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Title : CASTING PROCEDURE

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DOCUMENT TITLE:

CASTING PROCEDURE

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Title : CASTING PROCEDURE

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Vendor: Engineering Contractor: Owner:

Title : CASTING PROCEDURE

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CONTENT

Procedure for Manufacturing and Inspection of Pump Castings................4

1. Purpose....................................................................................................4
2. Scope....................................................................................................... 4
3. Responsibilities....................................................................................... 4
4. Procedure Steps......................................................................................6
4.1. Raw Material Receipt and Verification.........................................6
4.2. Pre-Casting Setup and Mold Preparation.....................................6
4.3. Melting and Pouring Process........................................................6
4.4. In-Process Inspection and NDT.....................................................7
4.5. Post-Casting Processing:...............................................................7
4.6. Final Inspection and Advanced NDT.............................................7
4.7. Documentation, Non-Conformance Management, and Product
Release.........................................................................................7
5. Equipment and Tools..............................................................................8
6. Health, Safety, and Environmental Requirements.................................8
7. References...............................................................................................8
Vendor: Engineering Contractor: Owner:

Title : CASTING PROCEDURE

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Below is a detailed, step-by-step procedure designed for manufacturing and quality

inspection of pump castings that comply with API, ASME, and DIN standards. This
procedure covers the entire production cycle—from raw material receipt through final
product certification—and ensures that every pump casting meets the rigorous quality and
performance requirements demanded by petrochemical applications.

Procedure for Manufacturing and Inspection of Pump Castings

1. Purpose

To produce pump castings that adhere to API, ASME, and DIN standards through a
controlled manufacturing process and systematic quality inspections. This procedure
outlines the steps required to ensure material integrity, process control, advanced NDT
testing, and final certification, thereby reducing the risk of failure in service environments.

2. Scope

This procedure applies to the production of pump castings within the foundry and
machining processes. It covers:

 Raw material verification

 Pre-casting setup and mold preparation
 Melting, pouring, and in-process monitoring
 Non-destructive testing (NDT) during and after casting
 Post-casting processing, final inspection, and product release

3. Responsibilities

 Production Supervisor: Oversees the entire casting process, ensures that process
parameters and safety protocols are observed, and coordinates with the quality
team.
 Quality Assurance (QA) Manager: Applies this procedure, examines documentation,
signs off on inspection protocols, and performs final reviews.
NDT Specialist: Executes advanced NDT techniques (e.g., UT, RT, PT, and MT) and
documents the results.
 Material Inspector: Verifies raw material certifications and performs incoming
inspection tests.
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 Operators: Follow the detailed work instructions for mold preparation, metal
handling, and process monitoring.
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4. Procedure Steps

4.1. Raw Material Receipt and Verification

1. Material Verification:
 Upon arrival, verify that material certificates meet the required API, ASME,
and DIN specifications for chemical composition and mechanical properties.
 Perform laboratory tests as necessary.
 Record all incoming material data and certificates.
2. Supplier Qualification:
 Confirm supplier pre-qualification and audit history.
 Ensure that materials are stored under specified conditions to preserve
integrity.

4.2. Pre-Casting Setup and Mold Preparation

1. Mold and Gating System Inspection:

 Inspect molds for defects, verify clean surfaces, and ensure proper alignment.
 Confirm the gating system is designed to minimize turbulence and promote
uniform solidification.
2. Documentation Review:
 Ensure that all engineering drawings and process parameters are current and
approved.
 Verify that the setup aligns with the design specifications dictated by API,
ASME, and DIN standards.

4.3. Melting and Pouring Process

1. Furnace Operation:
 Heat the metal in accordance with the predetermined temperature schedule.
 Monitor furnace parameters (temperature, de-gassing, alloy composition)
using calibrated sensors.
2. Pouring:
 Transfer molten metal carefully using automated or manually guided systems,
ensuring minimal turbulence.
 Document the pouring process, noting any deviations and corrective actions.
(If required)
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4.4. In-Process Inspection and NDT

1. Real-Time Process Monitoring:

 Use digital data loggers to continuously record temperature, flow rates, and
other critical variables. (If required)
 Supervisors perform regular visual inspections and process parameter checks.
2. Initial NDT Applications:
 Ultrasonic Testing (UT): Inspect critical sections such as weld zones and thick-
walled areas for internal discontinuities.
 Radiography Testing (RT): Assess internal integrity by detecting pores,
inclusions, or misruns. (If required)
 Record all results in a designated inspection. (If required)

4.5. Post-Casting Processing:

1. Cooling :
 Allow controlled cooling following the specified solidification curve. (If
required)
 Remove the casting from molds and clean off any residual materials.
2. Heat Treatment and Machining:
 Perform prescribed heat treatment cycles (annealing or tempering) to achieve
required mechanical properties.
 Machine casting surfaces to meet dimensional tolerances and surface finish
standards.

4.6. Final Inspection and Advanced NDT

1. Comprehensive NDT Suite:

 Magnetic Particle Testing (MP) / Dye Penetrant Testing (PT): Examine for
surface and near-surface cracks on ferromagnetic components.
2. Dimensional Verification and Mechanical Testing:
 Confirm that the casting dimensions meet design specifications using
calibrated metrology tools.
 Perform hydrostatic or pressure testing as per relevant API/ASME
requirements.

4.7. Documentation, Non-Conformance Management, and Product Release

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1. Record-Keeping:
 Compile records of process parameters, NDT results, and inspection reports.
 Maintain traceability records including batch numbers, production dates, and
material certifications.
2. Non-Conformance Actions:
 Identify and segregate any non-conforming products.
 Initiate corrective actions following root cause analysis and document
remediation steps.
 Re-inspect or rework casting components until conformity is achieved.
3. Final Certification:
 After successful completion of all inspections and tests, the QA Manager
reviews and signs off on the certification.
 Tag the pump casting with a unique certification number, and update the
release register.

5. Equipment and Tools

 NDT Equipment: UT system, etc.

 Data Acquisition: Calibrated temperature sensors, flow monitors.
 Inspection Tools: Calipers, micrometers, 3D laser scanners for dimensional
measurements. (If required)
 Documentation Systems: Electronic record-keeping software that integrates QC
data, inspection records, and certification records.

6. Health, Safety, and Environmental Requirements

 Adhere to all hazardous material handling, high-temperature operation, and

equipment safety protocols.
 Ensure that personal protective equipment (PPE) is provided and used by all
personnel.
 Comply with environmental regulations regarding waste disposal and energy
consumption during the casting process.

7. References

 API Standard 610, API documentation.

 ASME Boiler and Pressure Vessel Code.
 DIN Standards relevant to pump castings.
Vendor: Engineering Contractor: Owner:

Title : CASTING PROCEDURE

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 Internal Quality Control Plan and previous inspection records