-04
RKE-RD06-234-T-01
Dial setup
Dial setup
Engrave Idn. number apply Black Japan & store.
4. Perdendicularity
Page 3 of 5
Micrometer
V/Caliper / B.Protractor
17. (922.92) , (37) , 25.24, 8.9, angle18, angle 5639' and R2 Checking Template
15. 9930.2
Detail "Y"
10. 180+0.2/-0.0
Vernier Caliper
Checking Template
O/S Micrometer
DESCRIPTION
6. 25.0 & co-ordinate
8. Angle 30& 0.5 to 1mm
9. 195+0.0/-0.5
14. 9,R5, 15,48' &17.3mm (400 & 68.8)
5. Parallelism
11.
TOOLINGS
0.1 B
// 0.2 C
0.2 A
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PROCESS SHEET NO : REV.NO
CLIENT :PART NAME : RLV-SB HEAD END MATL :
RLV-SB
OPN.NO STAGE
005# Inspection
010 VTL / Lathe
015 Inspection
020# Heat
Treatment
030 # Hardness Grind /machine to depth of 3mm
Testing M/C
040 VTL /
CNC VTL
050# CNC VTL
VSSCRKE/RLV/68/PS-02 R1
RING (ANNEALED)
PART DRG.NO. REV NO. 15CDV6
SKIRT RING RKE-RD-06-234-02 R2
RAMAKRISHNA ENGINEERING COMPANY, CHENNAI-106.
PROCESS AND QUALITY CONTROL PLAN
RLV-SB MOTOR CASE
SHEET NO : 1 OF 4 PROJECT : RLV-SB
APPLICABILITY 02- 05
10.01.2009
SUB ASSY NAME : REF DRG. NO. REV.NO QUANTITY : 2 Nos. per
DESCRIPTION TOOLINGS
HEAD END SEGMENT
Note : The Iden shall be retained during m/cing & transferred to the job after m/cing
Verify the RMC No. and the acceptance of the material in correlation with the
RD06-25-05-02-3-17-13-10-110 R3 ASSY.
Inspect the dimensions as per sketch 1
TC issued by VSSC.
I/S, O/S Mic, Vernier
Supply condition of the forgings to be ensured and act accordingly
Allot part Iden.No as RLV-HES-02, 03 etc.,
REFER SKETCH - 01
True & Clamp the job from inside. Turn OD 1002x67mm depth.
unload and reverse the job.
Pre machining the forging as per sketch 1
Hardness tester
Load the job on VTL, True and clamp. Face to maintain a height of 112.0mm,
REFER SKETCH-03
Get clearance from VSSC for Heat treatment. Heat treat the forging as perDoc.No : MEE/QCI/QCP/007/2002, Issue 2, July 2005
REFER SKETCH - 02
Check hardness at 3 locations on both faces. Hardness value 34 to 40 HRC.
Portable Grinder
Note 1: Ensure that chart recorder is working
Note 2: A copy of the chart to be attached with Inspection Report.
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OPN.NO STAGE
060# CNC VTL
070# CNC VTL
075# Inspection
6) 20.1 (Inside )
11) R20 (Inside) RKE-RD06-234-T-005
RKE-RD06-234-T-0058) 40(Outside)
7) 20.1 (Outside) Vernier Caliper
10) 40 (Inside) Template No
# Mandatory stages to be cleared by RQS/VSSC
Mark/Paint Iden.no as RLV-HES-02,05,Apply Black Japan all over and preserve
TOOLINGS
12) 3.5+0.2-0
Vernier Caliper/ B. Protractor
Ball point mic
13) D.P Check all over D.P. Kit
Vernier Caliper
2) 108.0+0.0-0.2
DESCRIPTION
Page 2 of 4
Without disturbing the setup clamp the job from outside and remove the internal clamp.
Execute the programme as shown in sketch. Bore 953 through.Face to maintain
108.0/0.2mm Height.
REFER SKETCH-05
REFER SKETCH-04
Without disturbing the setup clamp the job from inside and remove the external clamp.Turn OD by keeping 1040.0 through. Execute the programme to achieve
1) 993+0.2/-0.0
Inspect & record the following dimensions
16)
14) Ovality on 993 ( at 8 Generators)
15) 30, 0.5-1mm land
9) R20 (Outside)
3) 1040
5)
Template No
Line Inspected
Vernier Caliper
Compute from IDInside Mic
Dial setupVernier Caliper
4) 953
3.5+0.2/-0.0. wall thickness R20 and 40angle.
Dial setupInspect Concentricity before unloading the job.
Inside Micrometer
Prepare weld edge 0.5 to 1mm lip distance and 30angle.
Inspect for 993.0, 953 and 1040 in the fixture condition.
0.2 A
0.2 A
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PROCESS SHEET NO : REV.NO
CLIENT :PART NAME : RLV-SB HEAD END MATL :
SUB ASSY NAME : RLV-SB HEAD END
OPN.NO STAGE
weld joint to be identified as shown in the drawing.
Note 2: Mismatch shall be calculated by taking thickness into account and reported
at every 50mm interval
Note 3: Apply Black Japan during all stages of fabricationNote 4: Mark RT zones by paint and retain the marking by paint and transfer
005 # Inspection
010 Welding
015 # Inspection
CS= Cirseam Weld
Inspect for :
RKE/RLV/68/PS-03 R1
1. Head End Dome Ring
2. Head End Skirt Ring
RAMAKRISHNA ENGINEERING COMPANY, CHENNAI-106.
PROCESS AND QUALITY CONTROL PLAN
RLV-SB MOTOR CASE
SHEET NO : 1 OF 1 PROJECT : RLV-SB
Load Head End Dome Ring and Head End Skirt Ring on the Welding Fixture,true within 0.2.mm and tack weld at intervals of 50mm
DESCRIPTION TOOLINGS
APPLICABILITY 02- 05
10.01.2009
VSSCPART DRG.NO. REV NO. 15CDV6
DOME PRE ASSY RKE-RD-06-234-03 R2
REF DRG. NO. REV.NO QUANTITY : 1 NO PER
SEG. WELDING RD06-25-05-02-3-17-13-10-110 R3 MOTOR CASE
Verify the acceptance of the following components and record the idn nos.
the RT marking to inspection log book.
Note 1: Identification No. shall be retained at all stages of fabrication and the
Note 5: The Film density shall be kept as 1.8 to 2.5mm for X-ray radiography
Mismatch checking templates
Feeler Gauge
Vernier Caliper
Vernier Caliper
Root Gap
Mismatch
Dial Gauge setup
Allot part identification number as RLV-HPA-02-05..Etc.,
Tack length & Tack Spacing
Welding Fixture
XX= Set Serial Number
1. 252.25+1.0/-0.5
Engrave paint part Iden No. as RLV-HPA-02-05..Etc., on the component.
2. Concentricity
Identify the weld joint as RLV-HS-CS-XX- 01
0.2 A
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12.01.2009
PROCESS SHEET NO : REV.NO
CLIENT :
PART NAME : RLV-SB TONGUED RING MATL :
RLV-SB
OPN.NO STAGE
005# Inspection
010 CNC VTL
015 Inspection
020# Heat
Treatment
030 # Hardness
Testing M/C
040# CNC VTL
True 1030 and clamp from outside. Face to maintain height 150mm
Step Bore 982 to a depth of 45mm
Turn ID 961.5 through Vernier Caliper
Vernier Caliper
Tape
I/S, Mic, Vernier Cali
Portable Grinder
Hardness tester
TC issued by VSSC.
Allot part Iden.No as RLV-TR-03,04,05 etc.,Supply condition of the forging to be ensured and act accordingly.
Note 1: Ensure that chart recorder is working
Get clearance from RQS for Heat treatment. Heat treat the forging as per
Note 2: A copy of the chart to be attached with Inspection Report.
DESCRIPTION TOOLINGS
Verify the RMC No. and the acceptance of the material in correlation with the
Note : The Idn. No shall be retained during m/cing & transferred to the job after m/cing
SUB ASSY NAME : REF DRG. NO. REV.NO QUANTITY : 2 NoS. per
NOZZLE END AND MIDDLE SEGMENT RD06-25-05-02-3-17-13-10-130 R2 ASSEMBLY
RKE/RLV/68/PS-04 R1 VSSC
FORGING (ANNEALED)
PART DRG.NO. REV NO. 15CDV6
RKE-RD-06-234-04 R2
RAMAKRISHNA ENGINEERING COMPANY, CHENNAI-106.
PROCESS AND QUALITY CONTROL PLAN
RLV-SB MOTOR CASE
SHEET NO : 1 OF 5 PROJECT : RLV-SB
APPLICABILITY 02- 05
Grind/Machine to a depth of 3mm and check hardness at 3 locations
REFER SKETCH - 2 I/S, O/S Mic
both sides Hardness 34 to 40 HRC.
Step Turn OD 1010 to a depth of 401mm
Pre m/c the forging as per sketch-1
Doc.No : MEE/QCI/QCP/007/2002, Issue 2, July 2005
Inspect the dimensions as per sketch-1
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OPN.NO STAGE
050# CNC VTL
055 # Inspection
(A)
996.60.2mm. Execute the program for outside by maintaining
DESCRIPTION
Inspect 996.00.2 and concentricity before unloading the job from VTL
2mm0.2/0.0 wall thickness. Prepare weld edge 30and root face of 0.5-1mm.
Reverse the job & true ID 961.5 and clamp.
1) 1010
3) 961.5
REFER SKETCH -3
Template RKE-RD06-23
I/S Mic
Tape
Vernier Caliper
12) 25
Vernier Caliper
Vernier Caliper
Vernier Caliper
V. Caliper/ B.Protract
Template RKE-RD06-23
Computed from OD7) 982.0
8) 961.5
11) 145.0 1.0
9) 45.010) 72.9
I/S Mic
(by computing thk)
Dial Setup
Vernier Caliper
1) 9960.2
2) Concentricity
6) 1010
Inspect the following dimensions
1) 1000.0
2) 996.0 0.2
5) 10.0,5, R20 and 44.09
3) 30x0.5 to 1mm
4) 20.0, 252', +0.5/-0.0
I/S Mic
I/S Mic2) 982 I/S Mic
Inspect for
Page 2 of 5TOOLINGS
Face to maintain 145mm height. Execute the programme for Inside turning by keeping
I/S, O/S Mic
0.2 A
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OPN.NO STAGE
Page 3 of 5DESCRIPTION TOOLINGS
13) Concentricity
# Mandatory stages to be cleared by RQS/VSSC
Dial Gauge
15) D.P test all over. D.P.Kit
I/S Mic14) Ovality on 961.5 (minimum 8 reading)
Apply Black Japan all over and preserve
Mark/Paint idn.no as RLV-TR-03,04,05 etc.,
0.2 A
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er
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-T-09
or
-T-08
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12.01.2009
PROCESS SHEET NO : REV.NOCLIENT :
PART NAME : RLV-SB GROOVED RING MATL :
RLV-SB
OPN.NO STAGE
005# Inspection
010 VTL/Lathe
015 Inspection
020# Heat
Treatment
030 # Hardness
Testing M/C
040 VTL /
CNC VTL
Inspect & record the following dimensions
RAMAKRISHNA ENGINEERING COMPANY, CHENNAI-106.
PROCESS AND QUALITY CONTROL PLAN
RLV-SB MOTOR CASE
SHEET NO : 1 OF 4 PROJECT : RLV-SB
APPLICABILITY 02- 05
RKE/RLV/68/PS-05 R1 VSSC
FORGING (ANNEALED)
PART DRG.NO. REV NO. 15CDV6
RKE-RD-06-234-05 R2
HE AND MIDDLE SEGMENT RD06-25-05-02-3-17-13-10-110 R3 MOTOR CASE
DESCRIPTION TOOLINGS
SUB ASSY NAME : REF DRG. NO. REV.NO QUANTITY : 2 Nos. per
TC issued by VSSC.
Note: The Idn No shall be retained during m/cing & transferred to the job after m/ching
Vernier Caliper
Verify the RMC No. and the acceptance of the material in correlation with the
Supply condition to be reported and act accordingly
Pre m/c the forging as per sketch-1
Tape
I/S, Mic
Allot part Iden.No as RLV-GR-03, 04, 05 etc.,
Grind/machine to a depth of 3mm and check hardness at 3 locations on
REFER SKETCH - 2
3) 993.5
True on 1030 clamp from O/S. Skin cut on the face bore ID 969.5 through.
Step turn OD 1018.5mm x 62mm, Step turn 993.5mm x 19.7mm
Get clearance from RQS for Heat treatment. Heat treat the forging as per
Note 1: Ensure that chart recorder is working
Note 2: A copy of the chart to be attached with Inspection Report.
Doc.No : MEE/QCI/QCP/007/2002, Issue 2, July 2005
I/S, Mic, Vernier
both faces. Hardness 34 to 40 HRC.
I/S Mic
Hardness tester
1) 969.5
2) 1018.5 Vernier Caliper
I/S, O/S Mic
Vernier Caliper
Vernier Caliper
Portable Grinder
REFER SKETCH - 1
Inspect the dimensions as per sketch-1
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OPN.NO STAGE
050# VTL /
CNC VTL
055 # Inspection
Inspect for
3) Concentricity
Page 2 of 4DESCRIPTION
9) 2+0.2/-0.0
1) 19.7
6) 969.50.8
4) 1018.51.0
5) 993.50.8
3) 142.5mm
10) 20,41.3 and 3 Template RKF-RD06-234-T-07
2) 40.5mm
7) 63.62
8) 9960.2
I/S Mic
Vernier Caliper
I/S Mic
UT Gauge
I/S Mic
12)10mm, 50.4,3,
11) WEP 30, 0.5 to 1mm root face.
Dial Setup
Bevel Protractor
Mark/Paint Idn.no as RLV-GR-03,04, etc.,
15) carry out D.P.test
13) Concentricity
# Mandatory stages to be cleared by RQS/VSSC
Apply Black Japan all over and preserve
D.P.Kit
14) Ovality 0n 969.5 (at 8 Generators)
O/S Mic
Vernier Caliper
Template RKE-RD06-234-T-06
Vernier Caliper
I/S Mic
Vernier Caliper
2) 2.0 +0.2-0.0.
I/S, O/S MicReverse the job True 969.5 & calmp on O/S. Face turn to maintain
1) 9960.2UT Gauge
I/S Mic
2 +0.2/0.0. Prepare weld edge as per detail A.
TOOLINGS
Dial setup
996+0.2/-0.0 & Execute the programme for outside profile maching by keeping
142.5mm height. Execute the programme from Inside profile machining by keeping ID Vernier Caliper
Inspect & record the following dimensions.
Ball point mic
REFER SKETCH - 3
0.2 A
0.2 A
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PROCESS SHEET NO : REV.NOCLIENT :
PART NAME : RLV-SB CYLINDERICAL MATL :
OPN.NO STAGE
005 # Inspection
010 Fitting
transfer the RMC numbers on the test pieces and left over portion by punching.
020 Shearing Shear the test pieces as per marking and identify. Preserve the test pieces.
2) 250 x 300 - 1no.
1) 150 x300 - 6nos.
Check the thickness at random.
UT guage
record.
Mark for the test pieces as per layout sketch-1(2nos. of sheets per shell).
Carry out Visual inpsection of the sheets for corosion etc.,
Allot part Identification number as RLV-CS-11,12, 13 etc., and record in the log book
2.2 mm thick sheet Annealed
DESCRIPTION TOOLINGS
Note 3: Mismatch shall be calculated by taking thickness into account and reported at every50mm interval. Mismatch tabulation shall contain thickness on either side of the weld, offset
Note 4: Apply Black Japan during all stages of fabrication.
Note 5: Mark RT zones by paint and retain the marking by paint and transfer the RT
RD06-25-05-02-3-17-13-10-110 R3
Note 6: Check hardness on the trimmed portion of the shell
RKE/RLV/68/PS-06 R1
QUANTITY : 10 No per
MOTOR CASE
VSSC
PART DRG.NO. REV NO. 15CDV6
SHELL RKE-RD-06-234-06 R2
SUB ASSY NAME : REF DRG. NO. REV.NO
marking to inspection log book.
RLV-SB HE,NE & MS WELD ASSY
Note 1: Idn.No shall be retained during all stages of fabrication like welding, Heat treatment andmachining.
Note 2: Welding and Heat treatment inspection as per Doc No.MEE/QCI/QCP/007/
2002-ISSUE 2, JULY 2005
and centerline mismatch.
RAMAKRISHNA ENGINEERING COMPANY, CHENNAI-106.
FABRICATION PROCESS AND QUALITY CONTROL PLAN
RLV-SB MOTOR
SHEET NO : 1 OF 10 PROJECT : RLV-SB
APPLICABILITY 02- 05
Verify the RMC No. & acceptance of the sheets in correlation with the TC issued by VSSC and
Note 7: The Film density shall be kept as 1.8 to 2.5mm for the X-ray radiograph.
12.01.2009
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OPN.NO STAGE
030 Fitting /
HBM
035# Inspection
040 Position the sheets set and clamp
045# Inspection
050 Welding
055 # Inspection
060 Fitting
Fitting /
Welding Clean the weld edges with emery and acetone. Welding fixture
Tack weld the sheets at 100mm intervel and test pieces in the LS welding fixture.
Prepare weld edge for 2 Nos of test pieces from each sheet and preserve the balance
Mismatch
TOOLINGS
Page 2 of 9
Mill one end of the sheet by discarding 25mm (minimum)
Conduct DP test on the weld edges of sheets and test pieces 2 Nos each per sheet.
- Filler wire code No and Dia.
Identify the weld joint as RLV-CS-XX-LS1 where XX = Set serial No
Prepare weld edge by maintaining 30angle and 0.5 to 1mm root face.
Load the sheet on table and clamp at four locations using suitable clamp
DESCRIPTION
Note: Identify LS1 & LF1 test coupon.
Inspect visual, weld bead dimensions & mismatch (Compute with thickness at 50mm interval)
Carry out welding as per WPS.
Start the welding on LS1 test coupon and finish LF1 coupon through the sheet.
Vernier Caliper
Ensure welders qualification and adaptation.Clean the weld edges for a band of 50mm with emery and acetone.
Ensure welders qualification and adaptation. Inspect and record
test piece.
- Name of welder
where XX=Set serial no.
- Root gap
Record current voltage, flow of argon gas for purging and shielding - filler wire size and
UT Gauge
Template
Inspect for angle 30& land 0.5 to 1mm identify the sheet and test pieces. Bevel Protractor
Vernier Caliper/ DP Kit
Feeler Gauge
Identify LS1 and LF1 test coupons by punching and preserve.
Feeler Gauge- Mismatch (compute by taking thickness into account at an interval of 50mm)
Checking template
RMC NO.
Identify the job as RLV-CS-11,12,13 etc and test coupons as RLV-CS-XX LS1/LF1
Note 2: Mismatch tabulation shall contain thickness on either side of the weld, offset and
centreline mismatch.
location shall be provided.
Note 1: If the mismatch observed is more than specified, detailed mapping of mismatch at that
1. Fix adhesive tape on both sides of the welding before grinding.
2. Flush grind the penetration (max 0.1 projection), without touching the parent metal.
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OPN.NO STAGE
065# Inspection
070 Welding/
080 Fitting
Check the thickness at grids of 100mmx100mm interval and
090 HBM
Fitting
Prepare weld edge 30angle and 0.5 to 1mm root face.
095 Inspection
5. Inspect the test pieces also for the above.
100 Rolling
Machine
1. Devloped length at 6 generators.
1) Machine rollers shall be thoroughly cleaned prior to bending.
3. Visual inspection
Mark the generation lines parallel to the edge.
4. WEP 30, 0.5-1mm land.
TOOLINGS
Flatten the sheet with out beating the weld (surroundings area of weld within 50mm)
Vernier CaliperCarry out repair, if any as per approved procedure and inspect.
Reverse and mill the other end of the sheet by keeping the developed length .
3) Carryout pre-bending of edges.
2. D.P.test on weld edges.
Inspect for
Do not repair LS1 & LF1 Coupons.
UT Gauged = ID of shell
t = Average thickness
Mill one end by keeping the long seam joint L-1 at middle of the developed length.
DP Kit
Incase if parent metal is touched, local thickness to be checked and reported.
Film density 1.8-2.5
2) Feed the sheet with generating lines on the top.
D.P.Kit
Bevel ProtractorVernier Caliper
Inspect & record the thickness near the welds at 50 mm interval.
Inspect visual for the penetration grinding.
Conduct DP test
Carry out 100% Xray radiography
DESCRIPTION
Page 3 of 9
Magnifying glass 3X
Prepare weld edge on 4 nos. of test pieces also (2 nos. each from one sheet)
DP Kit
Load the sheet on table and clamp at four sections using suitable plate
(996+2.2) = 3137 mm
compute for average thickness(t)
Mark the developed length as (d+t) and record the length. Vernier Caliper
Example for development length calculation. Average t = 2.2 and ID 996.0
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OPN.NO STAGE
130 Fitting
135 # Inspection
140 Welding
145 # Inspection
Get clearance from VSSC for Heat treatment.
150# Heat Note 1: Before loading confirm the RMC nos. of the shell and confirm the RMC number of test
Treatment
Note 2: Confirm that temperature recorder is working properly.
Note 3: Copy of the recorded chart has to accompany the Heat treatment inspection report.
Note 4: Ensure that shells and coupons are cleaned before heat treatment
Note 1: While removing ovality use only soft hammer (MS with aluminium tips
3. ID 996 0.2
4. Visual Inspection
1. Ovality 5.0mm (max)
2. Penetration Grinding (0.1 Max projection)
Micrometer
Fix adhesive tape on both sides of the welding before flush grinding.
I/S Mic
Feeler Gauge
Note 4: Incase if parent metal is touched while penertration grinding, local thickness to be
checked and reported.
Vernier Caliper
Carryout repair if any as per approved process and inspect
3X Magnifying glass
Flush grind the penetration (max 0.1mm projection) without touching the parent metal. 2. Inside checking template
Inspect for
Note 3: Identify the shell as RLV-CS-11, 12,13 etc., and weld joint No as RLV-CS-XX-LS2
Remove ovality (5mm max) by malleting with soft hammer.
on both ends)Note 2: Weld should not be beaten.
(xx = set serial no)
Visually inspect for penetration grinding. Ensure parent metal is not touched.
TOOLINGSDESCRIPTION
Carryout DP test and 100% X-ray radiography Dp Kit
X-ray machine
Page 5 of 9
1. Ovality removing set up
coupons.
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OPN.NO STAGE
Carry out Heat treatment as per the cycle given below:
Loading Temperature :
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OPN.NO STAGE
175# UTM
Cross section area. Get clearnace from VSSC for further processing of the shell.
180 Fititng
185 # Inspection
190 Welding
200 Lathe
205 # Inspection
5. DP of WEP Sheet A
9. 0.5 to 1mm other end
10. Angle 30
11. DP test on weld edge.
12. Length 975mm (approx.)
13. ID 9960.2
DESCRIPTION
Carry out mechanical testing as per ASTM-A370. Gauge length as 5.65 A, where A is theInspect the test specimen and record the dimensions in the log book.
TOOLINGS
beating should be done in and around weldments.) Ovality should be within 5 mm
Inspect/Record for
DP Kit
1. 0.5 to 1mm for sheet A
3. 0.5 to 1mm for sheet B Vernier caliper
Vernier caliper
DP Kit / X-ray m/c.
Remove ovality (Use M.S.hammer with aluminium tips on both ends and no
Page 7 of 9
Bevel protractor
Vernier caliper
DP Kit
Vernier caliper
Bevel protractor
Bevel protractor
Vernier Caliper
Face on one side and prepare weld edge maintaining 30angle 0.5 to 1mm root face
Repair defects if any and inspect as per approved procedure.
Load the shell on turning setup with spider and shaft between centers.
Inspect for the thickness near the weld and the shell.
Carryout 100% X-Ray radiography & D.P on both long seam weld joints
DP Kit
Vernier caliper
Inside mic
4. Angle 30
2. Angle 30
8. Angle 30 Bevel protractor
True the job within 0.2mm.
7. 0.5 to 1mm one end.
6. DP of WEP Sheet B
Note : Discard minimum 25mm from the edge of the shell. (WEP on one side only)
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OPN.NO STAGE
14.
15. 0.5 to 1mm
16. Angle 30
17. DP test on weld edge18. Thickness 2.0+0.2+0.0
19. T1,T2,T3,T4 Thickness near weld20. 180weld orientation
Do not remove the spiders before cirseam weld setup. Report the Dia of shells and thicknessof the edges to planning
Dial setup
2. Ensure that all inspection reports are prepared before clearing the job for further operation
Apply Black Japan and preserve
Note : 1. # Mandatory stages to be cleared by RQS/VSSC
DP Kit
Page 8 of 9
UT guage
Vernier caliper
Bevel protractor
TOOLINGSDESCRIPTION
0.1 C
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PROCESS SHEET NO : REV.NO
CLIENT :PART NAME : RLV-SB HE SEGMENT MATL :
OPN.NO STAGE
005# Inspection
issue 2, July 2005.
Note 5: Mark RT zones by paint and retain the marking by paint and transfer the RT
marking to inspection log book
untill proof pressure test with traceability.
Template and Feeler guage
to be identified as shown in drawing.Note 1: Idn.No shall be retained during all stages of fabrication and weld joint
Allot Assembly identification as RLV-HES-02,03,04&05
& Head End Dome pre assembly - 1No
Note 2: Welding inspection as per Doc No MEE/QCI/QCP/007/2002-
Note 3: Mismatch shall be calculated by taking thickness into account and checked by
Note 4: Apply black japan during all stages of fabrication
Verify the acceptance of Cylindrical Shell Qty-4 Nos. Grooved Ring - 1 No.
template and feeler guage at an interval of 50mm. If the mismatch observed is more than
Note 8: The Film density shall be kept as 1.8 to 2.5mm for X-Ray Radiography.
Note 6: Selective Assembly of the shells shall be done to match Dia 996 +0.2-0.0
Note 7: Hardness shall be checked on the trimmed portion of the shell and retained
the specified, detailed mapping of mismatch at that location shall be provided.
RLV-SB HE SEGMENT MACHINING RD06-25-05-02-3-17-13-10-110 R3 MOTOR CASE
DESCRIPTION TOOLINGS
RAMAKRISHNA ENGINEERING COMPANY, CHENNAI-106.
PROCESS AND QUALITY CONTROL PLAN
RLV-SB MOTOR CASE
SHEET NO : 1 OF 9 PROJECT : RLV-SB
10.01.2009APPLICABILITY 02- 05
VSSCPART DRG.NO. REV NO. 15CDV 6
RKE/RLV/68/PS-07 R1
SUB ASSY NAME : REF DRG. NO. REV.NO QUANTITY : 1 NO PER
WELDING RKE-RD-06-234-07 Sheet 1,2 &3 R4
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OPN.NO STAGE
010 Welding
Lathe
020 Fitting/
Welding
025# Inspection
5. Mismatch
030 Welding
040 Lathe
2. Trim one end of the shell by keeping 825mm length for shell 2 and prepare weld edge
3. Set the purging fixture and set the shells by keeping 0.5 to 2mm root gap and
2. Orientation of Long Seam Joint 90apart
4. Root gap,
3. Thickness of both ends at an interval of 50mm for computing mismatch UT Guage
1.Compute for the length appx. 1775mm for shell assembly.
Record the following
Vernier caliper
30 angle and 0.5 to 1 mm root face.
3. Preserve the discarded portion.
7. Get clearance from VSSC for welding
Complete the welding by GTAW process in 1G position.
shielding, inspect for the total length and record.
Vernier Caliper
Spider and shaft
1. Clean 50mm width band from inside and outside for both the shells with emery and
5. Inspect for the run out of the shell at both ends.
shell level) facing each other and the each long seam weld is staggered by 90
2. Spider should be positioned 60 mm inside from the shell end.
6. Carryout DP test on WEP of both the shells and record.
4. Load the shaft and spider assembly in the welding station and hold one end on the
1. Load shell 1and shell 2 on shaft using 4 Nos of spiders and true within 0.3mm TIR
D.P.Kit
acetone.
2. Clean the purging fixture also by blowing compressed air and finally by acetone.
0.3mm mismatch or as per WPS
1. Welder's qualification and adaptation
4. Clean with acetone, ensure purging gas flow.
Voltage, current, filler wire code number, diameter and gas flow for purging and
5. Tack weld the joint at 75 to 100mm interval
6. Tack length and spacing
Mismatch checking template
Feeler guage
REFER STAGE-1 WELDING
Page 2 of 9TOOLINGS
chuck and other end on the tail stock.
DESCRIPTION
3. Shells should be positioned in such a way that prepared weld edges (at cylindrical
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OPN.NO STAGE
045# Inspection
1
2
5. Angle 306. D.P.test
7. Thickness near weld edge at 50mm interval & record
050 Lathe
REFER STAGE - 2 WELDING
060 Fitting/ 1. Load the shell 3A on the shaft and check for the trueness, clamp, set the shell (shell 3A)Lathe
5. Clean the purging fixture also by blowing compressed air and finally by acetone.
6. Set the purging fixture and set the shells by keeping 0.5 to 2mm root gap and
0.3mm mismatch
7. Clean with acetone, ensure purging gas flow
8. Tack weld the joint at 75 to 100mm interval.
065# Inspection
4. Root gap
6. Tack length and spacing
070 Welding
and shell assembly with the root gap of 0.5 to 2mm and mismatch of 0.3mm or as per WPS Feeler Gauge2. The shells should be facing the WEP side of each other.
Vernier caliper
Dial setup
Dial setup
3. Thickness of both ends at an interval of 50mm UT guage
Mismatch checking template
Feeler guage
Record the following
Vernier caliper
1. Welder's qualification and adaptation
2. Orientation of shells LS 90apart
5. Mismatch
3. Long seam orientation should be staggered by 90for adjacent shells.4. Clean both the side of the shells with emery and acetone for a band of 50mm.
Vernier Caliper
3rd and 4th spiders at a distance of 375mm from the WEP edge.
edge. Identify 430mm length shell as A & other shell as B.
True the shell within 0.3mm TIR. Part off at a distance of 430mm from the prepared weld
Mismatch checking template
3. Length 1775 and ( 825mm)
4. Root face 0.5 to 1mm
Page 3 of 9
DESCRIPTION TOOLINGS
Vernier caliper
Set the third shell by using four spiders, two numbers at both ends leaving 60mm and
D.P.Kit
UT Gauge/Ball Point Mic
Bevel protractor
Inspect for
7. Get clearance from VSSC for welding
Complete the welding by GTAW process in 1G position.
Voltage, current, filler wire code number, diameter and gas flow purging and shielding
0.1 A
0.2 A
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OPN.NO STAGE
080 Lathe
085# Inspection
1
2
3. Length 2175 and (400mm)
4. Root face 0.5 to 1mm
5. Angle 30
6. D.P. test
090 Lathe Load the shell(4) on spiders by keeping the prepared weld edge facing
Clean the weld edges with emery and acetone.
Load the welding fixture and set the job in such a way that LS of welds are
Adjust the spiders to control mismatch with 0.3mm and a root gap of
095# Inspection
100 Welding
3.Preserve the discarded portions.
staggered by 90 apart.
REFER STAGE - 3 WELDING
DESCRIPTION
4. Root gap,
7. Get clearance from VSSC for welding
3. Thickness of both ends at an interval of 50mm
Feeler guage
6. Tack length and spacing
Vernier caliper
2. Orientation of shells LS 90apart
5. Mismatch.
each other as shown in Stage 3 Welding. True the shell on spider within 0.3mm.
Dial setup
Complete the welding by GTAW process in 1G position.
Record the following
Voltage, current, filler wire code number, diameter and gas flow for shielding and purging.
Vernier caliper
1.Compute for the total length of shell approx. 2175mm
TOOLINGS
root face and 30angle.
Dial setup
7. Thickness near weld edge at 50mm interval and record.
Inspect for
2. Trim the third shell by keeping a length of 400mm and prepare weld edges 0.5 to 1mm
Page 4 of 9
0.5 to 2 mm or as per WPS Tack weld at an intervel of 75 to100 mm
1. Welder's qualification and adaptation
Vernier caliper
Bevel protractor
D.P.Kit
UT Guage / Ball Point Mic
Mismatch checking template
UT guage
Unload the assembly from fixture, remove spider & shaft.
0.1 A
0.2 A
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OPN.NO STAGE
105# Inspection
110 Fitting
115# Inspection
1. Mismatch
the thickness where parent metal is touched and map the thickness.
120# Welding/
Inspection
130 Fitting
135# Inspection Inspect for
1.
4. Root face 0.5 to 1mm
5. Angle 30
UT gauge
3. Compute for the total length of the shells approximately 3075mm.
4. Trim one end of the shell (Shell 4) by keeping 900mm length and prepare weld edge
5. Preserve the discarded portion.
on tail stock.
2. Load the assembly in the welding station and hold one end on the chuck and other end
7. Thickness near the weld edge at 50mm interval and record.
Inspect for
DESCRIPTION TOOLINGS
Note: Fix adhesive tape on both sides before grinding
Flush grind the penetration without touching parent metal (0.1mm projection max permitted)
purging fixture
Template and feeler gauge
Page 5 of 9
6. D.P.test
3. Total length 3075 & (900 mm) Vernier caliper
3. DP test
Dial setup
Dial setup
2.
D.P.Kit
1. Load the shell assembly on shaft and spider and true within 0.3mm TIR
4. 100% RT
30angle and 0.5 to 1mm root face.
Carryout repairs if any by gouging the defective area , weld & Inspect as per approved
procedure.
Inspect visual, weld bead and penetration dimensions. Identify the weld joint as
RLV-HS-CS-XX-02 (shell 1 & 2)
Vernier Caliper
Mismatch Checking Template
2. Visual for penetration grinding
Note: Ensure that parent metal is not touched. Incase if parent metal is touched, record
RLV-HS-CS-XX-04 (shell 3 & 4)
CS = Cirseam Joint
XX = Set serial no
HS = Head end segment
RLV-HS-CS-XX-03 (shell 2 & 3)
0.2 A
0.1 A
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OPN.NO STAGE
140 Welding /
Fitting
150 Welding/
Fitting
155# Inspection
4. Mismatch
160 Welding
shell.
170 Lathe
175# Inspection
6. Get clearance from VSSC for welding
purging for both Joints.
1. Compute for the length 3276.16+0.5/-0.0.
Get clearance from inspection department for the computed length considering
groove ring height and get clearance from VSSC.
3. Preserve the discarded portion.length of (900mm)
Feeler guage
2. Thickness of both ends at an interval of 50mm for computing mismatch
Record the following
Voltage, current, filler wire code number, diameter and gas flow for sheilding and
Set the root gap 0.5 to 2mm and mismatch within 0.3mm or as per WPS
Tack weld the joint at 75 to 100mm intervals
3. Root gap,
5. Tack length and spacing
2. Considering the triming allowance, trim and prepare weld edge on first shell keeping a
1. Welder's qualification and adaptation
Complete the welding by GTAW process in 1G position for c/s of HEDR to skirt and
Vernier Caliper
Mismatch checking template
UT Guage
Page 6 of 9
DESCRIPTION TOOLINGS
and acetone.
Ensure cleanliness of the purging fixture and purging gas flow.
3. Clean WEP of HED Ring, HE skirt and 'Y' ring end (in tacked condition)
4. Clean 50mm band of shell circumference at WEP end outside and inside with emery
1. Load the HE Dome Pre Assembly and true within 0.2mm TIR
2. Insert cirseam Purging fixture on cleaned end of the shell.
REFER STAGE- 4 WELDING
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OPN.NO STAGE
1
2
3. Total Length 3276.16+0.5/-0.0 & (900mm)
4. Lip distance 0.5 to 1mm
5. D.P. test on weld edge.
6. Thickness near the weld edge at 50mm
180 Welding/ REFER STAGE - 5 WELDING
Fitting
185* Inspection
5. Tack length and spacing
6. Total length 3418.66
190* Welding
Inspect for
1
2
3
3. Root gap,
6. Inspect for the total length (3418.66)
5. Tack weld the joint at 75 to 100mm interval
2. Install cirseam Purging fixture
Vernier caliper
and inside with emery and acetone.
Ensure cleanliness of the purging fixture and purging gas flow.
3. Clean WEP of Grooved Ring
4. Set the grooved ring by keeping root gap of 0.5 to 2mm and mismatch within 0.3mm
4. Mismatch.
1. Welder's qualification and adaptation
Vernier caliper4. Total Length 3418.66
Dial setup
Vernier caliper
1.Clean 50mm band of shell circumference outside
Load the grooved ring in the shaft and spider assembly
D.P.Kit
Dial setup
Vernier caliper
UT guage
Purging Fixture
UT Gauge / Ball Point Mic
Dial setup
Feeler guage
Mismatch checking template
Dial setup
Dial setup
Complete the welding by GTAW process in 1G position.
7. Get clearance from VSSC for welding
Voltage, current, filler wire code number, diameter and gas flow for purging & sheilding.
Record the following
unload the job from the machine. Remove spider & shaft
TOOLINGS
Page 7 of 9
DESCRIPTION
Inspect for
2. Thickness of both ends at an interval of 50mm
0.5 A
0.2 A
0.5 A
0.1 A
0.2 A
P 8 f 9
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OPN.NO STAGE
195# Inspection
Identify the weld joint as
1. RLV-HS-CS-XX-01 (HEDR # HE Skirt)
2. RLV-HS-CS-XX-05 (HEDR # Shell 4)
3. RLV-HS-CS-XX-06 (Shell 1 # Grooved Ring)
CS = Cirseam JointXX = Set serial no
200 Fitting
205# Inspection
300# Welding/
Inspection
305* Inspection 1 of shell2
2
5. Angle 30
7 of shell 3
8
9. Length (400), 2175
Page 8 of 9
Note 1: Fix Adhesive tape on both sides of the welding before grinding.
3. Length (950), (825), (1775)
Note 2: Grinding need not be done for C/S joint between skirt and HEDR
6. D.P Test of weld edge of shell 2
1. Visual for penetration grinding. Ensure that parent metal is not touched. In case if
parent metal is touched, record the thickness where parent metal is touched and map.
procedure.
Record the inspected dimension and prepare inspection report
4. Lip distance 0.5 to 1mm
3. D.P.of weld joint
Carryout repairs if any by gouging the defective area , weld & Inspect as per approved
Inside mic
4. 100% RT X-Ray machine
HS = Head end segment
TOOLINGS
Inspect visual, weld bead and penetration of all joints
DESCRIPTION
Dial setup
Bevel Protractor
D.P.Kit
Vernier caliper
Vernier caliper
D.P.Kit
Dial setup
Dial setup
Vernier caliper
Inspect..
(0.1mm projection max. permitted)
Flush grind penetration without touching the parent metal
Dial setup
3X magnifying glass
2. Mismatch
0.1 A
0.2 A
0.1 A
0.2 A
P 9 f 9
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OPN.NO STAGE
11. Angle 30
13 of shell 4
14
19 of shell 1
20 of shell 1
23. Angle 30
24. D.P test of shell 1
25
29. 3418.66
# Mandatory stages to be cleared by VSSC
15. (length (900), 3075)
17. Angle 30
21. Length 3276.16+0.5/0.0
16. Lip distance 0.5 to 1mm
26
27
Bevel Protractor
Bevel Protractor
18. D.P test of weld edge of shell 4
Vernier caliper
22. Lip distance 0.5 to 1mm of shell 1 Vernier caliper
Dial setup
Dial setup
12. D.P test of shell 3 D.P.Kit
10. Lip distance 0.5 to 1mm
Get clearance from VSSC for further processing.
28. LS weld staggered by 90
Vernier caliper
Inside mic
Inside mic
30. Ovality grooved ring at 16 generators
31. Ovality HEDR at 16 generators
Dial setup
Vernier caliper
Page 9 of 9
DESCRIPTION TOOLINGS
Vernier caliper
Bevel Protractor
Dial setup
Dial setup
Dial setup
D.P.Kit
Vernier caliper
Dial setup
D.P.Kit
0.5 A
0.5 A
0.1 A
0.2 A
0.1 A
0.2 A
0.2 A
RAMAKRISHNA ENGINEERING COMPANY CHENNAI 106
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20.01.2009
PROCESS SHEET NO : REV.NO
CLIENT :
PART NAME : RLV-SB HEAD END MATL :
OPN.NO STAGE
005# Inspection
010 Lathe
020 Lathe
Vernier caliper
Face to maintain 20mm length (Refer the computed value for total length)
Bore ID 959.5 through
Turn OD 226 and face to maintain thickness 7 (min)
Vernier Caliper
Note: Ensure minimum thickness is achieved at one cross section
Bore ID 188+0.046 & ensure thickness 3.5min. form Radius 2.5
Turn OD 1033.5 -0.195 - 0.360 through
Inside Micrometer
Tape
UT Gauge
Record the setting reading in log book
MACHINING OF IGNITOR BOSS (Refer Drawing Detail H):
Confirm the acceptance of Head End Segment weld assy.
Spider & shaft
Check for the face out of grooved ring and skirt ring
True the shells within 0.3mm and record
Check for the runout of skirt ring 1040 and OD of the grooved ring.
Dial SetupTighten the spiders. Set HE,Skirt and Groove Ring to a minimum runout condition
RLV-SB MOTOR CASE ASSY RD06-25-05-02-3-17-13-10-110 Sheet 1 &2 R3 ASSY.
DESCRIPTION TOOLINGS
Verify that the Idn.No RLV-HES-02,03 etc., is painted on the shell portion
Load the job on spiders and shaft.
RKE-RD-06-234-08 Sheet 1 & 2 R5
SUB ASSY NAME : REF DRG. NO. REV.NO QUANTITY : 1 NO PER
SEGMENT MACHINING
15CDV6
RAMAKRISHNA ENGINEERING COMPANY, CHENNAI-106.
PROCESS AND QUALITY CONTROL PLAN
SHEET NO : 1 OF 7 PROJECT : RLV-SB
RLV-SB MOTOR CASE
APPLICABILITY 02- 05
RKE/RLV/68/PS-08 R1 VSSC
Compute for the machining allowance and record
MACHINING OF HE SKIRT RING (Refer Drawing Detail E):
PART DRG.NO. REV NO.
Dial on 180 and compute for the machining allowance to achieve 3.5mm thickness
of the flange. Skin cut on skirt ring face, HE dome ring face and grooved ring face
Page 2 of 7
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OPN.NO STAGE
025 # Inspection
4) 226.0
030 Lathe
040 Fitting
045# Inspection
Vernier Caliper
Vernier Caliper
groove to a depth of 38+0.5/-0.0 and ID 991.5 +0.17/-0.31 and groove OD
Note: Ensure smooth surface finish of 'O' ring groove. Inspect visual and record in
Page 2 of 7TOOLINGS
and form radius R0.5 at 4 locations Chemfer 2x45.
1004.5+0.5/-0.0.Turn 987.5-0.17/-0.31 to a depth of 14.8mm ( 6.7 + 4.1+4)
Taper turn 991.5-0.17/-0.31 to 987.5-0.17/-0.31 ensuring 21.7+0.5/-0.0
length. Form 'O' ring groove (3.95 depth x 6.7+0.1/-0.0 width)
Inspect for the following:
Section-XX
2) Length (3517.3),
1) Length 3385.30.5
Mark P+ Axis by taking reference on LS weld joint
Visual by QC
Compute for length 38+0.5/-0.0 and 3385.30.5 and face to maintain these lengths.
3) 1033.5 -0.195-0.360
MACHINING OF GROOVED RING (REFER DRAWING DETAIL F & F1):
Step turn 991.5-0.17/-0.31 for 24.1mm length. Inspect and record. Bore the
Inside Micrometer
Inspect for
I/S Micrometer
Compute from OD2) 959.5
DESCRIPTION
1) 188+0.046/-0.0
Vernier Caliper
Micrometer
Tape
Turn OD 1014.5+0.1/-0.0 through
Vernier Setup
Dial Setup
4) Skirt face
Marking shall be on grooved ring, skirt ring, 226 of HE dome ring & face
in log book.
3) Length 131.5
Mark 614.5,579.5,597 & 400 on HE Dome for weld pad location.
Dial Setup
5) Skirt OD
Bore ID 973.5+0.09/-0.0 through Compute from ID
0.1 C
0.4 E
Page 3 of 7
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OPN.NO STAGE
Detail E:
15) 959.5
16) 20 at two places.
14) 1033.5 -0.195-0.360 Tape
17) 1014.5+0.1
Computed from OD
Vernier Caliper
Detail- F
Tape
TOOLINGS
9) (3.5mm) minimum UT Gauge10) 7 (minimum) Vernier Caliper
Detail - H:
8) R2.5 Radius Gauge
13) Perpendicularity on Ignitor Boss face Dial Setup
6) 188+0.046 Inside Micrometer7) 226.0 Micrometer
Vernier Caliper12) Concentricity on 188 Dial Setup
22) Visual observation of groove
23) 2x45
29) 991.5-0.17/-0.31
Detail - F1:26) 987.5-0.17/-0.31
Dial Setup
Dial Setup24) Perpendicularity on grooved ring inner lip
Vernier Caliper
27) 973.5+0.09 Inside Micrometer
28) 979.60.1 Computed
30) 21.7+0.5 Vernier Caliper
18) 1004.5+0.5
20) 24.1-0.1/-0.2
DESCRIPTIONg
Computed Value
Depth Gauge
11) (45.3)mm
19) 38+0.5 Depth Gauge
21) R0.5 at 2 places Visual
25) Concentricity on 1004.5
Computed for ID
31) 6.7+0.1 Vernier Caliper
Micrometer computed
0.4 E
0.1 C
0.1 C
0.2 E
Page 4 of 7
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OPN.NO STAGE
050 Fitting DRILLING OF IGNITOR BOSS FLANGE:
055 # Inspection
060 Drilling Drill 4.9 holes 32nos. Equispaced on 210 PCD starting at Y+. Inspect and record
the orientation of the holes get clearance from QC.
065# Inspection
070 Fitting DRILLING OF SKIRT FLANGE:
075 # Inspection
080 Drilling
from QC. Tap M16 x1.5P 4 H 12 holes (tap depth 16 min).Note: Use first tap only
g
Vernier Caliper
RKE-JRJ-1930-202-16
2. Drill 4.9 holes 6 nos. at P+ axis (Drill depth 12 max). Inspect for orientation of
Note: Use first tap only
and record.
DESCRIPTION
32) (6.9)
Clamp the jig & transfer Y+, Y- & P- axis from Jig to the job and record.
Tap M6x1P -4H, 32 nos.
Vernier Caliper
TOOLINGS
37) Concentricity on 991.5 Dial Setup
36) 4.1+0.1 Vernier Caliper
Clamp the jig & transfer P-, Y+ & Y- axis on the job from the jig and record.
Dial Setup
Drill Jig No:
33) R0.5 at 4 places
35) 4.0
Get Clearance from VSSC for drilling operation.
Position the drill Jig by locating on 188, coincide P+ marking of Jig and the job.
Inspect for the holes with reference to Jig and get clearance for unloading the jig..
Visual
Visual
Drill Jig No:Position the drill Jig by locating on 1033.5 and coincide the P+ marking.
Inspect for the orientation of the drill Jig, alignment of P+ marking on the jig & job
RKE-RD-06-234-T-23
and record.
1. Drill 14.3 holes 12nos. Starting at 2230 min from P+ towards Y+ and on
Inspect for the orientation of drill Jig, alignment of P+ marking on the jig & job
996.5 PCD (Drill depth 20 max). Inspect for orientation of the holes and get clearance
34) Visual observation of groove
38) Concentricity on 973.5
the holes and get clearance from QC. Tap M6 x 1P 4H 6 holes (tap depth 9 min)
0.2 E
0.2 E
Note: Use first tap only
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OPN.NO STAGE
Tap M6 x 1P 4H 35 holes (tap depth 9 min)
Note: 1. Use first tap only2. Inspect visual for the liner bush ID after each drilling/reaming for damage
if any.
085 # Inspection Inspect for the holes with reference to Jig .
Get clearance from VSSC to unload the job from the machine.
090 IC Jig DRILLING OF SEGMENT PIN HOLES:
095# Inspection
100 Drilling
Ream the holes of 12+0.018.
Check with GO NO GO Plug guage. Lock the holes with pins.
Ream the holes of 12+0.018mm.
105 # Inspection
110 Fitting
120 Fitting
Mark the strap ring attachment holes at P+ and P-. Drill 3mm holes 6nos. each at
Bore Dial Gauge
Go & No Go Gauge
Get clearance from VSSC to unload the job from the Jig.
DESCRIPTION TOOLINGS
Load the assy on interchangable drill Jig & coincide the P+ marking on jig and job
Inspect for 12+0.018 & depth of 16.5mm+0.2 with Jig in position.
Feeler Gauge
True the groove ring OD within 0.1mm and clamp.
orientation holes and get clearance from QC.
Open up the hole to 11.5mm X 15mm depth.
Inspect for face butting with feeler gauge(max. gap 0.05mm), Jig orientation and
Drill 6 holes 3nos 120apart to a depth of 15.0mm and lock.
Depth Gauge
DRILLING OF STRAP RING ATTACHMENT HOLE:
Unload the segment and load on the trolley.
4. Drill 4.9 holes at 5 locations 7nos each (Drill depth 11 max). Inspect for the
setup. Verify the P+marking on Jig and job are coincided .
Complete tapping of M6 and M16 holes
1005.5 PCD. Inspect for the orientation of holes and get clearance from QC.
3. Drill and ream 5 holes 2 nos. at P+ axis 6 deep on 980.5 PCD and 7.5 deep on
Note: Check with Go & No Go plug Gauge after reaming of every 5 holes
Open up the hole to 11.5mm X 15mm depth.
Drill 6 holes 69nos to a depth of 15.0mm.
With flat drill increase the depth to 16.5mm,
With flat drill increase the depth to 16.5mm,
P+ and P- on grooved ring as shown in developed view R. Set one of the strap ring
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OPN NO STAGE DESCRIPTION TOOLINGS
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OPN.NO STAGE
130 Fitting
140 Fitting
145 # Inspection
Detail - F & Section ZZ:
40) 16.5 + 0.2
41) 42.1/-0.1/-0.2
42) R0.5 at 2 places
43) mm
44) Visual observation of hole & finish
49) 215' 0.2' (typ)
50) 430' 0.2' (typ)
51) 9 2' (typ)
55) 5 Hole, 6 Deep
56) 5 Hole, 7.5 Deep
view R. Tap M5x0.8P (4H). Repeat for other position also.
location as shown in view-M
Mark the cutout as per sketch inline with the P+ and P- axis
Drill 4.1holes x 6nos. each at P+ and P- on grooved ring as shown in Developed
DESCRIPTION
in position on grooved ring OD such that centre line of half ring matches with
P+ axis on grooved ring. Hold the strap ring in position and clamp . Verify the
Drill and open out the cutout 100x60mm and radius 30.0mm
matching of 5.2 holes on strap ring & 3 holes on grooved ring. Remove the strap.
53) 2230' 0.2' (typ)
Drill 3.1, 5nos through and 1no. 8mm deep as per drawing.
46) 439' 0.2' (typ)
39) 12+0.018x72nos 230' from Y+
Vernier Caliper
Go No Go Plug / Bore Dial Gauge
IC Jig
TOOLINGS
Tap M5x0.8P, 6H 2 nos.
Drill 4.1, 2 nos.x 8mm depth.
Inspect for the following:
Tap M4 x 0.7P, 6H 6 nos.
Go No Go Gauge / Vernier
Depth Gauge
Micrometer & Setup
47) 918' 0.2' (typ)
48)163' 0.2' (typ)
View N - Section BB ,Section DD and Detail - C:
45) M6 x1P 4H 41 holes 9(min) and 12(max)
Visual
Drill Jig
52) M16 x 1.5 4H 12 holes 20(max) for drilling 16(min) for tapping
57) M6x1 4H, 32nos starting at Y+
54) 15 0.2' (typ)
Drill Jig
Go No Go Gauge
Vernier Caliper
Go No Go Gauge / Drill Jig
18.0
OPN NO STAGE
Page 7of 7
DESCRIPTION TOOLINGS
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OPN.NO STAGE
68) 65.0mm
# Mandatory stages to be cleared by RQS/VSSC
Get Clearance from VSSC for weld pad welding.
P+ and P- axis x 8 deep.
removal of Spider. Ovality inspected at earlier stage of weld assembly & reported.
Note: Spider are not to be removed at this stage Ovality will be inspected after PPT &
65) 80mm
59) M4 x 0.7P 6H 6nos. each at P+and P- axis as shown.
60) Cutout at 2 locations P+ and P- axis
63) 40mm
64) 16mm
62) 60mm
72) 5
73) 18mm
58) M5x0.8-6H holes, 2 nos. each 50mm centre distance from
70) 115'
66) 100mm
67) 130mm
Developed view - R & Section -YY:
61) R30
View-M & Section - KK:
71) 345'
Radius Gauge
DESCRIPTION TOOLINGS
Go No Go Gauge
Go No Go Gauge69) M5x0.8-4H,6 nos each at P+ & P- inline with seg.holding pin
Vernier Caliper
Vernier Caliper
Vernier Caliper
Vernier Caliper
Chord Measurements
RAMAKRISHNA ENGINEERING COMPANY, CHENNAI-106.
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PROCESS SHEET NO : REV.NO
CLIENT :
PART NAME : RLV-SB HEAD END MATL :
OPN.NO STAGE
#005 Inspection
010 Fitting
015 # Inspection
020 Welding
025# Inspection
WELDING OF WIRE TUNNEL WELD PAD:
Antenna Mounting weld pad - 8 Nos.
Get clearance from VSSC for welding.
face, and 250mm from the first pair of weld pad at 12 locations on P+ axis
Set and tack weld wire tunnel weld pads at a distance of 223mm from the skirt ring
Inspect for the weld pad locations and orientation of the weld pads with reference
to the drawing.
as shown in drawing.
Mark the location of wire tunnel weld pads on segment assy with reference to
Destruct System weld pads Part-II-4 Nos.
Destruct System weld pads Part-I - 4 Nos.
Destruct System weld pads Part -IV-8 Nos.
Destruct System weld pads Part-V-16 Nos.
DESCRIPTION
Weld pad welding fixture No.
Inspect for the weld pad orientation and fixture position.
P+ axis as shown in drg. Clean the area with emery and acetone. RKE-RD-06-234-T-27
Position the weld pad welding fixture and assemble the pads in position.
Destruct System weld pads Part-III-10 Nos.
QUANTITY : 1 No.
TOOLINGS
Confirm the acceptance of the following:
Wire tunnel weld pad - 52 Nos.
Head End Segment Assy - 1 No.
RLV-SB MOTOR CASE ASSY RD06-25-05-02-3-17-13-10-170 R5
SUB ASSY NAME : REF DRG. NO. REV.NO
VSSCPART DRG.NO. REV NO. 15CDV6
SEGMENT WELD PADS WELDING RKE-RD-06-234-09 Sheet 1& 2 R3
RKE/RLV/68/PS-09 R1
PROCESS AND QUALITY CONTROL PLAN
RLV-SB MOTOR CASE
SHEET NO : 1 OF 5 PROJECT : RLV-SB
20.01.2009APPLICABILITY 02- 05
OPN NO STAGE
Page 2 of 5DESCRIPTION TOOLINGS
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OPN.NO STAGE
030 Welding
040 Fitting/ Welding
045 # Inspection
050 Fitting
055 Inspection
060 Fitting
070 Fitting/
Welding
075 Inspection
080 Welding
090 Fitting
095# Inspection
100 Fitting/
Welding
Carry out fillet weld of the pads on all four sides.
Repeat operation 50 to 80 at 20from P-axis.
Inspect for the orientation of weld pad.
maintained and tack weld.
1. Drill 4.1 holes 2nos. & Tap M5 x 0.8 P x 6H holes
2. Drill 18 holes 1no.
Position the weld pads in such a way that center distance of 88, 125 and 60mm are
3. 60mm, 21mm, 125mm for weld pads.
Inspect for marking.
Mark the following at 20away from P+ and P- Axis.
1. Centre distance of 60mm x12mm for two M5 x 0.8 P holes
issue 2, July 2005)
Complete the fillet welding (Ref. doc.no MEE/QCI/QCP/007/2002,
WELDING OF ANTENNA MOUNTING WELD PAD (REFER DRAWING VIEW F)
2. 67mm distance for 18 holes
D.P. Kit
Inspect the location of weld pad as per Section XX & Detail Z of the drawing.
Repeat operation 10 to 30 for the completion of weld pad at P- axis.
Mark 62', 718' position of weld pad part-I & part-II such a way that maintaining
Carry out DP Test on the fillet welds.
Mark the ref.circle 642.5, 597, 549 and transfer the center line P+,P-, Y+ & Y-
WELDING OF DESTRUCT SYSTEM WELD PADS( PART I & II)
Tack weld part I & II by maintaining 66mm & 11.5mm.
35mm as per drg. Clean the area with Emery & Acetone.
on head end dome.
DESCRIPTION TOOLINGS
Inspect for the location of weld pads, carry out DP test on fillet welds.
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OPN.NO STAGE
Page 3 of 5
DESCRIPTION TOOLINGS
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OPN.NO STAGE
110 Welding/
Fitting
Tack weld part III & IV by maintaining 9mm & 34mm.
120 Welding/Fitting
125# Inspection
130 Welding
135 Inspection
140# Inspection
45(typ) at Y+ and Y- axis. Clean the area with Emery & Acetone.
Mark the ref.circle 335.38, 400, 435.68 and mark line 14(typ) & 18(typ),
Carry out fillet weld of the weld pads (Ref. doc.no MEE/QCI/QCP/007/2002,
issue 2, July 2005)
Inspect for the orientation of the weld pads and carry out DP Test on fillet weld.
starting from P+ for weld pad & part-III. Clean the area with Emery & Acetone.
Inspect for the following:
9) 18(typ)
10) 36(typ)
View - N:
8) 45(typ)
WELDING OF DESTRUCT SYSTEM WELD PAD( Part III & IV)
Detail - Z:
4) 50
5) 110
6) 20
7) Fillet weld size 3mm
DESCRIPTION
Drawing.
Note: Fillet welding shall be done at two sides of the weld pad only as shown in
Section - XX:
Inspect the position of weld pads.
1) 223mm
2) 250x12nos.
Mark the ref.circle 614.5, 597, 579.5 and mark line 36(typ), 18(typ)
Welding Fixture No
RKE-RD-06-234-T-23
Tack weld part V by maintaining 9.67mm & 51.9mm.
WELDING OF DESTRUCT SYSTEM WELD PAD( Part V)
3) 38.0
Vernier Caliper
Vernier Caliper
D.P.Kit
TOOLINGS
Vernier Caliper
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OPN.NO STAGE DESCRIPTION TOOLINGS
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View - F:
37) 60mm
30) Fillet size 3x45
Vernier Caliper
15) 665.5 (Ref)16) 551.5 (Ref)
17) 11.5 + 2.0/+0.0
31) (38)mm Vernier Caliper
Detial - Z :
13) 549
14) 60(typ)
12) 597 (Ref)
11) 642.5
Section - AA :
32) (20)
33) 50
34) (110)mm
36) Orientation 20from P+ and P-
29) 35
Detail - X :
35) Fillet size 3 (typ)
27) (718')
28) (62')
Vernier Caliper
Vernier Caliper
Vernier Caliper
18) 66mm (typ)
20) 597 (Ref)
21) 579.5
22) 34mm
Section - BB :
19) 614.5
23) 635.5 (Ref)24) 576.5 (Ref)
26) 60
25) 9+2.0/+0.0
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OPN.NO STAGE
51) 435.68 (Ref)
Vernier Caliper
47) 75
48) 9.67
TOOLINGS
40) 12.0
GO NO GO Gauge
49) 335.38
50) 400 (Ref)
44) 455.38 (Ref)
45) 335.1 (Ref)
46) 51.9 (typ)
52) 14(typ)
# Mandatory stages to be cleared by RQS/VSSC
Vernier Caliper
DP Kit / Vernier Caliper
Vernier Caliper
53) 18(typ)
View - N:
Section - CC:
Get Clearance from VSSC for Proof Pressure Test.
54) DP test on all fillets & f illet size.
DESCRIPTION
41) 88.0
42) 125.043) 18 holes
38) M5 x 0.8 P- 6 H x 10 deep
39) 67.0
RAMAKRISHNA ENGINEERING COMPANY, CHENNAI-106.
PROCESS AND QUALITY CONTROL PLAN
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PROCESS SHEET NO : REV.NO
CLIENT :
PART NAME : RLV-SB MIDDLE SEGMENT MATL :
OPN.NO STAGE
005# Inspection
July 2005.
RLV-SB MOTOR CASE
SHEET NO : 1 OF 9 PROJECT : RLV-SB
12.01.2009
VSSC
PART DRG.NO. REV NO. 15CDV 6
SUB ASSY NAME : REF DRG. NO. REV.NO QUANTITY : 1 NO PER
WELDING RKE-RD-06-234-10 Sheet 1,2 & 3 R2
RKE/RLV/68/PS-10 R1
RLV-SB MIDDLE SEGMENT MACHINING RD06-25-05-02-3-17-13-10-120 R0 MOTOR CASE
DESCRIPTION TOOLINGS
&Tongued Ring - 1No
Verify the acceptance of Cylindrical Shell Qty-4 Nos. Grooved Ring - 1 No.
template and feeler guage at an interval of 50mm. If the mismatch observed is more than
Template and Feeler guage
to be identified as shown in drawing.
Allot Assembly identification as RLV-MS-02,03,04 & 05
the specified, detailed mapping of mismatch at that location shall be provided.
Note 8: The Film density shall be kept as 1.8 to 2.5mm for X-Ray Radiography.
Note 6: Selective Assembly of the shells shall be done to match Dia 996 +0.2-0.0
Note 7: Hardness shall be checked on the trimmed portion of the shell and retained
Note 1: Idn.No shall be retained during all stages of fabrication and weld joint
Note 2: Welding inspection as per Doc No MEE/QCI/QCP/007/2002- Issue 2,
Note 3: Mismatch shall be calculated by taking thickness into account and checked by
Note 4: Apply black japan during all stages of fabrication
Note 5: Mark RT zones by paint and retain the marking by paint and transfer the RT
marking to inspection log book
untill proof pressure test with traceability.
APPLICABILITY 02- 05
OPN.NO STAGEREFER STAGE-1 WELDING
TOOLINGSDESCRIPTIONPage 2 of 9
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010 Welding
Lathe
020 Fitting/
Welding
025# Inspection
5. Mismatch
030 Welding
040 Lathe
3. Thickness of both ends at an interval of 50mm for computing mismatch
REFER STAGE 1 WELDING
4. Root gap,
4. Load the shaft and spider assembly in the welding station and hold one end on the
shielding, inspect for the total length and record.
6. Carry out DP test on WEP of both the shells and record.
7. Get clearance from VSSC for welding
1. Welder's qualification and adaptation
2. Orientation of Long Seam Joint 90apart
3. Preserve the discarded portion.
Feeler guage
Voltage, current, filler wire code number, diameter and gas flow for purging and
30 angle and 0.5 to 1 mm root face.
chuck and other end on the tail stock.
5. Tack weld the joint at 75 to 100mm interval
4. Clean with acetone, ensure purging gas flow.
D.P.Kit
0.3mm mismatch or as per WPS
3. Shells should be positioned in such a way that prepared weld edges (at cylindrical
Spider and shaft
2. Clean the purging fixture also by blowing compressed air and finally by acetone.
1. Clean 50mm width band from inside and outside for both the shells with emery and
1. Load shell 1 and shell 2 on shaft using 4 Nos of spiders and true within 0.3mm TIR
shell level) facing each other and the each long seam weld is staggered by 90
5. Inspect for the run out of the shell at both ends.
acetone.
2. Spider should be positioned 60 mm inside from the shell end.
Complete the welding by GTAW process in 1G position.
Vernier Caliper
1.Compute for the total length of the shells app. 1895mm for shell assembly
& accordingly discard
Mismatch checking template
Vernier caliper6. Tack length and spacing
3. Set the purging fixture and set the shells by keeping 0.5 to 2mm root gap and
2.Trim one end of the shell by keeping 945mm length for shell 2 and prepare weld edge
UT Guage
Record the following
OPN.NO STAGE
045# Inspection
Page 3 of 9
DESCRIPTION TOOLINGS
Inspect for
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045# Inspection
1
2
3. Length 1895 & ( 945mm)
4. Lip distance 0.5 to 1mm
5. Angle 306. D.P.test
7. Thickness near weld edge at 50mm interval & record
REFER STAGE - 2 WELDING
050 Fitting/ 1. Load the shell 3B on the shaft and check for the trueness, clamp, set the shell (shell 3B)
Lathe
5. Clean the purging fixture also by blowing compressed air and finally by acetone.
6. Set the purging fixture and set the shells by keeping 0.5 to 1.5mm root gap and0.3mm mismatch
7. Clean with acetone, ensure purging gas flow
8. Tack weld the joint at 75 to 100mm interval.
055# Inspection
4. Root gap
6. Tack length and spacing
060 Welding
Voltage, current, filler wire code number, diameter and gas flow purging and shielding.
3. Thickness of both ends at an interval of 50mm
Vernier caliper
3. Long seam orientation should be staggered by 90for adjacent shells.
UT guage
7. Get clearance from VSSC for welding
5. Mismatch
Mismatch checking template
Record the following:
Mismatch checking template
and shell assembly with the root gap of 0.5 to 2mm and mismatch of 0.2mm or as per WPS Feeler Gauge
1. Welder's qualification and adaptation
Feeler guage2. Orientation of shells LS 90apart
Complete the welding by GTAW process in 1G position.
Dial setup
Dial setup
UT Gauge/Ball Point Mic
D.P.Kit
4. Clean both the side of the shells with emery and acetone for a band of 50mm.
Bevel protractor
Vernier caliper
2. The shells should be facing the WEP side of each other.
Vernier caliper
Inspect for
0.1 A
0.2 A
OPN.NO STAGE
070 Lathe
DESCRIPTION
Page 4 of 9TOOLINGS
1. Compute for the total length of the shells app. 2352mm for shell assembly
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075# Inspection
1
2
3. Length 2352 &(457mm)
4. Root face 0.5 to 1mm
5. Angle 30
6. D.P. test
080 Lathe Load the shell(4) on spiders by keeping the prepared weld edge facing
Clean the weld edges with emery and acetone.
Load the welding fixture and set the job in such a way that LS of welds are
Adjust the spiders to control mismatch with 0.2mm and a root gap of
Tack weld at an intervel of 75 to100 mm
085# Inspection
090 Welding
purging. Unload the assembly from the fixture, remove spider & shaft.
REFER STAGE - 3 WELDING
2. Trim one end of the shell by keeping 457mm length for shell 3B and prepare weld edge
30 angle and 0.5 to 1 mm root face.
Bevel protractor
UT guageVernier caliper
Dial setup
Vernier caliper
Vernier caliper
Dial setup
D.P.Kit
UT Guage / Ball Point Mic
1. Welder's qualification and adaptation
3. Thickness of both ends at an interval of 50mm
Inspect for
3. Preserve the discarded portion.
Mismatch checking template
7. Thickness near weld edge at 50mm interval and record.
staggered by 90 apart.
0.5 to 2 mm or as per WPS
each other as shown in Stage 3 Welding. True the shell on spider within 0.3mm.
2. Orientation of shells LS 90apart Feeler guage
5. Mismatch
6. Tack length and spacing
Record the following
Complete the welding by GTAW process in 1G position.
p g pp y
& accordingly discard
Voltage, current, filler wire code number diameter and gas flow for shielding and
4. Root gap
7. Get clearance from VSSC for welding
0.1 A
0.2 A
OPN.NO STAGE
095# Inspection Inspect visual, weld bead and penetration dimensions. Identify the weld joint as
TOOLINGSDESCRIPTION
Page 5 of 9
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p
100 Fitting
105# Inspection
1. Mismatch
the thickness where parent metal is touched and map the thickness.
110 Welding/
Inspection
120 Fitting
130 Lathe
30angle and 0.5 to 1mm root face.
1. Load the shell assembly on shaft and spider and true within 0.3mm TIR
2. Load the assembly in the welding station and hold one end on the chuck and other end purging fixture
5. Preserve the discarded portion.
on tail stock.
3. Compute for the total length of the shells approximately 3302mm .
4. Trim one end of the shell (Shell 4) by keeping 950mm length and prepare weld edge
3. DP test D.P.Kit
Carryout repairs if any by gouging the defective area , weld & Inspect as per approved
procedure.
4. 100% RT
Inspect for
MS = Middle segment
2. Visual for penetration grinding
Note: Ensure that parent metal is not touched. Incase if parent metal is touched, record UT gauge
RLV- MS - CS - XX - 09 ( Shell 2 & 3B)
RLV- MS - CS - XX - 10 ( Shell 1& 2)
Note : Fix adhesive tape on both sides before grinding
XX = Set serial no
CS = Cirseam Joint
Flush grind the penetration without touching parent metal (0.1mm projection max permitted)
p p y j
RLV- MS - CS - XX - 08 ( Shell 3B & 4)
30 angle and 0.5 to 1 mm lip distances
1. Compute for the total length of the shells app. 3302mm & accordingly discard
Template and feeler gauge
2. Trim one end of the shell (shell 4) by keeping 950mm length and prepare weld edge
3. Preserve the discarded portion.
OPN.NO STAGE
135# Inspection Inspect for
DESCRIPTION
Page 6 of 9
TOOLINGS
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1
2
3. Total Length 3302 & (950mm)
4. Root face 0.5 to 1mm
5. Angle 30
6. D.P. test
7. Thickness near the weld edge at 50mm interval and record.
140 Welding /
Fitting
150 Welding/
Fitting
155# Inspection
4. Mismatch
160 Welding
170 Lathe
175 # Inspection
Note: Compute for the length 3421.6+0.5/-0.0 and discard accordingly.
Get clearance from inspection department for the computed length considering
grooved ring height and get clearance from VSSC.
length of (950mm)
D.P.Kit
UT Guage
Bevel protractor
purging fixture
Mismatch checking template
Dial setup
Vernier caliper
Dial setup
1. Load the Tongued ring on the shaft and true within 0.2mm TIR
Complete the welding by GTAW process in 1G position for c/s of Tongued ring and shell.
Feeler guage
Voltage, current, filler wire code number,diameter and gas flow for sheilding and
Vernier Caliper
Considering the triming allowance, trim and prepare weld edge on first shell keeping a
5. Tack length and spacing
purging.
emery and acetone.
Record the following
1. Welder's qualification and adaptation
REFER STAGE - 4 WELDING
Tack weld the joint at 75 to 100mm intervals
6. Get clearance from VSSC for welding
2. Insert cirseam Purging fixture on cleaned end of the shell.
4. Clean 25mm band of shell circumference at WEP end outside and inside with
Vernier caliper
Set the root gap 0.5 to 1.5mm and mismatch within 0.2mm or as per WPS
2. Thickness of both ends at an interval of 50mm for computing mismatch
Ensure cleanliness of the purging fixture and purging gas flow.
3. Clean WEP of Tongued Ring & Shell
3. Root gap,
0.1 A
0.2 A
OPN.NO STAGE DESCRIPTION
Inspect for
Page 7 of 9
TOOLINGS
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1
2
3. Total Length 3421.6+0.5/-0.0 & (950mm)
4. Lip distance 0.5 to 1mm
5. D.P. test on weld edge.6. Thickness near the weld edge at 50mm
180 Welding/
Fitting
185# Inspection
5. Tack length and spacing
190# Welding
Inspect for
1
2
3
Dial setup
REFER STAGE - 5 WELDING
1.Clean 50mm band of shell circumference outside
Complete the welding by GTAW process in 1G position between GR & Shell 1.
Dial setup
Load the Grooved ring in the shaft and spider assembly and true within 0.5mm
2. Install cirseam Purging fixture
Ensure cleanliness of the purging fixture and purging gas flow.
3. Clean WEP of Grooved Ring
5. Tack weld the joint at 75 to 100mm interval
Dial setup
D.P.KitUT Gauge / Ball Point Mic
Vernier caliper
Purging Fixture
and inside with emery and acetone.
4. Set the Tongued ring by keeping root gap of 0.5 to 2mm and mismatch within 0.2mm
Vernier caliper
Dial setup
unload the job from the machine. Remove spider & shaft
Dial setup
4. Total Length 3564.1 Vernier caliper
3. Root gap,
4. Mismatch.
6. Get clearance from VSSC for welding
Feeler guage
1. Welder's qualification and adaptation
2. Thickness of both ends at an interval of 50mm
Record the followingVoltage, current, filler wire code number , diameter, gas flow for purging & sheilding.
UT guage
Mismatch checking template
Vernier caliper 0.1 A
0.2 A
0.5 A
0.2 A
0.5 A
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OPN.NO STAGE
V i li
TOOLINGS
Page9 of 9
DESCRIPTION
16 Li di t 0 5 t 1
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19 of shell 1
20 of shell 1
23. Angle 30
24. D.P test of shell 1
25
29. 3564.1
21. Length (950) & 32421.6+0.5/0.0
26
27
18. D.P test of weld edge of shell 4
22. Lip distance 0.5 to 1mm of shell 1
Dial setup
D.P.Kit
Dial setup
Bevel Protractor
Bevel Protractor
Vernier caliper
Dial setup
28. LS weld staggered by 90
Vernier caliper
Inside mic
Inside mic31. Ovality Tongued ring 961.5 at 16 generators
30. Ovality Grooved ring 969.5 at 16 generators
Get Clearance from VSSC for weld pad welding.
Vernier caliper
Dial setup
D.P.Kit
Vernier caliper
Dial setup
# Mandatory stages to be cleared by VSSC
17. Angle 30
16. Lip distance 0.5 to 1mm
0.5 A
0.5 A
0.1 A
0.2 A
0.2 A
RAMAKRISHNA ENGINEERING COMPANY, CHENNAI-106.
PROCESS AND QUALITY CONTROL PLAN
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PROCESS SHEET NO : REV.NO
CLIENT :
PART NAME : RLV-SB MIDDLE SEGMENT MATL :
OPN.NO STAGE005 # Inspection
010 Lathe
020 Lathe
025 # Inspection
Chamfer 2x45at 3 locations.
Skin cut on tongued ring face and grooved ring face.
Inspect for
Face to maintain 53.5+0.5/-0.0 depth
Bore 991.5+0.09+0.00 x 40.0 +.05/-0.0 depth
Taper turn 987.5 to 991.5 by keeping 7mm (47-40) taper length
Turn OD 1004.5-0.3/-0.7 through
Bore ID 987.5 x 40mm length
ptape/ Inside Mic & compute
3) 965.5+0.09/+0.0
Inspect for 987.5 +.09 +.00
I/S Micrometer
I/S Micrometer
I/S Micrometer
Compute for machining allowance and record. Record the setting reading in logbook.
Inspect & Compute for length 68.7
Face to maintain 68.7mm
Form groove of 64.7 +0.10+.00 from face and 987.5+.09 +.00 & 973.5 - 0.17-0.31
RLV-SB MOTOR CASE
SHEET NO : 1 OF 6 PROJECT : RLV-SB
20.01.2009
APPLICABILITY 02- 05
VSSC
PART DRG.NO. REV. NO. 15CDV6
MACHINING RKE-RD-06-234-11 R4
RKE/RLV/68/PS-11 R1
SUB ASSY NAME : REF DRG. NO. REV. NO. QUANTITY : 1 NO PER
RLV-SB MOTOR CASE ASSY RD06-25-05-02-3-17-13-10-120 R0 ASSY
True the shells within 0.3mm and record.
Verify that the Idn.No RLV-MS-02,03 etc., is painted on the shell portion
Load the job on spiders and shaft. Spider & shaft
DESCRIPTION TOOLINGS
Confirm the acceptance of the Middle segment Weld Assy.
2) 991.5+0.09
Tighten the spiders. Set for tongued ring and grooved ring with minimum runout. Dial Gauge setup
Check for the faceout of tongued ring and grooved ring.Check for the runout of tongued ring OD and grooved ring OD.
MACHINING OF TONGUED RING (REFER DRAWING DETAILS G & G1)
Bore ID 965.5 +.09+.00 through
I/S Micrometer1) 1004.5-0.3/-0.7
OPN.NO STAGE
Compute from OD5) 973 5 0 17/ 0 31
Page 2 of 6DESCRIPTION TOOLINGS
4) 987.5+0.09+0.00 checked before groove Machining I/S Micrometer
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030 Lathe
040 Fitting
045# Inspection
Compute from OD
Face turn 24.1 depth and step turn 991.5-0.17/-0.31 for 24.1mm length and Inspect
Inside Micrometer
Note: Ensure smooth surface finish of 'O' ring groove and record.
Turn OD 1014.5+0.1/-0.0 through
Bore ID 973.5+0.09/-0.0 Compute from ID
5) 973.5-0.17/-0.31
Compute for length 38+0.5/-0.0 and 35300.5 and face.
MACHINING OF GROOVED RING (REFER DRAWING DETAIL F & F1)
Vernier Caliper
Bore the groove to a depth of 38+0.5/-0.0 and ID 991.5 +0.17/-0.31
Inspect for the following
length. Form 'O' ring groove as per drawing (3.95 depth x 6.7+0.1/-0.0 width)
and form radius R0.5 at 4 locations Chemfer 2x45
6) Concentricity on 1004.5
8) Concentricity on 973.5
7) Concentricity on 987.5
Tape
and 1004.5+0.5/-0.0. Turn 987.5-0.17/-0.31, depth 14.8mm length ( 6.7 + 4.1+ 4)
Taper turn 991.5-0.17/-0.31 to 987.5-0.17/-0.31 ensuring 21.7+0.5/-0.0
Dial Setup
Detail - G:
Section - XX:
3) 1004.5-0.3/-0.7
Vernier Caliper
4) 991.5+0.09 I/S Micrometer
5) 965.5+0.09/+0.0 I/S Micrometer
6) (75) Vernier Caliper
7) (45) Vernier Caliper
Vernier Caliper / Depth Gauge
10) 53.5+0.5 Vernier Caliper
9) (68.7)
Mark P+ Axis by taking reference on LS weld joint
Marking shall be on grooved ring and tongued ring OD & taper.
1) 35300.5 Taper2) Concentricity on 1004.5 and 987.5
8) 64.7+0.1/+0.05
0.2 D
0.2 D
0.2 D
0.2 E
OPN.NO STAGE
12) 40+0 5
Page 3 of 6DESCRIPTION TOOLINGS
11) 47+0.5 Vernier Caliper
Vernier Caliper
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22) Concentricity on 973.5
14) Perpendicularity on Tongued Ring inner lip Dial setup
30) Perpendicularity on Grooved ring Inner lip Dial setup
16) Perpendicularity on Tongued ring Groove face.
19) 987.5+0.09 Computed I/S Micrometer
32) Concentricity on 1004.5
12) 40+0.5
31) Perpendicularity on Grooved ring Outer lip
15) Perpendicularity on Tongued Ring outer lip
17) Concentricity on 1004.5
Vernier Caliper
13) 2x45at 3 places Bevel Protractor
Detail - G1:
18) (15.2) Vernier Caliper
20) 973.5-0.17/-0.31 Computed I/S Micrometer
21) Concentricity on 987.5 Dial setup
23) R0.5 at 2 places Visual
24) 1014.5+0.1 TapeDetail - F:
29) 2x45
25) 1004.5+0.5 Computed
26) 38+0.5 ; Vernier Caliper
27) 24.1-0.1/-0.2
28) R0.5 at 2 places
I/S Micrometer
35) 979.60.1
34) 973.5+0.09
Computed
Detail - F1:
33) 991.5-0.17/-0.31 Micrometer computed
0.1 C
0.1 C 0.1 C
0.2 D
0.2 D
0.1 C
0.1 C
0.2 E
0.2 D
OPN.NO STAGE
Page 4 of 6DESCRIPTION
Vernier Caliper
37) 6.7+0.1 Vernier Caliper
TOOLINGS
36) 987.5-0.17/-0.31
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050 IC Jig
055# Inspection
060 Drilling
Ream the holes of 12+0.018 x 16.5 +0.2/-0.0mm depth
Check with GO NO GO Plug guage. Lock the holes with pins.
Ream the holes of 12+0.018mm x 16.5 +0.2/-0.0mm depth.
65 # Inspection
70 IC Jig
With flat drill increase the depth to 16.5mm,
Load the assy on interchangable drill Jig by facing tongued ring at bottom and
DRILLING OF SEGMENT PIN HOLES TONGUED RING:
Coincide the P+ marking on the Jig & job.
1. Load the assy on interchangable drill Jig by facing grooved ring at bottom and
Drill 6 holes 69nos to a depth of 15.0mm.
Depth Gauge
coincide P+ marking on Jig & Job.
Feeler Gauge
2. True the groove ring OD within 0.1mm and clamp
Open up the hole to 11.5mm X 15mm depth.
Dial Setup
Get clerance from VSSC to unload the job from the jig.
True the tongued ring OD within 0.1mm and clamp.
Inspect for 12+0.018 & depth of 16.5mm+0.2 with Jig in position. Go & No Go Gauge
Open up the hole to 11.5mm X 15mm depth.
Get clerance from VSSC to unload the job from the machine
Vernier Caliper
38) 21.7+0.5
39) (6.9)
With flat drill increase the depth to 16.5mm,
P+ marking of the Jig and job are coincided.
44) Concentricity on 991.5
DRILLING OF SEGMENT PIN HOLES GROOVED RING:
Dial Setup
41) 4.1+0.1
42) R0.5 at 4 places Radius Gauge
43) Concentricity on 973.5
37) 6.7+0.1 Vernier Caliper
Vernier Caliper
40) 4mm
Vernier Caliper
Note: Check with Go & No Go plug Gauge after reaming of every 5 holes
Inspect for face butting, with feeler gauge ( max. gap 0.05mm) Jig orientation and setup.
Drill 6 holes 3nos 120apart to a depth of 15.0mm and lock.
0.2 E
0.2 E
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OPN.NO STAGE
75# Inspection
TOOLINGSDESCRIPTION
Inspect for face butting, with feeler gauge (max. gap 0.05mm) Jig orientation and setup.
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80 Drilling
#85 Inspection
090 Fitting
100 Fitting
105 # Inspection
Open up the hole to 11.5mm.
Check with GO NO GO Plug guage.
Lock the holes with pins.
45) 12+0.018, 72 nos Bore Dial Gauge
46) Starting at 230' from Y+ towards P-
Section - ZZ :
Inspect the following dimensions:
View - A: Go No Go Plug Gauge
Go & No Go Gauge/ B.Gauge