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QA 20/2009 CRWS(BHOPAL) WEST CENTRAL RAILWAY Page 1 of7

QUALITY AUDIT REPORT

OF

WHEEL SHOP

NO. 20/2009

CARRIAGE REHABILITATION WORKSHOP

(CRWS) BHOPAL, WEST CENTRAL RAILWAY

OCTOBER 2009

QUALITY ASSURANCE (MECHANICAL) DIRECTORATERESEARCH DESIGNS & STANDARD ORGANISATON

MANAK NAGAR, LUCKNOW-226011


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Quality audit of Wheel Shop at Carriage Rehabilitation Workshop

(CRWS), Bhopal, West Central Railway

Quality audit of Carriage Rehabilitation Workshop (CRWS), Bhopal, West Central Railway was

carried out on 23.10.09 and 24.10.09 by Shri Deepak Tripathi, Director/I&L, Mumbai formaintenance, overhauling and repairs of Wheels and Axles of coaching stock. The scope of

audit was discussed with DyCME, Shri Shobhit Tandon. AWM (repairs) and SSE wheel shop

accompanied during the audit.

Strengths:

1. The repairs and overhauling practices are being followed by the workshop as per

maintenance manual. The wheels shop is located next to bogie shop and wheels after

being disassembled from the bogies are brought to wheel shop, where initial inspection is

done as prescribed. Proper system of recording is available under ISO9001:2000.

2. Adequate machinery and plant and test equipment in good working condition are available

with the workshop to undertake assigned workload.

3. Workshop is also carrying out additional check on axles with magnetic particle test

equipment. Magnetic particle test on new axles is done on entire surface, whereas used

and serviceable axles are given this test on wheel seat area to check surface and

subsurface defects. Total 400 axles (new and used) have been tested on this equipment in

the year 2009-10.

Magnetic particle test machine for new and serviceable axles


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3. Automated graphic recording facility has been installed by the workshop on wheel press with

the help of M/s BHEL. The online pressing in pressure can be read directly on LED display and

simultaneously graphs for both side wheel-discs pressures are also recorded.

Automated pressing in pressure graphic recording facility

4.The data obtained from the workshop for the period April 09 to September 09 shows that total

260 Re-discing (520 discs) and 161 Re-axling were done by the workshop. The AAC of axles

is 353 nos. and AAC of wheel discs is 1730 nos. The stock on hand of wheel discs and axles

was 56 and 997 respectively. This shows that more than two months stock is available with

the workshop.

The wheel and axle stock and supply position for April 09-Sept 09 is tabulated below

Nos. of wheel

press off

No. of wheel

Rediscing

No. of Wheels

Reaxling

AAC (Stock) of

Axle

AAC (stock) of

wheel discs

421 260 161 253 (56) 1730 (997)

Areas of Concerns:

1. The pressing in graphs are kept in F/WHS/007 record (register). This record was checked

and it was observed that in some cases the pressure displacement curve was not found to

be smooth and some abrupt changes could be noticed. Further the data collected from the

wheel press for August and September 2009 revealed that 6 out of 69 (9%) wheel

pressings in September 2009 and 7 out of 75 (9%) wheel pressings in October 2009 had to

be reworked due to lower pressing in pressure.

2. The wheel diameter needs to be measured with the help of trammel gauge with least count

of 0.5 mm. The difference in tread diameters of the two wheels on the same axle permitted

is 0.5 mm (max). However the least count of trammel gauge used in workshop is 1 mm in


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place of 0.5 mm as prescribed. Therefore, it is difficult to accurately ensure the difference

between wheel diameters.

3. The tapped holes are checked with the help of thread gauges and adequate numbers of

gauges are available. However it was observed that difficulty is being faced in checking

tapped holes due to inclusion of metal burs inside tapped holes as shop is using a setup,

which carries out tapping operation in vertical position. This may be reviewed and possibility

of using horizontal tapping operation may be explored.

Set up to for tapping in vertical position

4. It is found difficult to measure the surface finish of wheel disc bore and as such it is notbeing measured at present on 100% wheels discs taken for rediscing.


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INSPECTION & LIAISON DIRECTORATE

RDSO, LUCKNOW

CHECK-SHEET FOR QUALITY AUDIT OF WHEELS, AXLES (ICF WHEELS) & DIRECT MOUNTED ROLLER

BEARING CHAPTER-4 AND TECHNICAL PAMPHLET C-7817.

While dong the audit, ensure that the below mentioned activities are carried out as specified. Wherever

the activities are not performed correctly indicate the method adopted or the nature of non-

compliance.

S.No. Requirements Clause

No.

Observations

1. Check that wheel gauge (1600 + 2/-1) is

being measured at 3 locations 60 apart.

2.3.1 This is being done. Workshop has 3

gauges of Paragon Industries. The record

of wheel gauge is maintained in

F/RB/009.

2. Check that wheel dia is being measured

with the help of trammel gauge with

least count of 0.5 mm or wheel diameasuring gauge of least count of 0.1

mm. Check that wheel flanges are being

checked with the help of wheel profile

gauge and thickness and height of flanges

is being measured. The difference in

tread dia of the two wheels on the same

axle permitted is 0.5 mm max and this is

being measured. Check that wheels

turned out from wheel shop are

according to shop issue sizes. 16T wheels

New-1090 shop issue-996 ICF/BEML solidNew-915 shop issue 819

2.3.2 Trammel gauges are used for measuring

wheel diameters. Four numbers of

trammel gauges are available. Howeverthe least count of trammel gauges is 1

mm in place of 0.5 mm as prescribed.

Therefore, it is difficult to accurately

ensure the difference between wheel

diameters as 0.5 mm.

The shop issue size for wheel diameter is

837 mm and this is being maintained as

verified from the record F/RB/009.

3. Check that each axles are being

thoroughly cleaned for inspection &

inspected for pitting, ovality, taper, ridges

& ultrasonically as per RDSO procedure.

Taper must not exceed

0.015/0.01 mm.

Out of roundness must not exceed

0.015/0.02 mm.

2.3.4 This is being ensured. Ovality and taper

is checked with the help of micrometer,

but records are not being maintained.

Ultrasonic testing of axles is being

done. Workshop is also carrying out an

additional check for surface and

subsurface cracks by magnetic particle

testing of all new axles and wheel seat

area of used axles.

4. Check that wheels are being categorized

into following categories after pre-

inspection.

(i) Normal repair wheels.

(ii) Wheels requiring replacement of

Axle.

2.3.5 Yes this is being done. Wheels are

categorized into Re-turning (RT), Re-

discing (RD) and Re-axling (RA). Record

for incoming wheels is being maintained

in format F/RB/001.


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(iii)Wheels requiring replacement of

wheels discs

5. Check that wheels are being turned to

WWP & machining standard is N11 to IS:

3073

3.1.2 Yes, worn wheel profile is being used

6. Check that when wheels sent for turning

with roller bearings, a protective cover is

provided.

3.1.3 Wheel turning is not done with bearings

mounted on it.

7. Check that new axles are being machined

as per the correct drawing dimensions.

3.1.3 Yes, Workshop has CNC axle turning

lathe to machine axles as per drawing

dimensions.

It was informed that workshop is

receiving raw forged axles and these are

being rough machined from outside

sources and final machining is done in

house.

8. Check that dimensions of finished

journals is being measured with micro

meter at 3 points along length of thejournal both on horizontal & vertical axis.

3.2.4 Yes being done.

9. Check that axles are being given

ultrasonic flaw detection test.

3.2.5 Yes axles are being given ultrasonic flaw

detection test.

10. Check that the bore & the wheel seats

are having specified surface finish &

correct interference fit and pressing in

pressure. Interference allowed -0.20 to

0.24 mm surface finish 1.6 microns

Presssing in pressure -400 to 600 kg/mm

dia of wheel set.

3.2.9 &

3.4.5

The wheel seats are being checked with

surface finish of N 7 (0.8 to 1.6 microns)

and N6 for journal (0.4 to 0.8 microns).

However wheel disc bore is not checked

for surface finish.

The prescribed range for wheel pressingpressure is from 71 tonne to 108 tonne.

The wheel gauge is kept at 1597 mm to

1598 mm for keeping allowances for

machining.

11. Check that after dropping of axle boxes

and roller bearing dismounted, the

journal dia is being checked and wheels

are being ultrasonically tested for flaw

detection

3.4 Yes being done. Record is being

maintained in F/RB/009. Wheels are also

being ultrasonically checked for flaw

detection

Total 1377 axles have been testedultrasonically since April 2009 and 3out of them were found to have flaw(approximately 0.2%).

12. Check that cleaned wheel seat and bore

on wheel is being lubricated with a

mixture of basic carbonate white lead

3.2.10 Yes being done as prescribed


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and boiled linseed oil in the proportion of

1.2 kg of white lead to 1t. of boiled

linseed oil

13. Check that wheel press is equipped with

a dial pressure gauge and pressure

recording gauge with graph to record

mounting pressure diagram and also is

being recorded for each assembly .

3.2.11 Yes. The computerized graph recording

system is available and pressing in

graphs are being maintained for each

wheel set in register F/WHS/007.

14. Check that mounting particulars are

being punched on journal face.

5.1 The workshop pressing operation code is

being punched on axle journal. Following

other details are punched on wheel discs

1. Workshop code

2. New or RD

3. Wheel No.

4. Month/year

5. Right/Left side

6. Mounting pressure.

15. Check that journal is being cleaned and

inspected for concentricity, ovality and

dimensions, surface finish & cracks.

3.7.2 Yes this is being checked but individual

records are not maintained

16. Check that tapped holes of journal faceare being checked for correct size and

thread formation.

3.7.3. Yes being checked with the help ofthread gauges. However it was observed

that difficulty is being faced in check

tapped holes due to inclusion of metal

burs inside tapped holes, which need to

be removed. Workshop is using a setup,

which carries out tapping operation in

vertical position, which leads to

possibility of burs remaining inside

tapped holes.

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