RLV SB Process Sheet

RAMAKRISHNA ENGINEERING COMPANY, CHENNAI-106.
PROCESS AND QUALITY CONTROL PLAN

RLV-SB MOTOR CASE APPLICABILITY 02- 05
10.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-01 R1 PART NAME : RLV-SB HEAD END DOME RING SUB ASSY NAME : RLV-SB HEAD END DOME PRE ASSY
OPN.NO STAGE
SHEET NO :
1 OF 5 REV. NO. R2 REV.NO. R3
PART DRG.NO. RKE-RD-06-234-01 REF DRG. NO. RD06-25-05-02-3-17-13-10-110 Sheet 1 & 2

DESCRIPTION
PROJECT : RLV-SB CLIENT : VSSC 15CDV6 MATL : HEAT TREATED FORGING QUANTITY : 1 No per ASSY.
TOOLINGS
Note : The Idn shall be retained during m/cing & transferred to the job after machning. 005# Inspection Verify the RMC No. and the acceptance of the material in co-relation with the TC issued by VSSC. Confirm H/T by verifying hardness reported in TC Allot part Idn.No as RLV-HED-02-05. Supply condition to be reported and act accordingly. REFER SKETCH - 1 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. Turn OD 242.0 to 39.5mm depth. Inspect & record the following 1) 180+0.2/+0.0 REFER SKETCH - 2 Without disturbing setup, clamp the job from I/S & remove O/S clamp Form a groove as per sketch-2. Inspect for the following 1) 25mm 2) 1000+5.0
010
CNC VTL
015
Inspection
I/S Micrometer Vernier Caliper
020
CNC VTL
025
Inspection
Vernier Caliper Compute the depth
3) 89mm
Page 2 of 5 OPN.NO STAGE 030 CNC VTL
DESCRIPTION REFER SKETCH - 3 Reverse the job, Load the fixture and true within 0.1mm Load the job and Clamp on O/S. Check for runout within 0.1mm on 180 face turn to maintain total height 384.35mm. program & execute I/S profile by maintaining 996.00.2mm Turn on OD to a depth of 30mm to maintain a wall thickness of 2+0.2/+0.0 Prepare weld edge angle 30and 0.5 to 1mm root face. Inspect & record the following 1) 9960.2 2) 2+0.2/+0.0 3) 30mm 4) 384.35mm REFER SKETCH - 4 Load the machining fixture on VTL and true within 0.05mm. Reverse the job & clamp 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. Execute the programme as per detail "A" by maintaining 11.5+1.0/-0.50 wall thickness. REFER SKETCH - 5 In the same setup machine "V" groove as per drawing. Inspect and record the following dimensions 1. 9930.2 2. 2+0.2/+0.0 REFER SKETCH - 6 Without disturbing the setup, remove the outside clamp and clamp on OD. Execute the programme for 'Y' ring machining and merge on OD 0.2 A Inspect // 0.2 C unload the job. 0.1 B Inspect & Record 1. 996.00.2 2. 2.0+0.2 thk 3. 232+1.0/-0.5
TOOLINGS UT Gauge
I/S Checking template RKE-RD06-234-T-01
035 #
Inspection
I/S Mic UT Gauge Vernier Caliper
040
CNC VTL
Machining Fixture No Checking template No. RKE-RO06-234-T-17
050
CNC VTL
Checking template No : RKE-RD06-234-T-03
055 #
Inspection
O/S Mic & Compute UT gauge Checking template No RKE-RD06-234-T-02 Dial setup
060
CNC VTL
070 #
Inspection
Vernier Caliper UT Gauge Vernier Caliper
Page 3 of 5 OPN.NO STAGE 4. Perdendicularity 5. Parallelism 6. 25.0 & co-ordinate 7. 384.35 Detail "A" 8. Angle 30 & 0.5 to 1mm
DESCRIPTION
0.1
//
0.2
TOOLINGS Dial setup Dial setup Checking Template RKE-RD06-234-T-01 Height Guage
B
C
B. Protractor/ V. Caliper
Detail "Y" 9. 195+0.0/-0.5 10. 180+0.2/-0.0 0.2 A 11. 12. 50.31.0 13. 11.5+1.0/-0.5 14. 9,R5, 15,48' &17.3mm (400 & 68.8) Detail "X" 15. 9930.2 15. 3.5+0.2/-0.0 thk 16. 30, 0.5 to 1mm 17. (922.92) , (37) , 25.24, 8.9, angle18, angle 56 39' and R2 18. 2.0 +0.2/-0.0 19. R100, R87.24,10.16 and angle11 20. 144.25 21. Ovality on 996 and 180 (8 generators) 22. DP Test all over Engrave Idn. number apply Black Japan & store. # Mandatory stages to be cleared by RQS/VSSC * Dimensions to be checked in fixture condition.
O/S Micrometer Inside Micrometer Dial setup Vernier Caliper Vernier Caliper Checking Template RKE-RD06-234-T-04 Ball Point Mic Micrometer V/Caliper / B.Protractor Checking Template RKE-RD06-234-T-03 Ball Point Mic Checking Template RKE-RD06-234-T-02 Height Gauge I/S Mic DP Kit
RAMAKRISHNA ENGINEERING COMPANY, CHENNAI-106. PROCESS AND QUALITY CONTROL PLAN

10.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-02 R1 PART NAME : RLV-SB HEAD END SKIRT RING SUB ASSY NAME : RLV-SB HEAD END SEGMENT
OPN.NO STAGE
SHEET NO :
1 OF 4 REV NO. R2
PART DRG.NO. RKE-RD-06-234-02
PROJECT : RLV-SB CLIENT : VSSC 15CDV6 MATL : RING (ANNEALED) QUANTITY : 2 Nos. per ASSY.
TOOLINGS
REF DRG. NO. REV.NO RD06-25-05-02-3-17-13-10-110 R3

DESCRIPTION
005#
Inspection
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 TC issued by VSSC. Allot part Iden.No as RLV-HES-02, 03 etc., Supply condition of the forgings to be ensured and act accordingly
010 015 020#
REFER SKETCH - 01 VTL / Lathe Pre machining the forging as per sketch 1 Inspection Heat Treatment Inspect the dimensions as per sketch 1 Note 1: Ensure that chart recorder is working Note 2: A copy of the chart to be attached with Inspection Report. Get clearance from VSSC for Heat treatment. Heat treat the forging as per Doc.No : MEE/QCI/QCP/007/2002, Issue 2, July 2005 I/S, O/S Mic, Vernier
030 #
Hardness Grind /machine to depth of 3mm Testing M/C Check hardness at 3 locations on both faces. Hardness value 34 to 40 HRC. REFER SKETCH - 02 Load the job on VTL, True and clamp. Face to maintain a height of 112.0mm, unload and reverse the job. REFER SKETCH-03 True & Clamp the job from inside. Turn OD 1002x67mm depth.
Portable Grinder Hardness tester
040
VTL / CNC VTL CNC VTL
050#
Page 2 of 4 OPN.NO STAGE 060# CNC VTL
DESCRIPTION REFER SKETCH-04 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 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 3.5+0.2/-0.0. wall thickness R20 and 40 angle. Prepare weld edge 0.5 to 1mm lip distance and 30 angle. Inspect for 993.0, 953 and 1040 in the fixture condition. Inspect Concentricity before unloading the job. Inspect & record the following dimensions 1) 993+0.2/-0.0 2) 108.0+0.0-0.2 3) 1040 4) 953 A 0.2 5) 6) 20.1 (Inside ) 7) 20.1 (Outside) 8) 40 (Outside) 9) R20 (Outside) 10) 40 (Inside) 11) R20 (Inside) 12) 3.5+0.2-0 13) D.P Check all over 14) Ovality on 993 ( at 8 Generators) 15) 30, 0.5-1mm land 16)
0.2
A
TOOLINGS
070#
CNC VTL
Inside Micrometer Dial setup
075#
Inspection
Line Inspected Vernier Caliper Compute from ID Inside Mic Dial setup Vernier Caliper Vernier Caliper Template No RKE-RD06-234-T-005 Template No RKE-RD06-234-T-005 Ball point mic D.P. Kit Vernier Caliper Vernier Caliper/ B. Protractor
Mark/Paint Iden.no as RLV-HES-02,05, Apply Black Japan all over and preserve # Mandatory stages to be cleared by RQS/VSSC

10.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-03 R1 PART NAME : RLV-SB HEAD END DOME PRE ASSY SUB ASSY NAME : RLV-SB HEAD END SEG. WELDING
OPN.NO STAGE
SHEET NO :
1 OF 1
PART DRG.NO. REV NO. RKE-RD-06-234-03 R2 REF DRG. NO. REV.NO RD06-25-05-02-3-17-13-10-110 R3
DESCRIPTION
PROJECT : RLV-SB CLIENT : VSSC 15CDV6 MATL : QUANTITY : 1 NO PER MOTOR CASE
TOOLINGS
Note 1: Identification No. shall be retained at all stages of fabrication and the 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 fabrication Note 4: Mark RT zones by paint and retain the marking by paint and transfer the RT marking to inspection log book. Note 5: The Film density shall be kept as 1.8 to 2.5mm for X-ray radiography 005 # Inspection Verify the acceptance of the following components and record the idn nos. 1. Head End Dome Ring 2. Head End Skirt Ring Allot part identification number as RLV-HPA-02-05..Etc., Welding 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 Welding Fixture
010
015 #
Inspection Inspect for : Root Gap Mismatch Tack length & Tack Spacing 1. 252.25+1.0/-0.5 2. Concentricity
Mismatch checking templates Feeler Gauge Vernier Caliper Vernier Caliper
0.2
Dial Gauge setup
Engrave paint part Iden No. as RLV-HPA-02-05..Etc., on the component. Identify the weld joint as RLV-HS-CS-XX- 01 XX= Set Serial Number CS= Cirseam Weld
# Mandatory stages/dimensions to be cleared by RQS/VSSC

12.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-04 R1 PART NAME : RLV-SB TONGUED RING SUB ASSY NAME : RLV-SB NOZZLE END AND MIDDLE SEGMENT
OPN.NO STAGE
SHEET NO :
1 OF 5
DESCRIPTION
PROJECT : RLV-SB CLIENT : VSSC 15CDV6 MATL : FORGING (ANNEALED) QUANTITY : 2 NoS. per ASSEMBLY
TOOLINGS
005#
Inspection
Note : The Idn. No 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 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. Pre m/c the forging as per sketch-1 Inspect the dimensions as per sketch-1 Get clearance from RQS for Heat treatment. Heat treat the forging as per Doc.No : MEE/QCI/QCP/007/2002, Issue 2, July 2005 Note 1: Ensure that chart recorder is working Note 2: A copy of the chart to be attached with Inspection Report.
Vernier Caliper Tape
010 015 020#
CNC VTL Inspection Heat Treatment
I/S, Mic, Vernier Caliper
030 #
Hardness Grind/Machine to a depth of 3mm and check hardness at 3 locations Testing M/C both sides Hardness 34 to 40 HRC. CNC VTL REFER SKETCH - 2 True 1030 and clamp from outside. Face to maintain height 150mm Turn ID 961.5 through Step Bore 982 to a depth of 45mm Step Turn OD 1010 to a depth of 401mm
Portable Grinder Hardness tester I/S, O/S Mic Vernier Caliper
040#
Page 2 of 5 OPN.NO STAGE Inspect for 1) 1010 2) 982 3) 961.5 050# CNC VTL
DESCRIPTION
TOOLINGS (by computing thk) I/S Mic I/S Mic I/S, O/S Mic
REFER SKETCH -3 Reverse the job & true ID 961.5 and clamp. Face to maintain 145mm height. Execute the programme for Inside turning by keeping 996.60.2mm. Execute the program for outside by maintaining 2mm0.2/0.0 wall thickness. Prepare weld edge 30 and root face of 0.5-1mm. Inspect 996.00.2 and concentricity before unloading the job from VTL 1) 9960.2 2) Concentricity
I/S Mic Dial Setup
0.2
055 #
Inspection Inspect the following dimensions (A) 1) 1000.0 2) 996.0 0.2 3) 30x0.5 to 1mm 4) 20.0, 2 52', +0.5/-0.0 5) 10.0,5, R20 and 44.09 6) 1010 7) 982.0 8) 961.5 9) 45.0 10) 72.9 11) 145.0 1.0 12) 25
Vernier Caliper I/S Mic V. Caliper/ B.Protractor Template RKE-RD06-234-T-09 Template RKE-RD06-234-T-08 Tape Computed from OD I/S Mic Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper
Page 3 of 5 OPN.NO STAGE 13) Concentricity
DESCRIPTION
TOOLINGS Dial Gauge I/S Mic D.P.Kit
0.2
14) Ovality on 961.5 (minimum 8 reading) 15) D.P test all over. Mark/Paint idn.no as RLV-TR-03,04,05 etc., Apply Black Japan all over and preserve
# Mandatory stages to be cleared by RQS/VSSC
EERING COMPANY, CHENNAI-106. QUALITY CONTROL PLAN
-SB MOTOR CASE LICABILITY 02- 05

PROJECT : RLV-SB VSSC 15CDV6 FORGING (ANNEALED) QUANTITY : 2 NoS. per ASSEMBLY
TOOLINGS
I/S, Mic, Vernier Caliper
Portable Grinder Hardness tester I/S, O/S Mic Vernier Caliper
TOOLINGS (by computing thk) I/S Mic I/S Mic I/S, O/S Mic
I/S Mic Dial Setup
Vernier Caliper I/S Mic V. Caliper/ B.Protractor Template RKE-RD06-234-T-09 Template RKE-RD06-234-T-08 Tape Computed from OD I/S Mic Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper
TOOLINGS Dial Gauge I/S Mic D.P.Kit

12.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-05 R1 PART NAME : RLV-SB GROOVED RING SUB ASSY NAME : RLV-SB HE AND MIDDLE SEGMENT
OPN.NO STAGE
SHEET NO :
1 OF 4
DESCRIPTION
PROJECT : RLV-SB CLIENT : VSSC 15CDV6 MATL : FORGING (ANNEALED) QUANTITY : 2 Nos. per MOTOR CASE
TOOLINGS
005#
Inspection
Note: The Idn No shall be retained during m/cing & transferred to the job after m/ching Verify the RMC No. and the acceptance of the material in correlation with the TC issued by VSSC. Allot part Iden.No as RLV-GR-03, 04, 05 etc., Supply condition to be reported and act accordingly REFER SKETCH - 1 Pre m/c the forging as per sketch-1 Inspect the dimensions as per sketch-1 Get clearance from RQS for Heat treatment. Heat treat the forging as per Doc.No : MEE/QCI/QCP/007/2002, Issue 2, July 2005
010 015
VTL/Lathe Inspection
I/S, Mic I/S, Mic, Vernier
020# 030 #
Heat Treatment
Note 1: Ensure that chart recorder is working Note 2: A copy of the chart to be attached with Inspection Report. Portable Grinder Hardness tester I/S, O/S Mic Vernier Caliper I/S Mic Vernier Caliper Vernier Caliper
Hardness Grind/machine to a depth of 3mm and check hardness at 3 locations on Testing M/C both faces. Hardness 34 to 40 HRC. VTL / CNC VTL REFER SKETCH - 2 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 Inspect & record the following dimensions 1) 969.5 2) 1018.5 3) 993.5
040
Page 2 of 4 OPN.NO STAGE 050# VTL / CNC VTL
DESCRIPTION REFER SKETCH - 3 Reverse the job True 969.5 & calmp on O/S. Face turn to maintain 142.5mm height. Execute the programme from Inside profile machining by keeping ID 996+0.2/-0.0 & Execute the programme for outside profile maching by keeping 2 +0.2/0.0. Prepare weld edge as per detail A. Inspect & record the following dimensions. 1) 9960.2 2) 2.0 +0.2-0.0. 3) Concentricity
0.2 A
TOOLINGS I/S, O/S Mic Vernier Caliper Ball point mic
I/S Mic UT Gauge Dial setup
055 #
Inspection
Inspect for 1) 19.7 2) 40.5mm 3) 142.5mm 4) 1018.51.0 5) 993.50.8 6) 969.50.8 7) 63.62 8) 9960.2 9) 2+0.2/-0.0 10) 20,41.3 and 3 11) WEP 30, 0.5 to 1mm root face. 12)10mm, 50.4,3, 0.2 13) Concentricity 14) Ovality 0n 969.5 (at 8 Generators) 15) carry out D.P.test Mark/Paint Idn.no as RLV-GR-03,04, etc., Apply Black Japan all over and preserve
Vernier Caliper I/S Mic Vernier Caliper Vernier Caliper I/S Mic O/S Mic Vernier Caliper I/S Mic UT Gauge Template RKF-RD06-234-T-07 Bevel Protractor Template RKE-RD06-234-T-06 Dial Setup I/S Mic D.P.Kit
RAMAKRISHNA ENGINEERING COMPANY, CHENNAI-106. FABRICATION PROCESS AND QUALITY CONTROL PLAN
RLV-SB MOTOR APPLICABILITY 02- 05
12.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-06 R1 PART NAME : RLV-SB CYLINDERICAL SHELL SUB ASSY NAME : RLV-SB HE,NE & MS WELD ASSY
OPN.NO STAGE
SHEET NO :
1 OF 10
DESCRIPTION
PROJECT : RLV-SB CLIENT : VSSC 15CDV6 MATL : 2.2 mm thick sheet Annealed QUANTITY : 10 No per MOTOR CASE
TOOLINGS
Note 1: Idn.No shall be retained during all stages of fabrication like welding, Heat treatment and machining. Note 2: Welding and Heat treatment inspection as per Doc No.MEE/QCI/QCP/007/ 2002-ISSUE 2, JULY 2005 Note 3: Mismatch shall be calculated by taking thickness into account and reported at every 50mm interval. Mismatch tabulation shall contain thickness on either side of the weld, offset and centerline mismatch. 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. Note 6: Check hardness on the trimmed portion of the shell Note 7: The Film density shall be kept as 1.8 to 2.5mm for the X-ray radiograph. 005 # Inspection Verify the RMC No. & acceptance of the sheets in correlation with the TC issued by VSSC and record. 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 Check the thickness at random. Fitting Mark for the test pieces as per layout sketch-1(2nos. of sheets per shell). 1) 150 x300 - 6nos. 2) 250 x 300 - 1no. transfer the RMC numbers on the test pieces and left over portion by punching. Shear the test pieces as per marking and identify. Preserve the test pieces.
UT guage
010
020
Shearing
Page 2 of 9
OPN.NO STAGE DESCRIPTION TOOLINGS
030
Fitting / HBM
Load the sheet on table and clamp at four locations using suitable clamp Mill one end of the sheet by discarding 25mm (minimum) Prepare weld edge by maintaining 30 angle and 0.5 to 1mm root face. Prepare weld edge for 2 Nos of test pieces from each sheet and preserve the balance test piece. Bevel Protractor Vernier Caliper/ DP Kit Welding fixture
035# 040
Inspection Inspect for angle 30& land 0.5 to 1mm identify the sheet and test pieces. Conduct DP test on the weld edges of sheets and test pieces 2 Nos each per sheet. Fitting / Welding Position the sheets set and clamp Clean the weld edges with emery and acetone. Tack weld the sheets at 100mm intervel and test pieces in the LS welding fixture.
045#
Inspection Ensure welders qualification and adaptation. Inspect and record - Name of welder - Root gap - Mismatch (compute by taking thickness into account at an interval of 50mm) - Filler wire code No and Dia. Identify the weld joint as RLV-CS-XX-LS1 where XX = Set serial No Note: Identify LS1 & LF1 test coupon. Welding Ensure welders qualification and adaptation. Clean the weld edges for a band of 50mm with emery and acetone. Carry out welding as per WPS. Start the welding on LS1 test coupon and finish LF1 coupon through the sheet. Record current voltage, flow of argon gas for purging and shielding - filler wire size and RMC NO.
Feeler Gauge Template UT Gauge
050
055 #
Inspection Inspect visual, weld bead dimensions & mismatch (Compute with thickness at 50mm interval) Identify LS1 and LF1 test coupons by punching and preserve. Identify the job as RLV-CS-11,12,13 etc and test coupons as RLV-CS-XX LS1/LF1 where XX=Set serial no. Note 1: If the mismatch observed is more than specified, detailed mapping of mismatch at that location shall be provided. Note 2: Mismatch tabulation shall contain thickness on either side of the weld, offset and centreline mismatch. Fitting 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.
Vernier Caliper Mismatch Checking template Feeler Gauge
060
Page 3 of 9
065#
Inspection Carry out 100% Xray radiography Conduct DP test Inspect visual for the penetration grinding. Inspect & record the thickness near the welds at 50 mm interval. Incase if parent metal is touched, local thickness to be checked and reported. Welding/ Carry out repair, if any as per approved procedure and inspect. Do not repair LS1 & LF1 Coupons. Flatten the sheet with out beating the weld (surroundings area of weld within 50mm) Check the thickness at grids of 100mmx100mm interval and compute for average thickness(t) Mark the developed length as (d+t) and record the length. d = ID of shell t = Average thickness Example for development length calculation. Average t = 2.2 and ID 996.0 (996+2.2) = 3137 mm Load the sheet on table and clamp at four sections using suitable plate Mill one end by keeping the long seam joint L-1 at middle of the developed length. Reverse and mill the other end of the sheet by keeping the developed length . Prepare weld edge 30 angle and 0.5 to 1mm root face. Prepare weld edge on 4 nos. of test pieces also (2 nos. each from one sheet)
Film density 1.8-2.5 DP Kit Magnifying glass 3X
070
Vernier Caliper DP Kit
080
Fitting
Vernier Caliper UT Gauge
090
HBM Fitting
095
Inspection Inspect for 1. Devloped length at 6 generators. 2. D.P.test on weld edges. 3. Visual inspection 4. WEP 30, 0.5-1mm land. 5. Inspect the test pieces also for the above. Rolling Machine Mark the generation lines parallel to the edge. 1) Machine rollers shall be thoroughly cleaned prior to bending. 2) Feed the sheet with generating lines on the top. 3) Carryout pre-bending of edges.
Bevel Protractor Vernier Caliper D.P.Kit
100
Page 4 of 9 OPN.NO STAGE
DESCRIPTION 4) Feed the sheet and start rolling 5) Complete the rolling of the sheet to form shell and match the free edges as per the template. 6) Ensure that LS1 welding is not passing through the roller. 7) Complete the rolling to ID 996 to match the checking template. 8) Remove the rolled shell from the machine.
TOOLINGS Checking template
105 110
Inspection Inspect for the thickness near the weld edge at 50mm interval on both sides and record. Welding Clean the weld edges with emery and acetone to a length of 50mm and also clean the LS2& LF2 test pieces. Position the cylinder and test pieces in the long seam welding fixture and tack weld cylinder at an interval of 75mm and mismatch within 0.1mm tack weld LS2 & LF2 coupon also.
L/S welding fixture
115 #
Inspection Ensure welders qualification and adaptation. Inspect and record - Name of welder - Root gap - Mismatch (compute by taking thickness into account) - Filler wire code No and Dia. Identify the weld joint as RLV-CS-XX-LS2 where XX = Set serial No Note: Identify LS2 & LF2 coupon. Welding Clean the weld edges with acetone and emery for a band of 50mm. Carryout the welding as per WPS. Start the welding on the LS2 Test coupon and finish the welding on the LF2 test coupon through the cylinder. Record current, voltage flow of argon gas for purging /sheilding filler wire RMC No. and diameter.
Feeler Gauge Template
120
Longitudinal Welding fixture
125 #
Inspection Inspect visual and weld bead dimensions, mismatch and identify LS2 & LF2 test coupons by punching. Note 1: If the mismatch observed is more than specified, detailed mapping of mismatch at that location shall be provided. Note 2: Mismatch tabulation shall contain thickness on either side of the weld, offset and centreline mismatch.
Vernier Caliper Feeler Gauge
Page 5 of 9 OPN.NO STAGE 130 Fitting
DESCRIPTION Fix adhesive tape on both sides of the welding before flush grinding. Flush grind the penetration (max 0.1mm projection) without touching the parent metal. Remove ovality (5mm max) by malleting with soft hammer. Note 1: While removing ovality use only soft hammer (MS with aluminium tips on both ends) Note 2: Weld should not be beaten. Note 3: Identify the shell as RLV-CS-11, 12,13 etc., and weld joint No as RLV-CS-XX-LS2 (xx = set serial no) Note 4: Incase if parent metal is touched while penertration grinding, local thickness to be checked and reported.
TOOLINGS 1. Ovality removing set up 2. Inside checking template
135 #
Inspection Carryout DP test and 100% X-ray radiography Visually inspect for penetration grinding. Ensure parent metal is not touched. Welding Carryout repair if any as per approved process and inspect
Dp Kit X-ray machine 3X Magnifying glass
140 145 #
Inspection Inspect for 1. Ovality 5.0mm (max) 2. Penetration Grinding (0.1 Max projection) 3. ID 996 0.2 4. Visual Inspection Get clearance from VSSC for Heat treatment. Note 1: Before loading confirm the RMC nos. of the shell and confirm the RMC number of test Heat Treatment coupons. 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
Vernier Caliper Micrometer Feeler Gauge I/S Mic
150#
DESCRIPTION Load the shell (with metal tag/punch marked on the end) along with LS1 , LF1 LS2 & LF2 coupon (at the corresponding postion) and parent metal test pieces top & bottom in the heat treatment fixture. Carry out Heat treatment as per the cycle given below: Hardening: Loading Temperature : <600C Soaking Temperature : 97510C Soaking Time : 20 minutes Quench medium : Forced Air Quench Delay (max.) : 30 Seconds Tempering: Loading Temperature Soaking Temperature Soaking Time Quench medium Quench Delay (max.)
TOOLINGS
: : : : :
<500C 64010C 30 minutes Forced Air 30 Seconds
155#
Inspection Cut one piece from the discard portion of the shell and conform the hardness of the shell. Check hardness on test pieces (34 to 40 HRC) and record. Note: Chart recorded for the hardening and tempering cycle to be retained and submitted along with inspection report. Sand Blasting Fitting Milling Sand blast all over the cylinder and test pieces. Ensure Idn.Nos retained in the shell as well as test pieces. Prepare 3 Nos.each of test specimen each form LS1, LF1, LS2, LF2 and parent metal test Coupons represents top and bottom and record in QC log book. Preserve the balance of test coupons and parent metal pieces for retest if any.
160
170
Page 7 of 9 OPN.NO STAGE 175# UTM
DESCRIPTION Inspect the test specimen and record the dimensions in the log book. Carry out mechanical testing as per ASTM-A370. Gauge length as 5.65 A, where A is the Cross section area. Get clearnace from VSSC for further processing of the shell. Remove ovality (Use M.S.hammer with aluminium tips on both ends and no beating should be done in and around weldments.) Ovality should be within 5 mm
TOOLINGS Vernier Caliper
180
Fititng
185 #
Inspection Carryout 100% X-Ray radiography & D.P on both long seam weld joints Inspect for the thickness near the weld and the shell. Welding Lathe Repair defects if any and inspect as per approved procedure. Load the shell on turning setup with spider and shaft between centers. True the job within 0.2mm. Face on one side and prepare weld edge maintaining 30 angle 0.5 to 1mm root face Note : Discard minimum 25mm from the edge of the shell. (WEP on one side only)
DP Kit / X-ray m/c.
190 200
205 #
Inspection Inspect/Record for 1. 0.5 to 1mm for sheet A 2. Angle 30 3. 0.5 to 1mm for sheet B 4. Angle 30 5. DP of WEP Sheet A 6. DP of WEP Sheet B 7. 0.5 to 1mm one end. 8. Angle 30 9. 0.5 to 1mm other end 10. Angle 30 11. DP test on weld edge. 12. Length 975mm (approx.) 13. ID 9960.2 Vernier caliper Bevel protractor Vernier caliper Bevel protractor DP Kit DP Kit Vernier caliper Bevel protractor Vernier caliper Bevel protractor DP Kit Vernier caliper Inside mic
Page 8 of 9 OPN.NO STAGE 14. 0.1 15. 0.5 to 1mm 16. Angle 30 17. DP test on weld edge 18. Thickness 2.0+0.2+0.0 19. T1,T2,T3,T4 Thickness near weld 20. 180 weld orientation
DESCRIPTION
C
TOOLINGS Dial setup Vernier caliper Bevel protractor DP Kit UT guage
Do not remove the spiders before cirseam weld setup. Report the Dia of shells and thickness of the edges to planning Apply Black Japan and preserve Note : 1. # Mandatory stages to be cleared by RQS/VSSC 2. Ensure that all inspection reports are prepared before clearing the job for further operation

10.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-07 R1 PART NAME : RLV-SB HE SEGMENT WELDING SUB ASSY NAME : RLV-SB HE SEGMENT MACHINING
OPN.NO STAGE
SHEET NO : 1 OF 9 PART DRG.NO. RKE-RD-06-234-07 Sheet 1,2 &3 REF DRG. NO. RD06-25-05-02-3-17-13-10-110
DESCRIPTION
REV NO. R4 REV.NO R3
PROJECT : RLV-SB CLIENT : VSSC 15CDV 6 MATL : QUANTITY : 1 NO PER MOTOR CASE
TOOLINGS
005#
Inspection
Verify the acceptance of Cylindrical Shell Qty-4 Nos. Grooved Ring - 1 No. & Head End Dome pre assembly - 1No Allot Assembly identification as RLV-HES-02,03,04&05
Note 1: Idn.No shall be retained during all stages of fabrication and weld joint to be identified as shown in drawing.
Note 2: Welding inspection as per Doc No MEE/QCI/QCP/007/2002issue 2, July 2005. Note 3: Mismatch shall be calculated by taking thickness into account and checked by template and feeler guage at an interval of 50mm. If the mismatch observed is more than the specified, detailed mapping of mismatch at that location shall be provided. 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 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 untill proof pressure test with traceability. Note 8: The Film density shall be kept as 1.8 to 2.5mm for X-Ray Radiography. Template and Feeler guage
Page 2 of 9 OPN.NO STAGE 010 Welding Lathe
DESCRIPTION REFER STAGE-1 WELDING 1. Load shell 1and shell 2 on shaft using 4 Nos of spiders and true within 0.3mm TIR 2. Spider should be positioned 60 mm inside from the shell end. 3. Shells should be positioned in such a way that prepared weld edges (at cylindrical shell level) facing each other and the each long seam weld is staggered by 90 4. Load the shaft and spider assembly in the welding station and hold one end on the chuck and other end on the tail stock. 5. Inspect for the run out of the shell at both ends. 6. Carryout DP test on WEP of both the shells and record. 1. Clean 50mm width band from inside and outside for both the shells with emery and acetone. 2. Clean the purging fixture also by blowing compressed air and finally by acetone. 3. Set the purging fixture and set the shells by keeping 0.5 to 2mm root gap and 0.3mm mismatch or as per WPS 4. Clean with acetone, ensure purging gas flow. 5. Tack weld the joint at 75 to 100mm interval 1. Welder's qualification and adaptation 2. Orientation of Long Seam Joint 90 apart 3. Thickness of both ends at an interval of 50mm for computing mismatch 4. Root gap, 5. Mismatch 6. Tack length and spacing 7. Get clearance from VSSC for welding
TOOLINGS
Spider and shaft
D.P.Kit
020
Fitting/ Welding
025#
Inspection
UT Guage Mismatch checking template Feeler guage Vernier caliper
030
Welding
Complete the welding by GTAW process in 1G position. Record the following Voltage, current, filler wire code number, diameter and gas flow for purging and shielding, inspect for the total length and record. 1. Compute for the length appx. 1775mm for shell assembly. 2. Trim one end of the shell by keeping 825mm length for shell 2 and prepare weld edge 30 angle and 0.5 to 1 mm root face. 3. Preserve the discarded portion.
Vernier Caliper
040
Lathe
Page 3 of 9 OPN.NO STAGE 045# Inspection
DESCRIPTION Inspect for

1
0.2
TOOLINGS Dial setup Dial setup Vernier caliper Vernier caliper Bevel protractor D.P.Kit UT Gauge/Ball Point Mic Vernier Caliper
2 0.1 A 3. Length 1775 and ( 825mm) 4. Root face 0.5 to 1mm 5. Angle 30 6. D.P.test 7. Thickness near weld edge at 50mm interval & record 050 Lathe Set the third shell by using four spiders, two numbers at both ends leaving 60mm and 3rd and 4th spiders at a distance of 375mm from the WEP edge. True the shell within 0.3mm TIR. Part off at a distance of 430mm from the prepared weld edge. Identify 430mm length shell as A & other shell as B.
REFER STAGE - 2 WELDING
060
Fitting/ Lathe
1. Load the shell 3A on the shaft and check for the trueness, clamp, set the shell (shell 3A) and shell assembly with the root gap of 0.5 to 2mm and mismatch of 0.3mm or as per WPS 2. The shells should be facing the WEP side of each other. 3. Long seam orientation should be staggered by 90 for adjacent shells. 4. Clean both the side of the shells with emery and acetone for a band of 50mm. 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. 1. Welder's qualification and adaptation 2. Orientation of shells LS 90 apart 3. Thickness of both ends at an interval of 50mm 4. Root gap 5. Mismatch 6. Tack length and spacing 7. Get clearance from VSSC for welding Complete the welding by GTAW process in 1G position. Record the following Voltage, current, filler wire code number, diameter and gas flow purging and shielding
Mismatch checking template Feeler Gauge
065#
Inspection
Mismatch checking template Feeler guage UT guage Vernier caliper
070
Welding
Page 4 of 9 OPN.NO STAGE 080 Lathe
DESCRIPTION 1. Compute for the total length of shell approx. 2175mm 2. Trim the third shell by keeping a length of 400mm and prepare weld edges 0.5 to 1mm root face and 30 angle. 3. Preserve the discarded portions. Inspect for
1
0.2
TOOLINGS
085#
Inspection
2 0.1 A 3. Length 2175 and (400mm) 4. Root face 0.5 to 1mm 5. Angle 30 6. D.P. test 7. Thickness near weld edge at 50mm interval and record. REFER STAGE - 3 WELDING Load the shell(4) on spiders by keeping the prepared weld edge facing each other as shown in Stage 3 Welding. True the shell on spider within 0.3mm. 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 staggered by 90 apart. Adjust the spiders to control mismatch with 0.3mm and a root gap of 0.5 to 2 mm or as per WPS Tack weld at an intervel of 75 to100 mm 1. Welder's qualification and adaptation 2. Orientation of shells LS 90 apart 3. Thickness of both ends at an interval of 50mm 4. Root gap, 5. Mismatch. 6. Tack length and spacing 7. Get clearance from VSSC for welding 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. Unload the assembly from fixture, remove spider & shaft.
Dial setup Dial setup Vernier caliper Vernier caliper Bevel protractor D.P.Kit UT Guage / Ball Point Mic
090
Lathe
095#
Inspection
100
Welding
DESCRIPTION Inspect visual, weld bead and penetration dimensions. Identify the weld joint as RLV-HS-CS-XX-02 (shell 1 & 2) RLV-HS-CS-XX-03 (shell 2 & 3) RLV-HS-CS-XX-04 (shell 3 & 4) CS = Cirseam Joint XX = Set serial no HS = Head end segment Flush grind the penetration without touching parent metal (0.1mm projection max permitted) Note: Fix adhesive tape on both sides before grinding Inspect for 1. Mismatch 2. Visual for penetration grinding Note: Ensure that parent metal is not touched. Incase if parent metal is touched, record the thickness where parent metal is touched and map the thickness. 3. DP test 4. 100% RT Carryout repairs if any by gouging the defective area , weld & Inspect as per approved procedure. 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 on tail stock. 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 30 angle and 0.5 to 1mm root face. 5. Preserve the discarded portion. Inspect for 0.2 1. A 2. 0.1 A 3. Total length 3075 & (900 mm) 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.
TOOLINGS Vernier Caliper Mismatch Checking Template
110
Fitting
115#
Inspection
Template and feeler gauge UT gauge D.P.Kit
120#
Welding/ Inspection Fitting
130
purging fixture
135#
Inspection
Dial setup Dial setup Vernier caliper
Page 6 of 9 OPN.NO STAGE 140 Welding / Fitting
DESCRIPTION REFER STAGE- 4 WELDING 1. Load the HE Dome Pre Assembly and true within 0.2mm TIR 2. Insert cirseam Purging fixture on cleaned end of the shell. 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 and acetone. 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 1. Welder's qualification and adaptation 2. Thickness of both ends at an interval of 50mm for computing mismatch 3. Root gap, 4. Mismatch 5. Tack length and spacing 6. Get clearance from VSSC for welding Complete the welding by GTAW process in 1G position for c/s of HEDR to skirt and shell. Record the following Voltage, current, filler wire code number, diameter and gas flow for sheilding and purging for both Joints. 1. Compute for the length 3276.16+0.5/-0.0. 2. Considering the triming allowance, trim and prepare weld edge on first shell keeping a length of (900mm) 3. Preserve the discarded portion. Get clearance from inspection department for the computed length considering groove ring height and get clearance from VSSC.
TOOLINGS
150 155#
Welding/ Fitting Inspection
Mismatch checking template UT Guage Vernier Caliper Feeler guage
160
Welding
170
Lathe
175#
Inspection
Page 7 of 9 OPN.NO STAGE Inspect for

1
0.2
DESCRIPTION
A
TOOLINGS Dial setup Dial setup Vernier caliper Vernier caliper D.P.Kit UT Gauge / Ball Point Mic
2 0.1 A 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/ Fitting REFER STAGE - 5 WELDING Load the grooved ring in the shaft and spider assembly 1.Clean 50mm band of shell circumference outside and inside with emery and acetone. 2. Install cirseam Purging fixture 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 5. Tack weld the joint at 75 to 100mm interval 6. Inspect for the total length (3418.66) 1. Welder's qualification and adaptation 2. Thickness of both ends at an interval of 50mm 3. Root gap, 4. Mismatch. 5. Tack length and spacing 6. Total length 3418.66 7. Get clearance from VSSC for welding Complete the welding by GTAW process in 1G position. Record the following Voltage, current, filler wire code number, diameter and gas flow for purging & sheilding. Inspect for
1
0.2
Purging Fixture
185*
Inspection
Mismatch checking template UT guage Feeler guage Vernier caliper
190*
Welding
A A A
2 3 4. Total Length 3418.66
0.5 0.5
Dial setup Dial setup Dial setup Vernier caliper
unload the job from the machine. Remove spider & shaft
DESCRIPTION Inspect visual, weld bead and penetration of all joints 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 Joint XX = Set serial no HS = Head end segment Flush grind penetration without touching the parent metal (0.1mm projection max. permitted) Note 1: Fix Adhesive tape on both sides of the welding before grinding. Note 2: Grinding need not be done for C/S joint between skirt and HEDR
TOOLINGS
200
Fitting
205#
Inspection
Inspect.. 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. 2. Mismatch 3. D.P.of weld joint 4. 100% RT
3X magnifying glass
D.P.Kit X-Ray machine Inside mic
300#
Welding/ Inspection Inspection
Carryout repairs if any by gouging the defective area , weld & Inspect as per approved procedure. Record the inspected dimension and prepare inspection report 0.2 1 of shell2 A 2 0.1 A 3. Length (950), (825), (1775) 4. Lip distance 0.5 to 1mm 5. Angle 30 6. D.P Test of weld edge of shell 2 0.2 7 of shell 3 A 8 0.1 A 9. Length (400), 2175
305*
Dial setup Dial setup Vernier caliper Vernier caliper Bevel Protractor D.P.Kit Dial setup Dial setup Vernier caliper
Page 9 of 9 OPN.NO STAGE 10. Lip distance 0.5 to 1mm 11. Angle 30 12. D.P test of shell 3 0.2 13 14 0.1 15. (length (900), 3075) 16. Lip distance 0.5 to 1mm 17. Angle 30 18. D.P test of weld edge of shell 4 0.2 19 20 0.1 21. Length 3276.16+0.5/0.0 22. Lip distance 0.5 to 1mm of shell 1 23. Angle 30 24. D.P test of shell 1
25
0.2
DESCRIPTION
A A
of shell 4
A A
of shell 1 of shell 1
26 0.5 A 27 0.5 A 28. LS weld staggered by 90 29. 3418.66 30. Ovality grooved ring at 16 generators 31. Ovality HEDR at 16 generators Get clearance from VSSC for further processing. # Mandatory stages to be cleared by VSSC
TOOLINGS Vernier caliper Bevel Protractor D.P.Kit Dial setup Dial setup Vernier caliper Vernier caliper Bevel Protractor D.P.Kit Dial setup Dial setup Vernier caliper Vernier caliper Bevel Protractor D.P.Kit Dial setup Dial setup Dial setup Vernier caliper Inside mic Inside mic

20.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-08 R1 PART NAME : RLV-SB HEAD END SEGMENT MACHINING SUB ASSY NAME : RLV-SB MOTOR CASE ASSY
OPN.NO STAGE
SHEET NO :
1 OF 7 REV NO. R5 REV.NO R3
PART DRG.NO. RKE-RD-06-234-08 Sheet 1 & 2 REF DRG. NO. RD06-25-05-02-3-17-13-10-110 Sheet 1 &2
DESCRIPTION
PROJECT : RLV-SB CLIENT : VSSC 15CDV6 MATL : QUANTITY : 1 NO PER ASSY.

TOOLINGS
005#
Inspection Confirm the acceptance of Head End Segment weld assy. Verify that the Idn.No RLV-HES-02,03 etc., is painted on the shell portion Lathe Load the job on spiders and shaft. Tighten the spiders. Set HE,Skirt and Groove Ring to a minimum runout condition True the shells within 0.3mm and record Check for the runout of skirt ring 1040 and OD of the grooved ring. Check for the face out of grooved ring and skirt ring 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 Compute for the machining allowance and record Record the setting reading in log book MACHINING OF IGNITOR BOSS (Refer Drawing Detail H): Bore ID 188+0.046 & ensure thickness 3.5min. form Radius 2.5 Turn OD 226 and face to maintain thickness 7 (min) Note: Ensure minimum thickness is achieved at one cross section MACHINING OF HE SKIRT RING (Refer Drawing Detail E): Bore ID 959.5 through Face to maintain 20mm length (Refer the computed value for total length) Turn OD 1033.5 -0.195 - 0.360 through
010
Spider & shaft Dial Setup
020
Lathe
UT Gauge Inside Micrometer Vernier caliper
Page 2 of 7 OPN.NO STAGE 025 # Inspection Inspect for 1) 188+0.046/-0.0 2) 959.5 3) 1033.5 -0.195-0.360 4) 226.0 030 Lathe
DESCRIPTION
TOOLINGS I/S Micrometer Compute from OD Tape Micrometer
MACHINING OF GROOVED RING (REFER DRAWING DETAIL F & F1): Turn OD 1014.5+0.1/-0.0 through Bore ID 973.5+0.09/-0.0 through Compute for length 38+0.5/-0.0 and 3385.30.5 and face to maintain these lengths. Step turn 991.5-0.17/-0.31 for 24.1mm length. Inspect and record. Bore the groove to a depth of 38+0.5/-0.0 and ID 991.5 +0.17/-0.31 and groove OD 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) and form radius R0.5 at 4 locations Chemfer 2x45. Note: Ensure smooth surface finish of 'O' ring groove. Inspect visual and record in in log book. Mark P+ Axis by taking reference on LS weld joint Marking shall be on grooved ring, skirt ring, 226 of HE dome ring & face Mark 614.5,579.5,597 & 400 on HE Dome for weld pad location. Inspect for the following: Section-XX 1) Length 3385.30.5 2) Length (3517.3), 3) Length 131.5 4) 5)
Vernier Caliper Compute from ID
Inside Micrometer
Visual by QC
040
Fitting
045#
Inspection
Vernier Caliper Vernier Caliper Vernier Setup Skirt face Skirt OD Dial Setup Dial Setup
0.1 0.4
C E
Page 3 of 7 OPN.NO STAGE Detail - H: 6) 188+0.046 7) 226.0 8) R2.5 9) (3.5mm) minimum 10) 7 (minimum) 11) (45.3)mm 12) Concentricity 13) Perpendicularity Detail E: 14) 1033.5 -0.195-0.360 15) 959.5 16) 20 at two places. Detail- F 17) 1014.5+0.1 18) 1004.5+0.5 19) 38+0.5 20) 24.1-0.1/-0.2 21) R0.5 at 2 places 22) Visual observation of groove 23) 2x45 24) Perpendicularity 25) Concentricity Detail - F1: 26) 987.5-0.17/-0.31 27) 973.5+0.09 28) 979.60.1 29) 991.5-0.17/-0.31 30) 21.7+0.5 31) 6.7+0.1
DESCRIPTION
TOOLINGS Inside Micrometer Micrometer Radius Gauge UT Gauge Vernier Caliper Vernier Caliper Dial Setup Dial Setup
0.4
on 188
0.1
C on Ignitor Boss face
Tape Computed from OD Vernier Caliper Tape Computed Value Depth Gauge Depth Gauge Visual Vernier Caliper Dial Setup Dial Setup
0.1 0.2
C E
on grooved ring inner lip on 1004.5
Micrometer computed Inside Micrometer Computed Computed for ID Vernier Caliper Vernier Caliper
Page 4 of 7 OPN.NO STAGE 32) (6.9) 33) R0.5 at 4 places 34) Visual observation of groove 35) 4.0 36) 4.1+0.1 37) Concentricity 38) Concentricity
DESCRIPTION
0.2 0.2
E E
on 991.5 on 973.5
TOOLINGS Vernier Caliper Visual Visual Vernier Caliper Vernier Caliper Dial Setup Dial Setup
Get Clearance from VSSC for drilling operation. 050 Fitting DRILLING OF IGNITOR BOSS FLANGE: Position the drill Jig by locating on 188, coincide P+ marking of Jig and the job. Clamp the jig & transfer P-, Y+ & Y- axis on the job from the jig and record.
Drill Jig No: RKE-JRJ-1930-202-16
055 # 060
Inspection Inspect for the orientation of the drill Jig, alignment of P+ marking on the jig & job and record. 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. Tap M6x1P -4H, 32 nos. Note: Use first tap only
065# 070
Inspection Inspect for the holes with reference to Jig and get clearance for unloading the jig.. Fitting DRILLING OF SKIRT FLANGE: Position the drill Jig by locating on 1033.5 and coincide the P+ marking. Clamp the jig & transfer Y+, Y- & P- axis from Jig to the job and record.
Drill Jig No: RKE-RD-06-234-T-23
075 #
Inspection Inspect for the orientation of drill Jig, alignment of P+ marking on the jig & job and record. Drilling 1. Drill 14.3 holes 12nos. Starting at 22 30 min from P+ towards Y+ and on 996.5 PCD (Drill depth 20 max). Inspect for orientation of the holes and get clearance from QC. Tap M16 x1.5P 4 H 12 holes (tap depth 16 min). Note: Use first tap only 2. Drill 4.9 holes 6 nos. at P+ axis (Drill depth 12 max). Inspect for orientation of the holes and get clearance from QC. Tap M6 x 1P 4H 6 holes (tap depth 9 min)
080
Note: Use first tap only
DESCRIPTION 3. Drill and ream 5 holes 2 nos. at P+ axis 6 deep on 980.5 PCD and 7.5 deep on 1005.5 PCD. Inspect for the orientation of holes and get clearance from QC. 4. Drill 4.9 holes at 5 locations 7nos each (Drill depth 11 max). Inspect for the orientation holes and get clearance from QC. Tap M6 x 1P 4H 35 holes (tap depth 9 min) Note: 1. Use first tap only 2. Inspect visual for the liner bush ID after each drilling/reaming for damage if any.
TOOLINGS
085 # 090
Inspection Inspect for the holes with reference to Jig . Get clearance from VSSC to unload the job from the machine. IC Jig DRILLING OF SEGMENT PIN HOLES: Load the assy on interchangable drill Jig & coincide the P+ marking on jig and job True the groove ring OD within 0.1mm and clamp. Feeler Gauge
095# 100
Inspection Inspect for face butting with feeler gauge(max. gap 0.05mm), Jig orientation and setup. Verify the P+marking on Jig and job are coincided . Drilling Drill 6 holes 3nos 120 apart to a depth of 15.0mm and lock. Open up the hole to 11.5mm X 15mm depth. With flat drill increase the depth to 16.5mm, Ream the holes of 12+0.018. Check with GO NO GO Plug guage. Lock the holes with pins. Drill 6 holes 69nos to a depth of 15.0mm. Open up the hole to 11.5mm X 15mm depth. With flat drill increase the depth to 16.5mm, Ream the holes of 12+0.018mm. Note: Check with Go & No Go plug Gauge after reaming of every 5 holes
Depth Gauge
105 #
Inspection Inspect for 12+0.018 & depth of 16.5mm+0.2 with Jig in position. Get clearance from VSSC to unload the job from the Jig. Fitting Unload the segment and load on the trolley. Complete tapping of M6 and M16 holes DRILLING OF STRAP RING ATTACHMENT HOLE: Mark the strap ring attachment holes at P+ and P-. Drill 3mm holes 6nos. each at
Go & No Go Gauge Bore Dial Gauge
110
120
Fitting
P+ and P- on grooved ring as shown in developed view R. Set one of the strap ring
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 matching of 5.2 holes on strap ring & 3 holes on grooved ring. Remove the strap. Drill 4.1holes x 6nos. each at P+ and P- on grooved ring as shown in Developed view R. Tap M5x0.8P (4H). Repeat for other position also. Mark the cutout as per sketch inline with the P+ and P- axis location as shown in view-M Drill and open out the cutout 100x60mm and radius 30.0mm Drill 3.1, 5nos through and 1no. 8mm deep as per drawing. Drill 4.1, 2 nos.x 8mm depth. Tap M5x0.8P, 6H 2 nos. Tap M4 x 0.7P, 6H 6 nos.
TOOLINGS
130 140
Fitting Fitting
145 #
Inspection Inspect for the following: Detail - F & Section ZZ: 39) 12+0.018x72nos 2 30' from Y+ 40) 16.5 + 0.2 41) 42.1/-0.1/-0.2 42) R0.5 at 2 places 43) 18.0 mm 44) Visual observation of hole & finish View N - Section BB ,Section DD and Detail - C: 45) M6 x1P 4H 41 holes 9(min) and 12(max) 46) 4 39' 0.2' (typ) 47) 9 18' 0.2' (typ) 48)16 3' 0.2' (typ) 49) 2 15' 0.2' (typ) 50) 4 30' 0.2' (typ) 51) 9 2' (typ) 52) M16 x 1.5 4H 12 holes 20(max) for drilling 16(min) for tapping 53) 22 30' 0.2' (typ) 54) 15 0.2' (typ) 55) 5 Hole, 6 Deep 56) 5 Hole, 7.5 Deep 57) M6x1 4H, 32nos starting at Y+
Go No Go Plug / Bore Dial Gauge Depth Gauge Micrometer & Setup Visual Vernier Caliper IC Jig
Go No Go Gauge / Vernier Drill Jig
Go No Go Gauge Drill Jig Vernier Caliper Go No Go Gauge / Drill Jig
Page 7of 7 OPN.NO STAGE
DESCRIPTION View-M & Section - KK: 58) M5x0.8-6H holes, 2 nos. each 50mm centre distance from P+ and P- axis x 8 deep. 59) M4 x 0.7P 6H 6nos. each at P+and P- axis as shown. 60) Cutout at 2 locations P+ and P- axis 61) R30 62) 60mm 63) 40mm 64) 16mm 65) 80mm 66) 100mm 67) 130mm 68) 65.0mm Developed view - R & Section -YY: 69) M5x0.8-4H,6 nos each at P+ & P- inline with seg.holding pin 70) 1 15' 71) 3 45' 72) 5 73) 18mm Get Clearance from VSSC for weld pad welding. Note: Spider are not to be removed at this stage Ovality will be inspected after PPT & removal of Spider. Ovality inspected at earlier stage of weld assembly & reported. # Mandatory stages to be cleared by RQS/VSSC
TOOLINGS Go No Go Gauge Vernier Caliper Radius Gauge Vernier Caliper
Go No Go Gauge Chord Measurements Vernier Caliper Vernier Caliper

20.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-09 R1 PART NAME : RLV-SB HEAD END SEGMENT WELD PADS WELDING SUB ASSY NAME : RLV-SB MOTOR CASE ASSY
OPN.NO STAGE
SHEET NO :
PART DRG.NO. RKE-RD-06-234-09 Sheet 1& 2 REF DRG. NO. RD06-25-05-02-3-17-13-10-170

DESCRIPTION
PROJECT : RLV-SB CLIENT : VSSC 15CDV6 MATL : QUANTITY : 1 No.

TOOLINGS
#005
Inspection Confirm the acceptance of the following:

Head End Segment Assy - 1 No. Wire tunnel weld pad - 52 Nos. Destruct System weld pads Part-I - 4 Nos. Destruct System weld pads Part-II-4 Nos. Destruct System weld pads Part-III-10 Nos. Destruct System weld pads Part -IV-8 Nos. Destruct System weld pads Part-V-16 Nos. Antenna Mounting weld pad - 8 Nos.
010
Fitting
WELDING OF WIRE TUNNEL WELD PAD: Mark the location of wire tunnel weld pads on segment assy with reference to P+ axis as shown in drg. Clean the area with emery and acetone. Position the weld pad welding fixture and assemble the pads in position.
Weld pad welding fixture No. RKE-RD-06-234-T-27
015 # 020
Inspection Inspect for the weld pad orientation and fixture position. Welding Set and tack weld wire tunnel weld pads at a distance of 223mm from the skirt ring face, and 250mm from the first pair of weld pad at 12 locations on P+ axis as shown in drawing.
025#
Inspection Inspect for the weld pad locations and orientation of the weld pads with reference to the drawing. Get clearance from VSSC for welding.
Page 2 of 5 OPN.NO STAGE 030 Welding
DESCRIPTION Complete the fillet welding (Ref. doc.no MEE/QCI/QCP/007/2002, issue 2, July 2005) Repeat operation 10 to 30 for the completion of weld pad at P- axis.
TOOLINGS
040
Fitting/ Welding
045 #
Inspection Inspect the location of weld pad as per Section XX & Detail Z of the drawing. Carry out DP Test on the fillet welds. WELDING OF ANTENNA MOUNTING WELD PAD (REFER DRAWING VIEW F) Mark the following at 20 away from P+ and P- Axis. 1. Centre distance of 60mm x12mm for two M5 x 0.8 P holes 2. 67mm distance for 18 holes 3. 60mm, 21mm, 125mm for weld pads.
D.P. Kit
050
Fitting
055 060
Inspection Inspect for marking. Fitting 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 maintained and tack weld.
070
Fitting/ Welding
075 080 090 095# 100
Inspection Inspect for the orientation of weld pad. Welding Fitting Carry out fillet weld of the pads on all four sides. Repeat operation 50 to 80 at 20 from P-axis.
Inspection Inspect for the location of weld pads, carry out DP test on fillet welds. Fitting/ Welding WELDING OF DESTRUCT SYSTEM WELD PADS( PART I & II) Mark the ref.circle 642.5, 597, 549 and transfer the center line P+,P-, Y+ & Yon head end dome. Mark 62', 718' position of weld pad part-I & part-II such a way that maintaining 35mm as per drg. Clean the area with Emery & Acetone. Tack weld part I & II by maintaining 66mm & 11.5mm.
Page 3 of 5 OPN.NO STAGE Welding/ 110 Fitting
DESCRIPTION WELDING OF DESTRUCT SYSTEM WELD PAD( Part III & IV) Mark the ref.circle 614.5, 597, 579.5 and mark line 36(typ), 18(typ) starting from P+ for weld pad & part-III. Clean the area with Emery & Acetone. Tack weld part III & IV by maintaining 9mm & 34mm. WELDING OF DESTRUCT SYSTEM WELD PAD( Part V) Mark the ref.circle 335.38, 400, 435.68 and mark line 14(typ) & 18(typ), 45(typ) at Y+ and Y- axis. Clean the area with Emery & Acetone. Tack weld part V by maintaining 9.67mm & 51.9mm.
TOOLINGS
120
Welding/ Fitting
125# 130
Inspection Inspect the position of weld pads. Welding Carry out fillet weld of the weld pads (Ref. doc.no MEE/QCI/QCP/007/2002, issue 2, July 2005) Note: Fillet welding shall be done at two sides of the weld pad only as shown in Drawing. Welding Fixture No RKE-RD-06-234-T-23
135 140#
Inspection Inspect for the orientation of the weld pads and carry out DP Test on fillet weld. Inspection Inspect for the following: Section - XX: 1) 223mm 2) 250x12nos. Detail - Z: 3) 38.0 4) 50 5) 110 6) 20 7) Fillet weld size 3mm View - N: 8) 45 (typ) 9) 18 (typ) 10) 36 (typ)
D.P.Kit
Vernier Caliper
Vernier Caliper
Vernier Caliper
Page 4 of 5 OPN.NO STAGE Section - AA : 11) 642.5 12) 597 (Ref) 13) 549 14) 60 (typ) 15) 665.5 (Ref) 16) 551.5 (Ref) 17) 11.5 + 2.0/+0.0 18) 66mm (typ) Section - BB : 19) 614.5 20) 597 (Ref) 21) 579.5 22) 34mm 23) 635.5 (Ref) 24) 576.5 (Ref) 25) 9+2.0/+0.0 26) 60 Detail - X : 27) (718') 28) (62') 29) 35 30) Fillet size 3x45 Detial - Z : 31) (38)mm 32) (20) 33) 50 34) (110)mm 35) Fillet size 3 (typ) View - F: 36) Orientation 20 from P+ and P37) 60mm
DESCRIPTION
TOOLINGS Vernier Caliper
Vernier Caliper
Vernier Caliper
Vernier Caliper
Vernier Caliper
Page 5 of 5 OPN.NO STAGE 38) M5 x 0.8 P- 6 H x 10 deep 39) 67.0 40) 12.0 41) 88.0 42) 125.0 43) 18 holes Section - CC: 44) 455.38 (Ref) 45) 335.1 (Ref) 46) 51.9 (typ) 47) 75 48) 9.67 49) 335.38 50) 400 (Ref) 51) 435.68 (Ref) View - N: 52) 14 (typ) 53) 18 (typ) 54) DP test on all fillets & fillet size.
DESCRIPTION
TOOLINGS GO NO GO Gauge
Vernier Caliper
Vernier Caliper
Vernier Caliper DP Kit / Vernier Caliper
Get Clearance from VSSC for Proof Pressure Test.

12.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-10 R1 PART NAME : RLV-SB MIDDLE SEGMENT WELDING SUB ASSY NAME : RLV-SB MIDDLE SEGMENT MACHINING
OPN.NO STAGE
SHEET NO : 1 OF 9 PART DRG.NO. RKE-RD-06-234-10 Sheet 1,2 & 3 REF DRG. NO. RD06-25-05-02-3-17-13-10-120
DESCRIPTION
REV NO. R2 REV.NO R0
TOOLINGS
005#
Inspection
Verify the acceptance of Cylindrical Shell Qty-4 Nos. Grooved Ring - 1 No. &Tongued Ring - 1No Allot Assembly identification as RLV-MS-02,03,04 & 05 Note 1: Idn.No shall be retained during all stages of fabrication and weld joint to be identified as shown in drawing. Note 2: Welding inspection as per Doc No MEE/QCI/QCP/007/2002- Issue 2, July 2005. Note 3: Mismatch shall be calculated by taking thickness into account and checked by template and feeler guage at an interval of 50mm. If the mismatch observed is more than the specified, detailed mapping of mismatch at that location shall be provided. 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 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 untill proof pressure test with traceability. Note 8: The Film density shall be kept as 1.8 to 2.5mm for X-Ray Radiography. Template and Feeler guage
DESCRIPTION REFER STAGE-1 WELDING 1. Load shell 1 and shell 2 on shaft using 4 Nos of spiders and true within 0.3mm TIR 2. Spider should be positioned 60 mm inside from the shell end. 3. Shells should be positioned in such a way that prepared weld edges (at cylindrical shell level) facing each other and the each long seam weld is staggered by 90 4. Load the shaft and spider assembly in the welding station and hold one end on the chuck and other end on the tail stock. 5. Inspect for the run out of the shell at both ends. 6. Carry out DP test on WEP of both the shells and record. 1. Clean 50mm width band from inside and outside for both the shells with emery and acetone. 2. Clean the purging fixture also by blowing compressed air and finally by acetone. 3. Set the purging fixture and set the shells by keeping 0.5 to 2mm root gap and 0.3mm mismatch or as per WPS 4. Clean with acetone, ensure purging gas flow. 5. Tack weld the joint at 75 to 100mm interval 1. Welder's qualification and adaptation 2. Orientation of Long Seam Joint 90 apart 3. Thickness of both ends at an interval of 50mm for computing mismatch 4. Root gap, 5. Mismatch 6. Tack length and spacing 7. Get clearance from VSSC for welding Complete the welding by GTAW process in 1G position. Record the following Voltage, current, filler wire code number, diameter and gas flow for purging and shielding, inspect for the total length and record. 1. Compute for the total length of the shells app. 1895mm for shell assembly & accordingly discard 2.Trim one end of the shell by keeping 945mm length for shell 2 and prepare weld edge 30 angle and 0.5 to 1 mm root face. 3. Preserve the discarded portion.
TOOLINGS
Spider and shaft
D.P.Kit
020
Fitting/ Welding
025#
Inspection
030
Welding
Vernier Caliper
040
Lathe

1
0.2
TOOLINGS Dial setup Dial setup Vernier caliper Vernier caliper Bevel protractor D.P.Kit UT Gauge/Ball Point Mic
2 0.1 A 3. Length 1895 & ( 945mm) 4. Lip distance 0.5 to 1mm 5. Angle 30 6. D.P.test 7. Thickness near weld edge at 50mm interval & record
REFER STAGE - 2 WELDING
050
Fitting/ Lathe
1. Load the shell 3B on the shaft and check for the trueness, clamp, set the shell (shell 3B) and shell assembly with the root gap of 0.5 to 2mm and mismatch of 0.2mm or as per WPS 2. The shells should be facing the WEP side of each other. 3. Long seam orientation should be staggered by 90 for adjacent shells. 4. Clean both the side of the shells with emery and acetone for a band of 50mm. 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 and 0.3mm mismatch 7. Clean with acetone, ensure purging gas flow 8. Tack weld the joint at 75 to 100mm interval. 1. Welder's qualification and adaptation 2. Orientation of shells LS 90 apart 3. Thickness of both ends at an interval of 50mm 4. Root gap 5. Mismatch 6. Tack length and spacing 7. Get clearance from VSSC for welding Complete the welding by GTAW process in 1G position. Record the following: Voltage, current, filler wire code number, diameter and gas flow purging and shielding.
Mismatch checking template Feeler Gauge
055#
Inspection
060
Welding
Page 4 of 9 OPN.NO STAGE 070 Lathe
DESCRIPTION 1. Compute for the total length of the shells app. 2352mm for shell assembly & accordingly discard 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. 3. Preserve the discarded portion. Inspect for
1
0.2
TOOLINGS
075#
Inspection
2 0.1 A 3. Length 2352 &(457mm) 4. Root face 0.5 to 1mm 5. Angle 30 6. D.P. test 7. Thickness near weld edge at 50mm interval and record. REFER STAGE - 3 WELDING Load the shell(4) on spiders by keeping the prepared weld edge facing each other as shown in Stage 3 Welding. True the shell on spider within 0.3mm. 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 staggered by 90 apart. Adjust the spiders to control mismatch with 0.2mm and a root gap of 0.5 to 2 mm or as per WPS Tack weld at an intervel of 75 to100 mm 1. Welder's qualification and adaptation 2. Orientation of shells LS 90 apart 3. Thickness of both ends at an interval of 50mm 4. Root gap 5. Mismatch 6. Tack length and spacing 7. Get clearance from VSSC for welding 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. Unload the assembly from the fixture, remove spider & shaft.
Dial setup Dial setup Vernier caliper Vernier caliper Bevel protractor D.P.Kit UT Guage / Ball Point Mic
080
Lathe
085#
Inspection
090
Welding
DESCRIPTION Inspect visual, weld bead and penetration dimensions. Identify the weld joint as RLV- MS - CS - XX - 08 ( Shell 3B & 4) RLV- MS - CS - XX - 09 ( Shell 2 & 3B) RLV- MS - CS - XX - 10 ( Shell 1& 2) CS = Cirseam Joint XX = Set serial no MS = Middle segment Flush grind the penetration without touching parent metal (0.1mm projection max permitted) Note : Fix adhesive tape on both sides before grinding Inspect for 1. Mismatch 2. Visual for penetration grinding Note: Ensure that parent metal is not touched. Incase if parent metal is touched, record the thickness where parent metal is touched and map the thickness. 3. DP test 4. 100% RT Carryout repairs if any by gouging the defective area , weld & Inspect as per approved procedure. 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 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 30 angle and 0.5 to 1mm root face. 5. Preserve the discarded portion. 1. Compute for the total length of the shells app. 3302mm & accordingly discard 2. Trim one end of the shell (shell 4) by keeping 950mm length and prepare weld edge 30 angle and 0.5 to 1 mm lip distances 3. Preserve the discarded portion.
TOOLINGS
100
Fitting
105#
Inspection
Template and feeler gauge UT gauge D.P.Kit
110
Welding/ Inspection Fitting
120
purging fixture
130
Lathe

1
0.2
TOOLINGS Dial setup Dial setup Vernier caliper Vernier caliper Bevel protractor D.P.Kit
2 0.1 A 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 REFER STAGE - 4 WELDING 1. Load the Tongued ring on the shaft and true within 0.2mm TIR 2. Insert cirseam Purging fixture on cleaned end of the shell. Ensure cleanliness of the purging fixture and purging gas flow. 3. Clean WEP of Tongued Ring & Shell 4. Clean 25mm band of shell circumference at WEP end outside and inside with emery and acetone. Set the root gap 0.5 to 1.5mm and mismatch within 0.2mm or as per WPS Tack weld the joint at 75 to 100mm intervals 1. Welder's qualification and adaptation 2. Thickness of both ends at an interval of 50mm for computing mismatch 3. Root gap, 4. Mismatch 5. Tack length and spacing 6. Get clearance from VSSC for welding Complete the welding by GTAW process in 1G position for c/s of Tongued ring and shell. Record the following Voltage, current, filler wire code number,diameter and gas flow for sheilding and purging. 170 Lathe Considering the triming allowance, trim and prepare weld edge on first shell keeping a length of (950mm) Note: Compute for the length 3421.6+0.5/-0.0 and discard accordingly. # Inspection Get clearance from inspection department for the computed length considering grooved ring height and get clearance from VSSC.
purging fixture
150 155#
160
Welding
175
Page 7 of 9 OPN.NO STAGE Inspect for

1
0.2
DESCRIPTION
A
TOOLINGS Dial setup Dial setup Vernier caliper Vernier caliper D.P.Kit UT Gauge / Ball Point Mic
2 0.1 A 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 REFER STAGE - 5 WELDING Load the Grooved ring in the shaft and spider assembly and true within 0.5mm 1.Clean 50mm band of shell circumference outside and inside with emery and acetone. 2. Install cirseam Purging fixture Ensure cleanliness of the purging fixture and purging gas flow. 3. Clean WEP of Grooved Ring 4. Set the Tongued ring by keeping root gap of 0.5 to 2mm and mismatch within 0.2mm 5. Tack weld the joint at 75 to 100mm interval 1. Welder's qualification and adaptation 2. Thickness of both ends at an interval of 50mm 3. Root gap, 4. Mismatch. 5. Tack length and spacing 6. Get clearance from VSSC for welding Complete the welding by GTAW process in 1G position between GR & Shell 1. Record the following Voltage, current, filler wire code number , diameter, gas flow for purging & sheilding. Inspect for
1
0.2
Purging Fixture
185#
Inspection
Mismatch checking template UT guage Feeler guage Vernier caliper
190#
Welding
A A A
0.5 0.5
DESCRIPTION Inspect visual, weld bead and penetration of the joints Identify the weld joint as 1. RLV-MS-CS-XX-7 (Tongued ring # Shell 4) 2. RLV-MS-CS-XX-11 (Grooved ring #Shell 1) CS = Cirseam Joint XX = Set serial no MS= Middle Segment Assembly Flush grind penetration without touching the parent metal (0.1mm projection max. permitted) Note 1: Fix Adhesive tape on both sides of the welding before grinding. Note 2: Grinding need not be done for C/S joint between skirt and MSDR Inspect 1. Visual for penetration grinding. Ensure that parent metal is not touched. In case if parent metal is touched, record the thickness. 2. D.P.of weld joint 3. 100% RT Carryout repairs if any by gauging the defective area and welding. Inspect
TOOLINGS
200
Fitting
205#
Inspection
3X magnifying glass D.P.Kit X-Ray machine
210#
215#
Record the inspected dimension and prepare inspection report 0.2 1 A 2 0.1 A 3. (945), (950), 1895 4. Lip distance 0.5 to 1mm 5. Angle 30 6. D.P Test of weld edge of shell 2 0.2 7 of shell 3 A 8 0.1 A 9. (455), 2352 10. Lip distance 0.5 to 1mm 11. Angle 30 12. D.P test of shell 3 0.2 13 of shell 4 A 14 0.1 A 15. 3302
Dial setup Dial setup Vernier caliper Vernier caliper Bevel Protractor D.P.Kit Dial setup Dial setup Vernier caliper Vernier caliper Bevel Protractor D.P.Kit Dial setup Dial setup Vernier caliper
Page9 of 9 OPN.NO STAGE 16. Lip distance 0.5 to 1mm 17. Angle 30 18. D.P test of weld edge of shell 4 0.2 19 20 0.1 21. Length (950) & 32421.6+0.5/0.0 22. Lip distance 0.5 to 1mm of shell 1 23. Angle 30 24. D.P test of shell 1
25
0.2
DESCRIPTION
TOOLINGS Vernier caliper Bevel Protractor D.P.Kit Dial setup Dial setup Vernier caliper Vernier caliper Bevel Protractor D.P.Kit Dial setup Dial setup Dial setup Vernier caliper Inside mic Inside mic
A
A
of shell 1 of shell 1
26 0.5 A 27 0.5 A 28. LS weld staggered by 90 29. 3564.1 30. Ovality Grooved ring 969.5 at 16 generators 31. Ovality Tongued ring 961.5 at 16 generators Get Clearance from VSSC for weld pad welding. # Mandatory stages to be cleared by VSSC

20.01.2009
SHEET NO : 1 OF 6 PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-11 R1 PART DRG.NO. REV. NO. PART NAME : RLV-SB MIDDLE SEGMENT MACHINING RKE-RD-06-234-11 R4 SUB ASSY NAME : REF DRG. NO. REV. NO. RLV-SB MOTOR CASE ASSY RD06-25-05-02-3-17-13-10-120 R0 DESCRIPTION OPN.NO STAGE 005 # Inspection Confirm the acceptance of the Middle segment Weld Assy. Verify that the Idn.No RLV-MS-02,03 etc., is painted on the shell portion 010 Lathe Load the job on spiders and shaft. Tighten the spiders. Set for tongued ring and grooved ring with minimum runout. True the shells within 0.3mm and record. Check for the runout of tongued ring OD and grooved ring OD. Check for the faceout of tongued ring and grooved ring. Skin cut on tongued ring face and grooved ring face. Compute for machining allowance and record. Record the setting reading in logbook. MACHINING OF TONGUED RING (REFER DRAWING DETAILS G & G1) Turn OD 1004.5-0.3/-0.7 through Bore ID 965.5 +.09+.00 through Inspect & Compute for length 68.7 Face to maintain 68.7mm Bore ID 987.5 x 40mm length Inspect for 987.5 +.09 +.00 Form groove of 64.7 +0.10+.00 from face and 987.5+.09 +.00 & 973.5 - 0.17-0.31 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 Chamfer 2x45 at 3 locations.
PROJECT : RLV-SB CLIENT : VSSC 15CDV6 MATL : QUANTITY : 1 NO PER ASSY TOOLINGS
Spider & shaft Dial Gauge setup
020
Lathe
I/S Micrometer
I/S Micrometer
025 #
Inspection Inspect for 1) 1004.5-0.3/-0.7 2) 991.5+0.09 3) 965.5+0.09/+0.0
p tape/ Inside Mic & compute I/S Micrometer I/S Micrometer
DESCRIPTION 4) 987.5+0.09+0.00 checked before groove Machining 5) 973.5-0.17/-0.31 6) Concentricity 7) Concentricity 8) Concentricity
TOOLINGS I/S Micrometer Compute from OD
0.2
0.2 0.2
D
D D
on 1004.5 on 987.5 on 973.5
030
Lathe
MACHINING OF GROOVED RING (REFER DRAWING DETAIL F & F1) Turn OD 1014.5+0.1/-0.0 through Compute for length 38+0.5/-0.0 and 35300.5 and face. Bore ID 973.5+0.09/-0.0 Face turn 24.1 depth and step turn 991.5-0.17/-0.31 for 24.1mm length and Inspect Bore the groove to a depth of 38+0.5/-0.0 and ID 991.5 +0.17/-0.31 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 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 Note: Ensure smooth surface finish of 'O' ring groove and record. Mark P+ Axis by taking reference on LS weld joint Marking shall be on grooved ring and tongued ring OD & taper.
Vernier Caliper Compute from ID Inside Micrometer
040
Fitting
045#
Inspection Inspect for the following Section - XX: 1) 35300.5 2) Concentricity Detail - G: 3) 1004.5-0.3/-0.7 4) 991.5+0.09 5) 965.5+0.09/+0.0 6) (75) 7) (45) 8) 64.7+0.1/+0.05 9) (68.7) 10) 53.5+0.5
0.2
on 1004.5 and 987.5
Taper Dial Setup
Tape I/S Micrometer I/S Micrometer Vernier Caliper Vernier Caliper Vernier Caliper / Depth Gauge Vernier Caliper Vernier Caliper
Page 3 of 6 OPN.NO STAGE 11) 47+0.5 12) 40+0.5 13) 2x45 at 3 places 14) Perpendicularity 15) Perpendicularity 16) Perpendicularity 17) Concentricity Detail - G1: 18) (15.2) 19) 987.5+0.09 20) 973.5-0.17/-0.31 21) Concentricity 22) Concentricity 23) R0.5 at 2 places Detail - F: 24) 1014.5+0.1 25) 1004.5+0.5 26) 38+0.5 ; 27) 24.1-0.1/-0.2 28) R0.5 at 2 places 29) 2x45 30) Perpendicularity 31) Perpendicularity 32) Concentricity Detail - F1: 33) 991.5-0.17/-0.31 34) 973.5+0.09 35) 979.60.1
DESCRIPTION
0.1
0.1 0.1 0.2
C
C C D
on Tongued Ring inner lip on Tongued Ring outer lip on Tongued ring Groove face. on 1004.5
TOOLINGS Vernier Caliper Vernier Caliper Bevel Protractor Dial setup
0.2
0.2
D D
on 987.5 on 973.5
Vernier Caliper Computed I/S Micrometer Computed I/S Micrometer Dial setup
Visual Tape Computed Vernier Caliper
0.1
on Grooved ring Inner lip on Grooved ring Outer lip on 1004.5
Dial setup
0.1 0.2
C E
Micrometer computed I/S Micrometer Computed
Page 4 of 6 OPN.NO STAGE 36) 987.5-0.17/-0.31 37) 6.7+0.1 38) 21.7+0.5 39) (6.9) 40) 4mm 41) 4.1+0.1 42) R0.5 at 4 places 43) Concentricity 44) Concentricity
DESCRIPTION
TOOLINGS Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Radius Gauge
0.2 0.2
E E
on 973.5 on 991.5
Dial Setup Dial Setup
Get clerance from VSSC to unload the job from the machine 050 IC Jig DRILLING OF SEGMENT PIN HOLES GROOVED RING: 1. Load the assy on interchangable drill Jig by facing grooved ring at bottom and coincide P+ marking on Jig & Job. 2. True the groove ring OD within 0.1mm and clamp
055#
Inspection Inspect for face butting, with feeler gauge ( max. gap 0.05mm) Jig orientation and setup. P+ marking of the Jig and job are coincided. Drilling Drill 6 holes 3nos 120 apart to a depth of 15.0mm and lock. Open up the hole to 11.5mm X 15mm depth. With flat drill increase the depth to 16.5mm, 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. Drill 6 holes 69nos to a depth of 15.0mm. Open up the hole to 11.5mm X 15mm depth. With flat drill increase the depth to 16.5mm, Ream the holes of 12+0.018mm x 16.5 +0.2/-0.0mm depth. Note: Check with Go & No Go plug Gauge after reaming of every 5 holes
Feeler Gauge
060
Depth Gauge
65 #
Inspection Inspect for 12+0.018 & depth of 16.5mm+0.2 with Jig in position. Get clerance from VSSC to unload the job from the jig. IC Jig DRILLING OF SEGMENT PIN HOLES TONGUED RING: Load the assy on interchangable drill Jig by facing tongued ring at bottom and Coincide the P+ marking on the Jig & job. True the tongued ring OD within 0.1mm and clamp.
Go & No Go Gauge
70
Page 5 of 6 OPN.NO STAGE 75# 80
DESCRIPTION
TOOLINGS
Inspection Inspect for face butting, with feeler gauge (max. gap 0.05mm) Jig orientation and setup. P+ marking on Jig and job are coincided. Drilling Drill 6 holes 3nos through & 120 apart and lock. Open up the hole to 11.5mm. Ream the holes to 12+0.018. Check with GO NO GO Plug guage. Lock the holes with pins. Drill 6 holes, 69 nos and open up to 11.5mm. Ream 69 nos of holes 12+0.018. Note: Check with Go & No Go plug Gauge after reaming of every 5 holes Go & No Go Gauge/ B.Gauge
#85
Inspection Inspect for 12+0.018 with Jig in position. Get clerance from VSSC to unload the job from the jig. Fitting Open out 3 slotted holes, width 12mm, 30 & 5 +0.5 +0.0 at 230' off from Y+, P+ & Ytowards P+, Y- and P- respectively (Converted after drilling 12 holes) DRILLING OF STRAP RING ATTACHMENT HOLE: Mark the strap ring attachment holes at P+ and P-. Drill 3mm holes 6nos. each at P+ and P- on grooved ring as shown in developed view R. Set one of the strap ring 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 matching of 5.2 holes on strap ring & 3 holes on grooved ring. Remove the strap. Drill 4.1holes x 6nos. each at P+ and P- on grooved ring as shown in Developed view R. Tap M5x0.8P (4H) Repeat for other positions also.
090
100
Fitting
105 #
Inspection Inspect the following dimensions: View - A: 45) 12+0.018, 72 nos 46) Starting at 230' from Y+ towards P47) P+, P-, Y+ & Y- axis marking Section - ZZ : 48) 12+0.018, 72 nos 49) starting at 230' from Y+ towards P50) 16.5 +0.2/-0.0 51) LS weld orientation 45 & 180 52) P+, P-, Y+ & Y- axis marking Go No Go Plug Gauge Bore Dial Gauge IC Jig
Bore Dial Gauge Depth Gauge
DESCRIPTION Detail - H : 53) 3 slotted holes, width 12mm, 30 & 5+0.5 at 230' from Y+, P+ & Ytowards P+, Y- & P54) 12.0 55) 5+0.5/-0.0 56) 30 Developed View - R : 57) M5x0.8-4H, 5 long, 6 nos each at P+ & P- inline with seg.holding pin 58) 18mm 59) 5 (Typ) 60) 345' (Typ) 61) 115' (Typ) 62) Transfer the Idn.No.by engraving on taper portion of Grooved ring and Tongued Ring Get clearance from VSSC for weld pad welding.
TOOLINGS Vernier Caliper Bevel Protractor Vernier Caliper Vernier Caliper Bevel Protractor
GO NO GO Gauge Vernier Caliper Chord Measurements Vernier Caliper
Note: Spider are not to be removed at this stage Ovality will be inspected after PPT & removal of spider. Ovality inspected at earlier stage of weld assembly & reported. # Mandatory stages to be cleared by RQS/VSSC

21.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-12 R3 PART NAME : RLV-SB MIDDLE SEGMENT WELD PADS WELDING SUB ASSY NAME : RLV-SB MOTOR CASE ASSY
OPN.NO STAGE
SHEET NO :
1 OF 2
DESCRIPTION
PROJECT : RLV-SB CLIENT : VSSC 15CDV6 MATL : QUANTITY : 1 NO.

TOOLINGS
005 #
Inspection
Confirm the acceptance of the following: Middle seg.assy-1 No. Wire tunnel weld pads - 56 Nos. Mark the location of wire tunnel weld pads on segment assy with reference to P+ axis as shown in drg. Clean the area with emery and acetone. Position the weld pad welding fixture and assemble the pads in position. Weld pad welding fixture No. RKE-RD-06-234-T-27
010
Fitting
015 # 020
Inspection Inspect for the weld pad orientation and fixture position. Welding Set and tack weld the pads at a distance of 160mm from the center line of segment pin hole of tounged ring , and 250mm from the first pair of weld pad at 12 locations and 201mm for the last pad at P+ axis as shown in the drawing.
025#
Inspection Inspect for the weld pad locations and orientation of the weld pads with reference to the fixture. Get clearance from VSSC for Fillet Welding. Welding Complete the fillet welding (Ref.Doc.no MEE/QCI/QCP/007/2002, issue 2, July 2005)
030
040
Fitting/ Welding
Repeat operation 10 to 30 for the completion of weld pad at P- axis.
Page 2 of 2 DESCRIPTION OPN.NO STAGE 045 # Inspection Inspect the location of weld pad as per the drawing. Carry out DP Test on the fillet weld. 1) 160 2) 250x12 3) (201) mm 4) (38)mm 5) 20 mm 6) (110) m 7) 50 mm 8) 3mm Fillet weld Get Clearance from VSSC for Proof Pressure Test.
TOOLINGS D.P. Kit Vernier Caliper

23.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-13 R1 PART NAME : RLV-SB NOZZLE END DOME RING SUB ASSY NAME : RLV-SB NOZZLE END DOME PRE ASSY
OPN.NO STAGE
SHEET NO :
1 OF 3
DESCRIPTION
PROJECT : RLV-SB CLIENT : VSSC 15CDV6 MATL : HEAT TREATED FORGING QUANTITY : 1 No per. ASSEMBLY
TOOLINGS
005 #
Note : The Idn. shall be retained during m/cing & transferred to the job after m/cing Inspection Verify the RMC No. and the acceptance of the material in correlation with the TC issued by VSSC. Allot part Iden. No. as RLV-NED-01,02,.. Confirm H/T by verifying hardness report as in TC VTL / CNC VTL REFER SKETCH - 01 Load the job on VTL and true, clamp the job from outside. Face turn to maintain height of 287 mm. Bore ID 744-1.0/+0.5 through. M/c groove 1004x20 width at 80mm from larger face. Inspect 744+0.5/-1.0 and unload. I/S Mic
010
020
VTL / REFER SKETCH - 02 CNC VTL Reverse the job, true the ID 744 within 0.1mm(and record) & clamp on O/S. Face to maintain 280+1.0/-0.5 mm height, Program & execute I/S profile as per the co-ordinates and maintaining 996.0 0.20 as per drawing. Inspect 996.0 +0.2/-0.0 and record. VTL CNC VTL REFER SKETCH - 03 True the m/cing fixture within 0.1mm. Load the job clamp on fixture. True 744 face within 0.05mm. Turn OD 831+1.0/-0.5. Program & execute O/S profile by ensuring 3+0.2/-0.0 wall thickness (Note : Atleast one cross section the thickness shall be within 3.2mm). Execute the programme by maintaining wall thickness 17.2mm, 5 and radius 2mm. Face height 128.8mm of Y-ring.
I/S Mic I/S checking template RKE-RD06-234-T-10 M/cing Fixture No RKE-RD06-234-T-18 O/S Micrometer UT Gauge
030
Page 2 of 3 DESCRIPTION OPN.NO STAGE 035 # Inspection Inspect and record the following dimensions 1) * 831+1.0/-0.5 2) 3+0.2/-0.0 040 VTL / REFER SKETCH - 04 CNC VTL Clamp the job from inside. Execute the programme and machine the "Y" Ring groove and prepare weld edge. Execute the programme for "Y" Ring O/S profile and prepare weld edge. Inspect for 996, 744 and Concentricity before unloading. Inspection Inspect & record the following dimensions 1) 9960.2 2) 3.0 + 0.2/+0.0 3) 17.2 +1.0/-0.5 4) Height 280.0 5) 744 -0.1/-0.5 6) 831 +1.0/0.5 7) XY Co-ordinates, 25.0 8)
TOOLINGS O/S Mic UT Gauge
checking template RKE-RD06-234-T-11, 12 & 13 Dial Setup
045 #
0.2
I/S Mic UT Gauge Vernier Caliper Height Gauge I/S Mic Vernier Caliper Checking Template RKE-RD06-234-T-10 Dial setup Vernier Caliper Checking Template RKE-RD06-234-T-13 UT Gauge Bevel Protractor Vernier Caliper Compute from OD Ball Point Mic Vernier Caliper Bevel Protractor Checking Template RKE-RD06-234-T-12 Checking Template Template RKE-RD06-234-T-11 Vernier Caliper
9) (16.0) 10) 5, R2, 33, 51' , 847.74 11) 2+0.2/-0.0 12) 30 13) 0.5 to 1.0mm 14) 994 15) 3+0.2/-0.0 16) 0.5 to 1mm 17) 30 18) 60, 136.7, 905.84, 9.18, 20.1, R2, 75 19) 43.65, 3.13, 5 54'+0.0/-0.5, 37.55, R80, 8.59, 89.2, 11, 12, 12.02 20) 128.8
DESCRIPTION 21) Ovality on 996 and 744 at 8 generators 22) D.P Check all over Mark/Paint Idn.no as RLV-NED-03, 04. Apply Black Japan and credit to store.
TOOLINGS I/S Mic DP Kit
# Mandatory stages/dimensions to be cleared by RQS/VSSC

23.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-14 R1 PART NAME : RLV-SB NOZZLE END SKIRT RING SUB ASSY NAME : RLV-SB NOZZLE END DOME PRE ASSY
OPN.NO STAGE
SHEET NO :
1 OF 2
DESCRIPTION
PROJECT : RLV-SB CLIENT : VSSC 15CDV6 MATL : RING (ANNEALED) QUANTITY : 1 No per MOTOR CASE
TOOLINGS
005#
Inspection
Note : The idn shall 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 TC issued by VSSC. Allot part ident.No as RLV-NES-02,03,04 & 05 Pre m/c the forging as per sketch-1 Inspect the dimensions as per sketch-1 Note 1: Ensure that chart recorder is working Note 2: A copy of the chart to be attached with Inspection Report. 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, O/S Mic I/S, O/S Mic, Vernier
010 015 020#
VTL/Lathe Inspection Heat Treatment
030 #
Hardness Grind / machine to depth of 3mm. Testing M/C Check hardness at 3 locations on both faces. VTI / CNC VTI REFER SKETCH - 2 Clamp the job on OD. True OD, face to maintain 115mm height. Bore 908 through Step turn OD 1002 to depth of 15mm Inspect & Record the following dimensions (1) 908 (Record in Logbook) (2) 115mm (3) 1002
Portable Grinder Hardness tester I/S, O/S Mic Radius Gauge
040
I/S Mic Vernier Caliper
(4) 15mm
Vernier Caliper
Page 2 of 2 OPN.NO STAGE VTI / 050 CNC VTI
DESCRIPTION REFER SKETCH - 3 Reverse the job & true on 1002. Clamp from I/S. Turn on face to maintain a height of 1101.0mm. Turn 9940.2 up to a length of 82mm. Turn OD 1000 by maintaining thickness 3.0 0.2mm Prepare WEP 30, 0.5-1mm land. Remove I/S clamp. Clamp on top as per sketch-3 Taper turn 10 & R5 asper sketch-3 by retaining 16.1mm. Inspect & record the following dimensions. (1) 9940.2 (2) 1000 (3) 10, R5 (4) 1101.0 (5) WEP 30, 0.5-1mm land. (6) Concentricity Unload the job from the machine.
TOOLINGS Radius Gauge I/S checking template RKE-RD06-234-T-14
0.2
I/S Mic Vernier Caliper I/S checking template RKE-RD06-234-T-14 Vernier Caliper Bevel Protractor Dial Setup
055 #
Inspection
Inspect the following dimensions 1) 908 2) 1101.0 3) 1000mm 4) 9940.2 5) 10 , R5 6) 16.1+1.0/-0.5 7) WEP 30, 0.5-1mm land. 8) 3 + 0.2/-0.0 9) Concentricity 0.2 10) Ovality on 994 at 8 Generator. 11) Conduct D.P.Check all over
I/S Mic Vernier Caliper Vernier Caliper I/S Mic Template Vernier Caliper Bevel Protractor Ball Mic Dial Setup I/S Mic
060
Mark/Paint idn.no as RLV-NES-02,03 etc., Apply Black Japan all over and preserve # Mandatory stages to be cleared by RQS/VSSC
Coating

24.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-15 R1 PART NAME : RLV-SB NOZZLE END DOME PRE ASSY SUB ASSY NAME : RLV-SB NOZZLE END SEG.WELDING
OPN.NO STAGE
SHEET NO :
1 OF 1
DESCRIPTION
TOOLINGS
005 #
Inspection Verify the acceptance of the following components and record the idn. nos. in log books 1. Nozzle End Dome 2. Nozzle End Skirt Allot sub assy identification as RLV-NPA-02 to 05..Etc., Weld Setup Load Nozzle End Dome Ring and Nozzle End Skirt on the Welding Fixture. True within 0.2.mm Inspection Inspect for root gap 0.5 to 2mm, mismatch within 0.3mm and record. Record the component Identification numbers also Engrave part Iden No. as RLV-NPA-02,03..Etc., on the component as per drg. Identify the weld joint as RLV-NS-CS-XX-12 Inspect for 1. 238.8 +1.0/-0.5mm 2. Concentricity # Mandatory stages to be cleared by RQS/VSSC Welding Fixture
010
015 #
Mismatch checking templates Feeler Gauge Vernier Caliper
0.2
Vernier Caliper Dial Gauge setup
EERING COMPANY, CHENNAI-106. QUALITY CONTROL PLAN
-SB MOTOR CASE
LICABILITY 02- 05
PROJECT : RLV-SB VSSC 15CDV6 QUANTITY : 1 NO PER MOTOR CASE
TOOLINGS
Welding Fixture
Mismatch checking templates Feeler Gauge Vernier Caliper
Vernier Caliper Dial Gauge setup
y stages to be cleared by RQS/VSSC

24.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-16 R1 PART NAME : RLV-SB NOZZLE END SEGMENT WELDING SUB ASSY NAME : RLV-SB NE SEGMENT MACHINING
OPN.NO STAGE
SHEET NO : 1 OF 6 PART DRG.NO. RKE-RD-06-234-07 Sheet 1 & 2 REF DRG. NO. RD06-25-05-02-3-17-13-10-130
DESCRIPTION
REV. NO. R2 REV. NO. R2
TOOLINGS
005#
Inspection
Verify the acceptance of Cylindrical Shell Qty-2 Nos. Tongued Ring - 1 No. & Nozzle End Dome pre assembly - 1No Allot Assembly identification as RLV-NES-02,03,04&05 etc., Note 1: Idn.No shall be retained during all stages of fabrication and weldjoint to be identified as shown in drawing. Note 2: Welding inspection as per Doc No MEE/QCI/QCP/007/2002issue 2, July 2005. Note 3: Mismatch shall be calculated by taking thickness into account and checked by template and feeler guage at an interval of 50mm. If the mismatch observed is more than the specified, detailed mapping of mismatch at that location shall be provided. 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 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 untill proof pressure test with traceability. Note 8: The Film density shall be kept as 1.8 to 2.5mm for X-Ray Radiography. Template and Feeler guage
DESCRIPTION REFER STAGE-1 WELDING 1. Load shell 1 and shell 2 on shaft using 4 Nos of spiders and true within 0.3mm TIR 2. Spider should be positioned 60 mm inside from the shell end. 3. Shells should be positioned in such a way that prepared weld edges (at cylindrical shell level) facing each other and the each long seam weld is staggered by 90 4. Load the shaft and spider assembly in the welding station and hold one end on the chuck and other end on the tail stock. 5. Inspect for the run out of the shell at both ends. 6. Carryout DP test on WEP of both the shells and record. 1. Clean 50mm width band from inside and outside for both the shells with emery and acetone. 2. Clean the purging fixture also by blowing compressed air and finally by acetone. 3. Set the purging fixture and set the shells by keeping 0.5 to 2mm root gap and 0.3mm mismatch or as per WPS 4. Clean with acetone, ensure purging gas flow. 5. Tack weld the joint at 75 to 100mm interval 1. Welder's qualification and adaptation 2. Orientation of Long Seam Joint 90 apart 3. Thickness of both ends at an interval of 50mm for computing mismatch 4. Root gap, 5. Mismatch 6. Tack length and spacing 7. Get clearance from VSSC for welding
TOOLINGS
Spider and shaft
D.P.Kit
020
Fitting/ Welding
025#
Inspection
030
Welding
Complete the welding by GTAW process in 1G position. Record the following Voltage, current, filler wire code number, diameter and gas flow for purging and shielding, inspect for the total length and record. Compute for the total length of the shells app. 1775mm for shell assembly. Trim one end of the shell by keeping 825mm length for shell 2 and prepare weld edge 30 angle and 0.5 to 1mm root face. Preserve the discarded portion.
Vernier Caliper
040
Lathe
Page 3 of 6 OPN.NO STAGE 045 Inspection
DESCRIPTION Inspect for 1. 0.2 A 2. 0.1 A 3. Length (1775) and 825mm 4. Root face 0. 5 to 1mm 5. Angle 30 6. D.P.Test 7. Thickness near weld edge at 50mm interval and record. REFER STAGE 2 WELDING 1. Load the NE Dome Pre Assembly and true within 0.2mm TIR 2. Insert cirseam Purging fixture on cleaned end of the shell. Ensure cleanliness of the purging fixture and purging gas flow. 3. Clean WEP of NED Ring, NE skirt and 'Y' ring end (in tacked condition) 4. Clean 50mm band of shell circumference at WEP end outside and inside with emery and acetone. 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 1. Welder's qualification and adaptation 2. Thickness of both ends at an interval of 50mm for computing mismatch 3. Root gap, 4. Mismatch 5. Tack length and spacing 6. Get clearance from VSSC for welding Complete the welding by GTAW process in 1G position for c/s of NEDR to skirt and shell. Record the following Voltage, current, filler wire code number , diameter and gas flow for sheilding and purging. 1. Compute for the length 1964.4+0.5/-0.0 and discard accordingly. Considering the triming allowance, trim and prepare weld edge on first shell keeping a length of 925mm 2. Preserve the discarded portion.
TOOLINGS Dial setup Dial setup Vernier Caliper Vernier Caliper Bevel Protractor D.P.Kit UT Gauge/ Ball Point Mic
050
Welding / Fitting
purging fixture
060 065#
070
Welding
080
Lathe
DESCRIPTION Get clearance from inspection department for the computed length considering tongued ring height and get clearance from VSSC for further welding. Inspect for
19
0.2
TOOLINGS
20 0.1 A 21. Total Length 1964.4+0.5/-0.0 & (925mm) 22. Root face 0.5 to 1mm 23. D.P. test on weld edge. 24. Thickness near the weld edge at 50mm 090 Welding/ Fitting REFER STAGE - 3 WELDING Load the tongued ring in the shaft and spider assembly 1.Clean 25mm band of shell circumference outside and inside with emery and acetone. 2. Install cirseam Purging fixture Ensure cleanliness of the purging fixture and purging gas flow. 3. Clean WEP of tongued Ring 4. Set the tongued ring by keeping root gap of 0.5 to 2mm and mismatch within 0.2mm 5. Tack weld the joint at 75 to 100mm interval 1. Welder's qualification and adaptation 2. Thickness of both ends at an interval of 50mm 3. Root gap 4. Mismatch 5. Tack length and spacing 6. Total length 2109.4 7. Get clearance from VSSC for welding Complete the welding by GTAW process in 1G position. Record the following Voltage, current, filler wire code number , diameter and gas flow for purging & sheilding. Inspect for
1
0.2
Dial setup Dial setup Vernier caliper Vernier caliper D.P.Kit UT Gauge / Ball Point Mic
Purging Fixture
095#
Inspection
Mismatch checking template UT guage Feeler guage Vernier caliper Vernier caliper
100#
Welding
0.5
0.5
A A
DESCRIPTION Inspect visual, weld bead and penetration of all joints Identify the weld joint as RLV-NS-CS-XX-12 (Shell 1 # Tongued Ring) RLV-NS-CS-XX-13 (Shell 1 &2 ) RLV-NS-CS-XX-14 (NEDR # Shell 4) RLV-NS-CS-XX-15 (NEDR # NE Skirt) CS = Cirseam Joint XX = Set serial no NS = Nozzle end segment Flush grind penetration without touching the parent metal (0.1mm projection max. permitted) Note 1: Fix Adhesive tape on both sides of the welding before grinding. Note 2: Grinding need not be done for C/S joint between skirt and NEDR Inspect 1. Visual for penetration grinding. Ensure that parent metal is not touched. In case if parent metal is touched, record the thickness when parent metal is touched. 2. D.P.of weld joint 3. 100% RT 4. Inspect for free condition ovality on tongued ring ID & NEDR and record. Carryout repairs if any by gouging the defective area and welding. Inspect
TOOLINGS
110
Fitting
115#
Inspection
3X magnifying glass D.P.Kit X-Ray machine Inside mic
120#
125#
Record the inspected dimension and prepare inspection report 0.2 1 A 2 0.1 A 3. Length 825, 925, 1775 4. Lip distance 0.5 to 1mm 5. Angle 30 6. D.P Test of weld edge of shell 2 7. Length 1964.4+0.5/0.0 8. Lip distance 0.5 to 1mm of shell 1 9. Angle 30 10. D.P test of shell 1
Dial setup Dial setup Vernier caliper Vernier caliper Bevel Protractor D.P.Kit Vernier caliper Vernier caliper Bevel Protractor D.P.Kit

11.
0.2
DESCRIPTION
A
12. 0.5 A 13. 0.5 A 14. LS weld staggered by 90 15. 2109.4 16. Ovality on Tongued ring 961.5 at 16 generators 17. Ovality on NEDR 744 at 16 generators. Get Clearance from VSSC for further processing. # Mandatory stages to be cleared by VSSC
TOOLINGS Dial setup Dial setup Dial setup Vernier caliper Inside mic Inside mic

12.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-17 R1 PART NAME : RLV-SB NOZZLE END SEGMENT MACHINING SUB ASSY NAME : RLV-SB MOTOR CASE ASSY
OPN.NO STAGE
SHEET NO :
PART DRG.NO. RKE-RD-06-234-17 Sheet 1& 2 REF DRG. NO. RD06-25-05-02-3-17-13-10-130

DESCRIPTION
TOOLINGS
005 #
Inspection Confirm the acceptance of NE segment weld assy. Verify that the Idn.No RLV-NES-02,03 etc., Is painted on the shell portion
010
Lathe
Load the job on spiders and shaft. Tighten the spiders. Set the NE Skirt and tongued ring to minimum runout condition. True the shells within 0.3mm and record. Check for the runout of skirt ring OD and tongued ring OD Check for the face out of tongued ring and skirt ring. Compute for the m/cing allowance on 744 of NE ring. Skin cut on skirt ring face, NE dome ring face and tongued ring face Compute for the machining allowance and record Record the setting reading in log book. MACHINING OF NE SMALL END (Refer Drawing detail B): Bore ID 750+0.08 through. Turn OD 825+1.0 through. Face to maintain 12.5mm thickness. Note : Ensure minimum thickness is achieved at one cross section. Counter bore 763+0.4/+0.2 to a depth of 4-0.1/-0.2 and form R0.5 MACHINING OF NE SKIRT RING (Refer Drawing detail F): Bore ID 918 through and face to maintain a thickness of 12(min) Step turn 990-0.026/-0.082 to a depth of 7.5+0.5/0.2, Chamfer 1.5x45
Spider & shaft Dial Gauge setup
020
Lathe
O/S, I/S Mic Vernier caliper
O/S, I/S Mic Vernier caliper
Page 2 of 6 OPN.NO STAGE 025 # Inspection Inspect for 1) 750+0.08 2) 763+0.4/+0.2 3) 825+1.0 4) 990-0.026/-0.082 5) 918 030 Lathe
DESCRIPTION
TOOLINGS I/S Mic I/S Mic O/S Mic Computed I/S Mic
MACHINING OF TONGUED RING (Refer Drawing DETAILS E & E1) Turn OD 1004.5-0.3/-0.7 through Bore ID 965.5 +.09+.00 through Inspect & Compute for length 68.7mm Face to maintain 68.7mm Bore ID 987.5 x 40mm length Inspect for 987.5 +.09 +.00 and record Form groove of 64.7 +0.10+.00 from face and 987.5+.09 +.00 & 973.5 - 0.17-0.31 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 Chamfer 2x45 at 3 locations. Mark P+ Axis by taking reference on LS weld joint. Marking shall be on tongued ring, skirt ring, 825 of NE dome ring & face.
I/S Micrometer
I/S Micrometer
040
Fitting
045#
Inspection Inspect the following Section-XX 1) 2099.40.5 2) (2140.2) 3) 40.8mm Detail - B: 4) 825+1.0 5) 763+0.4/+0.2 6) 750+0.08 7) 12.5mm 8) (14.23) 9) 4-0.1/-0.2 10) R0.5 at 3 places 11) Perpendicularity 12) Concentricity
Tape Tape Vernier Setup O/S Mic I/S Mic, Computed I/S Mic Vernier Caliper Vernier Caliper Depth Gauge Visual Dial Setup
0.1 0.2
C D
on face on 763
Page 3 of 6 OPN.NO STAGE Detail- F: 13) 990-0.026/-0.082 14) 918 15) 12 (min) 16) 7.5+0.5/+0.2 17) 1.5x45 18) Perpendicularity 19) Concentricity 20) Concentricity Detail - E: 21) 1004.5-0.3/-0.7 22) 991.5+0.09 23) 965.5+0.09/+0.0 24) (75) 25) (45) 26) 64.7+0.1/+0.05 27) (68.7) 28) 53.5+0.5 29) 47+0.5 30) 40+0.5 32) 2 x 45 at 3 places 33) Perpendicularity 34) Perpendicularity 35) Perpendicularity 36) Concentricity Detail - E1: 37) 987.5+0.09 38) 973.5-0.17/-0.31
DESCRIPTION
TOOLINGS
Computed I/S Mic Vernier Caliper Depth Gauge Vernier Caliper
0.1 0.4 0.4
C D D
on face on 990 on 918
Dial Setup
Pie Tape Micrometer Computed I/S Mic I/S Mic Depth Gauge Vernier Caliper Depth Gauge Vernier Caliper Vernier Caliper
0.1 0.1 0.1 0.2
C C C D
on outer lip on inner lip on groove face on 1004.5
Dial Setup
I/S Mic Computed
39) (15)
Vernier Caliper
Page 4 of 6 OPN.NO STAGE 40) R0.5 at 2 places 41) Concentricity 42) Concentricity
DESCRIPTION
0.2 0.2
D on 987.5 D
on 973.5
TOOLINGS Visual Dial setup
Get Clearance from VSSC for Drilling operation. 050 Fitting DRILLING OF NE FLANGE: Position the drill Jig by locating on 750, coincide P+ marking of Jig and the job. Clamp the jig & transfer P-, Y+ & Y- axis on the job from the jig and record.
Drill Jig No: RKE-NDRJ-1930-202-40
055 #
Inspection Inspect for the orientation of the drill Jig, alignment of P+ marking on jig & job and record. Drilling Drill 10.65 holes 72nos on 790 PCD starting at 230' from Y+. Inspect & record the orientation of holes and get clearance from QC .Tap M12x1.25P - 4H, 72 nos Note: Use 1st tap only Drill 6+0.1 hole on 8150.5 PCD at Y+
060
065# 070
Inspection Inspect for the holes with reference to the Jig and get clearance for unloading the jig. Fitting DRILLING OF NE SKIRT FLANGE: Position the drill Jig locating on 990 and coincide the P+ marking of Jig & job. Clamp & transfer Y+, Y- & P- axis from Jig to the job and record.
Drill Jig No: RKE-RD06-234-T-19
075 # 080
Inspection Inspect for the orientation of the drill Jig, alignment of P+ marking Jig & Job and record. Drilling / Instruct the operator for identifying M12 holes on P+ P- Y+ & Y- axis as per drg. Drill 10.65 holes 8 nos, 2 nos each on either side of P+, P-, Y+,Y- axis on 958 PCD and 5 37' 30" to axis. Get clearance from QC. Tap M12x1.25P -4H, 8 nos. Drill 8.6 holes 24nos. on 958 PCD and 1115' from M12 holes. Get clearance from QC. Tap M10x1.25P -4H, 24 nos on 958 PCD. Note: Use 1st tap only
085 #
Inspection Inspect for the holes with reference to the Jig and get clearance for unloading the jig.
Page 5 of 6 OPN.NO STAGE 090 IC Jig
DESCRIPTION DRILLING OF SEGMENT PIN HOLES: Load the assy on interchangable drill Jig by facing grooved ring at bottom and coincide P+ marking on Jig & Job. True the tongued ring OD within 0.1mm and clamp.
TOOLINGS
095#
Inspection Inspect for face butting with feeler gauge (max gap 0.05mm) Jig orientation and setup. Verify the P+ marking of the Jig and job are coincided. Drilling Drill 6 holes 3nos through & 120 apart and lock. Open up the hole to 11.5mm. Ream the holes to 12+0.018. Check with GO NO GO Plug guage. Lock the holes with pins. Drill 6 holes, 69 nos and open up to 11.5mm. Ream 69 nos of holes 12+0.018. Note: Check with Go & No Go plug Gauge after reaming of every 5 holes
Feeler Gauge
100
105#
Inspection Inspect for 12+0.018 with Jig in position. Get clerance from VSSC to unload the job from the jig. Fitting Unload the segment & load on the trolley. Complete tapping of M12 & M10 holes. Mark the cutout as per drawing in line with P+ and P- as shown in View-H. Drill and open out the cutout 100x52mm and radius 26mm. Drill 4.1 holes, 4 nos.through. Tap M5x0.8P, 4 nos. Open out 3 slotted holes, width 12mm, 30 & 5 +0.5 +0.0 at 230' off from Y+, P+ & Ytowards P+, Y- and P- respectively (Converted after drilling 12 holes)
Go & No Go Gauge/ B.Gauge
110
120
Fitting
130
Fitting
ed
Page 6 of 6 DESCRIPTION OPN.NO STAGE 135# Inspection Inspect for Refer View-N: 43) M12x1.25P-4H, 72 nos equispaced on PCD 790 starting at 230' from Y+ towards P44) M12x1.25P-4H, 8 nos, equispaced on PCD 958 starting at 537'30" on each side of P+, P-,Y+ & Y- axis. 45) M10 x 1.25P - 4H 24nos. on 958 PCD and 1115' from M12 holes. 46) 60.1 hole at 'Y+' and on 8150.5 PCD 47) Orientation of LS weld 45 (typ) View -K: 48) 12+0.018 holes, 72 nos starting at 230' from Y+ to P49) 230' and 5 View-H : 50) M5x0.8-6H, 4 nos. 51) Cutout at 2 locations at P+ & P- axis 52) 130mm 53) 40mm at 2 places 54) 56mm 55) 52mm 56) 100mm 57) R26 at two places. View-J : 62) 3 slotted holes at 230' off from Y+, P+ & Y- towards P+, Y- & P- respectively 63) 5+0.5 64) 12mm 65) 30 66) Marking of axis P+, P-, Y+ & Y67) Transfer the Idn.No by engraving on taper portion of Tongued ring at P+, Skirt ring and nozzle end dome ring Get Clearance from VSSC for weld pad welding. Note: Spiders are not to be removed at this stage. Ovality will be inspected after PPT & removal of Spider. Ovality inspected at earlier stage of weld assembly & reported. # Mandatory stages to be cleared by RQS/VSSC
TOOLINGS
Go & NoGo Thread Plug Gauge Drill Jig Vernier Caliper
GO NO GO Plug Gauge I/C Jig / Bore Dial Gauge GO NO GO Plug Gauge Vernier Caliper
ed
Vernier Caliper

21.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-18 R1 PART NAME : RLV-SB NOZZLE END SEGMENT WELD PADS WELDING SUB ASSY NAME : RLV-SB MOTOR CASE ASSY
OPN.NO STAGE
SHEET NO :
1 OF 2
DESCRIPTION
PROJECT : RLV-SB CLIENT : VSSC 15CDV6 MATL : QUANTITY : 1 NO.

TOOLINGS
005 #
Inspection Confirm the acceptance of the following: Nozzle Seg.assy-1 No Wire Tunnel Weld Pad - 32 Nos. Fitting Mark the location of wire tunnel weld pads on segment assy with reference to P+ axis as shown in drg. Clean the area with emery and acetone. Position the weld pad welding fixture and assemble the pads in position. Weld pad welding fixture No. RKE-RD-06-234-T-27
010
015 # 020
Inspection Inspect for the weld pad orientation and fixture position. Welding Set and tack weld wire tunnel weld pads at a distance of 265mm from the Skirt ring face and 250mm from the first pair of weld pad at 6 locations and 201mm for the last pad at P+ axis as shown in the drawing.
025#
Inspection Inspect for the weld pad locations and orientation of the weld pads with reference to the fixture. Get clearance from VSSC for welding. Welding Complete the fillet welding (Ref.doc.no MEE/QCI/QCP/007/2002, issue 2, July 2005) Repeat operation 10 to 30 for the completion of weld pad at P- axis.
030
040
Fitting/ Welding
Page 2 of 2 OPN.NO STAGE 045 #
DESCRIPTION
TOOLINGS
Inspection Inspect the location of weld pad as per the drawing. Carry out DP Test on the fillet weld. 1) 265 2) 250x6 3) 201.0 4) (110mm) 5) 20.0 6) 50 7) 20.0 8) 38 9) 3mm Fillet weld
D.P. Kit Vernier Caliper
Get Clearance from VSSC for Proof Pressure Test.

27.01.2009 PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-19 R1 PART NAME : RLV-SB WIRE TUNNEL WELD PAD SUB ASSY NAME : RLV-SB WELD PAD WELDING
OPN.NO STAGE
SHEET NO :
1 OF 3
DESCRIPTION
PROJECT : RLV-SB CLIENT : VSSC 15CDV6 MATL : ANNEALED CONDITION QUANTITY : 140 Nos PER MOTOR CASE
TOOLINGS
005 #
Inspection Verify the acceptance of the raw material in correlation with the T.C issued by VSSC. Allot Idn.no as RLV-WTP-01,02,.. Cutting Cut the plate from the supplied material as per requirement of the drg
010 015
Heat Note 1: Ensure that chart recorder is working Treatment Note 2: A copy of the chart to be attached with Inspection Report. Heat treat the weld pad material as per Doc.No MEE/QCI/QCP/007/2002 Issue 2, July 2005
025 #
Hardness Grind the surface of material to 3mm depth and check hardness 34 - 40 HRC Testing M/c Milling Milling Mill & Cut the piece to required size Mill the job to size 36x15x21mm Mill flange to maintain 10mm thickness, depth 13mm Form groove as per drg (Detail-X), Form Chamfer 1x 45 and R2
030 040
Vernier Caliper Depth mic
050 055 #
Fitting File & suit to the profile Inspection Inspect the following dimensions 1) 36.0 mm 2) 15.0
Vernier Caliper Vernier Caliper
Page 2 of 3 OPN.NO STAGE 3) *(21.0) 4) 10mm 5) 8mm 6)*R500 7) 2 mm x 5 Depth 8) 2mm and 4.25mm 9) R1 at two places 10) R2 060 Fitting/ Drilling
DESCRIPTION
TOOLINGS Vernier Caliper Vernier Caliper Vernier Caliper Checking template Vernier Caliper Vernier Caliper Visual Radius Gauge Go & NoGo Gauge
1. Mark and drill 3.2 hole x7.5 (max) depth Tap M4 x0.7 P 6 H Thread 6 (min) depth 2. Mark and drill 4.1 holes x9 (max) depth Tap M5 x 0.8 P 6H Thread 7.5 (min) depth
065 #
Inspection Inspect for the following dimensions 1) M5x0.8P x 6H 2) 7.5 3) 9.0 4) M4 x 0.7 P x 6H 5) 7.5 6) 6.0 7) 8.0 8) 7.5 9) 6.0 10) 36.0 11) 15.0 12) 10.0 13) 15.5 14) 20.5 15) 2mm 16) 5mm
Go & NoGo Gauge Compute Depth Gauge Go & NoGo Gauge Compute Depth Gauge Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper
Page 3 of3 OPN.NO STAGE 17) 4.25mm 18) 2mm 20) R1 at two places 21) 1x 45 at 3 places 22) R2 23) R500 24) (21)
DESCRIPTION
TOOLINGS Vernier Caliper Vernier Caliper Radius Gauge Suited to shell profile V/C suited to shell profile
D.P test all over Apply Black Japan & credit to stores Note : Ensure that all Inspection reports are prepared before clearing the job for further operations # Mandatory stages to be cleared by RQS/VSSC * Will be checked at assembly stage

27.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-20 R1 PART NAME : RLV-SB DESTRUCT SYSTEM WELD PAD SUB ASSY NAME : RLV-SB HE SEGMENT WELD PAD WELDING
SHEET NO :
1 OF 4
PROJECT : RLV-SB CLIENT : VSSC 15CDV6 MATL : (ANNEALED CONDITION)

QUANTITY :WELD PAD I - 4 NOS WELD PAD II - 4 NOS WELD PAD III - 10 NOS WELD PAD IV - 8NOS WELD PAD V - 16NOS
OPN.NO
STAGE
DESCRIPTION
TOOLINGS
005 #
Inspection Verify the acceptance of the raw materials in correlation with the T.C issued by VSSC. RLV-DWP-I-01,02., RLV-DWP-II-01,02., RLV-DWP-III-01,02., RLV-DWP-IV-01,02., RLV-DWP-V-01,02., etc., Cutting Cut the plate from the supplied material as per requirement of the drg
010 020#
Heat Note 1: Ensure that chart recorder is working Treatment Note 2: A copy of the chart to be attached with Inspection Report. Heat treat the weld pad material as per Doc.no MEE/QCI/QCP/007/2002, Issue 2, July 2005.
025 # 030 040
Hardness Milling Milling
Grind the surface of material by removing 3mm and check hardness 34 38 HRC Mill & cut the plate to required size Weld pad I Mill the job to size 15 x 12 x 12 long Chamfer 2x450 as per drg. File to suit dome profile to maintain (10.2 mm) thickness
Vernier Caliper Bevel Protractor
050
Fitting
Checking template
Page 2 of 4
060
Drilling / Tapping
Drill 4.1 through hole & tap M5x0.8-6H
Go & NoGo Gauge
065 #
070
Inspection Inspect and record the following dimensions 1. 15mm 2. 12mm 3.*(10.2) mm 4. M5x0.8-6H 5. 2x45 D.P.Check all over Weld pad II Milling Mill the job to size 15 x 12 - 20 long 0 Chamfer 2x45 as per drg. Fitting File to suit dome profile to maintain *(15.2) thk on one side and *(17.6) thk on the other side Drill 4.1 through hole & tap M5x0.8Px6H
Vernier Caliper Vernier Caliper Vernier Caliper Go & NoGo Gauge D.P. Kit Vernier Caliper Bevel Protractor
080 090 095 #
Vernier Caliper Go & NoGo Gauge
100
Drilling / Tapping Inspection Inspect the following dimensions 1) 15 mm 2) 12mm 3) *(15.2) mm 4) *(17.6) mm 5) M5x0.8-6H 6) 2x45 D.P.Check all over Weld Pad III Milling Mill the job to size 25 x 12 - 14 long Mill to maintain flange thickness 10mm depth 5mm chamfer 2x45 0 (typ) VMC Drilling / Tapping File to suit dome profile to maintain *(8.3) thk and *(12.5) thk Drill 4.1, 2 holes & tap M5x0.8-6H as per drg
Vernier Caliper Vernier Caliper Vernier Caliper Go & NoGo Gauge D.P. Kit D.P. Kit Vernier Caliper Bevel Protractor
110 120
Vernier Caliper Go & NoGo Gauge
Page 3 of 4
125 #
Inspection Inspect and record the following dimensions 1) 12mm 2) 25mm 3) *(12.5) mm 4) *(8.3) mm 5) 5mm 6) 10mm 7) 2x45 (typ) 8)*7+0.5 9) 7.5 mm 10) M5x0.8- 6H D.P. check all over Milling Weld Pad IV Mill the job to size 25 x 12 - 20 long 0 Mill to a depth of 3mm, 30 , Chamfer 2x450 Program&execute radius to suit dome profile to maintain *(10.1) thk and *(17) thk Drill 4.1,2 holes & tap M5x0.8-6H as per drg.
Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Bevel Protractor
Go & NoGo Gauge D.P. Kit
130
Vernier Caliper Bevel Protractor Vernier Caliper Go & NoGo Gauge
140 150
VMC Drilling / Tapping
155 #
Inspection Inspect and record the following dimensions 1) 12mm 2) 25mm 3) 3 mm 4) 300 5) *(10.1) mm 6) *(17) mm 7) 2x45 (typ) 8) 7.5 mm 9) 10mm 10) 7+0.5 11) M5x0.8-6H D.P. check all over * Will be checked at assembly stage
Vernier Caliper Vernier Caliper Depth Mic Bevel Protractor Vernier Caliper Vernier Caliper Bevel Protractor Vernier Caliper Vernier Caliper Vernier Caliper Go & NoGo Gauge D.P. Kit
Page 4 of 4
160
Milling
Weld Pad V Mill the job to size 15 x 15 x 11.5mm Thickness for Chamfer 2x45 Programme &execute radius to suit dome profile by keeping *(10.2) and *(10.77)m.n Drill 4.1hole & tap M5x0.8P 6H as per drg.
Vernier Caliper Vernier Caliper Go & NoGo Gauge
170 180
VMC Drilling / Tapping
185 #
Inspection Inspect and record the following dimensions 1) 15.0 2) 15.0 3) *(10.2) 4) *(9.76) 5) *(10.1) mm 6) 2x45 7) 10.77 8) M5 x 0.8P x 6H Apply protective and store # Mandatory stages/dimensions to be cleared by RQS/VSSC * Will be checked at assembly stage
Vernier Caliper

27.11.2008
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-21 R0 PART NAME : RLV-SB STRAP RING SUB ASSY NAME : RLV-SB MOTOR CASE ASSY
OPN.NO STAGE
SHEET NO :
1 OF 2
DESCRIPTION
PROJECT : RLV-SB CLIENT : VSSC 15CDV6 MATL : 2.2mm SHEET ANNEALED QUANTITY : 2 Nos PER MOTOR CASE
TOOLINGS
005 #
Inspection
Verify the RMC No. and the acceptance of the material in correlation with the TC issued by VSSC. Allot part and Idn.No as RLV-SR-01,02,.. Mark and cut the size for a length of 1591.2 and 20 width - 2 Nos per assy
010
Fitting
Mark the developed length as (d+t) d = ID of ring t = Thickness Eg. Development length for 2t and 1011 ID (1011+2) = 3182.4 mm 3182.4/2 = 1591.2mm 2 Nos
020 030 Fitting Rolling Flatten the sheet and do the pre bend for R507.5 Clean the sheets and working area of the rolling machine. Feed the sheet and start rolling to complete the rolling of sheet for ring to suit 1015+0.5 as per the checking template Remove the ring from machine Remove ovality and bend on ring by using wooden mallet Set the locating plate on the table and load the ring over that and bring centre to the marked location and do the drill 4.1. Enlarge the hole to 10x5.2 at 3 locations 115', 345' and 5 at P+ and Peither side 3 holes (total 6 nos on each half) Checking template RKE-CT-1930-202-51
040 050
Fitting HBM
Page 2 of 2
055#
Inspection
Inspect the following dimensions 1) 10mm 2) 5.2mm 3) 2.6 Radius 4) 1015+0.5 5) 20mm 6) 10x5.2,6 nos on each half 7) 2mm thk 8) Gap 2mm on either side 9) 115' 10) 345' 11) 5 Apply protective coating and store
INEERING COMPANY, CHENNAI-106. ND QUALITY CONTROL PLAN
LV-SB MOTOR CASE
PPLICABILITY 02- 05
PROJECT : RLV-SB VSSC 15CDV6 2.2mm SHEET ANNEALED QUANTITY : 2 Nos PER MOTOR CASE
TOOLINGS
Checking template RKE-CT-1930-202-51
TOOLINGS

27.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-22 R1 PART NAME : RLV-SB RETAINER STRIP SUB ASSY NAME : RLV-SB MOTOR CASE ASSY
OPN.NO STAGE
SHEET NO :
1 OF 2
DESCRIPTION
PROJECT : RLV-SB CLIENT : VSSC SA515 Gr.70 MATL : QUANTITY : 1 NO PER MOTOR CASE
TOOLINGS
005 #
Inspection Verify the RMC No. and the acceptance of the material. Allot part and Idn.No as RLV-RS-01,02.., Note: Material grade to be ensured by chemical test Fitting Roll the plate of size 2820x28x16mm to form a ring size OD 925 Prepare the edge on both the ends. Clean the WEP by acetone
010
020
Tig Welding Carry out welding of the plate to form a ring of OD 925.0mm. Grind the weld bead and penetration and record the weld parameters. Inspection Carry out DP test on the weld joint. VTL Hold the job on the OD true and clamp skin cut the face. Clamp the job on face without disturbing the set up and skin cut on OD and ID. Reverse the job true & clamp on OD skin cut the face. Bore 877.1 through step turn 911+0.10+0.05 by keeping 5mm (8-3) flange thickness. Clamp on face from inside without disturbing the setup. Turn OD 915 through. I/S Mic
025 030
040
VTL
I/S Mic
045#
Inspection Inspect in the machine itself 877.1 911.0 +0.05+0.10
I/S Mic I/S Mic
Page 2 of 2
050# 060#
VTL
Face to maintain 3.0-0.1/-0.2mm depth.
Inspection Inspect for 8.0mm 3.0 -0.2/-0.1 mm DP Test all over Drilling Position the Drill Jig & Clamp. Inspect for the positioning of Jig. Drill 3.2 holes 72nos. Equispaced on PCD 902.0 .10. Get clearance from VSSC for unloading the jig.
Vernier Caliper Depth Gauge DP Kit Drill Jig No. RKE-RD06-234-T-21
070 #
075# 080
Inspection Inspect 3.2 holes 72nos. Fitting Mark & identify the ring to 24 segments by keeping 3.2 holes equi distant from the edge. Engrave the Identification numbers on each segment. Slit the ring using 1mm Slitting saw.
Vernier Caliper
085#
Inspection Inspect for the identification numbers. Apply Black Japan & preserve.

27.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-23 R0 PART NAME : RLV-SB SEGMENT HOLDING PIN SUB ASSY NAME : RLV-SB MOTOR CASE ASSY
OPN.NO STAGE
SHEET NO :
1 OF 2
DESCRIPTION
PROJECT : RLV-SB CLIENT : VSSC EN 19 RODS MATL : (ANNEALED CONDITION) QUANTITY : 144 NOS PER MOTOR CASE
TOOLINGS
005 #
Inspection Verify the RMC No. and the acceptance of the material in correlation with the TC issued by VSSC. Allot part and Idn.No as RLV-SH-01,02,.. Lathe Load the job on the chuck true & clamp Skin cut on face, turn the OD 12.3x35mm long Drill on centre 4.1x7 (max) depth Chamfer 1.25 x 45 (length to reduce to 16.5mm) Tap M5x0.8Px5(min) length by 1st tap only. Part off the rod to 20mm length. Reverse the job hold on OD, True within 0.01mm. Turn the face to 17mm and and chamfer 1.25 x 45 Turn 3 Nos Tensile specimen as per ASTM A-370 of 15x250 length Apply anticorp on threads.
010
020
Lathe
030 040 050 #
Lathe Fitting
Heat Load the material in heat treatment fixture and carry out heat treatment Treatment as per standard heat cycle for EN19 steel so as to achieve UTS of 110kg mm2 Hardening Cycle Loading temp. - Less than 650 C Soaking temp - 850 - 870C Soaking time - 40 minutes Quenching medium - Oil Quenching delay - 45 seconds
DESCRIPTION
TOOLINGS
060
Tempering cycle Loading temp. - Less than 400C Soaking temp. - 550 to 570C Soaking time - 80 minutes Quenching medium - Oil Quenching delay - 45 seconds Hardness Carryout hardness check 10 nos min in a batch of charge 341- 401 BHN Checking Lathe UTM Prepare 3nos. Of tensile test specimen and inspect & record the values. Carryout mechanical testing on test coupons (3 Nos)as per ASTM A-370 min. 2 UTS - 110 Kg/mm 0.2% PS 85 Kg/mm2 %Elongation 13% (min) Remove anticorp on threads completely Complete tapping of M5x0.8-6H x 5mm (min) depth. Thread plug Gauge
065 070
080
Fitting
090
Centreless Load the pins on m/c one by one on OD to maintain 12-0.016/-0.034 grinding Surface grinding Grind on both faces to maintain length 16.5-0.2.
Micrometer
100
Vernier Caliper
105 #
Inspection Inspect the following dimensions 1) 12-0.016/-0.034 2) 16.5-0.2 3 1x45 (typ) 4) M5x0.8P-6H 5) 5 (min) 6) 7 (max) 7) (8.5) D.P. test all over Apply rust prevent oil & store properly
Dial set up Vernier Caliper
Thread plug Gauge Vernier Caliper Vernier Caliper

28.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-24 R1 PART NAME : RLV-SB WELD PAD & SUPPORT PLATE FOR NOZZLE CONV. SUB ASSY NAME : RLV-SB NOZZLE CONVERGENT HARDWARE OPN.NO 005 # STAGE Inspection
SHEET NO :
1 OF 3
PART DRG.NO. REV NO. RKE-RD-06-234-24 (Sheet 2 of 3) R5 REF DRG. NO. REV.NO RD06-25-05-02-3-17-13-10-210 R2
PROJECT : RLV-SB CLIENT : VSSC 15CDV6 MATL : Annealed QUANTITY : WELD PAD - 16 NOS SUPPORT PLATE - 4 NOS TOOLINGS
DESCRIPTION Verify the acceptance of the raw material in correlation with the TC issued by VSSC. Allot Idn No as RLV-WP-17,18, & RLV-WSP-05,06,.etc., WELD PAD FOR NOZZLE CONVERGENT
010 015
Cutting Heat Treatment
Cut the material to 22mm sqare and Identify. Heat treat the weld pad material as per Doc.No.MEE/QCI/QCP/007/2002 Issue 2, July 2005 Note 1: Ensure that chart recorder is working Note 2: A copy of the chart to be attached with Inspection Report.
025 #
Hardness Testing m/c Milling Drilling
Grind the surface for 3mm on bothsides and check hardness 34 to 38 RC
030 040
Mill the job to 16mm square Drill 6.8 through and tap M8x1.0-4H
Page 2 of 3 OPN.NO STAGE 045 # Inspection
DESCRIPTION Inspect the following dimensions 1) 16mm square 2) (11.0) 3) M8x1.0-4H 4) Equi Distance D.P.Check all over SUPPORT PLATE : Mill the plate to a size of 100x70mmx7mm Heat treat the support plate as per Doc.No.MEE/QCI/QCP/007/2002 Issue 2, July 2005 Note 1: Ensure that chart recorder is working Note 2: A copy of the chart to be attached with Inspection Report.
TOOLINGS Vernier Caliper Vernier Caliper Go & NoGo thread plug
050 060
065#
Hardness Testing m/c Sandblast
Grind the surface to remove scales on bothsides and check hardness 34 to 38 HRC Sandblast the job
070 80 90
Milling/Fitting Form/ Roll the plate to 246.5 radius AT Inside. Milling/ Fitting Mill to size 90 x 60mm width Depth Mic
95 #
Inspection
Inspect the following dimensions 1) 90mm 2) 10.0 3) 7mm thickness 4) R246.5 D.P. check all over
Vernier Caliper Vernier Caliper UT Gauge Template D.P.Kit
Page 3 of 3 OPN.NO
STAGE
DESCRIPTION
TOOLINGS
100 Fitting Welding
Weld Pad Welding Mark centerline for positioning the weldpad. Suit the weld pad by maintaining 10mm Height at Middle.Tack weld four weld pad each on support plate and complete the welding. Correct the profile to suit the convergent by maintaining 3.97mm & 25.75mm as per drawing. Inspect and prepare report for Weldpad, Support plate & Assembly 1) 7mm Thickness 2) 60mm and equi distance 3) 25mm and equi distance 4) (10mm Height) 5) 3.97mm 6) 25.75mm 7) DP test Get clearance from VSSC for 4 sets of pad
110
Fitting
115 #
Inspection
Micro meter Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper DP Kit

28.01.2009 PROCESS SHEET NO : REV.NO SHEET NO : 1 OF 4
RKE/RLV/68/PS-25 R2 PART NAME : RLV-SB NOZZLE CONV. INTERMEDIATE M/CING, WELD PAD WELDING & NOZZLE CONV. H/W M/CING
SUB ASSY NAME :
PART DRG.NO. RKE-RD-06-234-24 Sheet 1,2 & 3
REV NO. R5
PROJECT : RLV-SB CLIENT : VSSC 15CDV6 MATL : HARDENED AND TEMPERED

QUANTITY : 1 No per
REF DRG. NO.
REV NO.
RLV-SB MOTOR H/W

OPN.NO STAGE
RD06-25-05-02-3-17-13-10-210
DESCRIPTION
R2
MOTOR CASE
TOOLINGS
005 #
Inspection Verify the acceptance of the Nozzle Convergent and support plate assembly with weld pad (4nos) Intermediate machining (Ref Drg No : RKE-RD06-234-24 sheet 1 of 3) Set the forging on machine table by resting smaller end True ID and clamp on OD and skin cut on face Bore 484 through.
010#
CNC VTL
Reverse the job true 484 +0.2/ -0.0. Skin cut the face.
Step turn 754 x 8.9mm depth. Taper turn 44 x 134.9mm depth. Execute the program for OD turning as per drg by maintaining 5mm wall thk on Cylindrical portion and 4.5mm on taper portion. Inspect 0.1 C Perpendicularity unload and reverse the job, true 484. Turn OD 543+0.5/-0.0 Face to maintain 414.5 0.1mm length. Inspect for Concentricity 0.2 M 0.1 C Perpendicularity 015 020 Inspection Inspect the job as per drawing and release for marking at HBM HBM Refer drawing Sheet No. 2 of 3 Mark P+, P- axis and 45 lines . Compute for the machining allowance and mark distance 50mm and 352mm 0.1 for weld pad orientation .
I/S Mic O/S checking templates RKE-RD06-234-T-15 & RKE-RD06-234-T-16
Dial Setup
Dial Setup Dial Setup
Page 2 of 5
025#
Inspection Inspect for Marking Welding
030
Fitting/ Welding
Position support plate weld assy at 4 locations. Coincide the marking and Tack weld. Insert Bunk on 484 under the weld to avoid suck back.
035 040
Inspection Inspection for the orientation of Support plate weld assy and gap if any at taper portion. Welding Complete the welding of support plate (25mm length at four corners one side only of support plate)
045#
Inspection Inspect for the following 1) 352 0.1 2) 25 3) 60 4) 10 5) Support Plate assy orientation at 45 DP Test Final machining (Ref Drg No RKE-06-234-24 Sheet 03 of 03) Load the job on CNC VTL and true 543 within 0.05mm . Compute for the machining allowance on ID , length and thickness of the flange. Bore 488 +0.063/+0.0 through. Ensuring min thickness of 2.50.1 and Turn OD to 8250.1. and face to maintain 21.4mm (12.5 + 8.9) Step turn 750/-0.026/-0.082 to a depth of 8.9mm by maintaining flange thickness 12.5mm. Taper turn 44 +0 /-4' so as to achieve the thickness of 2.5+0.1/+0.0 and depth of 132.9mm. Inspect and record 825, 750,angle 44, 488mm and perpendicularity of 750 face. Reverse true 488 within 0.05mm and clamp. Turn OD 540+0.1-0.0 through. Face to maintain 410.5 0.1 length and flange thickness 10mm Counter bore 498 +0.1/+0.0 x 3mm -0.1/-0.0 depth. Form Radius R0.5 at two locations Inspect perpendicularity concentricity and visual on the 'O' ring groove. (No scratch mark on "O" ring groove) Get clearance from VSSC for unloading the job.
Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper HBM DP Kit
050#
CNC VTL
Bore Dial gauge Dial Set up Micrometer Bevel Protractor UT guage
060#
CNC VTL
Bore Dial gauge Micrometer UT guage Dial Set up
Page 3 of 4
070#
Drilling
Position the drill jig by locating ID 498+0.1/+0.0 & coincide 'Y+' axis marking Drill 6.9 hole, 72 nos equispaced on 516 PCD starting at 230' from 'Y+' towards 'P-' Tap M8x1-4H, 72 nos and 0.2 Drill 4+0.1/-0.0 hole on 530 PCD at 'Y+' Position the drill jig by locating OD 750 & coincide 'Y+' axis marking Drill 13 holes, 72 nos equispaced on 790 PCD starting at 230' from 'Y+' towards 'P-' and 0.2 spot face 26, 72 Nos, within concentricity 0.1 with reference to axis.
Drill Jig No RKE-RD06-234-T-20
080#
Drilling
Drill Jig No RKE-NDRJ-1930-202-40 Process controlled
085#
Inspection Inspection Section AA: 1) 825.00.1 2) 750-0.026/-0.082 3) 549.5 4) 2.5+0.1-0.0 (at 8 generators & 4 places) 5) 132.9 0.1 C 6) 7) 350.00.5 8) 410.5 +0.10-0.10 (at 8 generators) 0.1 C 9) 0.2 M 10) Section KK: 11) 6 +0.10-0.00 12) 815.0 PCD,2, 30' 0.01 13) 13.0 x72 nos 0.2 14) PCD 790 15) 45 Weld Pad Orientation View X: 16) 4.0 +0.10-0.00 17) 530.0 PCD 18) M8 x1P 4H x 72nos 19) 516.0 PCD & 2, 30'
Micrometer Micrometer Micrometer UT Gauge V.Height Gauge Dial set up (line Inspection) Height Gauge Height Gauge Dial set up (line Inspection) Dial set up (line Inspection) Bore Gauge Qualified Drill Jig
Vernier Caliper
Qualified Drill Jig Line Inspection Bore Gauge Qualified Drill Jig Go, No Go Thread Qualified Drill Jig
Page 4 of 4
Detail A: 20) 8.90 21) 12.5 22) R1.5 23) R 70,R100, (44 on OD) 24) 26 x 0.5 max Spot Face 25) 44+0' -4' Detail B: 26) 10.0 27) 10, R5, 7,+4' -0 28) 3 -0.1/+0.0 0.1 C 29) 30) Ovality 488.0 31) Ovality 750 DP Test all over Axis marking on FE & AE flange.
0.1
Vernier Depth Gauge Micrometer Radius Guage Checking Template RKE-RD-06-234-T-16 Dial Setup V. Caliper Bevel Protractor
Vernier Caliper Checking Template RKE-RD-06-234-T-16 Vernier Depth Gauge Dial Setup Bore Dial Guage Bore Dial Guage DP Kit
# Mandatory stages /dimensions to be cleared by RQS/VSSC

RLV-SB
28.01.2009
PROCESS SHEET NO : RKE/RLV/68/PS-26
REV.NO R3
SHEET NO : PART DRG.NO.
PART NAME : RLV-SB NOZZLE DIVERGENT H/W
RKE-RD-06-234-25 Sheet 1& 2 SUB ASSY NAME : RLV-SB MOTOR H/W

OPN.NO STAGE
REF DRG. NO. RD06-25-05-02-3-17-13-10-220

DESCRIPTION
PROJECT : RLV-SB CLIENT : VSSC MATL : 15 CDV6 FORGING (Heat treated) QUANTITY : 1 NO PER MOTOR CASE
TOOLINGS
005 #
Inspection 1. Verify the acceptance of the raw material in correlation with the TC issued by VSSC. Allot Idn.No as RLV-DIV-01,02., etc 2. Verify the acceptance of the following components Valve mounting adaptor Support plate & weld pad assy
4 Nos 3 Nos
010
VTL
Stage - 1 Machining (Ref Sketch 1) Load the job on VTL by resting the smaller end on VTL, True OD at larger end within 0.5mm and clamp on chuck. Skin cut on the face to generate Datum Surface. Reverse the job and true OD at larger end within 0.5mm and clamp from outside. Taper turn ID to 1420'+1.5'-0'. Face to maintain 448.5mm step turn OD 550x37.8mm depth. Clamp from inside with out disturbing the set up and remove the outside clamp. Taper turn OD by keeping 52mm flange thickness. Turn OD 935 as per sketch. Stage - 2 Machining (Ref Sketch 2 ) Set the master taper and set the taper angle for the spindle. Load the job by resting smaller end flange on the table. True OD and face within 0.1mm and clamp at outside. Taper turn ID to maintain 457.8 at the smaller end. Without disturbing the setup clamp from inside. Remove the outside clamp. Face turn to maintain 885.2 at the larger end.
Dial Setup
020
VTL
Machining Master Taper RKE-RD06-234-T-023
Page 2 of 8
040
VTL
Stage - 3 Machining (Ref Sketch 3) Reverse the job, true ID and face within 0.1mm and clamp. Turn OD 549x30mm depth (to maintain 27.86mm) Turn OD 925 through at larger end. Taper turn OD1420'+1.5'-0' by maintaining 14mm wall thickness and 20mm thickness of flanges as shown in the sketch. Form Radius R5 and maintain thickness 27.86mm at smaller end and 39.14mm at the larger end.
045 050
Inspection Inspect for the dimensions as per sketch and record in the logbook. HBM Fitting Stage - 4 Cutout details (Ref Sketch4) Mark the cutout details , axis marking and centre lines at 4 locaitons, 90 apart as per sketch 4.
055# 060
Inspection Inspect the cutout & axis marking as per sketch 4 and record in the log book HBM Hold the job and true OD and face within 0.1mm open 4 cutouts at P+ PY+Y- locations by maintaining centre height of 295.4mm and width of 185mm x 72mm. Prepare weld edge.
065
Inspection Inspect the following: 1) 185mm 2) 30 3) 30 4) 72mm 5) 295.4mm Line inspected during marking of central line Carry out D.P Test Fitting Welding Stage -5 Valve Mounting Adaptor Welding (Ref. Sketch 5) Verify the acceptance of the valve mounting adaptor 4 Nos. Match the centre lines of the adaptor box and cut out openings marked on the cone. Position the support fixture from inside . Tack weld , ensure proper alignment and check the root gap. Fillet weld the boxes as per sketch.
Vernier Caliper Bevel Protractor Bevel Protractor Vernier Caliper Height Gauge Setup D.P Kit
070
Page 3 of 8
075#
Inspection Inspect the following: 1) 303.8 2) Visual Inspection 3) DP Test on the Fillet weld VTL Stage - 6 Machining for Weld Pad (Ref. Sketch 6) Set the master taper and set the machine spindle. Load the job true OD and face within 0.1mm and clamp. Taper turn OD as shown in the sketch by maintaining 7+0.2-0 thickness. Unload the job.
Height Gauge Setup D.P.Kit
080
090
Welding / Stage - 7 Weld Pad Welding (Ref. Sketch 7) Position the weld pad and support plate assembly at 3 locations Fitting a) 10 away from Y+ and towards P- b)130, c)120 apart and at a distance of 145.2mm as per drawing. Tack weld and check the alignment. Inspection Inspect for the weld pad orientation Welding Carry out fillet welding 25mm long at 4 locations
095 100 105
Inspection Inspect the following: 1) 145.2 2) Weld pad orientation 3) DP Test on welds 4) Length of fillet 25mm VTL Stage - 8 Outside Machining (Ref. Sketch 8) Set the master taper and set the taper angle of the spindle. Load the job on VTL by keeping larger flange on the base plate. True OD and face within 0.1mm and clamp. Skin cut on the face to keep 459.33mm. Taper turn OD as per sketch by maintaining flange thickness of 19 and 35.8mm, thickness 8mm at taper portion, and 14mm web thickness.
Height Gauge Setup D.P.Kit Vernier Caliper
110
Page 4 of 8
120
VTL
Stage - 9 Inside Machining (Ref. Sketch 9) Set the master taper and set the machine spindle. Load the job on VTL true face and OD within 0.1mm and clamp from outside. Taper turn inside. Face to maintain 890.8+0.8/+0.4 at the larger end. Turn OD 915 through. Step turn 911-0.086-0.226 x 3mm +0.1+0.2 .
# 125
Inspection Inspect for the following: 1) 915mm 2) 890.8+0.8/+0.4mm 3) 911-0.086/-0.226mm 4) 3+0.1/+0.2mm Record the fixture condition reading for 890,915 & 911.0mm VTL Stage - 10 Outside Machining (Ref. Sketch 10) Set the master taper and set the machine spindle. Load the job on VTL true 915 and face within 0.1mm and clamp. Record the setup reading. Face to maintain 468.5+0.2 Step turn 488-0.02-0.06 x 7-0.05-0.10. Taper turn outside by maintaining 3+0.1-0 thickness and the flanges as per sketch.
Pi tape Vernier Caliper Computation & Dial setup Vernier Depth Gauge
130
#135
Inspection Inspect for the following: 1) 468.5/+0.2/+-0.0 2) 488.0/-0.02/-0.06 3) Concentricity 4) 540/+0.1/0.0 5) Thickness 3+0.1 6) Perpendicularity 7) Perpendicularity 8) Perpendicularity 9) Perpendicularity 10) Angle 1420'+1.5'-0' and record the values
0.1 0.1
0.1
Inside Micrometer O/S Micrometer

0.5 M
Dial setup O/S Micrometer
C C
C
488 face 468 face 915 face 911 face
UT Gauge Dial Setup
0.1
Master taper/ Dialsetup RKE-RD06-234-T-30
Page 5 of 8
130
HBM
Stage - 11 Machining of Value Mounting Adaptors (Ref. Sketch 11) Set the divergent sub-assy on maching fixture by locating 540 Clamp the divergent sub assy. Set the adaptor face perpendicular to the Spindle axis. Check for the face out of the adaptors and the pair of opposite faces symmetry to the axis of the divergent assy. Skin cut on the valve mounting adaptor faces (4nos) to ensure symmetry of all adaptors. Compute for the facing allowance and face to maintain 689.7+0.5+0.0 (A/F) for the opposite boxes.
135# 145#
Inspection Inspect and Get clearance from QC HBM Bore 29.0 at the middle of the adaptor by ensuring 289.7+0.2-0.0mm height Bore 34+0.2-0.1mm(2nos) by keeping 63.5+0.5-0.0 from the centre hole and by ensuring 289.7+0.2-0.0mm. Enlarge the centre hole to 32+0.1/+0.0 to a depth of 6mm and other two holes enlarged to 37+0.1/+0.0 to a depth of 6mm. Bore Inner surface of the VM adaptors on 44+0.2/+0.1---3nos. To maintain 12mm distance from face. Repeat operation for the balance port. N Inspect for 0.5
0.01
Dial Setup Process controlled Bevel Protractor Dial Set up RKE-RD06-234-T-30
15 #150 HBM / Fitting Fitting Position the Drill Jig & clamp. Inspect for the drill jig set up. Drill and tap, 6nos of holes for M5x0.8P -6H,8.5 deep at 63.5 0.05 and 47.620.05. Inspect for the Drill jig set up and get clearance from VSSC for unloading the jig. Lap the surface to achieve three triangle finish and flatness within 0.01mm Note : Flatness has to be ensured by blue seating.
160 #165 170
Inspection Inspect for flatness and blue seating Drilling Position & clamp Drill Jig by locating on OD 488 and coincide the 'Y+' axis Inspect for the drill jig position and clamping. Transfer P+, P- and Y- axis. Drill 8.5 holes,72 Nos equispaced on 0.2 PCD 516 staring at 230' from Y+ towards 'P-' and Drill 4+0.1/0.0 alighment hole one No. on PCD 530 0.01at 'Y+' Inspect for the drill jig position and get clearance from VSSC for unloading. Drill Jig No. RKE-RD06-234-T-20
Page 6 of 8
180
Drilling
Position & clamp Drill Jig by locating 911 and coincide Y+ axis Inspect for the drill jig position and clamping. Transfer P+, P- and Y- axis Drill 2.46, 10 deep, 72 Nos equispaced on PCD 902 starting at 230' from 0.2 Y+' towards 'P-' and Tap M3x0.5-6H, 10 deep, 72 Nos Inspect for the drill jig position and get clearance from VSSC for unloading. Debur the holes
Jig No RKE-RD06-234-T-21
190
Fitting
195#
Inspection Inspect 1) 540.0/-0.1/-0.0 2) 488.0/-0.02/-0.06 3) 468.1/+0.6/+0.4 4) Angle 1420' 5) Distance 132.5 6) 289.7 7) 525.37 8) 827.37 9) 133 10) 915 11) 898 12) 12.0 13) R5 at two places 14) 821 15) 12.0 16) R5 at two places 17) 15 18) 689.7 (A/F) 19) 7.0 20) 10.0 21) 486.18 22) 495.86 C 23) 0.1
O/S Micrometer O/S Micrometer I/S Micrometer Master Taper Height Gauge Set up Height Gauge Set up
Vernier Caliper Micrometer Vernier Caliper Radius Gauge Micrometer Vernier Caliper Radius Gauge Process controlled/ Line insp. Micrometer Depth Gauge Vernier Caliper Process controlled Process controlled Dial Set up
Page 7 of 8
OPN.NO STAGE
C 24) 0.1 25) 890.8/+0.4/+0.8 26) 911.0/-0.086/-0.226 27) 30 28) 3.0 29) R5 30) (889.4) 31) (879.7) 32) 71 0.05 N 33) 0.01 34) 35) (32.67) 36) (15) 37) 10.0 38) (13) 39) R2 at two places 40) (591.3) 41) (656.44) Process controlled 42) 18.94 43) 15 44) 23 at two places 45) WEP angle 30 at two places 46) Root gap 0.5 to 1.5mm 47) Root face 1.00.5 to 1mm 48) 49) 32/+0.1/+0.0 50) 6mm at 3 places 51) 29/+0.2/+0.1 52) 44/+0.2/+0.1 53) Thickness 12.0 54) 10 from Y+ 55) 130
DESCRIPTION
TOOLINGS
Dial Set up Vernier Caliper Computed from OD Vernier Caliper Vernier Caliper Radius Gauge Process controlled Process controlled Vernier Caliper Dial Set up 90% Blueseating Vernier Caliper UT Gauge Vernier Caliper Visual Process controlled Process controlled Process controlled Bevel Protractor Bevel Protractor Visual & Feeler gauge 90 Blue seating Bore Gauge Vernier Caliper Bore Gauge
Line inspected at HBM
Page 8 of 8
56) 120 57) 25 long weld at four places 58) 5.0mm 59) 63.5 at 2 places 60) 47.62 at 2 places 61) M5 x0.8 P x 6 Nos 62) 8.5 (max) depth 63) 184 64) 34/+0.2/+0.10 at two places 65) 37/+0.1/-0.0 at two places 66) 44/+0.2/+0.1 at two places 67) 6.0 at 2 places 68) 12.0 at 2 places 0.05 69) 70) DP test on weld 73) M3x0.5-6H,10 deep,72nos equispaced on 902 PCD & starting at 230' from 'Y+' towards 'P-' 72) 8.5 holes, 72 Nos. equispaced on 516 PCD & 0.2 73) 4/+0.1/0.0 alignment hole on 530 PCD at 'Y +' 0.2
Line inspected at HBM Vernier Caliper Qualified Drill Jig GO NO GO Gauge Vernier Caliper Bore Dial Gauge
0.2
Vernier Caliper Vernier Caliper Process controlled DP Kit GO NO GO Gauge Drill Jig Dial Setup
Set the Master taper and tilt the spindle with respect to master taper. VTL / Inspection Load the job on VTL true 540 within 0.05mm. Inspect for the runout at smaller dia of taper within 0.05mm. Inspect for the co-ordinates at 18 points (mark 20 line on ID of cone) at 0, 50,100,150,200,250,300, 350 & 400 axial distance and record. Verify the axis marking at Y-, Y+, P+, P- on 540 & 915 by scribing. Free condition ovality on 468.5 & 915. DP test on weld and total surface 210 Painting Apply 2 coats of zinc rich primer & 2 coats of epoxy white paint on outside. Apply Black Japan inside surface and apply calcium based grease on holes and Valve Mounting faces. Get clearance from VSSC. Paint Y+Y- P+& P- axis on OD of 540 & 915. # Mandatory stages /dimensions to be cleared by RQS/VSSC
Inside Mic/ Vernier Caliper D.P.Kit

28.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-27 R1 PART NAME : RLV-SB VALVE MOUNTING ADAPTOR SUB ASSY NAME : RLV-SB NOZZLE DIVERGENT H/W
OPN.NO STAGE
SHEET NO :
PART DRG.NO. RKE-RD-06-234-26 REF DRG. NO. RD06-25-05-02-3-17-13-10-220

DESCRIPTION
PROJECT : RLV-SB CLIENT : VSSC MATL :

15 CDV6 FORGING
QUANTITY : 4 NOS PER DIVERGENT

TOOLINGS
005 #
Inspection Verify the acceptance of the raw material in correlation with the TC issued by VSSC. Allot Idn.No as RLV-VMA-01,02., etc Milling Machine the block to size 200X90X81mm maintaining the squareness and deburr Machine the block as per sketch-1 V.Caliper/ B. Protractor Vernier Caliper
010
020 030# 040
HBM
Inspection Inspect the block as per sketch Heat treat the block as per VSSC Doc No Heat Treatment MEE/QCI/QCP/007/2002 Issue No 2, July 2005
Note 1: Ensure that chart recorder is working Note 2: A copy of the chart to be attached with Inspection Report.
050
Inspection Grind to a depth of 3mm. Check hardness at 3 locations on both the faces and confirm the acceptance of the heat treatment. Hardness value : 34 to 40 HRC HBM Load the job in the machine table and mill the job as per sketch 2.
Portable Grinder Hardess testing M/c
060
Page 2 of 2
070
VTL
Set the tool slide travel to 1420' and form radius R 294.8 and R 312.9 on other side as per detail A of the sketch 2 and mark the center line.
075#
Inspection Inspect the following dimensions 1) 184 2) 28.53 3) 78.78 4) 35.5 5) 1420' 6) 15 7) 36.39 8) R 294.81 9) R 312.94 10) 68.86 11) 23 for 3 holes 12) 63.5 at 2 locations Apply black japan all over and credit to stores
Vernier Caliper Vernier Caliper Vernier Caliper Vernier Caliper Bevel Protractor Bevel Protractor Vernier Caliper Process Controlled Process Controlled Vernier Caliper Vernier Caliper Vernier Caliper
# Mandatory stages /dimensions to be cleared by RQS/VSSC

28.01.2009
PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-28 R2 PART NAME : RLV-SB WELD PAD & SUPPORT PLATE FOR NOZZLE DIVERGENT. SUB ASSY NAME : RLV-SB NOZZLE DIVERGENT H/W OPN.NO STAGE
SHEET NO :
PART DRG.NO. RKE-RD-06-234-27 REF DRG. NO. RD06-25-05-02-3-17-13-10-220 DESCRIPTION
PROJECT : RLV-SB VSSC CLIENT : 15CDV6 MATL : Annealed QUANTITY : WELD PAD - 12 NOS SUPPORT PLATE - 3 NOS TOOLINGS
005 #
Inspection
Verify the acceptance of the raw material in correlation with the TC issued by VSSC. Allot Idn No as RLV-WP-01,02, & RLV-WSP-01,02,. Weld Pads for Nozzle Divergent: Cut the material to 16mm x 300mm length. Heat treat the weld pad material as per Doc.No.MEE/QCI/QCP/007/2002 Issue 2, July 2005
010 015
020 #
Hardness Grind the surface for 3mm on bothsides and check hardness 34 to 40 HRC Testing m/c Milling Drilling Fitting Inspection Slit and mill the job to 16mm square Drill 6.8 through and tap M8x1.0-4H Suit the job to profile Inspect the following dimensions 1) 16mm square 2) (11.0) 3) M8x1.0-4H
030 040 050 065 #
Vernier Caliper Vernier Caliper Go & NoGo thread plug
D.P.Check all over
Page 2 of 2 OPN.NO STAGE 070 080 Shearing Heat Treatment
DESCRIPTION Support Plate: Shear the plate to 100x 200mm size. Heat treat the support plate as per Doc.No.MEE/QCI/QCP/007/2002 Issue 2, July 2005
TOOLINGS
085
Hardness Grind the surface for 3mm on bothsides and check hardness 34 to 40HRC Testing m/c Sandblast Sandblast the plate.
090 100 105 #
Milling/Fitting Form/ Roll the plate to suit the profile and mill to size of 90x60mm Inspection Inspect the following dimensions 1) 90mm 2) 60mm 3) 5mm thickness D.P. check all over Weld Pad Welding Mark centerline for positioning the weldpad. Tack weld four weld pad each on support plate. Fillet weld all four sides of the weld pad as per drawing. Inspect for 1) 60mm and equi distance 2) 30mm and equi distance 3) 10mm 4) 25mm and equi distance 5) D.P. Test all over # Mandatory stages /dimensions to be cleared by RQS/VSSC
Vernier Caliper Vernier Caliper Micrometer D.P.Kit
110
Fitting Welding
115 #
Inspection
Vernier Caliper Vernier Caliper Vernier Caliper D.P. Kit

28.01.2009 PROCESS SHEET NO : REV.NO RKE/RLV/68/PS-29 R0 PART NAME : RLV-SB ANTENA MOUNTING WELD PAD SUB ASSY NAME : RLV-SB WELD PAD WELDING
OPN.NO STAGE
SHEET NO :
1 OF 2
DESCRIPTION
PROJECT : RLV-SB CLIENT : VSSC 15CDV6 MATL : ANNEALED CONDITION QUANTITY : 08 Nos PER MOTOR CASE
TOOLINGS
005 #
Inspection Verify the acceptance of the raw material in correlation with the T.C issued by VSSC. Allot Idn.no as RLV-WTP-01,02,.. Cutting Cut the plate from the supplied material as per requirement of the drg
010 015
Heat Note 1: Ensure that chart recorder is working Treatment Note 2: A copy of the chart to be attached with Inspection Report. Heat treat the weld pad material as per Doc.No MEE/QCI/QCP/007/2002 Issue 2, July 2005
025 #
Hardness Grind the surface of material to 3mm depth and check hardness 34 - 40 HRC Testing M/c Milling Milling Fitting Mill & Cut the piece to required size. Mill the job to size 17x15x15mm Mark 7.5mm center distance. Drill 4.1mm hole to a depth of 7.5mm (max). Tap M5 x0.8P 6H x 6mm(min).
030 040 050
Vernier Caliper
055 #
Inspection Inspect the following dimensions 1. 17mm 2. 15mm
Vernier Caliper
Page 2 of 2 OPN.NO STAGE 3. 15mm 4. M5 x 0.8P 6H taped holes 5. 7.5 6. 7.5 7. 7.5 (max) 8. 6.0 (min)
DESCRIPTION
TOOLINGS Vernier Caliper GO NO GO TPG Vernier Caliper
Identify as AWP 1,2,3 etc and send it to stores.
RLV-SB
APPLICABILITY LIST FOR DRAWINGS AND PROCESS SHEETS AS ON 29.1.09
Sheet 01 of 02
S.NO
COMPONENT / ASSY
FAB.DRG.NO / REV NO
REF.DRG.NO / REV NO
PROCESS SHEET.NO/ REV NO
PAGE NO
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
HE DOME RING HE SKIRT RING HE DOME PRE ASSEMBLY TONGUED RING GROOVED RING CYLINDERICAL SHELL HE SEGMENT WELDING HE SEGMENT MACHINING HE SEGMENT WELD PAD WELDING MIDDLE SEGMENT WELDING MIDDLE SEGMENT MACHINING MIDDLE SEGMENT WELD PAD WELDING NOZZLE END DOME RING NOZZLE END SKIRT RING NOZZLE END DOME PRE ASSEMBLY
RKE-RD-06-234-01
R2
RKE-RD-06-234-02 R2 RKE-RD-06-234-03 RKE-RD-06-234-04 RKE-RD-06-234-05 RKE-RD-06-234-06 RKE-RD-06-234-07 Sheet 1,2 & 3 RKE-RD-06-234-08 Sheet 1&2 RKE-RD-06-234-09 Sheet 1 & 2 RKE-RD-06-234-10 Sheet 1,2 & 3 R2 R2 R2 R2 R4 R5 R3 R2
RD06-25-05-02-3-17-13-10-110 Sheet 1 & 2 RD06-25-05-02-3-17-13-10-110 Sheet 1 & 2 RD06-25-05-02-3-17-13-10-110 Sheet 1 & 2 RD06-25-05-02-3-17-13-10-130 RD06-25-05-02-3-17-13-10-110 Sheet 1 & 2 RD06-25-05-02-3-17-13-10-110 Sheet 1 & 2 RD06-25-05-02-3-17-13-10-110 Sheet 1 & 2 RD06-25-05-02-3-17-13-10-110 Sheet 1 & 2 RD06-25-05-02-3-17-13-10-170 RD06-25-05-02-3-17-13-10-120 RD06-25-05-02-3-17-13-10-120 RD06-25-05-02-3-17-13-10-170 RD06-25-05-02-3-17-13-10-130 RD06-25-05-02-3-17-13-10-130 RD06-25-05-02-3-17-13-10-130
R3 R3 R3 R2 R3 R3 R3 R3 R5 R0 R0 R5 R2 R2 R2
RKE/RLV/68/PS-01 RKE/RLV/68/PS-02 RKE/RLV/68/PS-03 RKE/RLV/68/PS-04 RKE/RLV/68/PS-05 RKE/RLV/68/PS-06 RKE/RLV/68/PS-07 RKE/RLV/68/PS-08 RKE/RLV/68/PS-09 RKE/RLV/68/PS-10 RKE/RLV/68/PS-11 RKE/RLV/68/PS-12 RKE/RLV/68/PS-13 RKE/RLV/68/PS-14 RKE/RLV/68/PS-15
R1 R1 R1 R1 R1 R1 R1 R1 R1 R1 R1 R1 R1 R1 R1
1-5 6-9 10 11-15 16-19 20-28 29-37 38-44 45-49 50-58 59-64 65-66 67-71 72-75 76
RKE-RD-06-234-11 R4 RKE-RD-06-234-12 R3 RKE-RD-06-234-13 R1 RKE-RD-06-234-14 R1 RKE-RD-06-234-15 R1
Sheet 02 of 02
S.NO 16 17 18 19 20 21 22 23 24 25 26 27 28 29
COMPONENT / ASSY NOZZLE END SEGMENT WELDING NOZZLE END SEGMENT MACHINING NOZZLE END SEGMENT WELD PAD WELDING WIRE TUNNEL WELD PAD DESTRUCT SYSTEM WELD PAD STRAP RING RETAINER STRIP SEGMENT HOLDING PIN WELD PAD & SUPPORT PLATE FOR NOZZLE CONVERGENT H/W NOZZLE CONVERGENT H/W NOZZLE DIVERGENT H/W VALVE MOUNTING ADAPTOR WELD PAD & SUPPORT PLATE FOR NOZZLE DIVERGENT H/W ANTENA MOUNTING WELD PAD
FAB.DRG.NO / REV NO RKE-RD-06-234-16 Sheet 1 &2 RKE-RD-06-234-17 Sheet 1 & 2 R2 R3
REF.DRG.NO / REV NO RD06-26-05-02-3-17-13-10-130 RD06-25-05-02-3-17-13-10-130 RD06-25-05-02-3-17-13-10-170 RD06-25-05-02-3-17-13-10-180 RD06-25-05-02-3-17-13-10-160 RD06-25-05-02-3-17-13-10-150 RD06-25-05-02-3-17-13-10-203 RD06-25-05-02-3-17-13-10-140 RD06-25-05-02-3-17-13-10-210 RD06-25-05-02-3-17-13-10-210 RD06-25-05-02-3-17-13-10-220 RD06-25-05-02-3-17-13-10-220 RD06-25-05-02-3-17-13-10-220 RD06-25-05-02-3-17-13-10-190 R2 R2 R5 R2 R2 R0 R0 R0 R2 R2
PROCESSSHEET.NO/ REV NO RKE/RLV/68/PS-16 RKE/RLV/68/PS-17 RKE/RLV/68/PS-18 RKE/RLV/68/PS-19 RKE/RLV/68/PS-20 RKE/RLV/68/PS-21 RKE/RLV/68/PS-22 RKE/RLV/68/PS-23 RKE/RLV/68/PS-24 RKE/RLV/68/PS-25 R1 R1 R1 R1 R1 R0 R1 R0 R1 R2 R3 R1 R2 R0
PAGE NO 77-82 83-88 89-90 91-93 94-97 98-99 100-101 102-103 104-106 107-110 111-130 131-134 135-136 137-138
RKE-RD-06-234-18 R3 RKE-RD-06-234-19 R3 RKE-RD-06-234-20 R3 RKE-RD-06-234-21 R1 RKE-RD-06-234-22 R1 RKE-RD-06-234-23 R0 RKE-RD-06-234-24 Sheet 2 of 3 RKE-RD-06-234-24 Sheet 1,2 & 3 RKE-RD-06-234-25 Sheet 1 & 2 RKE-RD-06-234-26 R5 R5 R3 R1
R3 RKE/RLV/68/PS-26 R3 RKE/RLV/68/PS-27 R3 RKE/RLV/68/PS-28 R0 RKE/RLV/68/PS-29
RKE-RD-06-234-27 R1 RKE-RD-06-234-28 R0
PROCESS SHEET FOR ASSEMBLY PRESSURE TEST & POST TEST INSPECTION RLV-SB MOTOR CASE Page:1/7 Issue No: 01 DATED; 25.01.2008 OPN.NO DESCRIPTION DRAWING NO. 005 Check for the following parts and ensure their acceptance and record in the logbook I- HARDWARE 1.RLV-SB Head End Segment 2.RLV-SB Middle Segment 3.RLV-SB Nozzle End Segment 4.Nozzle convergent 5.Segment holding pins 6.Strap Ring for segment joint II-FASTENERS & 'O' RINGS 1.'O' Rings for segment - face 'O' ring 2 Nos - shaft 'O' rings 2 Nos 2.'O' Rings for segment assy Nozzle H/W 3.'O' Rings for end closures 4.M12x1.25 P, 30 Lg Hex socket HD Cap screws 5.M8x1 P, 45 Lg Hex socket HD Cap screws 6.M5x0.8, 8 Lg Hex.socket HD cap screw 7.M6x1P, 40mm Lg Hex Socket Hd.Cap screws 8.Plain washers for M8 9.Plain washers for M12 10.Plain washers for M6 ACCESSORIES 1.Head End Closure 2.Nozzle end closure 3..Metal stands with castrol wheels 4.Assy fixture ring 5.Pressure test stand Supplied by VSSC Supplied by VSSC Supplied by VSSC Supplied by VSSC Supplied by VSSC Supplied by VSSC Supplied by VSSC Supplied by VSSC Supplied by VSSC 4 Nos 1 No 2 Nos 72 Nos 72 Nos 24 Nos 32 Nos 72 Nos 72 Nos 32 Nos RKE-RD06-234-09 RKE-RD06-234-12 RKE-RD06-234-18 RKE-RD06-234-24 RKE-RD06-234-23 RKE-RD06-234-21 1 No 1 No 1 No 1 No 144 Nos 4 Halves QTY
TOOLS/EQUIPMENTS/ ACCESSORIES REQUIRED
RKE-1930-202-053 RKE-RD-06-234-T-29
1 No 1 No 3 Nos 4Nos
RKE-1930-202-055
6.Hydraulic pump & pressure hose one end with 3/8" BSP other end 1/2" BSP adaptor
Page:2/7 7.Pressure Gauge 2 Nos, 0 to 100 KSC with L.C of 2 KSC - dully calibrated (1 pressure gauge on Head End closure, 2 Nos on the pump ) Note : Record the identification Nos in the log book 010 Assembly Procedure of Nozzle end segment & Middle segment 1.Clean the locating diameters/surfaces of Tongued ring , grooved ring Segment pin holes, 'O" ring grooves of the segment with banian waste soaked in petrol/acetone 2.Position the middle segment & Nozzle end segment supported at 2 position each over semi pedestal roller saddles lined with rubber.( coincide Y+ axis of both segments) 3.Position the O ring in O ring groove of Tongue ring in Nozzle segment and in the groove of Mid Segment. Apply grease. Ensure the O ring is located properly. 4.Ensure proper orientation of reference centre lines of MS & NES position the assy fixture rings on Groove & Tongue end of MS & NES.Insert the bolt and tighten simultaneously so as to ensure uniform entry of tongue ring in the groove. Insert 3 nos of segment pins in 120 the Tongue ring. Assemble the MS & NES using assy fixture. Insert remaining segment pins by malleting with soft hammer if required. 5.Position segment strap ring & fasten it with 12 nos of M5x0.8mm 8 Long screws. Inspect for the assy. 015 INSPECTION Inspect for the distance as per VSSC supplied procedure and calculate the 'O' ring compression 020 Assembly Procedure of Head end segment & Middle segment 1.Clean the locating diameters/surfaces of Tongued ring , grooved ring Segment pin holes, 'O" ring grooves of the segment with banian waste soaked in petrol/acetone Magnetic Vee Block Vernier Calliper
2.Position the middle segment & Head end segment supported at 2 position each over semi pedestal roller saddles lined with rubber.( coincide Y+ axis of both segments) 3.Position the O ring in O ring groove of Tongue ring in middle segment and in the groove of Head end Segment. Apply grease. Ensure the O ring is located properly.
Page:3/7 4.Ensure proper orientation of reference centre lines of MS & HES position the assy fixture rings on Groove & Tongue end of MS & HES.Insert the bolt and tighten simultaneously so as to ensure uniform entry of tongue ring in the groove. Insert 3 nos of segment pins in 120 the Tongue ring. Assemble the MS & HES using assy fixture. Insert remaining segment pins by malleting with soft hammer if required. 5.Position segment strap ring & fasten it with 12 nos of M5x0.8mm 8 Long screws. Inspect for the assy. 025 INSPECTION Inspect for the distance as per VSSC supplied procedure and calculate the 'O' ring compression 030 Assembly of Nozzle Convergent, HE-Closure & NE-Closure 1. Place the 'O' ring in 'O' ring groove of Nozzle end dome ring of NES. Apply grease ensure the 'O' rings are located properly Note: Ensure the proper Idn.No of 'O' rings are located properly. 2. Ensure Proper orientation of reference Centre lines of NES & Nozzle convergent h/w Insert 3 locating pins of M12x1.5P at 120 degree apart for guiding the Nozzle Convergent Assy. Assemble the NE-segment and Nozzle segment h/w and fasten it using M12x1.5, 30Lg Socket HD Screws and apply a torque of 10.7kg.m (Max) 3.Place the 'O' ring on HE & NE closures. Apply grease for the assy of NE closure and HE closures. Apply torque for M8 screws 3 Kg.m and for M6 x1 Screws 1.2Kg.m Magnetic Vee Block Vernier Calliper
Torque Wrench
Torque Wrench
4.Position the rubber lined stand in the order of inclination 4 in the pressure test bay (refer sketch) 040 LIFITING OF ASSY 1.Using the crane, lift the H/W assy carefully through lifting beam connecting the belts at 6 locations, mount the motor assy on pressure testing stand. Lifting arrangement Pressure test stands
Page:4/7 2.Arrange pipe connections as per layout drawing for Proof Pressure test. Two pressure gauges are to be fitted one on HE closure & one on hydraulic pump & 2 pressure transducers one at HE & another at NE side. 3.Mount the strain gauges on the assy on locations as given by VSSC. Ensure strain gauge, channel identification 4.Start filling the water. filling should be gradually through the Nozzle end of the assembled motor . After filling, allow water to flow sufficiently through the vent pipe so that no air is trapped inside. Bleeding should be done. Note : All pressure gauges to be duly calibrated. Record the Idn.No of the gauges. The Hydraulic system should withstand 50 Ksc. No leakage/loose connection in hydraulic connections. Connect the pressure transducer also at HE Closure & NE closure White papers shall be 5.Clean the complete area of the test pit, wipe off any water drops on the motor joints & hydraulic lines etc., placed underneath joint to Pressure gauge must be on sufficient height from test bay to view the reading on all gauges. White papers clearly observe any water shall be placed underneath joint to clearly observe any water drops. drops 50 PRESSURE TESTING 1. Ensure safety arrangements 2. Identify personnel for specific work like Pressurising/ depressurising. 3. Identify test co-ordinator. 4. Ensure strain monitoring/recording on. LEAK TEST 1.Gradually pressurise to 10Ksc and hold for 5 minutes for leak test. All Strain data shall be recorded and depressurise to 2 Ksc. Pressure gauge Hydraulic pump
Ensure PPT clearance
Page:5/7 2. TEST at 10 KSC Gradually pressurise to 10KSC and hold at that pressure for 2 minutes. Check for leak any. Record the strain and depressurise 3.PRESSURE TEST AT 29.2+0.5/-0 KSC Gradually pressurise in step of 10, 15, 20, 26.5 and 29.2 KSC. Hold the pressure for 2 minutes at each step and final test of 29.2 KSC for 4.5 minutes. Record data at each stage 4.DEPRESSURISATION Release the pressure gradually and drain the water fully, wipe throughly the water particles. ACCEPTANCE CRITERIA The motor shall withstand 29.2/+0.51 Ksc for 4.5 minutes without any leak. All the strain values shall be within acceptable limit 5.POST PRESURE TEST OBSERVATION Dismantle all pipe connections and fitting dismantle the segment & Nozzle Convergent Assembly Visually inspect for 'O' rings and segment pins damage if any. Clean the inner surfaces throughly. 055 INSPECTION AT FREE CONDITION Note: Inspect and record the following RLV-SB MOTOR CASE Igniter boss ID 188.0 at 6 places Grooved ring ID 973.5 at 12 places Tongued ring Dia 991.5 at 12 places Nozzle end dome Dia 750 at 12 places M6X1-4H,32 nos, on 210PCD M8X1-4H,36 nos, on 976PCD M12X1.25-4H, 72 nos. on 790PCD M14X1.5-4H, 16 nos. on 958PCD RLV-SB NOZZLE CONVERGENT Dia 750 at 12 places Depth 8.9 Depth 3.0 at 12 places Dia 498 at 12 places
Inside Micrometer -do-do-doGO-NOGO thread guage -do-do-do-
Micrometer Depth guage -doInside Micrometer
Page:6/7 Dia 488 at three planes, each plane 12 places Angle 44 degree at 8 places Visual inspection on Dia 13 holes M18X1-4H tapped holes Run out of face between 825 and 750 Run out of face between 540 and 498 TIR readings at fore end flange face (2 places, one towards ID and other towards OD), taper area ( 2 planes) and throat ID (3 equidistant places) as in PSO convergent h/w. Twelve readings shall be taken at each plane. 060 PAINTING: Clean the Motor case & Nozzle H/W / Divergent throughly MOTOR CASE Apply 2 coats of Zinc Rich primer, followed by 2 coats of white epoxy on outside. Apply 2 coats of Black Japan on interfaces & inside Apply calcium based grease on tapped holes. NOZZLE HARDWARE/DIVERGENT Apply 2 coats of Zinc rich primer, followed by 2 coats of white epoxy on outside. Apply 2 coats of Black Japan on interfaces & inside Apply calcium based grease on tapped holes. Apply Black Japan all over and on mating diameters and calcium based grease on threaded holes 070 Get clearance from VSSS for packing & Despatch Inside Micrometer
Using crane life the h/w assy carefully through lifting beam connecting the belts at 6 locations,
RAMAKRISHNA ENGINEERING COMPANY, CHENNAI-106

APPLICABLE LIST OF TOOL DRAWING FOR RLV-SB MOTOR CASE AS ON 04.02.2009
S.NO
1 2 3 4 5 6 7 8 9 10 11 12 13
DESCRIPTION
RLV-SB HEAD END DOME RING INSIDE PROFILE CHECKING TEMPLATE RLV-SB HEAD END DOME 'Y' RING OUTSIDE PROFILE CHECKING TEMPLATE RLV-SB HEAD AND DOME 'Y' RING 'V' GROOVE CHECKING TEMPLATE RLV-SB HEAD END DOME RING IGNITOR BOSS GROOVE CHECKING TEMPLATE RLV-SB HEAD END SKIRT CHECKING TEMPLATE RLV-SB GROOVED RING INSIDE CHECKING TEMPLATE RLV-SB GROOVED RING OUTSIDE CHECKING TEMPLATE RLV-SB TOUNGED RING INSIDE CHECKING TEMPLATE RLV-SB TOUNGED RING OUTSIDE CHECKING TEMPLATE RLV-SB NOZZLE END DOME RING INSIDE PROFILE CHECKING TEMPLATE RLV-SB NOZZLE END DOME RING 'Y' RING INSIDE CHECKING TEMPLATE RLV-SB NOZZLE END DOME RING 'V' GROOVE CHECKING TEMPLATE RLV-SB NOZZLE END DOME OUTSIDE TAPER CHECKING TEMPLATE
DRG.NO
RKE-RD06-234-T-01 RKE-RD06-234-T-02 RKE-RD06-234-T-03 RKE-RD06-234-T-04 RKE-RD06-234-T-05 RKE-RD06-234-T-06 RKE-RD06-234-T-07 RKE-RD06-234-T-08 RKE-RD06-234-T-09 RKE-RD06-234-T-10 RKE-RD06-234-T-11 RKE-RD06-234-T-12 RKE-RD06-234-T-13
REV .NO.
1 1 1 1 1 1 1 1 1 1 1 1 1
REF.DRG.NO
RKE-RD06-234-01 R2 RKE-RD06-234-01 R2 RKE-RD06-234-01 R2 RKE-RD06-234-01 R2 RKE-RD06-234-02 R2 RKE-RD06-234-05 R2 RKE-RD06-234-05 R2 RKE-RD06-234-04 R2 RKE-RD06-234-04 R2 RKE-RD06-234-13 R1 RKE-RD06-234-13 R1 RKE-RD06-234-13 R1 RKE-RD06-234-13 R1
14 15 16 17 18 19 20 21 22 23 24 25
RLV-SB NOZZLE END SKIRT RING INSIDE CHECKING TEMPLATE RLV-SB NOZZLE CONVERGENT FLANGE OUTSIDE CHECKING TEMPLATE(LARGER) RLV-SB NOZZLE CONVERGENT FLANGE OUTSIDE CHECKING TEMPLATE(SMALLER) DRILL JIG FOR RLV-SB NOZZLE END SKIRT RING
RKE-RD06-234-T-14 RKE-RD06-234-T-15 RKE-RD06-234-T-16 RKE-RD06-234-T-19 RKE-RD06-234-T-20 RKE-RD06-234-T-21 RKE-RD06-234-T-23 RKE-RD06-234-T-24 RKE-RD06-234-T-25
1 1 1 5 0 0 1 1 1 1 0 0
RKE-RD06-234-14 R1 RKE-RD06-234-25 SHEET1,2 &3 R5 RKE-RD06-234-25 SHEET1,2 &3 R5 RKE-RD06-234-17 SHEET 1 & 2 R3 RKE-RD06-234-25,26 SHEET 1,2,&3 R5 & R3 RKE-RD06-234-26 & 22 RKE-RD06-234-26 SHEET 1 & 2 R3 RKE-RD06-234-26 SHEET 1 & 2 R3 RKE-RD06-234-19 R3 RKE-RD06-234-110 R3 RKE-RD06-234-08 RKE-RD06-234-17 RKE-RD06-234-25 RKE-RD06-234-09,12 & 18 RKE-RD06-234-27 R1
COMMON DRILL JIG FOR RLV-SB NOZZLE CONVERGENT AND DIVERGENT HARDWARE COMMON DRILL JIG FOR RLV-SB NOZZLE DIVERGENT AND RETAINER STRIP RLV-SB DIVERGENT MASTER TAPER (INSPECTION MASTER TAPER) RLV-SB DIVERGENT MASTER TAPER (MACHINING MASTER TAPER) RLV-SB WIRE TUNNEL WELD PAD PROFILE CHECKING TEMPLATE DRILL JIG FOR RLV-SB HEAD END SKIRT RING PSO-HEAD END SEGMENT IGNITOR BOSS DRILL JIG NO CHANGE FOR PS0 TO RLV-SB PSO COMMON DRILL JIG FOR NOZZLE END DOME RING & NOZZLE CONVERGENT ASSEMBLY NO CHANGE FOR PS02 TO RLV-SB RLV-SB WELD PAD WELDING FIXTURE SHEET 1,2 & 3
RKE-HSJ-1930-202-15 RKE-IBJ-1930202-16 RKE-NDRJ-1930-202-40
26 27
RKE-RD06-234-T-27 RKE-RD06-234-T-30
0 1
RLV-SB DRILL JIG FOR VALVE MOUNTING ADAPTOR
* 1. New Tools fabricated and applicable for set 02 to 05.

2. All other tools no change. Revised based on Design Drawing revision for the assembly.

RLV SB Process Sheet

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RLV SB Process Sheet

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RAMAKRISHNA ENGINEERING COMPANY, CHENNAI-106.

PROCESS AND QUALITY CONTROL PLAN

1 OF 5 REV. NO. R2 REV.NO. R3

PART DRG.NO. RKE-RD-06-234-01 REF DRG. NO. RD06-25-05-02-3-17-13-10-110 Sheet 1 & 2

I/S Micrometer Vernier Caliper

Vernier Caliper Compute the depth

Page 2 of 5 OPN.NO STAGE 030 CNC VTL

I/S Checking template RKE-RD06-234-T-01

I/S Mic UT Gauge Vernier Caliper

Machining Fixture No Checking template No. RKE-RO06-234-T-17

Checking template No : RKE-RD06-234-T-03

Vernier Caliper UT Gauge Vernier Caliper

RAMAKRISHNA ENGINEERING COMPANY, CHENNAI-106. PROCESS AND QUALITY CONTROL PLAN

PART DRG.NO. RKE-RD-06-234-02

REF DRG. NO. REV.NO RD06-25-05-02-3-17-13-10-110 R3

010 015 020#

Portable Grinder Hardness tester

VTL / CNC VTL CNC VTL

Page 2 of 4 OPN.NO STAGE 060# CNC VTL

Inside Micrometer Dial setup

RAMAKRISHNA ENGINEERING COMPANY, CHENNAI-106. PROCESS AND QUALITY CONTROL PLAN

Mismatch checking templates Feeler Gauge Vernier Caliper Vernier Caliper

Dial Gauge setup

# Mandatory stages/dimensions to be cleared by RQS/VSSC

RAMAKRISHNA ENGINEERING COMPANY, CHENNAI-106. PROCESS AND QUALITY CONTROL PLAN

Vernier Caliper Tape

010 015 020#

CNC VTL Inspection Heat Treatment

I/S, Mic, Vernier Caliper

Portable Grinder Hardness tester I/S, O/S Mic Vernier Caliper

I/S Mic Dial Setup

Page 3 of 5 OPN.NO STAGE 13) Concentricity

TOOLINGS Dial Gauge I/S Mic D.P.Kit

# Mandatory stages to be cleared by RQS/VSSC

EERING COMPANY, CHENNAI-106. QUALITY CONTROL PLAN

-SB MOTOR CASE LICABILITY 02- 05

Vernier Caliper Tape

I/S, Mic, Vernier Caliper

Portable Grinder Hardness tester I/S, O/S Mic Vernier Caliper

I/S Mic Dial Setup

TOOLINGS Dial Gauge I/S Mic D.P.Kit

RAMAKRISHNA ENGINEERING COMPANY, CHENNAI-106. PROCESS AND QUALITY CONTROL PLAN

Vernier Caliper Tape

I/S, Mic I/S, Mic, Vernier

Page 2 of 4 OPN.NO STAGE 050# VTL / CNC VTL

TOOLINGS I/S, O/S Mic Vernier Caliper Ball point mic

I/S Mic UT Gauge Dial setup

# Mandatory stages to be cleared by RQS/VSSC

Feeler Gauge Template UT Gauge

Vernier Caliper Mismatch Checking template Feeler Gauge

Film density 1.8-2.5 DP Kit Magnifying glass 3X

Vernier Caliper DP Kit

Vernier Caliper UT Gauge

Bevel Protractor Vernier Caliper D.P.Kit

Page 4 of 9 OPN.NO STAGE

TOOLINGS Checking template

L/S welding fixture

Feeler Gauge Template

Longitudinal Welding fixture

Vernier Caliper Feeler Gauge

Page 5 of 9 OPN.NO STAGE 130 Fitting

TOOLINGS 1. Ovality removing set up 2. Inside checking template

Dp Kit X-ray machine 3X Magnifying glass

Vernier Caliper Micrometer Feeler Gauge I/S Mic