MANUFACTURING AND INSPECTION PROCEDURE

FOR PULLEYS


Raw material Identification:

Heat number co-relation(Plate, Shaft and Hub) shall comply with available test
certificates. If any ambiguities on co-relation Lab test mandatory for all available heats.
Plates Thk>12mm UT(Lamination check) shall perform with TIND surveyor and relevant
standard ASTM A435.
Shaft >50 and Castings on Hub UT shall perform with relevant standard ASTM A388
FBH-3mm and ASTM A609 respectively.
Mill Test certificates are not acceptable for shafts.
Lab test to be performed by NABL approved Labs only and TIND witness required on
LAB testing.
.
Fabrication and Welding:
Shell Welding:

Shell made by rolling of plates or by seamless pipes WRT higher side of the nominal
thickness.
Shell edge preparation shall conform as per the drawing and Cir-Seam and L-Seam welding
to be done as per the Approved welding process.
After completion of welding process 100% UT shall perform as per the approved QAP / Drg
/ relevant standard ASME Sec-VIII,Div-1(Appx-12) / DIN 22261-3.
If any ambiguities on weld test, repair work to be done and UT shall performed once again.
Necessary face and OD machining allowances (minimum 8 mm /side on face and 2.5mm
on OD) to be maintained.
Inspection to be performed out for dimensional(Ovality & Bend) and visual, re-rolling
process to be done; if any Ovality /bend issues

Shell ID step machining / Back-strip / stopper to be provided as per drawing details.


Hub with End Disc Welding:
Edge preparation on End-disc to be done as per drawings details.

Pre-heating (T>150C) to be done before start of Hub with end-disc welding.

Welding must be carried out as per approved process only and sequential welding process
to be carried out and distortions should be minimized on welding.

Bore-Pre machined Hub and Machined end-disc welding to be done as per drawing.

MANUFACTURING AND INSPECTION PROCEDURE
FOR PULLEYS

Inspection to be performed for visual(Welding-Distortion) and Dimensional part




Shell with End disc Fit-up, Welding and Stress relieve:

Before start-up End-disc closing two coats (minimum 80m) of Red-oxide paints to be
applied on inner surface of the shell with appropriate surface clean.
Shell with End-disc fit-up to be performed as per the approved drawing with proper
Root-Gap settings.
Root-Gap and dimensional part to be confirmed by Vendor / as per QAP before start of
welding process and record to be maintained.
Necessary Pre-heating to be done before start of Shell with end-disc welding.
Shell with End-disc welding should be performed as per approved welding process only.
After completion of welding process Pulleys shell must be cleaned free from visual defects
for UT to be performed as per the approved QAP/Drg/ relevant standard ASME Sec-
VIII,Div-1(Appx-12) / DIN 22261-3.
Shell Stress relieving (Volume) to be performed as per the recommended Temp / process
and timing. SR-temp charts mandatory.
However Random (20%) UT to be performed in stress relieved Shell and End-Disc weld
metal.

Machining for Shell and Shaft:
Once Stress relieving process completed, and then shell machining to be started.
Shell-OD WRT Hub-ID Concentric to be maintained as pre approved Drawing / QAP /
IS:8531-1986
Shell Hub-Bore final machining to be performed as a single machine setting with necessary
machining allowance minimum 0.20 mm to 0.30 mm to be maintained.

Shaft final machining to be done in all areas except bearing seating area.
Shaft machining allowance 0.20 mm to 0.30 mm to be maintained in the bearing seating
area for grinding.
Gib Head Key to be machined as per drawing.

Inspection to be carried out for shell OD run out & dimensions

Shaft Final Machining:

Shaft bearing seating OD to be ground as per the Drawing surface finish.

Inspection to be carried out.

MANUFACTURING AND INSPECTION PROCEDURE
FOR PULLEYS

Stage Assembly:

Shaft to be inserted into the hub ID and locked by Gib head key.

Static balancing to be done.

Inspection to be performed for static balancing by Vendor/ as per the approved QAP and
Drawing



Rubber Lagging:

Rubber lagging to be done by Hot/Cold vulcanizing method as per drawing.

The following properties of rubber to be inspected by using integral test piece

1. Hardness test.
2. Abrasion loss test.
3. Peel strength test
4. Adhersion test

Inspect OD of pulley after Rubber lagging.
Check groove details of Rubber lagging as per drawing.
balancing to be checked after rubber lagging.

Final Assembly:

a. Plummer block to be assembled on both side of shaft with adopter sleeve and bearing.

b Final assembly inspection to be carried out
1. Visual
2. Dimensions
3. Paint coat thickness.

NOTE:


Periodical calibration certificates with instruments to be produced during
inspection.
Welders should be qualified as per ASME sec IX / DIN:287
Internal inspection to be carried out by the vendor before TAKRAF inspection.
Test certificates of raw material and NDT reports to be submitted before TAKRAF
inspection. Without these reports inspection wont be carried out by TAKRAF.
Proper Jigs, Fixtures, Gauges and templates to be used for manufacturing and
inspection.
Machining to be done strictly as per the machining symbols shown in the drawing.

MANUFACTURING AND INSPECTION PROCEDURE
FOR PULLEYS