Gi PR.00004

Plant Client Code Doc.
ID-Code
Ipatinga
Usiminas Revamp COB3 GI_PR.00004
Coke Oven Battery #3
General Instruction for Job Execution

COKE OVEN BATTERY
Uhde Rev 00 Page 1 of 22
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0 IFI First Issue 28.02.2022 GHT 03.03.2022 EPA 03.03.2022 EPA

Rev. Status Description Date Prepared Date Checked Date Approved AC
Category Code: 3
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Plant Client Code Doc. ID-Code
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COKE OVEN BATTERY
Table of contents
1 Introduction 3
1.1 General Rules for Execution/Workmanship 4
1.2 Molded parts (Casting) 5
1.2.1 Pattern, pattern equipment and core boxes of sand molds & cores 5
1.2.2 Prototypes / Trial piece 5
1.2.3 Additional rules for molded parts 6
1.2.4 Assessment of casting quality 7
1.2.5 Heat treatment of cast iron parts 8
1.3 Machining of steel components and molded parts (casting) 9
1.3.1 General machining rules 9
1.3.2 Additional machining rules for molded parts 9
1.4 Welding 10
1.4.1 Welding rules 10
1.4.2 Welding materials 11
1.4.3 Quality level of welds 11
1.4.4 Welder’s test certificate, the qualification of personnel 11
1.4.5 Welding procedures qualification 12
1.5 Examination of welds 12
1.5.1 Quality level of welds 12
1.5.2 Testing methods and their range of application 12
1.5.3 Qualification of personnel 14
2 Materials 15
3 Painting and conservation 16
4 Supply of engineering, documentation and pertaining delivery dates 17
4.1 General requirements for documentation 17
4.2 Delivery of dimension protocols and check-up protocols 17
4.3 CONTRACTORs final documentation 17
5 Inspection and testing at CONTRACTOR’s works, trial operation 18
5.1 General requirements 18
6 Identification , Marking 19
7 Inspection by BUYER 19
8 Packing, transportation & storage 20
8.1 Packing 20
8.2 Transportation 20
8.3 Storage at CONTRACTOR’s works 20
9 Delivery 21
9.1 Delivery date 21
9.2 Progress reports 21
9.3 Technical documentation 21
9.4 Spare parts offer 21
9.5 Inspection and testing 21
9.6 Inspection readiness notice 21
9.7 Material and test certificates 21
10 Inspection Plan 22
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1 Introduction
The terms and conditions stablished in this document shall be applied for
manufacturing/supply of parts and equipment for the related Coke Oven Battery project.
The standards indicated in this file and/or supporting documentation shall comply with ISO
standards, or similar international recognized.
This General Instruction for Job Execution comprises guidelines, covers the general
instructions for manufacturing of different groups of materials. This general instruction
supplements the information contained in the TECHNICAL SPECIFICATIONS and
DRAWINGS.
All rules specified herein apply unless otherwise specified in the TECHNICAL
SPECIFICATIONS and DRAWINGS.
The plant owner hereinafter OWNER and thyssenkrupp Uhde Brazil (BUYER)
hereinafter BUYER, shall have unrestricted access to all areas of the workshop belonging
to manufacturer and and/or it’s sub-suppliers hereinafter CONTRACTOR, during the
execution of any service related to contracted scope of supply and may register through
photos all phases of the manufacturing process.
• The frequency of inspections which will be carried out by BUYER and OWNER will
be defined before beginning of manufacturing.
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1.1 General Rules for Execution/Workmanship
➢ During manufacture and production, the recognized rules of engineering as well as the
applicable codes and regulations shall be duly observed. In case of queries BUYER
shall be consulted prior to execution.
➢ All fabrication instructions, tolerances and remarks entered on relevant drawings and
supporting technical documentation attached to the purchase order (contract) shall be
duly and strictly observed.
➢ Normative references: for undated references, the latest edition of the undated
referenced document (including any amendments) applies.
➢ The scope of supply shall comply according general quality as per DIN / DIN EN / DIN
EN ISO / ISO codes, or equivalent international recognized codes.
➢ The processing of stainless materials must be carried out in a workshop separated from
unalloyed steels. This workshop must be equipped with special materials and tools,
such as non-ferrous grinding and cutting wheels.
➢ Steel structures: If parts and equipment become part of a coke making plant within
the EU, CONTRACTOR’s engineering and manufacturing must be in accordance with
the EU codes and standards listed below.
If parts and equipment become part of a non-EU coke plant CONTRACTOR must be
in accordance to equivalent internationally recognized codes:
➢ Design of steel structures acc. DIN EN 1993, Eurocode 3 and relevant National
Annexes for country of final place of installation (country to be determined by
BUYER). Execution class to be determined by BUYER. If no execution class is
specified, EXC 2 shall apply.
➢ Execution of steel structures and aluminum structures – Requirements for
conformity assessment of structural components acc. DIN EN 1090-1:2012-02.
➢ Execution of steel structures and aluminum structures – Technical requirements
for steel structures acc. DIN EN 1090-2:2011-10. Execution class to be
determined by BUYER. If no execution class is specified, EXC 2 shall apply.
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1.2 Molded parts (Casting)
1.2.1 Pattern, pattern equipment and core boxes of sand molds & cores
Regarding pattern, pattern equipment and core boxes of sand molds and sand cores
(Casting); following points must be observed.
➢ Pattern as per DIN EN 12890:2000-06, Quality class H1.
All required pattern and pattern equipment needed to manufacture in order to reach
BUYER detail engineering figures, tolerances and quality requirements, and these
remains to BUYER unrestricted property. It has to be properly stored on BUYER behalf at
CONTRACTOR’s warehouse for a minimum period of 5 years and be kept in an orderly,
usable status. If required BUYER is entitled to collect the pattern at any time;
1.2.2 Prototypes / Trial piece

Prior to start of production in series, at least 2 (two) prototype (part of scope) of the
unfinished castings shall be cast and presented for inspection. After BUYER approval, this
piece may be carried out further manufacturing procedure, e.g, shall be machined
completely, mounted and after completion presented to BUYER again for inspection. In
the course of inspection, BUYER will check whether the prototypes are in conformity with
our terms and conditions of order placement with regard to workmanship and function.
Only after receipt of BUYER approval CONTRACTOR shall commence with the
production in series.
The production in series will be monitored by BUYER continuously, according events to
be communicated prior to commencement of work.
The castings shall be adapted to the intended application in terms of their outer and inner
properties. This relates to the accuracy to size and the inner properties. The
CONTRACTOR will assure compliance therewith by making the following check-ups and
tests:
1.2.2.1 Testing the prototype / Trial piece
Each prototype of a series shall be subjected to a 100% visual check-up and dimensional
control. In case spots being difficult in terms of casting technology or which defects are
identified, CONTRACTOR must perform upon BUYER request non-destructive testing
NDT, such as VT, PT, UT, RT, MT, according suitability of scope and suitability of material.
Remark: the applicability of the NDT depends specially on the material class and parts
geometry which will be defined during detail engineering.
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For testing carried out in the EU: Testing shall be carried out according to below listed
codes and standards.
For testing carried out in all other countries according equivalent international recognized
codes.
Molded parts:
➢ VT, Visual testing acc. to EN 13018
➢ PT, Penetration testing acc. to EN ISO 3452
➢ UT, Ultrasonic testing acc. to DIN EN 12680-1:2003-06, DIN EN 12680-3:2012-02.
➢ RT, Radiographic testing acc. DIN EN 12681:2003-06
➢ MT, Magnetic particle test acc. to ISO 9934
The same NDTs applicable for the prototype inspection shall be carried out and recorded
by CONTRACTOR for the production of casting in on random sample basis.
1.2.2.2 Testing the pre-production series
Testing of the pre-production series shall be performed in according BUYER requirements
and in principal according as or more restricted condition them those requested by scope.
Unless otherwise noted in the related Technical Specification testing of the pre-production
series shall be performed as outlined as before on approx. 10 (ten) component casting
parts.
1.2.3 Additional rules for molded parts

Testing of the pre-production series shall be performed to assure product lot quality
requirements.
➢ The technical conditions of delivery shall be as per EN 1559.
➢ Allowable tolerances for finished feature of molded part for dimension between two
un-machined surfaces:
➢ Tolerances for length, widths, heights, center distance, diameters, radii, according:
DIN EN ISO 8062-3:2008-09, DCTG 11;
➢ Tolerances for thickness dimensions (Wall thickness, webbing and rips),
according:
DIN EN ISO 8062-3:2008-09, max. 80% of DCTG 12.
The approach of the specified dimension tolerance grades is symmetrical (±
Tolerance).
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➢ The remark “smooth” for the un-machined casting surfaces means the DIN EN ISO
1302:2002-06 & DIN EN ISO 1302 rectification 1:2008-08, Roughness value Ra 25.
If parts and equipment become part of a Japanese coke plant respective casting
surfaces in accordance to JIS B 0659 Class SN11 to SN12.
➢ All castings shall receive sample bars as per DIN according to which strength values
and analyses (e.g. chemical analysis, microscopic structure analysis, hardness and
tensile strength test) shall be verified by CONTRACTOR. The sample bars examined
at CONTRACTOR’s works shall be stored by CONTRACTOR for one year longer
than the guarantee period.
➢ Unless otherwise explicitly pointed out in the related drawings as per Technical
Specification, permissible deflection for unfinished castings as per DIN EN ISO 8062-
1: 2007-06
Permissible deflection, deflection orientation and twisting which is separately defined
in the related drawings as per Technical Specification by illustration on drawings shall
be strictly observed.
➢ Brushing: The casting surface shall be cleaned from molding material. Identifying
marks and burrs at the mound partition shall be removed.
➢ The castings must be cast properly and skillfully and must not show distortions,
unclean profiles, cracks, black wash strips, blowholes or irregularities such as
projections or misalignments, as per tolerances on detail drawings.
1.2.4 Assessment of casting quality

The following assessments must be carried out on all cast bodies.
All cast parts must be thoroughly checked for any casting defects (e.g. cracks, porosity,
blow holes etc.).
1.2.4.1 Assessment of machined surfaces:
➢ All machined surfaces must be free of any defect.
➢ Any repairs on the machined surfaces are strictly prohibited (e.g. repair by welding,
etc.).
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1.2.4.2 Assessment of non-machined surfaces:

Depending on the type and size of the defects that occur, a certain error level can be
tolerated.
The following applies as guideline:
• 1.: Defects with diameter <10mm x depth <5mm: only 4 within one cast body tolerable
• 2.: Defects with diameter 10~20mm x depth <5mm: only 2 within one cast body
tolerable
• 1.+ 2.: In total only 5 defects within one cast body are tolerable.
• Defects bigger than described under 1. + 2. are not tolerable.
• The minimum wall thickness must never be <10mm.
• Holes with a diameter <3mm and depth <3mm shall not be judged as defects.
• The distance between two defects shall be at least 100mm. This distance applies for
defects between
- outside to outside,
- outside to inside and
- inside to inside defects
➢ Repairs may be carried out in non-critical areas, but only after consultation and express
permission from the BUYER.
➢ Any re-adjustment of castings as well as repair of cast by welding shall only be permitted
with BUYER approval.
1.2.5 Heat treatment of cast iron parts

CONTRACTOR shall ensure by application of proper and adequate measures (e.g.
annealing / stress relieve heat treatment, controlled cooling process) that no deformations
or cracks on cast iron parts occur during further manufacturing, machining or operation
which are related to internal stresses of cast iron parts.
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1.3 Machining of steel components and molded parts (casting)
1.3.1 General machining rules

Unless otherwise noted on drawings listed in the relevant technical specification,
the following general machining rules shall become applicable:
➢ Fabrication hints in drawings shall be observed by all means.
➢ All holes shall be drilled.
➢ All edges shall be freed from burrs.
➢ All threaded holes shall be cut appropriately.
➢ General tolerances; Tolerances for linear and angular dimensions without individual
tolerances indications; acc. DIN ISO 2768-1:1991-06, unless otherwise noted on
drawings listed in the relevant technical specification, class M shall become
applicable.
➢ General tolerances; Geometrical tolerances for features without individual tolerances
indications; acc. DIN ISO 2768-2:1991-04, unless otherwise noted on drawings listed
in the relevant technical specification, class K shall become applicable.
1.3.2 Additional machining rules for molded parts

➢ Allowable tolerances for finished feature of molded part for dimension between two
machined surfaces: refer to above mentioned DIN EN ISO 2768, unless otherwise
noted on drawings listed in the relevant technical specification, class M and class K
shall become applicable.
➢ Allowable tolerances for finished feature of molded part for dimension between one
un-machined surface and one machined surface:
- Tolerances for length, widths, heights, center distance, diameters, radii, according:
DIN EN ISO 8062-3:2008-09, DCTG 11.
- Tolerances for thickness dimensions (Wall thickness, webbing and rips): according:
DIN EN ISO 8062-3:2008-09, max. 80 % of DCTG 12.
The approach of the specified Dimension Tolerance Grades is symmetrical (±
Tolerance)
REMARK: the CONTRACTOR must plan carefully the casting procedure and foreseen
enough machine-allowance to reach the specified tolerances according the drawing; even
if not specified the surface/machining requirement in the drawing, the geometrical
tolerance is utmost and must be achieved.
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1.4 Welding
1.4.1 Welding rules

Unless otherwise noted on drawings listed in the relevant technical specification,
the following general requirements for welding shall become applicable:
CONTRACTOR shall bear full warranty for quality of welding work.
➢ Welding – General tolerances for welded constructions: Clearance tolerances for
length, shape, angular dimensions as per DIN EN ISO 13920:1996-11, Table 1&2,
75% of tolerance class B
➢ Welding – General tolerances for welded constructions: Straightness, plainness and
parallelism tolerance as DIN EN ISO 13920:1996-11 Table 3, tolerance class E
Welding - Welding; Recommendations for welding of metallic materials
DIN EN ISO DIN EN 1011-1/2/3/4, according scope of work;
Quality requirements for fusion welding for metallic materials - Part 3: Standard quality
requirements acc. DIN EN ISO 3834-3:2006-03. In order to meet the standard quality
requirements of DIN EN ISO 3834-3:2006-03 the requirements for the documents in
accordance with DIN EN ISO 3834-5:2006-03 shall be observed.
CONTRACTOR must comply with welding procedures/standards, attending highlighted
points:
➢ Weld preparation shall be carried out according to DIN EN ISO 9692-1:2013-12.
➢ The welding specification procedure (WPS), be applied for seems on scope must be
prepared according welding applicable standards and shall within scope must be make
available for BUYER and OWNER inspectors upon request;
➢ All welds shall be visually inspected after completion. According the type of welding
typology, groove, material type, as per detail engineering, the proper NDT will be
suggested.
➢ Welds shall be free of grooves, pitting, cracks, excessive porosity, slag inclusion,
undercutting, defects in the root and bonding defects. The welding slag and spatter have
to be removed. Welds with defects shall be grouted and properly re-welded.
➢ The surfaces in the area of welding joints shall be dry and free from any impurities (e.g.
grinding dust, welding slag, grease).
➢ The oxidation products and excessive fins formed during oxygen-cutting shall be
removed by grinding or other suitable procedures.
➢ The adequate welding procedure shall be selected for the specific material and welding
connection, which is accepted for this application by the inspection authorities and / or
relevant technical association.
➢ The arc may only be ignited in such places where weld passes will subsequently be
applied.
➢ The heat input shall be adjusted such that the hardness achieved is as low as possible.
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➢ If distortion becomes evident after welding, BUYER must be communicated and

rectifying and/or alignment shall be effected.
➢ Assembly aids by means of tack welds or bolted joints shall be removed in such a way
that the quality requirements specified for the main component are met.
➢ Welding work at an ambient temperature of less than +5°C is not permitted without any
additional measures, e.g. preheating.
➢ Tempering colours on chrome-nickel steels and nickel alloys shall be removed.
➢ Avoiding and/or removing oxides/weld discolouration:
Oxides/weld discolouration is inacceptable. They shall be removed before and after
welding. The welds shall be brushed after welding while still hot.
➢ Weld root shielding: The inner surface of the welds - even tack welds - shall be sufficiently
purged with shielding gas.
➢ Welding sequence and heat management: The welding sequence and geometry shall
be selected such that weld discolouration is avoided by clever heat.
➢ Pickling and passivation: If visual testing cannot prove the absence of oxides/weld
discolouration the weld shall be pickled, passivated and cleaned. EN 1011-3 shall apply
to pickling and passivation.
➢ Welds on hand rails of railings have to be smoothed by grinding.
1.4.2 Welding materials

➢ Minimum requirements for welding material, such as yield strength, tensile strength, etc.,
shall be the same as for the parent material.
➢ All filler metals have been approved by international recognized inspection institute (e.g.
TÜV, Germanischer Lloyd, American Bureau of Shipping, Lloyd's Register of Shipping).
➢ Welding filler metals used shall be accompanied by specifications and/or approval
certificates.
➢ Welding filler metals shall be kept stored in proper moist control containers for
preservation until before actual welding procedure preparation starting.
1.4.3 Quality level of welds

The outer and inner irregularities of the welds shall be assessed in according:
DIN EN ISO 5817 - Welding: Quality level for imperfections - unless otherwise noted on
drawings listed in the relevant technical specification, the following acceptance level shall
become applicable: Acceptance level C.
1.4.4 Welder’s test certificate, the qualification of personnel

Welder’s test certificate, the qualification of personnel shall be made according to
the following codes and standards:
➢ Qualification test of welders - Fusion welding - Part 1: Steels, acc.
DIN EN ISO 9606-1:2013-12.
➢ Welding coordination - Tasks and responsibilities, acc. DIN EN ISO 14731:2006-12.
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➢ Welding personnel - Approval testing of welding operators for fusion welding and
resistance weld setters for fully mechanized and automatic welding of metallic
materials, acc. DIN EN ISO 14732:2013-12.
When assigning a welder, the groups of material and the procedures indicated in certificate
shall be observed.
1.4.5 Welding procedures qualification

Welding-specific documents shall be produced prior to start of welding work in accordance
with the codes and standards listed below and submitted to the BUYER:
➢ Specification and qualification of welding procedures for metallic materials:
General rules, acc. DIN EN ISO 15607:2004-03.
Welding procedure specification - Part 1: Arc welding, acc. DIN EN ISO 15609-
1:2006-01.
Qualification based on tested welding consumables, acc. DIN EN ISO 15610-1:2004-
02.
Qualification based on previous welding experience, acc. DIN EN ISO 15611-1:2004-
03.
Qualification by adoption of a standard welding procedure, acc. DIN EN ISO 15612-
1:2004-10
Welding procedure test – Part 1, acc. DIN EN ISO 15614-1:2012-06.
The welding procedures qualification records and welding procedure specifications shall be
handed over to the BUYER prior to start of welding work.
1.5 Examination of welds
1.5.1 Quality level of welds

The outer and inner irregularities of the welds shall be assessed in accordance with:
DIN EN ISO 5817:2014-06 - Welding: Quality level for imperfections - unless otherwise noted
on drawings listed in the relevant technical specification, the following acceptance level shall
become applicable: Acceptance level C.
1.5.2 Testing methods and their range of application

For testing/examination carried out in the EU: Testing shall be carried out according to
below listed codes and standards.
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For testing/examination carried out in all other countries according equivalent international
recognized codes.
Designations of NDT (non-destructive testing) methods for fusion welds according to EN
ISO 17635(2016.12):
➢ Visual testing VT; Visual testing shall be carried out according to EN ISO
17637(2016.12).
➢ Magnetic particle test MT; Magnetic particle testing of structural components shall be
carried out according to EN ISO 17638(2016.11). Acceptance level 1 according to EN
ISO 23278(2016.11) must be achieved.
➢ Penetration testing PT; Penetration testing of components shall be carried out according
to EN ISO 23277(2015.03).
➢ Ultrasonic testing UT; In the case of ultrasonic testing, quality class A according to EN
ISO 17640(2018.11) is required. Acceptance level according to EN ISO 11666(2018.02).
➢ Radiographic testing RT; In the case of radiographic testing, quality class B according to
DIN EN ISO 17636-1(2013.05) must be achieved. Acceptance levels according to
EN ISO 10675-1(2021.12).
➢ All weld seams (100%) shall be subjected to a visual inspection (VT) by
CONTRACTOR’s qualified personal to verify and confirm proper weld seam
workmanship;
➢ All full penetration welding seams (100%) of plates ≥35mm thickness shall be subjected
to UT.
The choice of welding seam to be inspected, extension and type of testing are defined
according particularity of scope of work and if not defined in the related technical
specification or drawings, it shall be presented by CONTRACTOR for BUYER approval;
BUYER will monitor the production and in case of welding imperfection are noticed, further
and appropriate NDT shall be applied to assure seem integrity;
BUYER reserve the rights to subject 10 % of welding seams to non-destructive radiographic
testing (RT):
Extension of RT depends on the rate of founding defects:
Rate of defects Extension of RT Costs
0%-5% The scope of examination shall To be borne by
not be extended. CONTRACTOR.
> 5% - ≤ 20 % The scope of examination shall Total costs of RT shall
be extended by the number of be borne by
radiographs showing defects. CONTRACTOR.
> 20% All welding seams shall be Total costs of RT shall
subjected to RT. be borne by
CONTRACTOR.
An examination as defined in this section shall mean one radiograph. The length of a
radiograph that can be evaluated shall be agreed between both parties before start of
radiographic testing.
- Example 1:
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100 m weld,
specified scope of examination: 10 %,
length of radiograph: 400 mm.
⇒ number of radiographs: 100 m × 0.1 : 0.4 m = 25;
determined number of radiographs showing defects: 5; ⇒ rate of defects: 20
%,
⇒ additional scope of examination: All welding seams shall be subjected to
RT.
- Example 2:
100 m weld,
specified scope of examination: 10 %,
length of radiograph: 400 mm.
⇒ number of radiographs: 100 m × 0.1 : 0.4 m = 25;
determined number of radiographs showing defects: 2; ⇒ rate of defects: 8
%,
⇒ additional scope of examination: 2 radiographs.
The extension of the scope of examination shall be borne by the
CONTRACTOR.
Repaired welds shall be subjected again to RT. Examination of repaired welds shall be
borne by CONTRACTOR.
Test findings and results shall be recorded in inspection protocols and incorporated in the
scope databook to be submitted and approved by BUYER;
1.5.3 Qualification of personnel

CONTRACTOR shall have qualified and certified personnel for the performance and
evaluation of non-destructive testing to verify and confirm proper results. For
testing/examination carried out in the EU:
Qualification and certification of NDT personnel have to meet the requirements at least
Level 2 acc. DIN EN ISO 9712:2012-12. For testing/examination carried out in all other
countries according equivalent international recognized codes .
The certification which attests the capacity of welders to perform a specific test as well as
the calibration certificate of the none-destructive test apparatus, make available for BUYER
and OWNER inspectors upon request;
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2 Materials
➢ The material to be applied and incorporated into the scope of supply shall comply with
the relevant bill of material and cast analysis on drawings.
➢ The material quality values indicated on relevant drawings and/or parts lists shall be
exactly observed. The quality code in conformity with international recognized
standards.
➢ The material especially for steel structure products shall comply with relevant European
and/or international normative references shall apply to general structural steels.
➢ DIN EN 10025-Part 1 up to Part 6 - Hot Rolled Products of Structural Steel.
➢ The certificates which brings chemical and mechanical composition of the material
must comply with the standards tolerances deviation and it shall be available for
BUYER and OWNER and be incorporated in the final databook;
Remarks:
If any of the material quality codes given in our drawings and/or bill of materials will be
replaced with respective materials codes, the CONTRACTOR shall inform prior to the
procurement the respective similar one with the comparison chart specially regarding:
• Chemical composition;
• Yield strength N/mm² or MPa / ksi;
• Tensile strength N/mm² or MPa / ksi;
• Elongation min (%);
No material replacement from the information contend in BUYER technical documentation
can be exchanged prior consultation and approval of BUYER;
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3 Painting and conservation

All parts shall receive a protection according to the relevant technical specification
and the related painting specification: PAINTING – GENERAL SPECIFICATION;
attached to the relevant technical specification.
In case of doubts of the applicable system CONTRACTOR has to clarify before
applying a system.
CONTRACTOR equipment property, such as pumps, motors, instruments, compressor,
blowers, fans, valves and actuators, others, shall apply the MUNSEL / RAL color touching
according its own standard as long as the painting layers and material within painting is
suitable with here above mentioned standards;
Steel structures equipment shall follow the instructions on relevant technical documentation
and comply with ISO and International recognized standards for painting:
DIN EN ISO 12944-1@8 – Corrosion protection of steel structures by protective paint
system
General requirements:
Nevertheless, following general requirements shall be applied for the scope:
➢ CONTRACTOR must provide good conditions for surface preparation and final coating
protection, with enclosed room and moist control system;
➢ CONTRACTOR must control between each coating application the dry thickness of
painting and the final one according relevant technical documentation;
➢ Any type of defects and necessity of touch-ups shall be immediately communicated
with BUYER and job must only be carried on after BUYER approval;
➢ The bores and threads without painting but shall be well oil/greased and protected from
damage or corrosion.
➢ The sealing faces shall be provided with an easily strippable lacquer.
➢ Threaded holes shall be closed before painting.
➢ Functional surfaces which shall receive no painting shall be properly protected against
corrosion (e.g. by Tectyl 506 or comparable). This coating must be applied in the entire
surface in enough thickness to assure parts will be duly protected until final delivery at
site;
➢ Surfaces which are embedded or in direct contact with concrete or represents a friction
connection, shall not receive any painting or surface protection.
➢ Unless not otherwise specified in the relevant technical specification and/or the related
painting specification, equipment made of stainless steel shall receive no painting.
➢ After site delivery touch-up painting has to be included by CONTRACTOR in the scope
of delivery.
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4 Supply of engineering, documentation and pertaining delivery dates
4.1 General requirements for documentation

All machines and components as well as the belonging documentations have to meet the
requirements of all relevant EC-rules (e.g. machinery directive, pressure equipment
directive, ATEX production guidelines). In accordance to the respective EC-rule, the
conformity has to be affirmed by a EC declaration of conformity, a EC certificate of
conformity, respectively a declaration of incorporation, as appropriate. If it is required by the
respective EC-rule, a CE labelling has to be performed.
The documentation has to be written in English as well as in the national language of the
end-user (specified by BUYER in the relevant Technical Specification). The number of
copies and further requirements for the CONTRACTOR documentation are assigned in the
BUYER-working instruction (CONTRACTOR documentation). The Doc.ID-Code of BUYER
working instruction is specified in the relevant Technical Specification.
At minimum the following documents and certificates are required:
➢ DIN EN 10204:2005-01 - Type of document: 3.1, for all castings
➢ DIN EN 10204:2005-01 - Type of document: 3.1, for all stainless steel otherwise as per
➢ DIN EN 10204:2005-01 - Type of document: 2.2
Latest date of delivery:
➢ DIN EN 10204:2005-01 - Type of document: 3.1 - after casting, but prior to further
processing
➢ DIN EN 10204:2005-01 - Type of document: 3.1 - on inspection and testing
➢ DIN EN 10204:2005-01 - Type of document: 2.2- on inspection and testing.
Mill test certificates should indicate the material quality codes. In case of replacement with
conversation material the European material quality code in conformity with European
normative references should be indicated, too.
4.2 Delivery of dimension protocols and check-up protocols

Latest date of Delivery: on inspection and testing
The type of protocols shall be harmonized by CONTRACTOR in coordination with BUYER.
4.3 CONTRACTORs final documentation

For CONTRACTOR’s final documentation the instructions given in the document
“Requirements to be met by CONTRACTOR's documentation” shall be strictly observed.
The Doc.ID-Code of “Requirements to be met by CONTRACTOR's documentation” is
specified in the relevant Technical Specification.
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5 Inspection and testing at CONTRACTOR’s works, trial operation
5.1 General requirements

Random samples are taken from the production series, devoting special attention to critical
areas.
CONTRACTOR shall subject all components to a visual check which has to be recorded in
writing relative to the component.
➢ Molded parts: Utmost attention shall be dedicated here to check casting radii and cross-
sectional transitions for fissures, etc. by non-destructive testing (NDT) as per specific
chapter of this document.
➢ Steel components: Utmost attention shall be dedicated here to check weld seams by
non-destructive testing (NDT) as per specific chapter of this document, edges and bore
holes shall be freed from burrs, threaded holes shall be well threaded and be freed from
burrs, etc.
➢ Castings shall be presented for testing without any preservation and painting.
➢ Applying grease or painting on defective spots to achieve a smooth surface and
optically improved appearance is prohibited.
The CONTRACTOR shall subject all components to a dimensional check which has to be
recorded in writing. A permanent numbering of components is absolutely required for this
purpose (e.g casting number). In particular, this relates to micrometer measures and
tapping measures which are important for assembly later-on.
In minimum the following check-ups shall be made by CONTRACTOR and recorded in
writing:
• Quantity check
• Checking the finished assembly (100 % shall be checked)
• Checking workmanship in general, including all connections according to standards
and drawings
• Dimensional check for all principal, connecting, tolerance measures and fits
• Check for surface treatment and protection
• Rust removal
• Painting (includes painting conditions: air temperature, relative air humidity, etc.)
• Film thickness measurement of the coating
• Check-up for greasing and smearing
• Check-up for packing
• Protocols of non-destructive testing (VT, RT, etc.)
• Regularly check-up for storage appropriate for the material codes involved
In case an additional test plan is required, these check-ups shall be made by
CONTRACTOR and recorded in writing too. For additional tests and inspections refer to
relevant Technical Specification.
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6 Identification , Marking
➢ All items must receive a permanent marking to allow their identification for storage,
handling and assembly on site.
➢ Casted parts >100kg shall receive a cast-on identification showing drawing- and BoM
item-number, casting serial number, material and, if necessary, battery side orientation
CS or PS.
➢ Structural steel components shall receive stamped marking showing drawing- and BoM
item-number.
➢ Further and/or deviating requirements as per related Technical Specification.
➢ Assemblies and loose parts shall be packed or bundled and to be marked by tags
fastened by stainless steel wire in clear and visible as well as weather-resistant manner.
Tags should show the relevant contract-no., drawing-no. and bill of material item
number and the TON number.
➢ Marking should be written in English language.
7 Inspection by BUYER
BUYER reserves the right to monitor the production in series continuously.
Upon completion of items a final inspection will be made on a random sample basis. It shall
be assured to BUYER’s and OWNER ‘s authorized inspector shall always be granted free
access to the fabrication shops, at CONTRACTOR’S and SUB-CONTRACTOR’s shops in
order to run the desired inspections with regard to fabrication, material quality, and property
of supplied parts.
For the a.m. tests and inspections all the required equipment and instruments shall be
furnished and made available free of charge to BUYER, our OWNER and OWNER’s
authorized inspector.
The cost for the inspection expenditure as well as for all the documentation shall be to
CONTRACTOR’s account. The same shall apply to the necessary repeat inspections and
tests.
A refusal to have a check made may entail the cancellation of the order.
All items must be inspected as descripted in this document and in the relevant Technical
Specification.
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8 Packing, transportation & storage
8.1 Packing
➢ Packing shall be dimensioned to suit weights and must be suitable for ocean, truck or
railway transport as well as for transshipment by crane and floor mounted conveyors.
➢ Connecting nozzles and other protruding parts shall be protected by transport securing
means from damage and deformation.
➢ All openings and/or ports shall be closed and sealed with blind covers and/or plastic
caps, while major openings and/or ports shall be closed and sealed with at least 25 mm
thick wooden covers.
REMARK: packing shall be properly executed to rule out any damage. CONTRACTOR is
liable for any and all damage demonstrably attributable to a deficient packing.
8.2 Transportation
According to formal purchase order.
8.3 Storage at CONTRACTOR’s works

Unless not otherwise specified in BUYER’s purchase order or other documents as integral
part of the purchase order, all items shall be kept constantly sheltered throughout the time
of CONTRACTOR until transportation to protect them properly. Items shall be stored
indoors, properly and appropriate for the material codes involved. CONTRACTOR shall
regularly perform a visual check to all stored items, which has to be recorded in writing.
In case that the delivery date will be postponed by BUYER more than 6 months after formal
purchase order delivery date, storage and check-up’s should be handled as described
before. For this case the CONTRACTOR are requested to inform the BUYER in
CONTRACTOR’s quotation about additional storage costs, after a period of 6 months after
formal purchase order delivery date.
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9 Delivery
9.1 Delivery date

According to formal purchase order.
REMARK: CONTRACTOR is liable to guarantee the agreed dates and deadlines, for its
own goods, as well as in case SUB-CONTRACTOR/THIRD-PARTS are involved. In case
that predictable time delays occur due to any event or circumstance that may even have
their origin outside CONTRACTOR’s sphere of responsibility, such predictable time delays
shall be notified to BUYER immediately.
9.2 Progress reports

According to formal purchase order or other documents as integral part of the purchase
order.
9.3 Technical documentation

order and as per related Technical Specification.
9.4 Spare parts offer

9.5 Inspection and testing

REMARK: Unless not otherwise specified in BUYER’s related Technical Specification or
purchase order or other documents as integral part of the purchase order, an inspection
plan suitable according the SCOPE OF SUPPLY must be submitted by CONTRACTOR for
BUYER’s approval, based on the “Inspection Code List” attached.
9.6 Inspection readiness notice

REMARK: Unless not otherwise specified in BUYER’s related Technical Specification or
purchase order or other documents as integral part of the purchase order, the events
WITNESS and/or HOLD-POINT inspection events shall be communicated by
CONTRACTOR to BUYER, with at least 2 complete weeks, before the time.
9.7 Material and test certificates

Ipatinga

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10 Inspection Plan
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Plant Client Code Doc.

General Instruction for Job Execution

0 IFI First Issue 28.02.2022 GHT 03.03.2022 EPA 03.03.2022 EPA

General Instruction for Job Execution

General Instruction for Job Execution

General Instruction for Job Execution

1.1 General Rules for Execution/Workmanship

General Instruction for Job Execution

1.2 Molded parts (Casting)

1.2.2 Prototypes / Trial piece

General Instruction for Job Execution

1.2.3 Additional rules for molded parts

General Instruction for Job Execution

1.2.4 Assessment of casting quality

General Instruction for Job Execution

1.2.4.2 Assessment of non-machined surfaces:

1.2.5 Heat treatment of cast iron parts

General Instruction for Job Execution

1.3 Machining of steel components and molded parts (casting)

1.3.1 General machining rules

1.3.2 Additional machining rules for molded parts

General Instruction for Job Execution

1.4.1 Welding rules

General Instruction for Job Execution

➢ If distortion becomes evident after welding, BUYER must be communicated and

1.4.2 Welding materials

1.4.3 Quality level of welds

1.4.4 Welder’s test certificate, the qualification of personnel

General Instruction for Job Execution

1.4.5 Welding procedures qualification

1.5 Examination of welds

1.5.1 Quality level of welds

1.5.2 Testing methods and their range of application

General Instruction for Job Execution

General Instruction for Job Execution

1.5.3 Qualification of personnel

General Instruction for Job Execution

General Instruction for Job Execution

3 Painting and conservation

General Instruction for Job Execution

4 Supply of engineering, documentation and pertaining delivery dates

4.1 General requirements for documentation

4.2 Delivery of dimension protocols and check-up protocols

4.3 CONTRACTORs final documentation

General Instruction for Job Execution

5 Inspection and testing at CONTRACTOR’s works, trial operation

5.1 General requirements

General Instruction for Job Execution

General Instruction for Job Execution

8 Packing, transportation & storage

8.3 Storage at CONTRACTOR’s works

General Instruction for Job Execution

9.1 Delivery date

9.2 Progress reports

9.3 Technical documentation

9.4 Spare parts offer

9.5 Inspection and testing

9.6 Inspection readiness notice

9.7 Material and test certificates