ES0001_Rev3.pdf

Workmanship Standards

Approved date:6 Aug 2012 Created by: R. Radl Approved by: G Weaver

Doc. No.: ES0001 Rev. 3

ES0001 WORKMANSHIP STANDARD

Table of Contents 1.0

MATERIAL STANDARDS .................................................................................. 3

2.0

CASTING STANDARDS .................................................................................... 5

3.0

ELASTOMER/RUBBER STANDARD ................................................................... 6

4.0

FIBER REINFORCED PLASTIC (FRP) ............................................................... 7

5.0

FABRICATION STANDARD .............................................................................. 7

6.0

HEAT TREATING STANDARD ......................................................................... 13

7.0

MACHINING TOLERANCE STANDARD ........................................................... 14

8.0

BLASTING/PAINTING & COATING STANDARD ............................................. 14

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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ES0001 WORKMANSHIP STANDARD

1.0 MATERIAL STANDARDS 1.1

All material shall be purchased in accordance with FLSmidth (FLS) purchase orders, drawings, and applicable material specifications. Turn6key equipment shall meet all the requirements outlined in the FLS purchase order.

1.2

All material purchased shall meet the requirements of the applicable material specification and shall maintain traceability back to the original Material Test Report (MTR). All purchased material at a minimum shall have the material type, grade and applicable heat number permanently marked into the part (new steel bars, plates, and shapes in accordance with ASTM A6 or other acceptable marking specification). This marking shall be applied by the supplier of the raw material. Material that falls outside the acceptable range or does not have the proper marking shall be replaced or have a formal request for deviation sent to FLS. FLS Engineering will review and determine if this deviation is acceptable.

1.3

(When required by contract) All plate, piping, beams, or other material that are cut into different sections shall have the applicable material type, grade and applicable heat number transferred onto them by stamping using low stress stamps, etching or other FLS approved method.

1.4

Typical Materials used on FLS product are outlined below: Ferrous Materials

FORMS Plate, Sheet, Bar and Structural Shapes

GENERIC SPECIFICATION Mild Stl, Stl, Carbon Stl, H.R. St!

Plate, Sheet

STANDARD ASTM A36

6,

Abrasion/Impact Resistant Steel, AR Steel Pipe, welded and seamless Carbon Steel Pipe

***

Seamless Pipe

Carbon Steel Pipe

ASTM A106 GRADE B

Structural Tubing

Stl/Carbon Steel Tubing

ASTM A6500 GRADE B

Alloy Mechanical Tubing

Stl/Carbon Stl Tubing

AISI 4140/4142 ASTM A519

ASTM A53

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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ES0001 WORKMANSHIP STANDARD FORMS Mechanical Tubing

GENERIC SPECIFICATION Stl, Carbon Stl Tubing

STANDARD 6, ASTM A513 TYPE 1 (HR) ASTM A513 TYPE 2 (CR)

Bar, Rounds/Shafting

CRS, STL

AISI C61018,1020

Castings

Steel

ASTM A27 ASTM A148

All

Alloy STL

Grade A for 2" diameter or smaller. Grade B for larger than 2" diameter. Below 2" Could be ASTM A6500 or ASTM A6513, Verify ASTM Specification with FLS Engineering. Stainless Steel FORM

GENERIC SPECIFICATION

STANDARD

Plate, Sheet, Bar, Shapes, Rounds

Stainless Steel

ASTM A240 TYPE 354 ASTM A276 TYPE 304

Plate, Sheet, Bar, Shapes, Rounds

304SS / 304LSS

ASTM A240 TYPE 304/304L

Plate, Sheet, Bar, Shapes, Rounds

316SS / 316LSS

ASTM A240 TYPE 316/316L

Non5Ferrous Materials FORM

GENERIC SPECIFICATION

Plate, Sheet, Bar, Coil

Aluminium

Structural Shapes

Aluminium

Castings

Aluminium

STANDARD

60616T6 A356

Non5Metallic Non

Metallic

Non

Non

Metallic

Non

1.5

MTR’s are required by the Purchase Order and shall become part of the final document package as well as any dispositioned Deviation Request.

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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ES0001 WORKMANSHIP STANDARD

2.0 CASTING STANDARDS 2.1

All casting chemical and mechanical test results shall conform to the applicable material standard that was specified.

2.2

Castings shall be in a normalized and tempered condition.

2.3

All heat treatments including Post Weld Heat Treatment (PWHT) shall be documented and reported.

2.4

All Castings require a 100% visual inspection in accordance with ASTM A802 or MSS6SP655 using a SCRATA reference comparator.

2.5

Other Non6destructive Examination such as Magnetic Particle, Liquid Penetrant or Ultrasonic Examination may be required.

2.6

Casting repair 2.6.1 All casting indications shall be mapped. 2.6.2 All discrepancies shall be removed until the indication has been terminated and verified by either Magnetic Particle or Liquid Penetrant Examination. 2.6.3 Casting indications that meet or exceed 20% of wall thickness, 1inch (25.4 mm) or 10 inches (254 mm) square shall be considered MAJOR repairs. 2.6.4 Repairs shall be made using FLS approved welding procedures. Note that all Major indications shall be repaired. 2.6.5 Where required by the material specification all repairs shall receive a PWHT. 2.6.6 All repairs shall be blended to an as6cast profile. 2.6.7 10% of all repairs shall receive a Brinell hardness test. Each test shall consist of one reading on the base (parent) material, one reading on the Heat Affected Zone (HAZ), and one reading on the weld itself. Hardness test shall be documented and reported.

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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ES0001 WORKMANSHIP STANDARD

3.0 ELASTOMER/RUBBER STANDARD FLSmidth shall specify in the Engineering Drawing or Purchase Order the proper elastomer/rubber compound for the application in which the coated parts shall be used. 3.1

Drawings shall specify generic elastomer compounds (i.e. neoprene, natural rubber, butyl, etc.). FLS Engineering shall supply applicable compound or mechanical properties to be used if other than standard ASTM specification.

3.2

All elastomers shall be inspected for blistering, tears, or other defects that are deemed detrimental to the wear life of the elastomer both pre and post cure.

3.3

A spark test shall be required to ensure there are no discontinuities in the coated surface.

3.4

All elastomers shall have a durometer (hardness) value assigned to them. This shall be verified using a durometer gage. The allowable durometer range where not stated shall be +/6 5. The test results shall be documented and made available to FLS.

3.5

Standard ASTM specifications used for testing are as follows: •

ASTM D412 6 Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers—Tension

•

ASTM D2240 6 Standard Test Method for Rubber Property— Durometer Hardness

•

ASTM D 378 Standard Test Methods for Rubber (Elastomeric) Conveyor Belting, Flat Type

•

ASTM D624 6 Standard Test Method for Tear Strength of Conventional Vulcanized Rubber and Thermoplastic Elastomers

•

ASTM D1646 6 Standard Test Methods for Rubber— Viscosity, Stress Relaxation, and Pre6Vulcanization Characteristics

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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ES0001 WORKMANSHIP STANDARD

4.0 FIBER REINFORCED PLASTIC (FRP) FLSmidth Engineering shall specify the FRP type to be used. FLS Procurement shall reference all applicable documentation in the Purchase Order to ensure that all requirements are met. 4.1

All FRP parts shall have a visual inspection for defects in accordance with ASTM D2563 with acceptance criteria per Table 1 of ASTM D2563.

4.2

A Barcol hardness test shall be performed in accordance with ASTM D2583. The test results shall be documented and made available to FLS.

4.3

Where applicable per project specification, the following standards may also be applied and shall be specified in the Purchase order and or ITP: •

ASTM D2584 – Standard Test Method for Ignition Loss of cured reinforced resins (burn test).

•

ASTM D638 – Standard test method for tensile properties of plastics.

•

ASTM D790 – Standard test method for flexural properties of unreinforced and reinforced plastics and electrical insulating materials.

•

ASME RTP61 – Reinforced Thermoset Plastic corrosion6resistant equipment.

5.0 FABRICATION STANDARD All fabricated components made for FLS shall meet the minimum requirements of this standard. 5.1

Weld Procedures Specifications (WPS) 5.1.1 All Welding Procedure Specifications (WPS) shall be written in accordance with the appropriate welding specification. Unless otherwise specified, FLS Salt Lake City uses the American Welding Society (AWS) specification D1.1 or D1.6 as the standard. However other standards such as ISO, EN, CSA, CWB, or ASME may be used once approved by FLS. All suppliers

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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ES0001 WORKMANSHIP STANDARD

are expected to maintain the most recent copy of the welding standard to which they are working. 5.1.2 All WPS’s shall be submitted to FLS for review and approval prior to start of fabrication. 5.1.3 Once a WPS has been approved by FLS it shall be followed for all work performed on FLS product. 5.1.4 It is the supplier’s responsibility to provide FLS updated WPS’s. 5.2

Procedure Qualifications Record (PQR) 5.2.1 All WPS’s shall be qualified where required by the welding standard. 5.2.2 All PQR’s shall be submitted to FLS for review and approval prior to start of any fabrication. 5.2.3 Any weld process used that has not successfully been qualified shall be rejected.

5.3

Welder Qualification Recorded 5.3.1 All welders performing work for FLS shall be qualified in accordance with the applicable standard for the welding process they are using. 5.3.2 Any welding performed by an unqualified welder shall be subject to rejection by FLS.

5.4

Welding Process 5.4.1 All welding shall be done in accordance with this specification and the applicable Welding Standard as well as the approved WPS/PQR. All Fabrication suppliers shall be approved for work by FLS Purchasing/Contract Fabrication Department. 5.4.2 All Filler material to be used on FLS product shall be stored, handled and used in accordance with manufacturers recommendations. The filler material shall be per the WPS.

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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ES0001 WORKMANSHIP STANDARD

5.4.3 All flux, spatter, slag and scale shall be removed from surfaces, welds and edges. Acceptable methods for removal are chipping, grinding, chiselling or chemical (anti6spatter). 5.4.4 All holes, edges and corners shall be ground or deburred. All sharp edges shall be removed by grinding. Unsightly marks or gouges shall be blended by grinding. 5.4.5 All rust, scale and/or tint shall be removed from welding surfaces by grinding, sanding, brushing or chemical means. (Note: Abrasive tools used on stainless steel shall not be contaminated by another material, likewise blast media shall be of same type as parent material). 5.4.6 No splices are permitted in structural members unless specified in FLS drawings or approved by FLS Engineering. 5.4.7 Weldment dimensions are finished dimensions and allowance for shrinkage or other fabrication techniques shall be the responsibility of the fabricator. 5.4.8 The faces of fillet welds may be slightly convex, flat or slightly concave. (Reference Figure 1: Acceptable and Unacceptable Weld Profiles).

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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ES0001 WORKMANSHIP STANDARD

Figure 1: Acceptable and Unacceptable Weld Profiles

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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ES0001 WORKMANSHIP STANDARD

5.5

Weld Repairs All welds shall be visually inspected to ensure that workmanship meets the requirements of the appropriate specification, drawings, PO requirements and this standard. All repairs shall be made using an approved weld procedure. 5.5.1 Overlap, excessive convexity or excessive reinforcement shall be removed. 5.5.2 Excessive concavity of weld or crater, undercutting or undersize welds shall be repaired by adding additional material. 5.5.3 Incomplete fusion, excessive porosity, slag inclusions or other unacceptable defects shall be removed and repaired by re6 welding. 5.5.4 Cracks in either the weld or base material shall be examined by Magnetic Particle or Liquid Penetrant Examination to assess the severity of the crack and to ensure that the crack has been terminated. All cracks shall be removed as well as 2” (50 mm) of sound material on either side of the crack and repaired by re6 welding. Note: Removal of weld metal or portions of base material may be done by grinding, chipping, machining or gouging. Care shall be given to assure that adjacent weld or base material is not nicked or gouged.

5.6

Weld Inspection/Acceptance Criteria 5.6.1 All welds shall be Visually Inspected in accordance with the applicable AWS (or other approved) Standard, FLS Drawings and ITP. All Visual Inspection shall be done by a qualified inspector as defined by AWS D1.1 section 6.1.4. See section 5.7 below for a description of Qualifications. 5.6.2 All cracks and other rejectable defects shall be repaired using the approved welding process. All welds shall be free of slag inclusions and porosity. 5.6.3 Welds shall exhibit no indications of overlap. Thorough fusion shall exist between adjacent weld layers, weld metal and base metal interface.

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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ES0001 WORKMANSHIP STANDARD

5.6.4 All craters shall be filled to the full cross section of the weld. 5.6.5 For materials less than 1” thick (25 mm), undercut shall not exceed 1/32” (1 mm), except that a maximum of 1/16” (1.5 mm) is permitted for accumulated length of 2” (50 mm) in any 12” (300 mm). For material greater than or equal to 1” (25 mm) thick a maximum of 1/16” (1.5 mm) is permitted for any length of the weld. 5.6.6 Fillet welds in any single continuous length shall be permitted to under6run the nominal filet size specified by 1/16” (1.5 mm) uncorrected, provided that the undersize portion of the weld does not exceed 10% of the length of the weld. 5.7

Qualification of Weld Inspector 6 All Inspectors authorized to perform inspection of welds shall meet the requirements of AWS D1.1 Section 6.1.4. 5.7.1 May be a Certified Weld inspector from AWS or equivalent such as CWBI, CGBS, IWI B or ASNT Level II or III in VT 5.7.2 May be an individual who by training or experience or by both in metal fabrication, inspection and testing is competent to perform inspection of work. This will be reviewed and approved by FLS.

5.8

Fabrication Dimensional Tolerances 6 Where dimensions are not specified by FLS Engineering the following shall apply. 5.8.1 Non6Locating: +/6 1/8” (3 mm) +/6 1/4” (6 MM)

0 to 40’ (0 to 12.2 M) over 40’ (12.2 m)

5.8.2 Positioning and Locating: Bolt Circles – Diameters Solid Flange +/6 1/32” (1 mm) Rim Flange +/6 1/16” (1.5 MM)

0 to 4’ (0 to 1.2 M) 0 to 20’ (0 to 6 M)

Bolt Spacing, Locating Chord or Mating Dimensions +/6 1/32” (1 MM) less than 2’ (610 mm) Non6accumulative +/6 1/16” (1.5 MM) 2’ (610 mm) & over Non6accumulative

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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ES0001 WORKMANSHIP STANDARD

5.8.3 Fabrication camber or sweep & flatness Permissible variation

(in) =.013 X Length (ft) / 10 (mm) =10.8 X Length (m) / 10

5.8.4 Butt joint alignment Offset shall not exceed 10% of the thickness of the thinner material being joined. Maximum allowable offset shall be 1/8” (3mm).

5.8.5 Plumbness of tanks The maximum out6of6plumbness of the top shell relative to the bottom shell shall not exceed 1/200 of the total tank height. 5.8.6 Roundness Radii measured at the 1 foot (0.3 m) mark above the bottom corner weld shall not exceed the following: Under 20 foot (6 m) 20 to 40 foot (6 to 12 m) 40 to 150 foot (12 to 45 m) 150 to 250 foot (45 to 75 m) Over 250 foot (75 m) 5.9

+/61/4 inch (6 mm) +/61/2 inch (13 mm) +/63/4 inch (19 mm) +/61 inch (25 mm) +/61 ¼ inch (32 mm)

Welding Symbols 6 All weld symbols shall be per either AWS A2.4 or ISO 2553

6.0 HEAT TREATING STANDARD 6.1

Materials shall be heat treated (where required) to WPS or applicable ASTM standard. If no procedure is stated then supplier must contact FLS engineering for further instructions.

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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ES0001 WORKMANSHIP STANDARD

7.0 MACHINING TOLERANCE STANDARD 7.1

Standard Tolerance when not called out on the FLSmidth 7.1.1 Standard Surface Finish a) Machine Surfaces 125 RMS b) Threads & Thread Reliefs 63 RMS c) Non6Standard Finish 250 RMS d) Remove all sharp edges and burrs

drawings (3 µm) (1 µM) (6 µm)

7.1.2 Angles & Radius Angle Tolerance Fillet Radius

+/6 1 Degree .030 min. (1 mm)

7.1.3 Dimensional call outs

7.1.4 Undersize dimensions cannot be brought back into tolerance by the build6up of coatings or plating.

8.0 BLASTING/PAINTING & COATING STANDARD 8.1

Uncoated machined surfaces, cast iron surfaces, shafting, mating surfaces, threaded and bolting surfaces and flange faces, shall be cleaned, free of rust and other foreign matter, and given a heavy coating with a solvent removable rust inhibiting compound suitable for extended storage.

8.2

All blasting, painting and coatings shall be done in accordance with FLSmidth drawings, manufactures recommendation and/or inspection and test plans.

8.3

Abrasive basting shall be done in accordance with either Steel Structures Painting Counsel (SSPC) or NACE standards.

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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ES0001 WORKMANSHIP STANDARD

8.3.1 White Metal Blast (SSPC 6 SP5, NACE #1) In this method, all visible rust, mill scale, paint and contaminants are removed, leaving the metal uniformly white or gray in appearance. This method is to be used where maximum performance of protective coatings is necessary due to exceptionally severe conditions such as constant immersion in water or liquid chemicals. 8.3.2 Commercial Blast (SSPC – SP6, NACE #3) In this method, all oil, grease, dirt, rust scale and foreign matter are completely removed from the surface and all rust, mill scale and old paint are completely removed by abrasive blasting except for slight shadows, streaks or discolorations caused by rust stain, mill scale oxides or slight residues of paint or coating that remain. If the surface is pitted, slight residue of rust or paint may be found in the bottom of pits; at least two6thirds of each square inch of surface area shall be free of all visible residues and the remainder shall be limited to the light residues mentioned above. 8.3.3 Brush Off Blast (SSPC – SP7, NACE #4) In this method, all oil, grease, dirt, rust scale, loose mill scale, loose rust and loose paint or coatings are removed completely. Tight mill scale and tightly6adhered rust, paint and coatings are permitted to remain. However all mill scale and rust must have been exposed to the abrasive blast pattern sufficiently to expose numerous flecks of the underlying metal fairly uniformly distributed over the entire surface. 8.3.4 Near White Blast (SSPC – SP10, NACE #2) In this method, all oil, grease, dirt, mill scale, rust, corrosion products, oxides, paint or other foreign matter have been completely removed from the surface by abrasive blasting, except for very light shadows, very slight streaks or slight discolorations caused by rust stain, mill scale oxides or slight, tight residues of paint or coating. At least 95% of each square inch of surface area shall be free of all visible residues, and the

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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ES0001 WORKMANSHIP STANDARD

remainder shall be limited to the light discolorations mentioned above. 8.4

All coating applications shall be done in accordance with SSPC – PA1 and the manufactures recommendations. All required criteria shall be followed to ensure that desired results are achieved.

8.5

Prior to applying the coating all surfaces shall be blasted in accordance with the required surface preparation and shall have achieved the required anchor (blast) profile per the manufactures recommendations or per FLSmidth drawing(s). Area shall be dry, free from dust, dirt, grease, or other contaminates that could affect the performance of the coating.

8.6

Coating should be applied in an environmentally controlled coating booth or room where possible. If coatings are to be applied outside, then they shall be done during the daylight hours and shall only be done when weather is permitting. If there is a possibility of rain, fog, mist or if relative humidity is at or above 85%, coatings shall not be applied until such time as weather permits. Surface temperature shall be maintained at a minimum of 5°F above the dew point to prevent oxidation of the cleaned surface.

8.7

Large areas shall be sprayed in two directions to ensure even and complete coating coverage.

8.8

Runs, sags, drips, skips or other surface defects are not acceptable and shall be removed and recoated. In the event that a large area is found to be unacceptable the paint shall be removed by blast and recoated.

8.9

All coated surfaces shall meet the required minimum dry film thickness (DFT). If the surface is found to not meet the required mil thickness another layer of coating shall be applied. If the coating exceeds the required mil thickness a deviation shall be submitted to FLS for disposition by FLS Engineering.

8.10

Coated surfaces shall be inspected in accordance with SSPC – PA2. At a minimum the following shall be recorded for all coated surfaces and be submitted to FLSmidth at the completion of the coating process: • Coating to be used • Blast Profile

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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ES0001 WORKMANSHIP STANDARD

• • •

Dry Film Thickness (DFT) per PA2 Visual Inspection Drawing used

Where required by FLSmidth purchase order the following may also be required to be recorded • • • • • • • • 8.11

Air Temperature Relative humidity Surface Temperature Dew Point Wet Mil Thickness (each coat) DFT each coat Adhesion Test Holiday Test

Hot6Dip Galvanizing shall be applied per ASTM A123 / A123M.

The information transmitted by this document is the proprietary and confidential property of FLSmidth and may not be duplicated, disclosed or utilized without written consent from FLSmidth.

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