RLV SB Process Sheet

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


3/155

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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5/155

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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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



RLV-SB MOTOR CASE



10.01.2009

SUB ASSY NAME : REF DRG. NO. REV.NO QUANTITY : 2 Nos. per


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


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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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



RLV-SB MOTOR CASE


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



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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10/155

12.01.2009


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.


Get clearance from RQS for Heat treatment. Heat treat the forging as per




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)


RKE-RD-06-234-04 R2



RLV-SB MOTOR CASE



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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12/155

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


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


14/155

er


15/155


16/155

-T-09

or

-T-08


17/155


18/155

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



RLV-SB MOTOR CASE




FORGING (ANNEALED)


RKE-RD-06-234-05 R2

HE AND MIDDLE SEGMENT RD06-25-05-02-3-17-13-10-110 R3 MOTOR CASE


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


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



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


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


20/155

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


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


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.


FABRICATION PROCESS AND QUALITY CONTROL PLAN

RLV-SB MOTOR



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


21/155

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.


22/155

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


23/155


24/155

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.


25/155

OPN.NO STAGE

Carry out Heat treatment as per the cycle given below:

Loading Temperature :


26/155

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)


27/155

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


28/155


CLIENT :PART NAME : RLV-SB HE SEGMENT MATL :

OPN.NO STAGE

005# Inspection

issue 2, July 2005.


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




RLV-SB MOTOR CASE


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


29/155

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


30/155

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



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


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


Feeler guage


Vernier caliper


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


3. Length 1775 and ( 825mm)

4. Root face 0.5 to 1mm

Page 3 of 9


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



Voltage, current, filler wire code number, diameter and gas flow purging and shielding

0.1 A

0.2 A


31/155

OPN.NO STAGE

080 Lathe

085# Inspection

1

2

3. Length 2175 and (400mm)


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.


DESCRIPTION

4. Root gap,


3. Thickness of both ends at an interval of 50mm

Feeler guage


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



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


Vernier caliper

Bevel protractor

D.P.Kit

UT Guage / Ball Point Mic


UT guage

Unload the assembly from fixture, remove spider & shaft.

0.1 A

0.2 A


32/155

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.


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


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


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


CS = Cirseam Joint

XX = Set serial no

HS = Head end segment


0.2 A

0.1 A


33/155

OPN.NO STAGE

140 Welding /

Fitting

150 Welding/

Fitting

155# Inspection

4. Mismatch

160 Welding

shell.

170 Lathe

175# Inspection


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


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,


2. Considering the triming allowance, trim and prepare weld edge on first shell keeping a


Complete the welding by GTAW process in 1G position for c/s of HEDR to skirt and

Vernier Caliper


UT Guage

Page 6 of 9


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


34/155

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


6. Total length 3418.66

190* Welding

Inspect for

1

2

3

3. Root gap,

6. Inspect for the total length (3418.66)


2. Install cirseam Purging fixture

Vernier caliper

and inside with emery and acetone.


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.


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


Dial setup

Dial setup



Voltage, current, filler wire code number, diameter and gas flow for purging & sheilding.


unload the job from the machine. Remove spider & shaft

TOOLINGS

Page 7 of 9

DESCRIPTION

Inspect for


0.5 A

0.2 A

0.5 A

0.1 A

0.2 A

P 8 f 9


35/155

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


3. D.P.of weld joint


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


36/155

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


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


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


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


37/155

20.01.2009


CLIENT :


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.


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


SEGMENT MACHINING

15CDV6




RLV-SB MOTOR CASE



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


38/155

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


39/155

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


Micrometer computed

0.4 E

0.1 C

0.1 C

0.2 E

Page 4 of 7


40/155

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


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


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


41/155

Page 5 of 7


42/155

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.


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


Drill 6 holes 69nos to a depth of 15.0mm.

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


43/155

OPN NO STAGE DESCRIPTION TOOLINGS

Page 6 of 7


44/155

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


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.


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



45/155

OPN.NO STAGE

68) 65.0mm


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


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



46/155


CLIENT :


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


RLV-SB MOTOR CASE


20.01.2009APPLICABILITY 02- 05

OPN NO STAGE



47/155

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.


Inspect for the location of weld pads, carry out DP test on fillet welds.


48/155

OPN.NO STAGE

Page 3 of 5



49/155

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.


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


50/155

OPN.NO STAGE DESCRIPTION TOOLINGS

Page 4 of 5


51/155

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

Page 5 of 5


52/155

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)


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




53/155


CLIENT :

PART NAME : RLV-SB MIDDLE SEGMENT MATL :

OPN.NO STAGE

005# Inspection

July 2005.

RLV-SB MOTOR CASE


12.01.2009

VSSC

PART DRG.NO. REV NO. 15CDV 6


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


&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


marking to inspection log book

untill proof pressure test with traceability.


OPN.NO STAGEREFER STAGE-1 WELDING

TOOLINGSDESCRIPTIONPage 2 of 9


54/155

010 Welding

Lathe

020 Fitting/

Welding

025# Inspection

5. Mismatch

030 Welding

040 Lathe


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.



2. Orientation of Long Seam Joint 90apart


Feeler guage

Voltage, current, filler wire code number, diameter and gas flow for purging and


chuck and other end on the tail stock.


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


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.


Vernier Caliper

1.Compute for the total length of the shells app. 1895mm for shell assembly

& accordingly discard


Vernier caliper6. Tack length and spacing


2.Trim one end of the shell by keeping 945mm length for shell 2 and prepare weld edge

UT Guage


OPN.NO STAGE

045# Inspection

Page 3 of 9


Inspect for


55/155

045# Inspection

1

2

3. Length 1895 & ( 945mm)


5. Angle 306. D.P.test

7. Thickness near weld edge at 50mm interval & record


050 Fitting/ 1. Load the shell 3B on the shaft and check for the trueness, clamp, set the shell (shell 3B)

Lathe


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


060 Welding

Voltage, current, filler wire code number, diameter and gas flow purging and shielding.


Vernier caliper

3. Long seam orientation should be staggered by 90for adjacent shells.

UT guage


5. Mismatch


Record the following:


and shell assembly with the root gap of 0.5 to 2mm and mismatch of 0.2mm or as per WPS Feeler Gauge


Feeler guage2. Orientation of shells LS 90apart


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


56/155

075# Inspection

1

2

3. Length 2352 &(457mm)


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.


2. Trim one end of the shell by keeping 457mm length for shell 3B and prepare weld edge


Bevel protractor

UT guageVernier caliper

Dial setup

Vernier caliper

Vernier caliper

Dial setup

D.P.Kit

UT Guage / Ball Point Mic



Inspect for



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




p g pp y

& accordingly discard

Voltage, current, filler wire code number diameter and gas flow for shielding and

4. Root gap


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


57/155

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


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


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


OPN.NO STAGE

135# Inspection Inspect for

DESCRIPTION

Page 6 of 9

TOOLINGS


58/155

1

2

3. Total Length 3302 & (950mm)


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


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


purging.

emery and acetone.




Tack weld the joint at 75 to 100mm intervals


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



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


59/155

1

2

3. Total Length 3421.6+0.5/-0.0 & (950mm)


5. D.P. test on weld edge.6. Thickness near the weld edge at 50mm

180 Welding/

Fitting

185# Inspection


190# Welding

Inspect for

1

2

3

Dial setup


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


3. Clean WEP of Grooved Ring


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.


Feeler guage



Record the followingVoltage, current, filler wire code number , diameter, gas flow for purging & sheilding.

UT guage


Vernier caliper 0.1 A

0.2 A

0.5 A

0.2 A

0.5 A


60/155

OPN.NO STAGE

V i li

TOOLINGS

Page9 of 9

DESCRIPTION

16 Li di t 0 5 t 1


61/155

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


0.5 A

0.5 A

0.1 A

0.2 A

0.2 A




62/155


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


20.01.2009


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


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


4) 987.5+0.09+0.00 checked before groove Machining I/S Micrometer


63/155

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




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


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


11) 47+0.5 Vernier Caliper

Vernier Caliper


64/155


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


12) 40+0.5

31) Perpendicularity on Grooved ring Outer lip

15) Perpendicularity on Tongued Ring outer lip


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


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


TOOLINGS

36) 987.5-0.17/-0.31


65/155

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


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


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


Get clerance from VSSC to unload the job from the machine

Vernier Caliper

38) 21.7+0.5

39) (6.9)


P+ marking of the Jig and job are coincided.


DRILLING OF SEGMENT PIN HOLES GROOVED RING:

Dial Setup

41) 4.1+0.1

42) R0.5 at 4 places Radius Gauge



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


66/155

OPN.NO STAGE

75# Inspection

TOOLINGSDESCRIPTION

Inspect for face butting, with feeler gauge (max. gap 0.05mm) Jig orientation and setup.

Page 5 of 6


67/155

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

RLV SB Process Sheet

Documents

Transcript of RLV SB Process Sheet