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This standard is developed in accordance with the rules given in GB/T 1.1-2009.
This standard replaces TB/T 1900-1998 General Technical Specifications for Air Reservoir of Railway Vehicle. The following technical changes have been made with respect to TB/T 1900-1998:
——Working pressure is modified (see 4.1.3; 3.4.2 of Edition 1998);
——Requirements for air reservoir of D-Series High-Speed Train are added (see Chapter 4);
——Composition and classification of air reservoirs are added (see Chapter 3);
——Service environment requirements are added (see 4.1.2);
——Material requirements are modified (see 4.2; 3.2 of Edition 1998);
——Design Requirements are added (see 4.3);
——Welding requirements are added (see 4.5);
——Requirements for installation and resistance to corrosion are added (see 4.3.12 and 4.6);
——Inspection methods are added (see Chapter 5);
——Inspection rules are modified (see Chapter 6; see Chapter 4 of Edition 1998);
——Marking and packaging requirements are added (see 7.1 and 7.2).
This standard is under the jurisdiction of Qingdao Sifang Rolling Stock Research Institute Co., Ltd., CRRC.
The previous versions of the standard replaced by this standard are as follows:
TB/T 1900-1987, TB/T 1900-1998.
Air Reservoir of Railway Vehicle
1 Scope
This standard specifies composition and classification, technical requirements, inspection methods, inspection rules, and marking, packaging, transportation and storage of air reservoir of railway vehicle.
This standard is applicable to welded air reservoirs for D-Series High-Speed Train, passenger cars and trucks with the working pressure less than or equal to 1 MPa and the product of pressure and volume more than 5 MPa·L (hereinafter referred to as air reservoir).
2 Normative References
The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.
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 Specification for Phosphate 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)
GB/T 9286 Paints and Varnishes—Cross Cut Test for Films (GB/T 9286-1998, eqv ISO 2409:1992)
GB/T 9792-2003 Conversion Coatings on Metallic Materials — Determination of Coating Mass Per Unit Area — Gravimetric Methods(ISO 3892:2000, MOD)
GB/T 15055 Permissible Stamping Variations in Dimensions without Tolerance Indication
GB/T 19804-2005 Welding—General Tolerances for Welded Constructions — Dimensions for Lengths and Angles — Shape and Position (ISO 13920:1996, IDT)
GB/T 21563-2008 Railway Applications — Rolling Stock Equipment — Shock and Vibration Tests (IEC 61373:1999, IDT)
GB/T 25198-2010 Heads for Pressure Vessels
NB/T 47013.2-2015 Nondestructive Testing of Pressure Equipments — Part 2: Radiographic Testing
NB/T 47013.4-2015 Nondestructive Testing of Pressure Equipments—Part 4: Magnetic Particle Testing
NB/T 47013.5-2015 Nondestructive Testing of Pressure Equipment — Part 5: Penetrant Testing
NB/T 47014-2011 (JB/T 4708) Welding Procedure Qualification for Pressure Equipment
JB/T 4381 Permissible Limit Deviation in Dimensions without Tolerance Indication for Shearing of Metal Plate
JB/T 4732-1995 Steel Pressure Vessels—Design by Analysis
JB/T 4734 Aluminium Welded Vessels
TB/T 3218-2009 Air Brake Fitting Guard for Railway Rolling Stock
TB/T 3462 Stainless Steel Plate (Sheet) for Railway Freight Wagon
ISO 209:2007 Aluminium and Aluminium Alloys — Chemical Composition
ISO 6362-2 Wrought Aluminium and Aluminium Alloys — Extruded Rods/Bars, Tubes and Profiles-Part 2:Mechanical Properties
ISO 15614-1 Specification and Qualification of Welding Procedures for Metallic Materials — Welding Procedure Test—Part 1:Arc and Gas Welding of Steels and Arc Welding of Nickel and Nickel Alloys
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 Detectors
3 Composition and Classification
Generally, air reservoir consists of head, cylinder, draining seat, pipe seat or flange weld.
Air reservoir may be classified by structure type into single-chamber one and multi-chamber one; it may be classified by interface type into air reservoir with threaded interface and air reservoir with flange interface.
4 Technical Requirements
4.1 Basic Requirements
4.1.1 Air reservoirs shall conform to the product drawings approved according to the procedures and the requirements of this standard.
4.1.2 As for air reservoirs of D-Series High-Speed Train, the operating ambient temperature is -25℃~60℃; as for air reservoirs of passenger cars, the operating ambient temperature is -40℃~60℃; as for air reservoirs of trucks, the operating ambient temperature is -50℃~70℃, and they shall meet the service requirements of thermal insulation for 3h in 110℃ unfreezing warehouse. The special service environment may be determined through negotiation between the supplier and the purchaser.
4.1.3 Air reservoirs of D-Series High-Speed Train have the maximum working pressure of 1000 kPa. Air reservoirs of passenger cars and trucks have the maximum working pressure of 600 kPa.
4.1.4 Air reservoirs shall have favorable airtightness. After hydrostatic test and air-tightness test, air reservoirs shall be free from permanent deformation, crack or leakage.
4.1.5 Air reservoirs shall have such overall strength that they shall be able to bear their own weight and vibration and shock generated from vehicle operation. For the air reservoirs installed on the vehicle body, their vibration and shock performance shall meet the requirements of Grade B, Category 1 in GB/T 21563-2008. For the air reservoirs installed in special positions, their vibration and shock performance is determined through negotiation between the supplier and the purchaser.
4.2 Material Requirements
4.2.1 Head and cylinder of a steel air reservoir should be made of the materials specified in GB 150.2-2011; trucks should be made of the stainless steel materials specified in TB/T 3462 or others that can meet the performance requirements.
4.2.2 Head and cylinder of an aluminum air reservoir shall be made of aluminum alloy plate in which magnesium is the main alloy element as specified in ISO 209:2007 or JB/T 4734, and should be made of the materials specified in Table 1.
Table 1 Head and Cylinder Material of Aluminum Air Reservoir
No. Material designation Designation in the international four-digit system
1 AlMg2Mn0.8 5049
2 AlMg3 5754
3 AlMg3Mn 5454
4 AlMg4 5086
5 AlMg4.5Mn0.7 5083
4.2.3 Pipe seats and draining seats of air reservoirs shall be made of materials of the same strength as those for heads and cylinders or of materials satisfying the operating requirements of air reservoirs.
4.2.4 Accessories welded to the air reservoirs shall match with the air reservoirs with respect to material performance grade. Accessory materials shall be liable to welding and shall not reduce the air reservoirs' strength.
4.2.5 Filling materials welded to air reservoirs or welding air reservoirs shall match with base metal. Aluminum air reservoirs should be made of aluminum alloy of 5183 and 5356 (designation in the international four-digit system).
4.3 Design Requirements
4.3.1 Air reservoirs shall be free from longitudinal weld on the lower part of the cylinder, within the range of an included angle of 30° with the vertical shaft on both sides. The angle between two longitudinal welds on the same cylinder shall be greater than 40°, see Figure 1.The special circumstances may be determined by the supplier and the purchaser through negotiation.
Figure 1 Schematic Diagram for Position of Longitudinal Weld in Air Reservoir
4.3.2 The cylinder should be welded with seamless pipe or a piece of steel plate; in special circumstances, the cylinder may be spliced with two pieces of steel plate.
4.3.3 The head should adopt the structure types with type codes EHA, EHB, THA and THB in Table 1 of GB/T 25198-2010.
4.3.4 As for air reservoirs of passenger cars and D-Series High-Speed Train, circumferential weld connection in cylinder and head may be in the structure types as shown in Figures 2a), 2b) and 2c); as for air reservoirs of trucks, circumferential weld connection may be in the structure type as shown in Figure 2d).
a) Butt weld connection in head and enclosure b) Butt weld connection for head flanging and end-lock
c) Butt weld connection for head flanging d) Butt weld connection for head end-lock
Keys:
e——Head plate thickness;
e1——Cylinder plate thickness.
Figure 2 Connection Structure Type of Head and Cylinder
4.3.5 Head and cylinder thickness of an air reservoir shall be above the minimum thickness calculated according to the calculation method specified in GB 150.3-2011 or relevant standards.
4.3.6 Openings on cylinder and head shall not pass through welds, which shall be made away from the welds as far as possible.
4.3.7 Thread in pipe seat and draining seat interface of air reservoir shall meet the requirements of GB/T 7307 or GB/T 7306.2.
4.3.8 The distance between edges of any two adjacent welds shall be 6 times greater than the cylinder plate thickness of air reservoir. In special circumstances, it is determined by the supplier and the purchaser through negotiation.
4.3.9 Pipe seat and draining seat wall thickness of steel air reservoir shall not be less than 1.5 times of the thickness of steel plate welded to it; pipe seat and draining seat wall thickness of aluminum air reservoir should not be less than twice of the thickness of sheet welded to it.
4.3.10 As for steel air reservoirs of passenger cars and D-Series High-Speed Train, pipe seats should adopt the external and internal welding mode as shown in Figure 3a), and weld dimension, g, shall be greater than or equal to 0.7 times of head wall thickness, e; where the outer diameter of pipe seat, d, is less than or equal to 65mm, the external welding mode as shown in Figure 3b) may also be adopted, and weld dimension, g, shall be greater than or equal to 1.5 times of head wall thickness, e. As for aluminum air reservoirs, pipe seats should adopt the external and internal welding mode as shown in Figure 3c), and the full-penetration weld shall be adopted in the case of the external welding mode as shown in Figure 3d); in the case of the external and internal fillet weld welding mode for pipe seat as shown in Figure 3e) adopted, partial penetration weld shall be adopted, and the weld leg dimension, g, shall be greater than or equal to 3mm and less than or equal to the head wall thickness, e. As for air reservoirs of trucks, the welding mode of flange pipe seat is as shown in Figure 3f), and the weld dimension, g, shall be greater than or equal to the head wall thickness, e. The welding modes of other structural pipe seats are determined by the supplier and the purchaser through negotiation.
Foreword i
1 Scope
2 Normative References
3 Composition and Classification
4 Technical Requirements
4.1 Basic Requirements
4.2 Material Requirements
4.3 Design Requirements
4.4 Manufacture Requirements
4.5 Welding Requirements
4.6 Resistance to Corrosion
5 Inspection Methods
5.1 Surface Quality
5.2 Dimension and Geometric Tolerance
5.3 Weighing
5.4 Weld
5.5 Hydrostatic Test
5.6 Air-tightness Test
5.7 Volume Inspection
5.8 Shock and Vibration Test
5.9 Paint Adhesion Test
5.10 Phosphate Coating Inspection
6 Inspection Rules
6.1 Type Test
6.2 Ex-factory Inspection
7 Marking, Packaging, Transportation and Storage
7.1 Marking
7.2 Packaging
7.3 Transportation
7.4 Storage
