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TB/T 1900-2016: Air reservior of railway vehicle Delivery: 9 seconds. True-PDF full-copy in English & invoice will be downloaded + auto-delivered via email. See step-by-step procedure Status: Valid TB/T 1900: Historical versions
TB/T 1900-2016: Air reservior of railway vehicle---This is an excerpt. Full copy of true-PDF in English version (including equations, symbols, images, flow-chart, tables, and figures etc.), auto-downloaded/delivered in 9 seconds, can be purchased online: https://www.ChineseStandard.net/PDF.aspx/TBT1900-2016TB RAILWAY INDUSTRY STANDARD OF THE PEOPLE’S REPUBLIC OF CHINA ICS 45.060 S 34 Replacing TB/T 1900-1998 Air reservoir of railway vehicle ISSUED ON: SEPTEMBER 30, 2016 IMPLEMENTED ON: APRIL 01, 2017 Issued by: National Railway Administration Table of ContentsForeword ... 3 1 Scope ... 4 2 Normative references ... 4 3 Composition and classification ... 6 4 Technical requirements ... 6 4.1 Basic requirements ... 6 4.2 Material requirements ... 7 4.3 Design requirements ... 7 4.4 Manufacturing requirements ... 11 4.5 Welding requirements ... 12 4.6 Anti-corrosion ... 15 5 Inspection methods ... 15 5.1 Surface quality ... 15 5.2 Dimension and geometric tolerances ... 16 5.3 Weighing ... 16 5.4 Welds ... 16 5.5 Water pressure test ... 16 5.6 Air tightness test ... 16 5.7 Volume inspection ... 17 5.8 Impact vibration test ... 17 5.9 Paint adhesion test ... 17 5.10 Phosphate film inspection ... 17 6 Inspection rules ... 17 6.1 Type inspection ... 17 6.2 Exit-factory inspection ... 18 7 Marking, packaging, transportation, storage ... 18 7.1 Marking... 18 7.2 Packaging ... 19 7.3 Transportation ... 20 7.4 Storage ... 20 Air reservoir of railway vehicle1 ScopeThis standard specifies the composition and classification, technical requirements, inspection methods, inspection rules, marking, packaging, transportation and storage of air reservoir of railway vehicles. This standard applies to welded air reservoirs for EMUs, passenger trains, freight trains with a working pressure less than or equal to 1 MPa and a product of pressure and volume greater than 5 MPa•L (hereinafter referred to as air reservoirs).2 Normative referencesThe following documents are essential to the application of this document. For the dated documents, only the versions with the dates indicated are applicable to this document; for the undated documents, only the latest version (including all the amendments) is applicable to this standard. GB 150.2-2011 Pressure vessels - Part 2: Materials GB 150.3-2011 Pressure vessels - Part 3: Design GB/T 1184 Geometrical tolerancing - Geometrical tolerance for features without individual tolerance indications (GB/T 1184-1996, eqv ISO 2768-2:1989) GB/T 1804 General tolerances - Tolerances for linear and angular dimensions without individual tolerance indications (GB/T 1804-2000, eqv ISO 2768-1:1989) GB/T 4956-2003 Non-magnetic coatings on magnetic substrates - Measurement of coating thickness - Magnetic method (ISO 2179:1982, IDT) GB/T 6417.1-2005 Classification and explanation of imperfections in fusion welded joints (ISO 6520-1:1998, IDT) GB/T 6807-2001 Specifications for phosphating treatment of iron and steel parts before painting GB/T 7306.2 Pipe threads with 55 degree thread angle where pressure-tight joints are made on the threads - Part 2: Taper internal and external threads (GB/T 7306.2- 2000, eqv ISO 7-1:1994) GB/T 7307 Pipe threads with 55-degree thread angle where pressure-tight joints are not made on the threads (GB/T 7307-2001, eqv ISO 228-1:1994) ISO 15614-2 Specification and qualification of welding procedures for metallic materials - Welding procedure test - Part 2: Arc welding of aluminium and its alloys ISO 17636-1:2013 Non-destructive testing of welds - Radiographic testing - Part 1: X-and gamma-ray techniques with film ISO 17636-2:2013 Non-destructive testing of welds - Radiographic testing - Part 2: X-and gamma-ray techniques with digital detectors3 Composition and classificationThe air reservoir is generally composed of a head, a cylinder, a drain seat, a pipe seat or a flange through welding. According to the structural form, the air reservoir can be divided into a single-chamber air reservoir and a multi-chamber air reservoir; according to the interface form, it can be divided into a threaded interface type and a flange interface type.4 Technical requirements4.1 Basic requirements 4.1.1 The air reservoir shall comply with the product drawings approved according to the procedure and the provisions of this standard. 4.1.2 The operating environment temperature of the EMU air reservoir is -25 °C ~ 60 °C; the operating environment temperature of the passenger train air reservoir is -40 °C ~ 60 °C; the operating environment temperature of the freight train air reservoir is -50 °C ~ 70 °C, meanwhile it shall be able to adapt to the use requirements of the thawing warehouse at 110 °C for 3 h. Special use environments can be determined by negotiation between the supplier and the buyer. 4.1.3 The maximum working pressure of the EMU air reservoir is 1000 kPa. The maximum working pressure of the passenger train and freight train air reservoir is 600 kPa. 4.1.4 The air reservoir shall have good air tightness. After the water pressure test and air tightness test, the air reservoir shall not have permanent deformation, cracks or leakage. 4.1.5 The overall strength of the air reservoir shall be able to withstand its own weight and the vibration and impact caused by the operation of the train. The vibration and impact performance of the air reservoir installed on the train shall meet the requirements of Class 1B of GB/T 21563-2008. The vibration and impact performance requirements c) Butt weld connection with folded edge of head d) Butt weld connection with bottom lock of head Note: e - Thickness of head plate; e1 - Thickness of cylinder plate. Figure 2 -- Connection structure form between head and cylinder 4.3.5 The thickness of the head and cylinder of the air reservoir shall comply with the minimum thickness, which is calculated by the calculation method specified in GB 150.3-2011 or relevant standards. 4.3.6 The openings on the cylinder and head shall be as far away from the weld as possible; the openings shall not pass through the weld. 4.3.7 The threads of the air reservoir's pipe seat and drain seat interface shall comply with the requirements of GB/T 7307 or GB/T 7306.2. 4.3.8 The distance between any two adjacent weld edges shall be greater than 6 times the thickness of the air reservoir body plate. Special cases shall be determined by negotiation between the supplier and the buyer. 4.3.9 The wall thickness of the steel air reservoir's pipe seat and drain seat shall not be less than 1.5 times the steel plate welded to it; the wall thickness of the aluminum air reservoir's pipe seat and drain seat shall not be less than 2 times the plate welded to it. 4.3.10 The steel air reservoir pipe seat for passenger trains and EMUs shall adopt the external and internal welding methods shown in Figure 3a); the weld size g shall be greater than or equal to 0.7 times the wall thickness e of the head. When the outer diameter d of the pipe seat is less than or equal to 65 mm, the external welding method shown in Figure 3b) may also be adopted, but the weld size g shall be greater than or equal to 1.5 times the wall thickness e of the head. The external and internal welding methods shown in Figure 3c) should be used for the aluminum air reservoir's pipe seat. When the external welding method shown in Figure 3d) is used, the weld shall be a full penetration weld; when the external and internal fillet welds of the pipe seat shown in Figure 3e) are used, the weld shall be a partial penetration weld; the weld leg size g shall be greater than or equal to 3 mm and less than or equal to the head wall thickness e. The welding method of the flange pipe seat of the air reservoir for freight train is shown in Figure 3f); the weld size g shall be greater than or equal to the head wall thickness e. The welding method of other structural pipe seats shall be determined by negotiation between the supplier and the buyer. not have defects such as bumps, burrs, scratches. 4.4.6 There shall be no longitudinal wrinkles on the straight edge of the head. 4.4.7 If the wall thickness is reduced due to the manufacturing process during the forming of the head and cylinder, the thickness of the head and cylinder shall be corrected when calculated according to 4.3.5. 4.4.8 The unindicated machining dimension tolerance shall comply with the provisions of GB/T 1804-m; the unindicated shape and position tolerance shall comply with the provisions of GB/T 1184-K; the unindicated shear tolerance shall comply with the provisions of JB/T 4381-B; the unindicated stamping dimension tolerance shall comply with the provisions of GB/T 15055-c. 4.4.9 The linear dimension tolerance of the air reservoir welding structure shall comply with Class B of GB/T 19804-2005; the geometric tolerance shall comply with Class F of GB/T 19804-2005; when the outer diameter of the air reservoir is not greater than 500 mm, the deviation shall not exceed 3 mm; when the outer diameter of the air reservoir is greater than 500 mm, the deviation shall not exceed 0.6% of the basic outer diameter. 4.4.10 The deviation of the weight of the air reservoir shall not exceed 3% of the rated value. 4.4.11 The deviation of the volume of the air reservoir should not exceed 3.5% of the rated value. 4.5 Welding requirements 4.5.1 The storage of welding rods or welding wires and flux materials shall be kept dry; the relative humidity shall not be greater than 60%. 4.5.2 Before welding, oxides, oil stains, slag and other harmful impurities within 20 mm (measured by the distance from the edge of the groove) on both sides of the groove and the surface of the parent material shall be removed. 4.5.3 When the temperature of the weldment is below 0 °C, it shall be preheated to about 15 °C within 100 mm of the welding location. 4.5.4 The welding procedure qualification of steel air reservoirs for passenger trains and EMUs shall be carried out in accordance with relevant provisions such as NB/T 47014-2011 or ISO 15614-1. The welding procedure qualification of aluminum air reservoirs for passenger trains and EMUs shall be carried out in accordance with relevant provisions such as NB/T 47014-2011 or ISO 15614-2. The welding process specification shall be formulated according to the qualified welding procedure. 4.5.11 Air reservoirs with welded hangers shall be tested according to the requirements of Chapter 5 after welding. 4.5.12 The quality of radiographic flaw detection of passenger train and EMU welds shall meet the requirements of Level II specified in NB/T 47013.2-2015. The quality of magnetic particle flaw detection shall meet the requirements of Level I specified in NB/T 47013.4-2015. The quality of penetrant flaw detection shall meet the requirements of Level I specified in NB/T 47013.5-2015. Welds that are confirmed as unqualified by the test can be repaired; the defects can be cleaned and then re-welded. When repairing, the number of repairs on the same part should not exceed two. After repair, resubmit for acceptance and re-inspect according to the test method of this standard until qualified. 4.6 Anti-corrosion 4.6.1 After welding and passing the test, all oil stains, scale, welding slag and other debris inside and outside shall be removed. The inner surface of the carbon steel air reservoir shall be phosphated according to GB/T 6807-2001; the phosphating film thickness shall not be less than 5 μm or the film weight shall not be less than 7.5 g/m2. The phosphating film shall meet the requirements of GB/T 6807-2001. 4.6.2 The inner surface of the air reservoir after phosphating treatment should be protected by anti-rust oil and other protective methods; the protective layer shall not fall off. 4.6.3 The inner surface of the aluminum air reservoir shall be deeply cleaned, to ensure that there are no impurities and corrosion. 4.6.4 The outer surface of the air reservoir shall be coated with primer and topcoat according to relevant requirements; the installation surface of the pipe seat and drain seat shall only be coated with anti-rust primer. The outer surface of the stainless steel air reservoir shall only be coated with topcoat; the installation surface of the flange and drain seat shall not be painted. The adhesion of the paint shall be tested by cross-cutting in accordance with the requirements of GB/T 9286; it shall meet at least the requirements of Level 1.5 Inspection methods5.1 Surface quality The surface quality shall be visually inspected. 5.2 Dimension and geometric tolerances Dimension and geometric tolerances shall be inspected by measuring tools of corresponding accuracy. 5.3 Weighing Weighing shall be carried out using a weighing device which has a measuring accuracy of not less than 100 g. 5.4 Welds 5.4.1 Inspection of weld surface and shape defects Visual inspection of butt weld surface and shape defects shall be carried out. 5.4.2 Weld flaw detection Butt welds and circumferential welds shall be subjected to radiographic flaw detection, in accordance with NB/T 47013.2-2015 or ISO 17636-1:2013, ISO 17636-2:2013. Carbon steel air reservoirs with other welds shall be inspected by magnetic particle inspection or penetrant inspection, according to NB/T 47013.4-2015, NB/T 47013.5- 2015 or other standards. Stainless steel and aluminum alloy air reservoirs with other welds shall be inspected by penetrant inspection, according to NB/T 47013.5-2015 or other standards. 5.5 Water pressure test At room temperature, fill the air reservoir with water and pressurize it to 1.5 times the maximum working pressure; keep it at this pressure for at least 5 minutes; then reduce the test pressure to the maximum working pressure; inspect the air reservoir to meet the requirements of 4.1.4. 5.6 Air tightness test When the air reservoirs that have passed the water pressure test are inspected one by one, only one air filling interface is left, whilst the other interfaces are sealed with screw plugs, meanwhile the air inlet is connected to the pressure test device. The following two methods can be used for inspection: engraved before the cylinder and the head are welded. The engraving position of the mark shall avoid the weld and be easy to see. 7.1.3 When the mark seat is used, the mark seat can be welded on the middle side of the air reservoir or the end of the head. The welding position shall avoid the weld and be easy to see. 7.1.4 The mark shall include the following: a) Manufacturer name or code; b) Manufacturing date; c) Rated volume; d) Product serial number (optional); e) Implemented standard number (optional); f) Maximum working pressure (optional); g) Operating temperature range (optional). 7.1.5 The mark shall be permanent, clear, recognizable. 7.2 Packaging 7.2.1 The air path interface of the air reservoir's pipe seat and the drain seat shall be rust-proofed; the protective seal shall be used in accordance with the provisions of TB/T 3218-2009 to prevent debris from invading the cylinder. 7.2.2 The packaging shall be moisture-proof and dust-proof. The air reservoir in the packaging box shall be protected, to prevent possible damage during transportation. 7.2.3 The packaging box shall be accompanied by a product certificate and a packing list from the manufacturer's inspection department. 7.2.4 The product quality certificate shall at least include the following: a) Product name and specifications; b) Manufacturer name or code; c) Manufacturing date; d) Inspector name or code; e) Qualification stamp; ......Source: Above contents are excerpted from the full-copy PDF -- translated/reviewed by: www.ChineseStandard.net / Wayne Zheng et al. 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