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Painted Post Operations

Edition 1
Material Specification
Gray Iron Castings for Pressure-Containing Parts to Minus 60F (Minus 51C)
Note: The most recent changes are indicated with an asterisk (*).
1.1 This Specification covers a Class 40 gray cast iron suitable for pressure-
containing parts for use at temperatures down to 60F (51C), conforming with
the basic requirements of ASTM A278, date of latest issue.
1.2 Castings to this specification shall be in compliance with SA 278, Section II of
the ASME Boiler and Pressure Vessel Code and American Petroleum Institute
Standard 618, dates of latest issue.
1.3 Castings to this Specification shall be a Class 40 gray iron [i.e., 40 ksi (276 MPa)
tensile strength] when tested in accordance with Paragraph 5 of this
2.1 The type of melting unit and choice of melting procedure are optional with the
manufacturer. Ladle inoculation is recommended but is left to the discretion of
the supplier so long as the specified properties are produced.
3.1 Castings to this specification shall be of the following chemical composition:
C Si Mn P S Mo
% Minimum 3.30 1.60 0.25
% Maximum 3.50 1.80 0.90 0.065 0.12 0.35
3.2 Heat analysis records must be maintained by the manufacturer for verification of
compositional control.
4.1 A subcritical stress relief anneal is required when so designated by an Dresser-
Rand Heat Treatment Standard on the casting drawing. Test bars or coupons
shall be heated in the same furnace charge and immediately adjacent to the
castings they represent.
5.1 The manufacturer shall cast test bars or integrally cast coupons in accordance
with the requirements of ASTM A278, to ensure the compliance of each casting
lot or individual casting over 2000 lbs (907 kg). Results shall be recorded and
maintained on file for inspection by Dresser-Rand Company. (A lot is defined as
that metal, of controlled chemical composition, which is poured during one
working shift from the same melting unit employing continuous practice, or from
the same heat in a batch operation.)
5.1.1 The cast test bar and machined specimen sizes shall be determined on
the basis of the casting controlling section per the correlation established
in ASTM A278. The correlation for section sizes beyond 2 inches (50 mm)
shall be extended in accordance with the S(1), S(2) and S(3) test bars
defined in Table I.
5.1.2 Except as permitted in Paragraph 5.1.4, test bars shall be separate
castings poured from the same iron as the castings they represent, and
shall have dimensions as shown in Table II.
5.1.3 For castings having a controlling section greater than 2 inches (50 mm),
where it is impractical to establish a satisfactory degree of correlation
between test bars and castings, the castings shall be considered as
having met the tensile strength of the class specified when test coupons
cut from the castings or integral projections thereof, the cross section of
which is not less than that of the controlling section of the casting, have a
tensile strength not less than 80 percent of the specified class.
5.1.4 Castings weighing in excess of 2000 lbs (907 kg) may be represented
either by separately cast test bars poured from the same ladle of iron or
by integrally cast test bars having a cooling rate closely approximating that
of the controlling section of the casting, upon prior agreement between
Dresser-Rand and the casting supplier.
6.1 The casting shall conform substantially to the dimensions on drawings furnished
by Dresser-Rand Company.
6.2 Castings, as received by Dresser-Rand Company, shall be well cleaned with
fins, risers and gates removed; and free from fused-on sand, shrinkage cavities,
sand holes, cracks, excessive free carbides or any defect which, in the
judgement of Dresser-Rand Company, would be detrimental to machinability,
appearance or end use of the castings.
6.3 The use of chaplets shall be held to a minimum. They shall be cleaned and rust
free (plating permitted) and of a composition compatible with the castings.
6.4 Machined surfaces shall be sound and free from "open grained" iron.
6.5 Welding, peening or impregnation of castings is not permitted.
6.6 Castings may be repaired by plugging within the limits and in accordance with
all requirements of ASTM A395; however, plugs shall not be used in the gas
pressure-containing wall sections, including the bore under the liner. The drilled
hole for a plug shall be subjected to a dye penetrant examination to ensure the
removal of all defective material. All repairs shall be subject to the purchasers
prior written approval.
6.7 Deviations from this specification are permissible only if a waiver, stating the full
extent of non-compliance, is submitted by the manufacturer and written
approval is obtained from an authorized representative of the appropriate
Engineering Department, Dresser-Rand Company.
7.1 The microstructure is expected to consist essentially of Type VII A 3-6 flake type
graphite in a lamellar pearlite matrix. Free ferrite should not exceed 10 percent;
carbides and/or phosphide eutectic should be well dispersed and not exceed five
percent, combined.
8.1 Pressure Tightness:
8.1.1 Finish machined castings to this specification shall show no leaks when
tested to the Dresser-Rand pressure test requirements specified on the
8.1.2 Although the foundry cannot perform the pressure test on unmachined
castings, they shall be responsible for the satisfactory performance of the
castings under the final tests required by Paragraph 8.1.1.
8.2 Other Special Requirements:
8.2.1 Special requirements such as heat treatment, hardness, microstructure,
radiographic soundness, dimensions, surface finish, serialization of
castings, etc., may be specified in the purchase order or on the
accompanying part drawing.
8.2.2 All requirements of ASTM A278 not specifically covered in this
specification shall apply.
9.1 Where practicable, the castings shall be marked with the pattern number and
foundry symbol in such a manner that the number and symbol will not be
removed in subsequent machining operations.
9.1.1 The pattern number must appear at the location shown on the casting
drawing when so designated.
9.2 The manufacturer shall furnish the appropriate Purchasing Department of
Dresser-Rand Company with a notice of shipment. The notice shall specify
Dresser-Rand pattern number, purchase order number and the total weight of
the castings.
10.1 Dresser-Rand Company shall have the option of inspecting all material and
applicable documents for compliance with the requirements of this
10.2 Failure of the manufacturer to comply with all requirements of this
Specification shall cause the material to be subject to rejection. If the material
is rejected, the manufacturer shall be notified. After acceptance of the rejection
by the manufacturer, the material shall be returned for full credit at prices
charged, including transportation expenses.
1st Edition Approved: 12/07/92, D.C. Zimmerman T60006.std\Network