ENGINEERING STANDARD SPECIFICATION Ontario

TITLE

SPECIALTY ENGINEERING MATERIALS ENGINEERING NDE – VEHICLE MOUNTED AERIAL

VALE # SPEC-83051

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Rev Description Revision by

Approved by

Issue Date YYYY/MM/DD

1 New standard for vehicle mounted aerial devices AA 2013/12/12

PB 2013/12/12 2014/01/22

2 Updated section 14.0 PB 2014/06/24

PB 2014/06/24 2014/07/07

3 Updated Section 3.0, 6.0, 13.0, Removed Appendix C PB 2016/03/10

PB 2016/03/10 2016/03/11

ENGINEERING STANDARD SPECIFICATION Ontario

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SPECIALTY ENGINEERING MATERIALS ENGINEERING NDE – VEHICLE MOUNTED AERIAL

VALE # SPEC-83051

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3 1.0 PURPOSE

This specification describes the minimum required technical information to conduct the periodic inspections and Nondestructive Evaluation in accordance with established Vale practices and industry standards. As per CSA C225-10, an aerial lifting device will refer to: extensible boom aerial device, aerial ladder, articulating boom aerial device, vertical tower, or any combination of these items. 2.0 REFERENCE DOCUMENTATION

The following documents were used in the development of this document or have instructions and procedures applicable to it. They shall be used in their most recent revision. ASTM E269 Magnetic particle examination – Definitions ASTM E709 Magnetic particle examination ASTM E114 Ultrasonic examinations - General ASTM E317 Ultrasonic examinations – Evaluating performance characteristics ASTM E500 Ultrasonic examinations - Definitions CSA C225-10 Vehicle-mounted aerial devices CSA W59 Welded steel construction SPEC-83039 QA - New Surface and Underground Elevating Work Platform Quality

Assurance Requirement SPEC-83040 QA - Reconditioned Surface and Underground Elevating Work Platform

Quality Assurance Requirement SPEC-83021 NDE - Ultrasonic and Magnetic Particle examinations of Round Bar

Stock 3.0 INSPECTION REQUIREMENTS

NDE Type 1 (STRUCTURAL) – All items evaluated while partially disassembled. - 24 months frequency for arm lift devices - Or after any actual, suspected or potential damage, sustained during an incident, that could affect the structural integrity or stability of the lift.

ENGINEERING STANDARD SPECIFICATION Ontario

TITLE

SPECIALTY ENGINEERING MATERIALS ENGINEERING NDE – VEHICLE MOUNTED AERIAL

VALE # SPEC-83051

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3 4.0 PRE NDE REQUIREMENTS (CLEANING AND PREPARATION)

Areas of cleaning and inspection. See sketches (section 14.0) for typical vehicle mounted aerial device assembly and identification of areas to be cleaned and inspected. The pivot assembly must be disassembled, lifted, and cleaned so that a magnetic particle inspection can be performed in a safe manner. See section 14.0 – Figure 3 for details on this pivot assembly. Ultrasonic Inspection - all ends of all pins inspected must be made exposed and free of any rust, scale or paint. The ends of pins must also be flat and smooth. Magnetic particle & visual inspections - all items to be free of grease, rust scale and loose paint. Method of cleaning – sandblasting, steam cleaning, wire brushing and chemical cleaner can be used. Note: Any method or combination can be used. If paint is properly adhered, then it does not have to be removed, as it does not interfere with magnetic particle evaluation. 5.0 RESPONSIBILITY

Pre-NDE cleaning and disassembly is the responsibility of the HDET. All performing evaluations are to ensure compliance to this specification. Any deviation from this specification must be noted and is subject to VALE approval. Preliminary inspection by mechanical or structural engineer should be carried out, when required, to determine the feasibility of a repair. 6.0 PERSONNEL QUALIFICATION

Nondestructive Evaluation (NDE) personnel performing the evaluation shall be certified by the Canadian General Standards Board standard CAN CGSB-48.9712, Level II, or III or Equivalent to International Certification to ISO 9712 Level II or III in the appropriate method(s).

ENGINEERING STANDARD SPECIFICATION Ontario

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SPECIALTY ENGINEERING MATERIALS ENGINEERING NDE – VEHICLE MOUNTED AERIAL

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3 CGSB Level I personnel performing the inspection are to have been certified by the Vale NDE supervisor to be able to perform these inspection or are to work in strict accordance with a written instruction prepared by a CGSB Level II or III. Any suspect indications are to be reported to a CGSB Level II or III. 7.0 MAGNETIC PARTICLES INSPECTION (MT)

Magnetic particle inspection is to be carried out in accordance with ASTM E709 using the following: .1 AC yoke with lifting force of 10 lbs. .2 Dry or wet magnetic particles. .3 Continuous magnetization. Area of inspection .1 All accessible welds, edges and change of sections.

Magnetization

.1 Each part must be magnetized in at least two directions approximately at right angles to each other.

8.0 ULTRASONIC INSPECTION (UT)

Longitudinal ultrasonic inspection is to be carried out in accordance with ASTM E114 using 5.0 or 2.25 Mhz transducers with a maximum 15mm diameter. Inspection to be performed in the axial direction from both ends covering 100% of cross-section and full length. Sweep calibration shall be established externally from the part utilizing a suitable calibration standard for the entire range at a minimum of five points through the range. Sensitivity shall be established at 6db over 100% of back echo or 100% second back echo whichever is the lesser.

ENGINEERING STANDARD SPECIFICATION Ontario

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SPECIALTY ENGINEERING MATERIALS ENGINEERING NDE – VEHICLE MOUNTED AERIAL

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3 Each area with grease grooves shall be inspected using a maximum of 5" sweep. This

shall be achieved by using the zoom function. Sensitivity shall be established at 80% screen height from the grease hole in the area inspected.

9.0 VISUAL INSPECTION (VT)

Direct visual inspection is to be carried out using white light. 10.0 NDE ACCEPTANCE CRITERIA

All methods: No linear discontinuities are acceptable. Inherent discontinuities may be acceptable if approved by design engineer. Ultrasonic inspections All indications greater than 20 % reference shall be fully investigated. Discontinuity rejection is based on an indication of greater than 20 % reference screen height. Inspection of welds as per CSA W59 dynamically loaded structures. 11.0 REPAIR PROCEDURE

Repair is to be approved by design engineer or OEM. Welding is to be done in accordance with CSA W47.1 and W59. Defects are to be removed by grinding or gouging. Defect areas are to be re-inspected* prior to welding to ensure removal of defects. Final inspection* is to be conducted on all repaired areas. * Magnetic particle method.

ENGINEERING STANDARD SPECIFICATION Ontario

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SPECIALTY ENGINEERING MATERIALS ENGINEERING NDE – VEHICLE MOUNTED AERIAL

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3 12.0 NDE REPORT

The report shall include following;

• Background information. • Detailed description of evaluated items. • Name & signature of the inspector. • Method used for evaluation of each item. • Date of inspection. • Reference dwg. when applicable. • Qualification of the inspector to the method used. • All recordable discontinuities or indications on a sketch showing size and

location. • A clear statement of acceptance with reference to specification

acceptance criteria. • Extent of inspected area. • Description of test method. • Equipment used.

ENGINEERING STANDARD SPECIFICATION Ontario

TITLE

SPECIALTY ENGINEERING MATERIALS ENGINEERING NDE – VEHICLE MOUNTED AERIAL

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3 13.0 VALE ESTABLISHED PRACTICE FOR NDE INSPECTION

ITEM NO.

ITEM PROCEDURE RESULTS REMARKS

1 Boom welds (see sketch and pictures) MT

2 Upper cylinder pin (4)

(size 8" x 1" )

UT

3 Lower cylinder pin (5)

(size 10 3/4" x 1" )

UT

4 Boom main pin (8)

(size 11 3/4" x 1 1/4" )

UT

5 Inner cylinder top pin (18)

(size 2 1/8" x 3/8" )

MT Requires removal

6 Inner cylinder bottom pin (18)

(size 2 1/4" x ¾" )

UT See R1

7 Bucket main pin and weld

(hollow tube)

UT+MT See R2

8 Pivot assembly main shaft welds (2)

(Upper welds only)

MT

9 Bucket VT

1. This item is inspected from one end only as the other end has a washer

welded on it. (UT is somewhat limited due to cotter pin hole in the end that is UT inspected).

2. This item is inspected on the unit as it is welded on one end.

ENGINEERING STANDARD SPECIFICATION Ontario

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SPECIALTY ENGINEERING MATERIALS ENGINEERING NDE – VEHICLE MOUNTED AERIAL

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3 Fig. 1

ENGINEERING STANDARD SPECIFICATION Ontario

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SPECIALTY ENGINEERING MATERIALS ENGINEERING NDE – VEHICLE MOUNTED AERIAL

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3 Fig. 2

Fig. 3

Item 9

ENGINEERING STANDARD SPECIFICATION Ontario

TITLE

SPECIALTY ENGINEERING MATERIALS ENGINEERING NDE – VEHICLE MOUNTED AERIAL

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NDE Item 8 (top weld only)

NDE Item 1

ENGINEERING STANDARD SPECIFICATION Ontario

TITLE

SPECIALTY ENGINEERING MATERIALS ENGINEERING NDE – VEHICLE MOUNTED AERIAL

VALE # SPEC-83051

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3 14.0 APPENDICES

Appendix A: Revision and Transition Notes Appendix B: Keywords

ENGINEERING STANDARD SPECIFICATION Ontario

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SPECIALTY ENGINEERING MATERIALS ENGINEERING NDE – VEHICLE MOUNTED AERIAL

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Appendix A: Revision and Transition Notes

(Revisions are listed in reverse chronological order with most recent revision at the top. Revision notes describe: what was changed, why it was changed, and the plan to implement the change, including whether changes are retroactive) Revision 3 Section 3.0: Changed frequency to 24 months and removed section 4.1 (HDET Inspection requirements). Section 6.0 Updated Section inspector certification requirements. Section 13.0 Turret is no longer lifted to check weld underneath and Updated Sketch Appendix C – Removed in entirety All changes were made to align with new Maintenance Standard MSPEC-81002 Revision 2 Section 14.0 Changed NDE requirement for Item 5 (MT instead of UT) Section 14.0 Added requirement to do visual inspection on Bucket Item 9 Revision 1 New standard Specification

Appendix B: Keywords CSA C225, vehicle mounted aerial devices,