Revision Index

220801BNEJS3963

Eni Muara Bakau B.V.

MATERIAL REQUISITION FOR
ANCHOR PILE

4.5.

Rev
Number

Validity
Status

X0

CD-FE

Sheet of
Sheets
18 of 33

CASTING PADEYE MANUFACTURING

4.5.1. General
A Manufacturing Procedure Specification (MPS) detailing manufacturing and testing
requirements shall be submitted to the CLIENT for approval prior to production. The
MPS shall describe, step by step in a logical and correct sequence all important
manufacturing activities with reference to detailed procedures. A short description and
the main parameters for each activity shall be included. The production process shall be
illustrated with a flow chart. These procedures shall comprise, but not be limited to:
x
x
x
x
x
x
x
x
x
x

x
x
x
x
x
x
x
x

Name and address of Supplier

Grade of material with reference to applicable standard
Type and size range of products for which the MPS applies
Mold type and pattern method
Type of sand and binding/curing agent
Steel manufacturing process
Chemical composition with target chemistry and allowable ranges
Melting and refining processes
Casting techniques
Heat treatment methods including, but not limited to: furnace description,
furnace calibration and accuracy, diagram showing loading of components and
thermocouples in furnace, temperature control, loading temperature, heating
rate holding temperature range, maximum operating temperature of furnaces,
soaking time, quenching equipment including flow arrangement and capacities,
cooling rate, maximum time from furnace to quenching bath
Cleaning equipment
Repair welding
Post weld heat treatment
Non destructive testing
material testing including position of test coupons and sampling requirements
Dimensional control
Shipment & handling 
Documentation

4.5.2. Steelmaking
All steel shall be produced by the basic electric arc or basic oxygen steelmaking
processes followed by secondary vessel refining to obtain the specified properties. All
other steel production methods shall be approved by the CLIENT prior to production. All
steel shall be fully killed prior to teeming, vacuum or argon degassed and made to fine
grain practice, and shall have a prior austenitic grain size 5 or finer in accordance with
ASTM E112 at subsurface, 1/4T and 1/2T locations.
4.5.3. Chemical Analysis
Ladle and product analyses shall be provided by the SUPPLIER with one ladle analysis
for each heat and one product analysis for each casting. Acceptance shall be based on
product analysis for each casting. All elements listed in Table-1 shall be analyzed for
and the SUPPLIER shall make no other intentional additions without prior agreement of

This document is property of Eni Muara Bakau B.V.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

Revision Index
220801BNEJS3963

Eni Muara Bakau B.V.

MATERIAL REQUISITION FOR
ANCHOR PILE

Rev
Number

Validity
Status

X0

CD-FE

Sheet of
Sheets
19 of 33

the CLIENT. SUPPLIER may propose other proprietary steel grades with prior
agreement of the CLIENT.
SUPPLIER shall propose allowable ranges for all listed elements in their MPS.
Table 1 Chemical Analysis
ELEMENT

2)

Weight %
(maximum)

0.14

Mn

1.60

Si

0.60

0.005

0.012

Cr

1.30

Mo

0.55

Ni

2.70

Cu

0.25

Nb

0.030

0.050

Ti

0.040

Al

1)

0.02-0.05

0.010

Nb + V

0.050

0.0005

1.5 ppm

As

0.010

Sb

0.010

Sn

0.010

P+As+Sb+Sn

0.030

Cev

0.55

NOTES :
1): Soluble Al:N ratio shall exceed 2:1.
2): The SUPPLIER shall analyze for all specified elements even when they are not added
intentionally.
Supplier proposed chemical composition shall be documented in the MPS. Values shall
apply to both ladle and product analyses:
x Deviations from these values shall require the written approval of CLIENT.
x Ladle analysis shall be performed for each heat, and product analysis shall be
performed for each casting in accordance with ASTM A 29.
This document is property of Eni Muara Bakau B.V.
It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

Revision Index
220801BNEJS3963

Eni Muara Bakau B.V.

MATERIAL REQUISITION FOR
ANCHOR PILE

Rev
Number

Validity
Status

X0

CD-FE

Sheet of
Sheets
20 of 33

4.5.4. Casting
Each casting shall be made from only one furnace heat. SUPPLIER should specify
minimum and maximum ladle pouring temperature and method of monitoring.
4.5.5. Head Removal
Feeder heads and risers shall be removed at a minimum distance of from the
casting followed by grinding flush. If damage to the casting occurs, the cutting distance
shall be increased for subsequent removals.
SUPPLIER shall specify the method of thermal cutting and the minimum preheating
requirements for head removal
4.5.6. Heat Treatment
All castings shall be supplied in the homogenized, normalized, and stress relieved
condition, or in homogenized, quenched and tempered condition, including any post
weld heat treatment after repair welding.
Heat treatments shall be carried out in suitable furnaces and shall be outlined in a heat
treatment procedure approved by the CLIENT. The furnace shall be either electrically or
gas heated (LNG) with a neutral atmosphere. The equipment shall be regularly and
efficiently maintained. Furnaces fueled by kerosene or liquid petroleum are prohibited.
The heat treatment variables shall be selected to ensure satisfactory microstructure and
mechanical properties in the finished casting. Heating and cooling rates above 570F
shall not exceed 125F and 90F per hour respectively except for quenching. The
temperature of the quench bath temperature shall be monitored continuously. For
water based quench media, the temperature shall not exceed 100 deg F (38 deg C)
prior to quenching.
The temperature in the furnace at the time of loading shall not exceed 400 deg F (200
deg C).
Below 300F, the castings shall be cooled down in still air.
The heat treatment temperature and time shall be in accordance with the heat
treatment procedure in the MPS approved by the CLIENT. All temperatures shall be held
within a tolerance of 30F or better. The temperature of each casting during heat
treatment shall be determined by thermocouples in effective contact with the casting. A
minimum of six (6) thermocouples per furnace load shall be used. Furnace
thermocouples only are not acceptable to monitor heat treatment temperature of the
castings.
Welding Procedure test blocks shall be subjected to the same production route and heat
treatment as the production castings. Each block shall be monitored by the attachment
of thermocouples to ensure identical heat treatment to the production castings.

This document is property of Eni Muara Bakau B.V.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

Revision Index
220801BNEJS3963

Eni Muara Bakau B.V.

MATERIAL REQUISITION FOR
ANCHOR PILE

Rev
Number

Validity
Status

X0

CD-FE

Sheet of
Sheets
21 of 33

All thermocouples, compensating cables and temperature recorders shall have valid
calibration certificates dated not earlier than six (6) months prior to heat treatment of
the castings.
Heat treatment curves shall be recorded for each furnace charge detailing the full heat
treatment cycle. The furnace calibration curve shall always be attached to such
recordings.
Castings shall be post-weld heat treated at a temperature not to exceed 30F below the
tempering temperature after all repair welding has been completed for one hour per 1
inch of the thickest wall at the actual weld repair area. The furnace temperature at the
time of loading shall not exceed 400F. All PWHT shall be carried out in a closed
furnace. The soaking temperature shall be as qualified during the repair welding
procedure.
Local PWHT using heating mats with heating elements are not allowed. The quality heat
treatment/quench procedure shall include, where applicable:
a) Furnace type
b) Furnace atmosphere
c) Location of casting in furnace
d) Location of thermocouples controlling furnace temperature
e) Location of thermocouples attached to casting
f) Heat treatment/quench cycle including:
i.

Heating rate

ii.

Holding time and temperature

iii.

Method of quench and temperature at the start and end of quench

iv.

Cooling rate of external surface of casting

v.

Tempering temperature and hold time

vi.

Post weld heat treatment temperature and hold time

vii.

Max. temperature differentials during stress relief

viii.

Max. Temperature below which unrestricted cooling is acceptable in each

case.

4.5.7. Load Testing

Casting padeye shall be load tested at 70% of design MBL. SUPPLIER shall satisfy the
requirements of the CVA/Classification agency in order to be able to provide the proper
certification for the SUPPLIERs product.

This document is property of Eni Muara Bakau B.V.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.

Revision Index
220801BNEJS3963

Eni Muara Bakau B.V.

MATERIAL REQUISITION FOR
ANCHOR PILE

Rev
Number

Validity
Status

X0

CD-FE

Sheet of
Sheets
22 of 33

SUPPLIER shall provide all test procedures to COMPANY for approval in the MPS.
SUPPLIER is required to notify COMPANY fourteen (14) days in advance of the start of
tests with a final confirmation of forty-eight (48) hours before the test.
SUPPLIER shall provide all test samples and fittings. All tested samples shall be
scrapped after the tests. Test certificates shall be provided according to BS EN 10204,
Type 3.2.
Load testing be in accordance within the limits set in this document and the referenced
codes and standards in section 4.3.3.

This document is property of Eni Muara Bakau B.V.

It shall neither be shown to Third Parties not used for purposes other than those for which it has been sent.