Forging Inspection

Excel Foundry and Machine, Inc.

Procedure

Doc #: PR7.4.1-10/ Rev. 1 Appr By: Tommy G. Wienke Rev. Date: 03/31/2010 Page: 1 of 4

Gyratory Crusher Shafting Inspection and Testing Requirements 1.0 PURPOSE The purpose of this procedure is to define the minimum inspection and testing requirements for Gyratory Crusher Main Shafts, Countershafts, and Countershaft Extensions for Excel Foundry & Machine, Inc. 2.0 SCOPE This procedure pertains to gyratory crusher Main Shafts, Countershafts, and Countershaft Extensions supplied to Excel Foundry & Machine, Inc. by any supplier. 3.0 DEFINITIONS All terms and definitions used throughout Excel Foundry & Machine, Inc. are defined in Terms and Definitions (QPM03). Any term that is not understood by any supplier and is not present on Terms and Definitions (QPM03) shall be brought to the attention of the QMR, so that it may be added to the list. Contact the Quality Management Representative at Excel Foundry & Machine, Inc. if a copy of these definitions is needed. Where the term ‘supplier’ appears shall refer to the direct provider of material to Excel Foundry & Machine, Inc. 4.0 REFERENCES 4.1 ASTM A338 – Standard Practice for Ultrasonic Examination of Heavy Steel Forgings. 4.2 ASTM A668 – Standard Specification for Steel Forgings, Carbon and Alloy, for General Industrial Use. 4.3 ASTM A788 – Standard Specification for Steel Forgings, General Requirements. 4.4 ASTM E709 – Standard Guide for Magnetic Particle Examination. 4.5 SQR01 ATT01 (Dimensional Inspection Report) 4.6 SQR01 ATT02 (Supplier Chemical Report) 4.7 SQR01 ATT03 (Supplier Mechanical Report) 4.8 SQR01 ATT04 (Supplier Deviation Report)

5.0 RESPONSIBILITIES Any supplier that provides steel cone Gyratory Crusher Main Shafts, Countershafts, and Countershaft Extensions to Excel Foundry & Machine, Inc. is responsible for ensuring that all aspects of this procedure are followed, or that another written agreement is reached between Excel and the supplier prior to shipment of part(s).

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Doc #: PR7.4.1-10/ Rev. 1 Appr By: Tommy G. Wienke Rev. Date: 03/31/2010 Page: 2 of 4

Excel Foundry and Machine, Inc.

Procedure

Gyratory Crusher Shafting Inspection and Testing Requirements 6.0 PRODUCT QUALITY REQUIREMENTS Forging Material Specifications 6.1 Forgings shall comply with ASTM A668, and the material class specified in the purchase order. 6.1.1

Standard temperature applications utilize ASTM A668 Class C and Supplementary Requirement S4 (0.35% Maximum Carbon Content for Welding).

6.1.2

Low temperature applications utilize ASTM A668 Class G and Supplementary Requirement S4 (0.35% Maximum Carbon Content for Welding).

6.1.3

Chemical composition for standard applications shall comply with ASTM A668 Class C and Supplementary Requirement S4 (0.35% Maximum Carbon Content for Welding).

6.1.4

Mechanical properties for standard applications shall comply with ASTM A668, Class C.

Size in Inches Over

Not Over

Tensile Strength Minimum PSI

----12 20

12 20 -----

66,000 66,000 66,000 6.1.5

Yield Strength

Reduction of Area

Minimum PSI

Elongation in 2 Inches Minimum %

33,000 33,000 33,000

23% 22% 21%

36% 36% 32%

Brinnel Hardness

Minimum %

137-183 137-183 137-183

Chemical composition for special low temperature applications shall comply with ASTM A668 Class G, Supplementary Requirement S4 (0.35% Maximum Carbon Content for Welding), and with the following requirements: 6.1.5.1 Must contain 3.25%-3.75% Nickel.

6.1.6 Chemical composition shall be measured and recorded on SQR01 ATT02 (Supplier Chemical Report) or equivalent. 6.2 Mechanical properties for special low temperature applications shall comply with ASTM A668 Class G. Size in Inches Over

Not Over

Tensile Strength Minimum PSI

----12

12 -----

80,000 80,000

Yield Strength

Reduction of Area

Minimum PSI

Elongation in 2 Inches Minimum %

50,000 50,000

24% 22%

40% 38%

Brinnel Hardness

Minimum %

163-207 163-207

6.3 Mechanical properties shall be measured and recorded on SQR01 ATT03 (Supplier Mechanical Properties Report) or equivalent. Forging Reduction 6.4 Forging reduction ratio shall be no less than 3 to 1, with actual reduction ratio certified by the manufacturer.

Uncontrolled Document If Printed

Excel Foundry and Machine, Inc.

Procedure

Doc #: PR7.4.1-10/ Rev. 1 Appr By: Tommy G. Wienke Rev. Date: 03/31/2010 Page: 3 of 4

Gyratory Crusher Shafting Inspection and Testing Requirements Ultrasonic Testing 6.5 All forgings shall be ultrasonically tested in the final heat treated condition, and in accordance with ASTM A388. 6.6 Longitudinal beam examination shall be carried out using the back reflection calibration technique. 6.7 Testing surfaces shall be machined and possess a surface roughness no greater than 250 micro inches (6.3 micrometers). 6.8 Discontinuity indications shall be recorded and reported in accordance with the following instructions: 6.8.1

Discontinuity indications whose amplitude equals or exceeds 20% of the calibrated back reflection shall be reported in increments of 10%.

6.8.2

Discontinuity indications equal to or exceeding 5% of the back reflection, providing they present themselves as traveling indications, are continuous, or appear as clusters (See ASTM A388).

6.8.3

A reduction of back reflection of 30% or greater when associated with the presence of a discontinuity indication.

6.9 Acceptance Criteria: 6.9.1

Forgings shall be free of cracks, flakes, bursts, piping, and open segregation.

6.9.2

Forgings shall be rejected if testing detects any discontinuities that produce indications with a complete loss of back reflection. A complete loss of back reflection is assumed when the back reflection falls below 5%.

Magnetic Particle Testing 6.10 Finish Machined Main Shafts shall be magnetic particle tested in accordance with ASTM E709. 6.11 Report all indications – No linear indications are permitted. A linear indication is defined as an indication whose length is equal to or greater than three (3) times its width. Machining 6.12 Machined features and dimensions shall comply with machining drawings provided as attachments to the applicable purchase order.

Uncontrolled Document If Printed

Excel Foundry and Machine, Inc.

Procedure

Doc #: PR7.4.1-10/ Rev. 1 Appr By: Tommy G. Wienke Rev. Date: 03/31/2010 Page: 4 of 4

Gyratory Crusher Shafting Inspection and Testing Requirements Inspection of Machined Features and Dimensions 6.13 Machined features and dimensions shall be measured and recorded on SQR01 ATT01 (Dimensional Inspection Report) or equivalent. Vendor Test Reports 6.14 The supplier shall retain the following documentation to be provided to Excel Foundry & Machine, Inc. upon completion of work. Additionally, any documentation that is required on the Excel Foundry & Machine, Inc. approved Inspection and Test Plan where applicable shall be submitted prior to beginning any new job. 6.14.1 Chemical Report (SQR-01 ATT 02 or equivalent) 6.14.2 Mechanical properties (SRQ-01 ATT 03 or equivalent) 6.14.3 Heat treat reports (When applicable) 6.14.4 Magnetic Testing results (When applicable) 6.14.5 Ultrasonic Testing reports (When applicable) 6.14.6 Dimensional Inspection Form (SQR-01 ATT 01 or equivalent) 6.14.7 Certificate of actual forging reduction 6.14.8 Any deviation requests. These deviation requests shall require review and disposition by Excel Foundry & Machine, Inc. and documented on SQR01 ATT04 (Supplier Deviation Request). Source Inspection and Expediting 6.15 The supplier shall allow workshop access to Excel Foundry & Machine, Inc. and/or a third party for purposes of inspection and/or expediting.

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