MP 0 4900 11 (Rev 1) Jan 10
MP 0 4900 11 (Rev 1) Jan 10
MP 0 4900 11 (Rev 1) Jan 10
TECHNICAL SPECIFICATION
FOR
EQUALISER BEAMS, COMPENSATING BEAMS & LINKS
OF HIGH ADHESION & EQUALISER BEAMS (LONG & SHORT) OF TRIMOUNT
LOCOMOTIVE BOGIES
Technical Specification for Equaliser Beams, Compensating Beams & Links of High Adhesion and Equaliser Beams (Long & Short) of Trimount Locomotive Bogies
CONTENTS
Sl. No.
Description
Page No.
1.
Scope
2.
Definitions
3.
4.
5.
Deviation(s)
6.
7.
Manufacturing Procedure
8.
Identification Marking
9.
Stages of Inspection
10.
11.
Packing
12.
Warranty
Annexure
1.
Technical Specification for Equaliser Beams, Compensating Beams & Links of High Adhesion and Equaliser Beams (Long & Short) of Trimount Locomotive Bogies
TECHNICAL SPECIFICATION
FOR
EQUALISER BEAMS, COMPENSATING BEAMS & LINKS
OF HIGH ADHESION & EQUALISER BEAMS (LONG & SHORT) OF TRIMOUNT
LOCOMOTIVE BOGIES
1.
SCOPE
1.1
1.2
The Equaliser Beams, Compensating Beams & Links of high adhesion &
Equaliser Beams (Long and Short) of trimount locomotive bogies shall be
supplied conforming to this specification and RDSO Drawings given below:
Sl.No
Drawing No.
Locomotive
i.
SK.VL-146
ii.
Modified
design
of
Equaliser
Beam,
SK.VL-180 & 181 Compensating Beam & Link for WDG3A
Locomotives
iii.
Modified
design
of
Equaliser
SK.VL-292 & 293 Compensating Beam & Link for
Locomotives
iv.
53.07.01 &
53.07.02
v.
SK.VL-178
Beam,
WAG7
2. DEFINITIONS
i.
ii.
iii.
Technical Specification for Equaliser Beams, Compensating Beams & Links of High Adhesion and Equaliser Beams (Long & Short) of Trimount Locomotive Bogies
3.2
The tenderer shall be an RDSO Approved Vendor and the firms name shall
be on the current list of RDSO Vendor Directory for supply of Equaliser
Beams, Compensating Beams & Links of high adhesion & Equaliser Beams
(Long & Short) of trimount locomotive bogies as per Relevant RDSO
Drawing given at Para 1.2.
3.3
3.4
Spec. No.
1.
IS: 2062
2.
General Tolerances
3.
IS: 3703
4.
IS: 4225
5.
IS: 5517
6.
ASTM A: 435
RDSO
7. Procedure No.
MC-92
Description
Technical Specification for Equaliser Beams, Compensating Beams & Links of High Adhesion and Equaliser Beams (Long & Short) of Trimount Locomotive Bogies
5.
4.1
4.2
4.3
Any special requirements given in the relevant drawings will override this
specification.
DEVIATION(s)
If deviation(s) from original design, material specifications, dimensions etc. are
desired by the tenderer, specific proposals with reasons shall be submitted to the
purchaser. The manufacturer shall not commence manufacture of Equaliser
Beams, Compensating Beams & Links and Equaliser Beams (Long & Short) till
clear authorization for acceptance of the deviation is granted by Motive Power
Directorate, RDSO, Lucknow.
6.
The firm shall submit two copies of Quality Assurance Plan (QAP) for the
product detailing various manufacturing aspects for RDSOs approval. The
QAP shall include the following:
.1
Organization chart
.2
.3
.4
.5
.6
.7
Identification Marking
6.3
6.4
The QAP shall require renewal after every two years. Any changes
incorporated in the manufacturing procedure / Machinery & Plants
associated with the manufacture of Equaliser Beams, Compensating Beams
& Links of high adhesion & Equaliser Beams (Long and Short) of locomotive
trimount bogies should be duly incorporated in QAP and approved.
Technical Specification for Equaliser Beams, Compensating Beams & Links of High Adhesion and Equaliser Beams (Long & Short) of Trimount Locomotive Bogies
7.
MANUFACTURING PROCEDURE
7.1
7.2
7.3
Raw Material
7.4
.1
.2
.3
.4
.2
.3
.4
.5
Only those plates which have been tested and found acceptable being
free from any defect stated above shall be used for manufacture.
Technical Specification for Equaliser Beams, Compensating Beams & Links of High Adhesion and Equaliser Beams (Long & Short) of Trimount Locomotive Bogies
7.5
7.6
The Equaliser Beams, Compensating Beams & Links of high adhesion &
Equaliser Beams (Long and Short) of trimount locomotive bogies shall
be cut from the plate by Automatic Flame / Laser / CNC Wire Cut /
Water Jet Machine along the grains to required dimensions as per
RDSO drawing. The end of Equaliser Beams (Long & Short) shall be cut
shorter by approx. 4 mm to facilitate weld deposition at position where
hard facing is required.
.3
All notches, gouges, flame and tool marks on the profile-cut surface
shall be ground smooth and surface blended to achieve a surface finish
as specified in the RDSO Drawing.
.4
After plate cutting, the Equaliser Beams & Compensating Beams shall
be subjected to stress relieving. For this, raise the temperature slowly up
to 640C and after 4 hrs. of slaking period. Allow cooling in furnace upto
200C. It shall then be allowed to cool in still air.
.2
.3
.4
7.8
7.9
Technical Specification for Equaliser Beams, Compensating Beams & Links of High Adhesion and Equaliser Beams (Long & Short) of Trimount Locomotive Bogies
IDENTIFICATION MARKING
Each Equaliser Beams, Compensating Beams & Links & Equaliser Beams (Long
and Short) shall be provided with identification marking for traceability by stamping
in 6 mm letters as given below:
.1
Manufacturers initial
.2
.3
Serial No. of Equaliser Equaliser Beams, Compensating Beams & Links &
Equaliser Beams (Long and Short) manufactured in particular month.
.4
.5
STAGES OF INSPECTION
9.1 The inspection of Beams & Links shall be carried out by the Inspecting
Agency in the following stages of manufacture:
.1
.2
.3
9.2 The manufacturer shall fabricate the Beams & Links in stages as detailed in
Para 9.1. The manufacturer shall start each stage of manufacturing only after
receipt of clearance of previous stage by the Inspecting Agency.
Technical Specification for Equaliser Beams, Compensating Beams & Links of High Adhesion and Equaliser Beams (Long & Short) of Trimount Locomotive Bogies
Technical Specification for Equaliser Beams, Compensating Beams & Links of High Adhesion and Equaliser Beams (Long & Short) of Trimount Locomotive Bogies
ANNEXURE I
Procedure for Hard Facing of New Equaliser Beams
of Co-Co Trimount Bogies
of Diesel & Electric Locomotives
(M&C Directorates Procedure No. MC-92)
Introduction
Equaliser Beam is a very important component used in Trimount Bogies of
Locomotives. The end portions of these Beams rest on axle boxes and get worn out
during service. A procedure No. MC-43 (of August 2001) had been made for
reclamation of worn out equalizing Beams. Fabrication of these Beams is carried out
using steel to Gr. C of IS: 2062, which is mild steel and may wear out fast at the ends
during service. It was decided to carryout hard facing of the ends of new equalizing
Beams as well to increase their service life. This procedure outlines the procedure of
hard facing of new Equaliser Beams.
1.
Material
The material used in manufacturer of Equaliser Beams (both short & long type) is
steel to IS: 2062 Gr. C (Normalized & killed quality).
2.
3.
Welding Consumables
MMAW electrodes as well as MIG / MAG filler wires can be employed.
3.1 MMAW electrodes approved under IRS Class H4B as per M-28-02 shall be
used for above reclamation purpose. The diameter of electrodes used shall
preferably be 4.0 mm. Higher diameter electrodes can be used in exceptional
circumstances.
3.2 MIG/MAG welding filler wires approved under class V as per IRS: M-46-03
may also be used. The diameter of MIG/MAG wire used shall be 1.2 mm.
4.
Preheating of Electrodes
The electrodes shall be preheated to about 2500C for two hours or as
recommended by the manufacturer. To avoid further absorption of moisture by the
preheated electrodes, they should not be taken out from over at a time. They
should be drawn from the oven so, as to be consumed within 30 minutes to one
hour.
Manufacturers recommendations regarding current conditions, preheating of
electrodes and any other special characteristics shall be followed.
Technical Specification for Equaliser Beams, Compensating Beams & Links of High Adhesion and Equaliser Beams (Long & Short) of Trimount Locomotive Bogies
Technical Specification for Equaliser Beams, Compensating Beams & Links of High Adhesion and Equaliser Beams (Long & Short) of Trimount Locomotive Bogies
5.
Remove all dirt, dust, oil grease etc. properly from the area to be
reclaimed.
ii. Grind the faces properly to remove all oxidised layer formed during profile
cutting of Beam.
iii. Check the face to be reclaimed by Dye Penetrant test to ensure absence
of any crack or other defect.
iv. Ensure complete removal of dye from the hard faced zone.
v. If any crack is noticed on the area to be hard faced the same may be
removed by grinding. Such removal however shall not reduce the
thickness by more than 4 mm.
B.
During Welding
i.
Preheat the ends of Beam to be hard faced to about 1500C by to & fro
motion of oxy-acetylene torch. Check correctness of temperature using
thermal chalks.
ii. Set the Welding current & Voltage in the welding power source as per
recommendations of electrode manufacturer depending upon the
diameter of electrodes used.
iii. Interpass temperature of zone to be hard faced shall be maintained to
about 1500C during welding.
iv. Connect the electrode with positive terminal of battery while welding using
DC current.
v. Weld the area in down hand welding position.
vi. The runs should be deposited only in longitudinal direction.
vii. After each run, slag shall be removed.
viii. Each run should immediately be peened when weld metal is in hot
condition i.e. dull red colour. Peening should be preferred utilising a to
diameter round nosed Pound hammer. Repeated moderate blows
should be used instead of few heavy blows. The effect of peening is to
relieve internal stresses, minimise distortion and refine the microstructure.
ix. Welding shall be commenced from mid thickness of Beam & progressed
towards the edges or started from one edge & progressed upto other
edge.
x. Put the stringent beads. Weaving shall not be more than two times of the
diameter of electrodes.
xi. The crater end shall always be filled up by moving the electrode
backwards for a distance of about 15 mm from finishing end and then
electrode should be taken out from molten pool.
xii. Maintain appropriate welding speed to get smooth weld bead.
xiii. Deposit 1-2 mm of extra metal so that after grinding & finishing the Beam
ends are of required dimensions.
Motive Power Directorate (Vehicle Dynamics Group), RDSO, Lucknow
Technical Specification for Equaliser Beams, Compensating Beams & Links of High Adhesion and Equaliser Beams (Long & Short) of Trimount Locomotive Bogies
After Welding
i.
Inspect the weld area by magnifying glass for any welding defect
especially for any crack & short weld metal.
ii. Grind the weld by using surface grinder to get required finish &
dimensions.
iii. The hard faced area finally shall have no any sharp edge, stress raiser, or
any potential source of fatigue.
iv. To avoid localized overheating of weld & subsequent cracking the grinder
shall not locally grind at one place for longer duration.
v. The finished weld shall then be checked visually & by Dye Penetrant test
for presence of surface defects.
vi. Magnetic Particle test may be used in place of Dye Penetrant test to
check weld quality for surface & sub-surface defects.
vii. Any crack or harmful defect if noticed, the same shall be gouged out and
re-welded by using the welding technique as stated above.
viii. The hardness of weld shall be in the range of 300 to 350 BHN.
ix. Stress relieving treatment shall not be required for new hard faced
Equaliser Beams.
Precautions
i.
ii.
iii. The welding electrodes shall be of good conditions. Any electrode with
damaged coating or rusted core wire shall not be used.
iv. Adjust proper current & polarity in the machine during welding.
v.