Mip - Chain Va.754

-------- CONTENTS --------

1.0 SCOPE

2.0 APPLICABLE SPECIFICATION AND DOCUMENTS

3.0 MANUFACTURING AND INSPECTION PROCESS

4.0 MANUFACTURE

5.0 CASTING PROCEDURE

6.0 MECHANICAL TEST

7.0 NON DESTRUCTIVE EXAMINATION

8.0 DIMENSION CHECK AND TOLERANCE

9.0 HARDNESS CHECK

10.0 DEFECT

11.0 FINAL INSPECTION

12.0 DOCUMENTATION

APPENDIX 1: PRODUCTION FLOW CHART

APPENDIX 2: QUALITY CONTROL FLOW CHART

Y u n a n B a c h t i a r Park Ki Hyong Lee Kyung Pok Leem, S.T. PhD

2013.04.22 2013.04.23 2013.04.23 2013.04.24

NAME & DATE

PREPARED

NAME & DATE

REVIEWED

NAME & DATE

APPROVED

NAME & DATE

APPROVED

NAME & DATE

APPROVED

NAME & DATE

APPROVED

PRODUCTION DEPT. Q.A DEPT. DIRECTOR CLIENT

MANUFACTURING AND INSPECTION PROCEDURE OF

Chain Conveyor 4.6M Length Type VA-754/859 and Supporting Plate of

White Cast Iron; Mark VA-411 753081, Term of Reference (TOR)

Replacement Drag Chain, Supporting Plate dan Drive Sprocket (W1U05)

for PT. Semen Padang Indarung II/III - Indonesia

PAGE : 1 OF 14

DOCUMENT NO:MIP 130422-1






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1.0 Scope :

This Procedure is applied to the manufacturing, testing and inspection of Chain Conveyor 4.6M

Length Type VA-754/859 and Supporting Plate of White Cast Iron; Mark VA-411 753081 for PT.

Semen Padang Indarung II/III – Indonesia.

2.0 Applicable specification and documents :

ASTM A 128 : Standard Specification for Steel Castings, Austenitic Manganese.

FLS Standard Material 33.A; Mo Alloyed 12% Manganese Steel

ASTM A 532 : Standard Specification for Abrasion-Resistant Cast Irons.

ASTM A 370 : Standard Test Methods and Definitions for Mechanical Testing of Steel Products.

ASTM E 165 : Test Method for Liquid Penetrant Examination.

ASTM E 1220 : Standard Test Method for Visible Penetrant Examination using Solvent-

Removable Process.

ASTM E114: Ultrasonic Pulse-Echo Straight-Beam Examination by Contact Method.

3.0 Manufacturing and Inspection Process : be shown as bellow.

Process InspectionInspection

PointReport

Remark

Designing Casting Design Pattern Making Dimension Check of Pattern Report Review Dimension ReportMouldingMelting Chemical Analysis(Sample) Report Review Chemical AnalysisPouring Pouring Temperature Pouring Temperature Shake Out

Riser Cutting / Flattening

Visual Inspection Neck Down Core Area

Heat Treatment Heat Treatment Condition Report Review Heat Treatment Report

Shot Blasting & Grinding

Visual Inspection

Mechanical Test Tensile Strength Inspection Report Review Tensile Test ReportNon Destructive Test

Penetrant Test Inspection Report Review P.T Report

Dimension Check Based on Drawing Report Review Dimension ReportHardness Check Specification from client Report Review Hardness Check ReportFinal Inspection Dimension, P.T (if requested

by QC or client)Witness Point Dimension Report

P.T Report






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4.0 MANUFACTURE

4.0.1.Material for Chain Conveyor Type VA-754/859 is High Manganese Steel based on ASTM

Standard A 128 Grade E-1 or equivalent to FLS Standard Material 33A : Mo-Alloyed 12%

Manganese Steel.

Material Application C Si Mn Mo P

ASTM A 128 Grade E-1 for Chain

Conveyor Type VA-754/8590.7/1.3 1.00 max 11.5/14.0 0.9/1.2 0.07 max

4.0.2.Material for Supporting Plate Type VA-411 753081 is Abrasion Resistant Cast Irons based on

ASTM Standard A 532 Class III Type A : 25% Cr.

Material Application C Si Mn Cr Mo Ni

ASTM A 532 Class III Type A

for Supporting Plate Type

VA-411 753081

2.0/3.3 1.5 max 2.0 max 23.0/30.0 3.0 max 2.5 max

5.0 CASTING PROCEDURE

5.1 Designing

a). Casting design is prepared by expert of casting and then modeling and simulation process.

Figure 5.1 shown 3D modeling casting design using Solid Works Software.

Figure 5.1

b). Figure 5.2 – 5.5 shown casting flow filling process using Z-Cast software. We can predict

the defects such a cold shut, inclusions and blow holes from flow filling analysis. For example

, if there too much turbulence during pouring process, this can make defect like cold shut.






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Figure 5.2 Figure 5.3 Figure 5.4

c). Figure 5.5, 5.6 and 5.7, shown solidification process that we can predict internal defect such

as hot tear, shrinkage and others.

Figure 5.5 Figure 5.6 Figure 5.7

d). Design and simulation will be repeated until we meet appropriate casting design.

5.2 Pattern Making : Patterns ( wooden pattern ) are made in accordance with the casting design

which describes pattern type, shrinkage rule, gating system and riser method as follow photo

or drawing.

Chain Conveyor VA-754 Pattern Supporting Plate VA-411 Pattern

5.3 Moulding

Using silica sand for base material and mixed with alkaline phenolic resin which it is useful as

an adhesive and filling into flask from mixer on the moulding line machine.

Chain Conveyor VA-754 Mold Supporting Plate VA-411 Mold

5.4 Melting

1.1.1. Melting Process

1.1.2. Sample making ( Cone Shape) for

Chemical Analysis

4.2.1 Chemical Analysis





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PAGE : 6 OF 14


Chemical Composition Reports

4.2.2 Tapping Process

Temperature check Tapping Process

4.3 Pouring

The surface of the mold to be coated with coating agent which is based Zircon floor mixing

with alcohol. After coating, mold is to be dried by burner and assembling for pouring process

SPECTROMETER






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4.1 Shake Out : No need to shaking out.

4.2 Riser Cutting / Flattening : The riser is removed by striking of hammer at neck down core zone.

5.5 Heat Treatment : Using Automatic Temperature Controlled Furnace for heat treating process.

For Chain Conveyor and Supporting Plate that made from two kind of

materials, heat treating prosess will be controlled in accordance on table

below.

Material ApplicationHeat Treatment Process

Annealing Quenching Tempering

SCMnH11 for Chain Conveyor Type

VA-754/859-

1100 °C X 4 Hours,

Water Cooling-

HPCr 2525 for Supporting Plate Type

VA-411 753081

860 °C X 5 Hours Min,

Furnace Cooling

980 °C X 4 Hours,

Forced Air Cooling

400 °C X 4 Hours,

Air Cooling

4.4





for PT. Semen Padang Indarung II/III - Indonesia.

PAGE : 8 OF 14


4.1 Shot Blasting & Grinding : Grinding is determined by Superintendent confirmation.

4.1 Cleaning

4.2 Final Inspection

4.2.1 Liquid Penetrant Test to detect discontinuities.

4.2.2 Hardness Test

4.2.3 Dimension Check

4.2.4 Visual Test

4.2.5 Assembly Test

4.3 Packing: Wooden Box Packing, Net Weight: +/- 1.5 ton/box.

All package should be made firmly enough and tightened using steel bending to endure heavy

duty.

4.0 MECHANICAL TEST

6.0.1 Tensile Test Inspection

The test specimen is to be prepared as below.






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6.0.2 Acceptance Criteria

Type Tensile Strength (N/mm²) Impact Value (J/cm2) Hardness, (HRC)

SCMnH11 for Chain Conveyor

Type VA-754/859

Min

740-

Min

20

HPCr 2525 for Supporting Plate

Type VA-411 753081- -

Min

55

7.0 NON DESTRUCTIVE EXAMINATION

7.0.1 Liquid Penetrant Examination

Using ASTM Standard E1220 : Standard Test Method for Visible Penetrant Examination

using Solvent – Removable Process and ASTM Standard E165 : Test Method for Liquid

Penetrant Examination. Liquid Penetrant test is used to detect discontinuities that opened to

the surface of nonporous metals. Process flow of Liquid Penetrant Examination that we

appliying for our product shown in figure below.

LIQUID PENETRANT TEST PROCES S






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LIQUID PENETRANT TEST CERTIFICATE

7.0.2. Ultrasonic Test

Ultrasonic test is used to detect inside discontinuities such as porosity, shrinkage and others

a) Tested in accordance with ASTM E114: Ultrasonic Pulse-Echo Straight-Beam

Examination by Contact Method.

b) Test has to cover on the whole area of liner for sample product and on the critical

area (possibly defect area) for mass products.

c) Test point: After pouring – stop point.

.






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REPORT OF ULTRASONIC TEST PROCESS

8.0 DIMENSION CHECK AND TOLERANCE

Casting products is to be grinding in accordance with the drawing. Unless specified on the drawing,

the tolerance of the as-cast dimension is to comply with JIS B0412 fine grade.






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DIMENSION CHECK WITH VERNIER CALIPER AND SPECIAL GAUGE

9.0 HARDNESS CHECK

Before final inspection, products must be completed in hardness test in accordance with following

step :

9.0.1 Test is carried out using EQUOTIP Potable Hardness Tester.

9.0.2 Surface of tested liner is grinded smoothly by fine grinder to obtain accurate result.

9.0.3 Each plate have to be tested on 3 point of working surface.

9.0.4 Detail test procedure is in accordance with standard of ASTM A370: Standard Test

Methods and Definitions for Mechanical Testing of Steel Products.

9.0.5 Acceptance Criteria: refer to attached Material Specification.

9.1 DEFECT

Castings are to be inspected after grinding and thorough cleaning in order to be insured that the

castings are free from defects. Casting surface is to be completely inspected in accordance with

the requirement of MSS-SP55.

9.2 FINAL INSPECTION






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P/T, UT, Hardness Check, Dimension Check and Assembly Test






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CHAIN CONVEYOR TYPE VA-754/859 ASSEMBLY TEST

Appendix 1: Production Flow Chart

Appendix 2: Quality Control Flow Chart

Date post:	13-Nov-2014
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Mip - Chain Va.754

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