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MANUFACTURING AND INSPECTION PROCEDURE OF

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Chain Conveyor 4.6M Length Type VA-754/859 and Supporting Plate of DOCUMENT NO:MIP 130422-1 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

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CONTENTS

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1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0

SCOPE APPLICABLE SPECIFICATION AND DOCUMENTS MANUFACTURING AND INSPECTION PROCESS MANUFACTURE CASTING PROCEDURE MECHANICAL TEST NON DESTRUCTIVE EXAMINATION DIMENSION CHECK AND TOLERANCE HARDNESS CHECK

10.0 DEFECT 11.0 FINAL INSPECTION 12.0 DOCUMENTATION APPENDIX 1: PRODUCTION FLOW CHART APPENDIX 2: QUALITY CONTROL FLOW CHART

Yunan Bachtiar 2013.04.22 NAME & DATE PREPARED NAME & DATE REVIEWED PRODUCTION DEPT.

Park Ki Hyong 2013.04.23 NAME & DATE APPROVED

Lee Kyung Pok 2013.04.23 NAME & DATE APPROVED Q.A DEPT.

Leem, S.T. PhD 2013.04.24 NAME & DATE APPROVED DIRECTOR NAME & DATE APPROVED CLIENT

MANUFACTURING AND INSPECTION PROCEDURE OF

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Chain Conveyor 4.6M Length Type VA-754/859 and Supporting Plate of DOCUMENT NO:MIP 130422-1 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 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 : 3.0 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 SolventRemovable Process. ASTM E114: Ultrasonic Pulse-Echo Straight-Beam Examination by Contact Method.

Manufacturing and Inspection Process : be shown as bellow. Process Inspection Casting Design Dimension Check of Pattern Chemical Analysis(Sample) Pouring Temperature Visual Inspection Heat Treatment Condition Visual Inspection Tensile Strength Inspection Penetrant Test Inspection Based on Drawing Specification from client Dimension, P.T (if requested by QC or client) Report Review Report Review Report Review Report Review Witness Point Tensile Test Report P.T Report Dimension Report Hardness Check Report Dimension Report P.T Report Inspection Point Report Review Report Review Report Remark

Designing Pattern Making Moulding Melting Pouring Shake Out Riser Cutting / Flattening Heat Treatment Shot Blasting & Grinding Mechanical Test Non Destructive Test Dimension Check Hardness Check Final Inspection

Dimension Report Chemical Analysis Pouring Temperature

Neck Down Core Area Report Review

Heat Treatment Report

MANUFACTURING AND INSPECTION PROCEDURE OF

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Chain Conveyor 4.6M Length Type VA-754/859 and Supporting Plate of DOCUMENT NO:MIP 130422-1 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 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-754/859

0.7/1.3

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.

MANUFACTURING AND INSPECTION PROCEDURE OF

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Chain Conveyor 4.6M Length Type VA-754/859 and Supporting Plate of DOCUMENT NO:MIP 130422-1 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

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

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

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White Cast Iron; Mark VA-411 753081, Term of Reference (TOR) DOCUMENT NO:MIP 130422-1 Replacement Drag Chain, Supporting Plate dan Drive Sprocket (W1U05) for PT. Semen Padang Indarung II/III - Indonesia 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 5.4 Melting 5.4.1. Melting Process

Supporting Plate VA-411 Mold

5.4.2. Sample making ( Cone Shape) for Chemical Analysis

4.2.1 Chemical Analysis

SPECTROMETER

MANUFACTURING AND INSPECTION PROCEDURE OF

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Chain Conveyor 4.6M Length Type VA-754/859 and Supporting Plate of DOCUMENT NO:MIP 130422-1 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

Chemical Composition 6.4.3 Tapping Process

Reports

Temperature check 6.5 Pouring

Tapping Process

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

MANUFACTURING AND INSPECTION PROCEDURE OF

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Chain Conveyor 4.6M Length Type VA-754/859 and Supporting Plate of DOCUMENT NO:MIP 130422-1 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

5.6 5.7

Shake Out : No need to shaking out. Riser Cutting / Flattening : The riser is removed by striking of hammer at neck down core zone.

5.8

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.
Heat Treatment Process Material Application Annealing Quenching 1100 C X 4 Hours, Water Cooling 980 C X 4 Hours, Forced Air Cooling Tempering 400 C X 4 Hours, Air Cooling

SCMnH11 for Chain Conveyor Type VA-754/859 HPCr 2525 for Supporting Plate Type VA-411 753081

860 C X 5 Hours Min, Furnace Cooling

MANUFACTURING AND INSPECTION PROCEDURE OF

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Chain Conveyor 4.6M Length Type VA-754/859 and Supporting Plate of DOCUMENT NO:MIP 130422-1 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.

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

5.10 5.11

Cleaning Final Inspection 5.11.1 Liquid Penetrant Test to detect discontinuities. 5.11.2 Hardness Test 5.11.3 Dimension Check 5.11.4 Visual Test 5.11.5 Assembly Test

5.12 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.

6.0 MECHANICAL TEST 6.0.1 Tensile Test Inspection The test specimen is to be prepared as below.

MANUFACTURING AND INSPECTION PROCEDURE OF

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Chain Conveyor 4.6M Length Type VA-754/859 and Supporting Plate of DOCUMENT NO:MIP 130422-1 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.

6.0.2 Type

Acceptance Criteria Tensile Strength (N/mm) Min 740 Impact Value (J/cm2) Hardness, (HRC) Min 20 Min 55

SCMnH11 for Chain Conveyor Type VA-754/859 HPCr 2525 for Supporting Plate Type VA-411 753081

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 PROCESS

MANUFACTURING AND INSPECTION PROCEDURE OF

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Chain Conveyor 4.6M Length Type VA-754/859 and Supporting Plate of DOCUMENT NO:MIP 130422-1 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.

LIQUID PENETRANT TEST CERTIFICATE

MANUFACTURING AND INSPECTION PROCEDURE OF

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Chain Conveyor 4.6M Length Type VA-754/859 and Supporting Plate of DOCUMENT NO:MIP 130422-1 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. 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.

REPORT OF ULTRASONIC TEST PROCESS

MANUFACTURING AND INSPECTION PROCEDURE OF

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Chain Conveyor 4.6M Length Type VA-754/859 and Supporting Plate of DOCUMENT NO:MIP 130422-1 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.

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.

DIMENSION CHECK WITH VERNIER CALIPER AND SPECIAL GAUGE

MANUFACTURING AND INSPECTION PROCEDURE OF

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Chain Conveyor 4.6M Length Type VA-754/859 and Supporting Plate of DOCUMENT NO:MIP 130422-1 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. 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.

10.0

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.

11.0

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

MANUFACTURING AND INSPECTION PROCEDURE OF

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Chain Conveyor 4.6M Length Type VA-754/859 and Supporting Plate of DOCUMENT NO:MIP 130422-1 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.

CHAIN CONVEYOR TYPE VA-754/859 ASSEMBLY TEST

Appendix 1: Production Flow Chart

Appendix 2: Quality Control Flow Chart