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PRESENTED BY MR.

TINKU SAHA
(SR. SURVEYOR OF QUEST KOLKATA)

Introduction of the Inspection call


M/S. Premium Transmission Limited.

1.0

Customer

2.0

Item description

GEAR BOX (Export Quality)

3.0

Qty

01 no.

4.0

PO no

M/S. IS International to PTL


PO 1412223 Date: 20.01.2015

5.0

Schedule date of inspection

17.02.2015

6.0

Special instructions

Nil

7.0

Selection of surveyor

Mr. Tinku Saha

Skill level on

Familiar with all type of measuring Instruments related


to Gear Box Inspection. Awareness
of geometrical
2
parameters. Inspection experience
of Gear Box
Components.

8.0

End Customer M/s. IS International.

Planning for inspection


1.0

Approved drawing

2.0 Approved QAP

U311-2000-0040-01, REV. 0
QAP/STD/14/01
Cases of Gear Boxes rejection due to

3.0 Past performance or feedbacks

dimensional error and incorrect Gear


Ratio.

4.0 Samples

100%

5.0 Workmanship standards

As per approved Drawing

6.0 Check lists

As per approved 3QAP & Drawing


parameters

Review of Supplier submitted


Documents
1.0 Supplier internal IR

59806/2013-15 & 21/PTL/15-16

2.0 Material Test Certificates

PTL compliance certificate

3.0 NDT Reports

NA

4.0 Painting Report

NA

5.0

Calibration certificates of measuring


instruments

6.0 Accept/ Reject/ rework/ Hold

Verified and found in order. History chart


Attached.

Accepted.

Visual Examination
1.0 Identification

SL NO. HGF-46352

2.0 Orientations

Orientations have been checked on assembled Gear Box


and found as per drawing.

3.0 Surface preparations

4.0 Shade of finish

5.0

Casting defects

6.0 Overall fitting and assembly

NA

Light Grey final Paint condition, where DFT measured


and found more than 150 Microns. Requirement is 100
micron (min). But As per QAP Painting checking was not
Quest scope of work. Checking DFT for Value addition.
It is a final inspection call and PTL offered assembled
Gear box after final painting. No casting defect could not
visualized due to final painting.
Found as per Drawing.

5
7.0 Sharp edges and corners removed Checked visually and found no sharp edges.

Dimensions
Tolerance and specified values

As per Drawing
(U311-2000-0040-01, REV. 0)

2.0

Measured dimensions

Reviewed internal IR (IR no. 21/PTL/15-16)


tallying with the drawing and cross checked.
Dimensions, found within Drawing limit of
tolerances.

3.0

Using measuring instruments

Vernier caliper, Micrometer,


Steel scale and Elco meter.

4.0

Shaft handing and rotation

P1, RHB, CW

5.0

Gear ratio

Gear ratio checked manually and


6
found 34.68:1 instead of 34.7 : 1.

1.0

Performance Test Witnessing


1.0

Sample size

100%

2.0

Run test

No load trial run test by test bed motor


(11 KW)

Duration of run test

As per QAP no load trial run test should


be 2 hours (min). But as it is a export
quality job so run test Conducted more
than 2 hours. (2 hours and 45 min).

4.0

Type of or scope of tests

Noise level, Vibration (Vertical,


Horizontal & Axial), Oil temp. rise,
Excessive bearing Hammering, knocking
and oil leakage.

5.0

Procedure

As per QAP

6.0

Specified values/tolerances

As per QAP

3.0

Performance Test Witnessing

7.0

Actual values/Observations

Noise level
Specified Noise level 85 dBA max (At one meter distance)
Observed 78.5dBA with surrounding noise, found within limit.
Vibration (Vertical / Horizontal / Axial)
Specified 4.5 mm/Sec Max.
Observed 1.36 / 0.87 / 2.41 mm/Sec, found within limit.
Oil temp rise
Specified Amb + 45 0 C
Observed 29 + 9 0 C, found within limit.
No excessive bearing Hammering and knocking has been
observed during performance test.
No oil leakage or Seepage has been observed during and
after completion of the performance test

8.0

Using measuring instruments

Digital Vibration meter, Sound level meter, Infrared


thermometer and hand Techometer

9.0

Accept /Reject /Hold /rework

Accepted

Generation of Inspection Report


1.0 Report no

QR/KOL/1621/1502/0610/010 Date: 17.02.2015

2.0 Selection of format

Quest format

3.0 Calibration status due date

As per attached History chart

4.0 Specified values with tolerances

Drawing No. U311-2000-0040-01, REV. 0 and


QAP no. QAP/STD/14/01

5.0 Actual values

Recorded in Report No. 21/PTL/15-16

6.0 Sample size in numbers/Sampling plan

100 %

7.0 Sample selection procedure

NA

8.0 Status : Accept /reject /hold /rework

Accepted

Visuals

At the time of the inspection


10

CHECKING DIMENSIONS

MANUALLY GEAR RATIO CHECKING

CHECKING PAINTING DFT

VIBRATION CHECKING

TACKING RPM READING

TEMP RISE MEASURED AT INPUT SHAFT AREA

NOISE LEVEL MEASURED

STAMPING ON OUTPUT SHAFT OF THE INSPECTED GEAR BOX FOR IDENTIFICATION

Thank you