1. Specification/Drawing : RDSO Spec. No. IRS T-46-1996; RDSO Drg. No. RDSO/T-381 Alt 9
2. Date of Inspection :
3. Place of Inspection :
4. Size of Lot :
5. Size
of Sample : Sampling as per Spec.
No. IRS T-46-1996. Para 12 &13
For dimensional check:-IS 2500 Pt I double sampling AQL 2.5 % & inspection
level II
for weight :- IS 2500 Pt I double sampling AQL 4 % & inspection
level II
No. Of defective insert out of 50 nos. for Dimensional check
i) < = 2 Lot is accepted
ii) > = 5 Lot is rejected
iii) 3 to 4 50 more sample inserts are selected
Total no. of defective insert in 100 samples
(A) < = 6 Lot is accepted
(B) > 6
Lot is rejected
No. Of defective insert out of 50 nos. for Weight check
i) < = 3 Lot is accepted
ii) > = 6
Lot is rejected
iii) 4 to 5
50 more sample selected
Total no. of defective insert in 100 samples
(A) < = 9 Lot is accepted
(B) > 9 Lot is rejected
Material should be offered heat
wise.
Measurement- 50 pieces from batch of 1200, followed by 50 more. One
sample per heat
For all other tests.
6. Document Check : a)
Internal/External test certificate for raw material.
b)
Internal inspection report including 100% visual, 100% gauging (clause 9.7), 100%
weight (clause 9.7) and hammer test (clause 9.8),
2% for hardness test (clause 9.4).
c) 100% hammer
test report with 4 kg hammer.
d) Calibration record of gauges, measuring
instruments & test Equipment.
e) RDSO Approval for manufacturing of Insert
f) RDSO Approval for manufacturing of gauges
7. Tests/Checks (to be witnessed by
inspector)
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Sno |
Parameter |
Value
Specified |
Observation |
Remarks |
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1 |
Visual |
· The
castings shall be sound, clean and free from blow holes, slag Inclusions,
distortion, hard spots, sand fusion. ·
Free from surface defects. |
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2 |
Dimensional
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As per Drawing Number RDSO/T-381 Alt 9 |
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To be
conducted by RDSO Approved Inspection Gauges to drg. No. RDSO/T-454 alt. 9 |
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3 |
Material Composition |
Phosphorus
= 0.08 % max |
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One per heat |
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4 |
Tensile
test a) Test Bar of each heat b) Test piece from casting |
Tensile
Strength Elongation 500 N/mm 2 Min. 7% Min 400 N/mm 2 Min 5.6 % Min. |
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Clause 11.4.2 &
11.4.3. of IRS T-46-1996 One
sample per heat Test method IS:1608 |
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5 |
Hardness at end face of the head |
170 - 241
BHN |
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One sample per heat
Test method IS:1500 |
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6 |
Microstructure |
The castings shall be subjected to micro examination and the structure shall contain minimum of 80 % graphite in the form of V or VI as specified in IS:7754-1975 |
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Clause 9.1 and 9.2 of
IS:1865-1991 One sample per heat |
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7 |
Internal soundness |
One piece
from each batch shall be subjected to destruction test by sectioning in order
to ensure internal soundness |
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One sample per heat |
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8 |
Weight |
1.55 kg (-3%) ie 1.504 kg min. |
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Sample as per IS
2500 Pt I double sampling AQL4 % & inspection level II |
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9 |
Gating Projection |
Gating
projection on stem shall be finished within tolerance of (+1.5mm, -1.0 mm). However
if gating projection is provided outside the stem portion, it shall be finished
smooth and shall match the profile of insert. |
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10 |
Hammer test |
Every insert shall be given hammer blow with 4 Kg
hammer. The insert should not break. |
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(As per Annexure-XII) |
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11 |
Marking |
· Heat no.
in raised letter at location marked in drg. · RT-381
and Maker’s Initials/Trade mark in depressed letters at the location marked
in drawing. · Heat
numbers in raised letters at the location marked in drawing. · Last two
digits of year of manufacture in sunk letters at the location marked in
drawing. · Pattern
no. in sunk letters at the location marked in drawing. |
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Note: These depressed markings (not with raised letters
in recess) shall be achieved by machine engraving the letters of 8 mm height
in the patterns as per Note 5 of RDSO Drg. No. RDSO/T-381
Alt 9. |
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12 |
Packing |
· The
inserts shall be packed in suitable double gunny bags weighing not more than
50 Kg & stitched with hessian thread. · The bags
shall be sealed at the centre & not on the corners to avoid breakage of
seals while handling the bags. Extra stitching thread shall be cut off to
avoid pulling of the same, which may lead to snapping of stitches. · Each bag
shall show the number of inserts packed in that. · The gunny
bag shall not have any exterior stitching, except for the edge to be sealed.
The hessian thread used for stitching the gunny bag shall be in one piece
& free from any knots except at the sealing point. · Suitable
chemically based plastic bags may be used in lieu of gunny bags with prior
approval of the purchaser in writing. · The
manufacturer shall ensure correct quantity packed in the bags. For any short
supply, the manufacturer shall be responsible. |
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Note: No Used bags/bags with inappropriate marking will
be permitted as per GGM/I/WR’s Instruction No.
15/2-18-19 dated 13.07.2018 |
Retest: Should any of the
tests carried out for tensile, hardness, micro-examination & internal
soundness on the castings selected fails to meet the specified requirements,
two or more castings from the same batch represented shall be selected for
testing in respect of each failure. Should the test pieces from both these
additional samples pass, the casting represented by the test samples shall be
deemed to comply with the requirements of that particular test. Should the test
pieces from either of these additional samples fail, the castings represented
by the test samples shall be considered as not having complied with this
standard & shall be rejected.
Note: i) Sampling
shall be done according to IS:2500 - 2000 Pt I single sampling plan (normal),
GIL-II, AQL 2.5
unless
mentioned otherwise.
ii)
In case a quality plan is mentioned in the Purchase Order, Inspecting Engineer
shall also take the same into
consideration during inspection, and mention
the same in Inspection Records.
iii) In case purchase order mentions different drawing/specification, then that will be applicable.
Cross check original PO
(Either in physical form or online)
1.
In case place of inspection is mentioned in
PO, do not undertake inspection elsewhere.
2.
Do not undertake inspection if quantity
offered is less than quantity mentioned in call letter.
3.
Do not inspect part quantity unless provided
in PO or authorised by client.
4.
Remember to stamp/seal complete material
after drawing samples for lab testing and before leaving site.
5.
Use check sheet for recording observations.
TEST RESULTS
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Heat
No. |
Phosphorus
% (0.08%
Max) |
Tensile
Strength (N/mm²) |
Elongation
% |
Hardness (BHN) 170-241 |
Microstructure (Nodularity
80% Min) |
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Test Bar 500 N/mm² |
Casting 400 N/mm² |
Test Bar 7% |
Casting 5.6% |
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Dimension Sheet:
(All dimensions in mm)
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S.
NO. |
Description
of Dimension |
Dimension
as per Drg |
Tolerance |
*Lot
No. |
L1 |
L2 |
L3 |
L4 |
L5 |
L6 |
L7 |
L8 |
L9 |
L10 |
TOTAL |
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No. of sampled
inserts per lot |
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1 |
Hole
Dia |
22.00 |
+1.00, -0.00 |
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2 |
Top
Radius |
24R |
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3 |
Length |
75.00 |
±
1 |
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4 |
Width |
67.00 |
+1.00, -0.50 |
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5 |
Hole
Position 1 |
25 |
± 0.8 |
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6 |
Hole
Position 2 |
14 |
+0.00,
-1.00 |
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7 |
Gating
Position |
Over
Stem |
+1.50, -1.00 |
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8 |
Weight |
1.550
Kg |
-3.00% |
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Note: (i) The approved jigs shall only be used for checking dimensions of inserts as per clause 12.2 of IRS T-46: 1996.
(ii) *L1 to L10 are the lots offered for inspection. As per Clause 12.3 of IRS T-46: 1996 inserts shall be arranged in convenient lots of
Approximate 1000 (between 501 to 1200). Additional sheets maybe used if required.
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