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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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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 GENERIC SPECIFICATION STANDARD
6,
Plate, Sheet, Bar and Mild Stl, Stl, Carbon Stl, ASTM A36
Structural Shapes H.R. St!

Plate, Sheet Abrasion/Impact Resistant ***


Steel, AR Steel
Pipe, welded and seamless Carbon Steel Pipe ASTM A53

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

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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WORKMANSHIP STANDARD

FORMS GENERIC SPECIFICATION STANDARD


6,
Mechanical Tubing Stl, ASTM A513 TYPE 1 (HR)
Carbon ASTM A513 TYPE 2 (CR)
Stl
Tubing

Bar, Rounds/Shafting CRS, STL AISI C61018,1020


ASTM A27
Castings Steel
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 STANDARD
SPECIFICATION
Plate, Sheet, Stainless Steel ASTM A240 TYPE 354
Bar, Shapes, ASTM A276 TYPE 304
Rounds
Plate, Sheet, 304SS / 304LSS ASTM A240 TYPE 304/304L
Bar, Shapes,
Rounds

Plate, Sheet, 316SS / 316LSS ASTM A240 TYPE 316/316L


Bar, Shapes,
Rounds

Non5Ferrous Materials
FORM GENERIC SPECIFICATION STANDARD

Plate, Sheet, Bar, Coil Aluminium


60616T6
Structural Shapes Aluminium
Castings Aluminium 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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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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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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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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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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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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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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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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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) 0 to 40’ (0 to 12.2 M)
+/6 1/4” (6 MM) over 40’ (12.2 m)

5.8.2 Positioning and Locating:

Bolt Circles – Diameters


Solid Flange +/6 1/32” (1 mm) 0 to 4’ (0 to 1.2 M)
Rim Flange +/6 1/16” (1.5 MM) 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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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) +/61/4 inch (6 mm)


20 to 40 foot (6 to 12 m) +/61/2 inch (13 mm)
40 to 150 foot (12 to 45 m) +/63/4 inch (19 mm)
150 to 250 foot (45 to 75 m) +/61 inch (25 mm)
Over 250 foot (75 m) +/61 ¼ inch (32 mm)

5.9 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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7.0 MACHINING TOLERANCE STANDARD

7.1 Standard Tolerance when not called out on the FLSmidth drawings
7.1.1 Standard Surface Finish
a) Machine Surfaces 125 RMS (3 µm)
b) Threads & Thread Reliefs 63 RMS (1 µM)
c) Non6Standard Finish 250 RMS (6 µm)
d) Remove all sharp edges and burrs

7.1.2 Angles & Radius

Angle Tolerance +/6 1 Degree


Fillet Radius .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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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

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
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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

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
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• 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

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

8.11 Hot6Dip Galvanizing shall be applied per ASTM A123 / A123M.

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and may not be duplicated, disclosed or utilized without written consent from FLSmidth.
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