ENGINEERING STANDARD SPECIFICATION Ontarioextportal.vale.com/eng/Sud/standards/pdf/SPEC-83044.pdfWeld acceptance criteria shall conform to CSA W59 section 12. ... Undercut is not more

ENGINEERING STANDARD SPECIFICATION Ontario

TITLESPECIALTY ENGINEERINGMATERIALS ENGINEERINGQA – INSPECTION CRITERIA OF RIM ASSEMBLIES (12MONTH INSPECTION)

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1.0 PURPOSE

This specification describes the minimum required quality assurances and quality controls that amanufacturer and/or supplier must have when reconditioning rim assemblies owned by Vale. Itapplies to mobile equipment where the diameter of the rim is twenty-four inches (24") or greater (splitrim style).

Note: The following specification was developed for use with rims, which are in pneumatic serviceonly. This document excludes non-pneumatic rims assemblies used in Core, and Solid applicationswith the exception of the requirement for visual inspection. These rims are still subject to a visualinspection to determine general condition and serviceability, by a qualified inspector as outlined insections 2.0 and 3.0, prior to being re-used. Non-Destructive Examination is not required, but may berequested by the Vale as required.

Background: With use, rim assemblies are subject to loads and forces, which can lead to corrosion,wear and fatigue within the material of construction. This can lead to cracking of the rim assembly. Ifdefects are left undetected, the rim may suffer a catastrophic failure with potential risk to the healthand safety of persons in the vicinity.

2.0 LEVELS OF INSPECTION CRITERIA

a.) Preliminary Inspection - These are inspections, which are done between annual inspections.All rim base(s) which have been dismounted prior to their annual Nondestructive Examination(NDE) shall be visually inspected for defects.(no sand blasting is required for this inspection).The assessment shall be based on paragraph 5.4 (A, B & C).

b.) 12 Month Rim Base Inspection - Annual inspection of rim base shall occur in accordance withthe Inspection Criteria Table (Sections 1, 2, 3, 4, 5) or the wheel OEM specificrecommendations

c.) Hardware Inspection - Hardware is defined as the Bead Seat Bands, Rim Flanges andLocking Rings and is considered a consumable product. These are inspected in accordancewith sections 5.1, 5.2 and 5.3.. Hardware, which is suspected of having defects or distortion,shall be discarded. Sandblasting is not required for this inspection.



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3.0 VISUAL INSPECTORS QUALIFICATIONS

The visual inspector shall possess the following prerequisites:

· Understand the intent of this document in its entirety (Inspection Criteria of Rim Assemblies)

4.0 CLEANING PRIOR TO NONDESTRUCTIVE EXAMINATION INSPECTION

The rim base shall be cleaned to an Industrial Blast Cleaning (Nace No 8 / SSPC-SP-14) using oneof the following techniques Abrasive Blasting, Sand Blasting, or Shot Blasting. All areas to beexamined shall be free of foreign materials as they can interfere with the interpretation of results.

NACE no 8 / SSPC SP-14 - Industrial Blast cleaning:An Industrial blast cleaned surface when viewed without magnification, shall be free of all visible oil,grease, dust, dirt. Traces of tightly adherent mill scale, rust and coating residues are permitted toremain on 10% of each unit area of the surface if they are evenly distributed.

5.0 INSPECTION REQUIREMENTS

For a rim assembly schematic see Figures A1 & A2.

5.1 LOCKING RING

The locking ring shall be visually inspected for wear, corrosion, flat spots, out-of-roundness andwarping misalignment (sprung).

5.2 BEAD SEAT BAND

The bead seat band shall be visually inspected for cracks, wear or corrosion in the area in contactwith the locking ring flange, rim base or any weld.

5.3 RIM FLANGES

The area of the flange which is in contact with the bead seat band or the rim base as well as any buttweld, or other form of weld on the flange, shall be subject to visual inspection for wear, cracking,fretting, corrosion or damage.

5.4 RIM ASSEMBLY VISUAL INSPECTION (PRELIMINARY INSPECTION)

a.) Rim Base - The area of the rim base in contact with any flange, bead seat band or lockingring shall be subject to visual inspection for wear, cracking, fretting, corrosion or damage. Go-No-Go Gauge shall be used where tolerances are questionable.



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b.) Wheel Disc / Center Plate / Bolting Plate - In addition to the testing requirements ofparagraph 5.4 (a.) Mounting holes shall be inspected for physical damage, out-of-roundnessand circumferential cracking.

c.) Support Band - The area of the support band which comes in contact with the axle hub shallbe subject to visual inspection for wear, weld defects, cracking, fretting, corrosion or damage.Go-No-Go Gauge shall be used where tolerances are questionable.

5.5 GO-NO-GO GAUGE TOLERANCES

For Go-No-Go Gauge dimensional tolerances see the wheel OEM specifications.

5.6 WELDING

All welding shall conform to CSA W47.1 and CSA W 59.

5.7 NONDESTRUCTIVE EXAMINATION

All NDE shall be performed by personnel certified to Canadian General Standards Board (CGSB)level II minimum. Magnetic Particles Inspection techniques shall conform to Vale SPEC-83012. Weldacceptance criteria shall conform to CSA W59 section 12. All other visual inspection criteria shallconform to the guidelines set out in this specification.



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Inspection Criteria Section 1 Rim Base CenterMethod Identified Issue Acceptance Criteria Resolution

Visual / pit gauge Corrosion Pitting

Circumferential corrosion pitting shall notexceed the following limitations.· Circumferential corrosion pitting 1/8" in

depth running in a narrow band, in closesuccession to one another. Figure B ,or

· In general corrosion loss or pittingexceeding 1/8" and an area of 1/2square foot.

Destroy Rim

NDEMagnetic particles

and visualexamination

Circumferential ButtWeld Inspection

All welds shall be inspected. A weld subjectto inspection shall be acceptable ifinspection shows:(a) No surface cracks(b) No Visible lack of fusion between welds

and base metal(c) No craters(d) Weld profiles are in accordance with

Figure C(e) That frequency of visible porosity in fillet

welds does not exceed one in each 4inches of length and the maximumdiameter does not exceed 3/32 inch

(f) That groove welds have no visibleporosity.

(g) Undercut is not more than 0.01 inchdeep.

Repairable



Cracking of parentmetal

Parent metal cracking which emanatecompletely through the rim base, shall notbe repaired

Destroy Rim

Cracking of welds

All weld defects may be repaired providingNDE verifies that the defect was removed.(MT) Final inspection of the weld repair(MT) is mandatory upon completion of theweld repair.

Repairable

Visual / go-no-gogauge Wear In general base metal wear loss exceeding

1/16" and an area of 1/2 square foot. Destroy Rim

Visual / go-no-gogauge Distortion Check

Distortion inspection shall be performedvisually. All noted distortions shall besubject to the manufacturer tolerances.

Per OEM.Specifications



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Inspection Criteria Section 2 Rim Base GutterMethod Identified Issue Acceptance Criteria Resolution

Visual / go-no-gogauge

Gutter / GrooveVerification

All gutter / groove radius inspection shall beperformed using a Go-No-Go Gage.Rims falling outside of the acceptabletolerances shall be destroyed.

Visual / pit gaugeCorrosion Pitting

Circumferential corrosion pitting shall notexceed the following limitations.· Circumferential corrosion pitting 1/16" in

depth running in a narrow band, in closesuccession to one another. Figure B , or

· In general corrosion loss or pittingexceeding 1/16" and an area of onesquare foot

Destroy Rim



Circumferential ButtWeld Inspection







Repairable



Cracking Cracking in the lock-ring gutter, shall notbe repaired Destroy Rim

All weld defects may be repaired providingNDE verifies that the defect was removed.(MT/VT) Final inspection of the weld repairis mandatory upon completion of the weldrepair.

Repairable

Visual / go-no-gogauge Wear In general base metal wear loss exceeding

1/16" and an area of 1/2 square foot. Destroy Rim


Distortion inspection shall be performedvisually. All noted distortions shall besubject to the manufacturer tolerances.

Per OEM.Specification



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Inspection Criteria Section 3 Rim Base Back FlangeMethod Identified Issue Acceptance Criteria Resolution


Back FlangeVerification

All back flange radius inspection shall beperformed using a Go-No-Go Gage. The gagewill be used to verify the thickness of the materialbased on the flange interface area.Rims falling outside of the acceptable tolerancesshall be destroyed or replaced. (replace not morethan once)

Visual / pit gaugeCorrosion Pitting

Circumferential corrosion pitting shall not exceedthe following limitations.

· Circumferential corrosion pitting 1/8" indepth running in a narrow band, in closesuccession to one another. Figure B , or

· In general corrosion loss or pittingexceeding 1/8" and an area of 1/2 squarefoot

Destroy Rim



Groove and FilletWeld Inspection

All welds shall be inspected. A weld subject toinspection shall be acceptable if inspectionshows:(a) No surface cracks(b) No Visible lack of fusion between welds and

base metal(c) No craters(d) Weld profiles are in accordance with Figure

C(e) That frequency of visible porosity in fillet

welds does not exceed one in each 4 inchesof length and the maximum diameter doesnot exceed 3/32 inch

(f) That groove welds have no visible porosity.(g) Undercut is not more than 0.01 inch deep.

Repairable



CrackingCracking in the Back Flange shall not berepaired. Cracks which emanate completelythrough the rim base, shall not be repaired

Destroy Rim

All weld defects may be repaired providing NDEverifies that the defect was removed. (MT/VT)Final inspection of the weld repair is mandatoryupon completion of the weld repair.

Repairable


Wear

In general base metal wear loss exceeding 1/16"and an area of 1/2 square foot.Bead seat knurling shall show little or no signs ofwear. An example of wear is when the rim hasbeen spinning on the tire the knurling will showsigns of grooving from the bead seat of the tireriding on the knurling.

Destroy Rim


Distortion inspection shall be performed visually.All noted distortions shall be subject to themanufacturer tolerances.

Per OEM.Specification



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Inspection Criteria Section 4 Support BandMethod Identified Issue Acceptance Criteria Resolution



CrackingCracking which emanate completelythrough the support band shall not berepaired

Replacesupport band



Fillet Weld Inspection




welds does not exceed five in each 4inches of length and the maximumdiameter does not exceed 1/4 inch


WearIn general base metal wear loss shall bemeasured using a Go-No-Go Gage.



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Inspection CriteriaSection 5 Wheel Disc/Center Plate/Bolting Plate

Method Identified Issue Acceptance Criteria Resolution



CrackingCracking which emanate completelythrough the wheel disc, shall not berepaired

Replacewheel disc

All weld defects may be repaired providingNDE verifies that the defect was removed.(MT/VT) Final inspection of the weld repairis mandatory upon completion of the weldrepair.

Repairable


and visualexamination Groove, Fillet Weld

and Puller NutInspection







Repairable

Visual / go-no-gogauge Wear

The wheel disc shall be examined for:(a) Lug nut hole wear and or elongation.(b) Puller nut damaged threads and or weld

defects.(c) Center hole inside diameter tolerances.

Repairable



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Figure A - 1



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Figure A - 2



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Figure B Corrosion Pitting

Figure C



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6.0 REFERENCE DOCUMENTATION

The following documents were used in the development of this document or have instructions andprocedures applicable to it. They shall be used in their most recent revision.

SPEC-83012 NDE – MPI AND LPI – GENERIC APPLICATIONSSSPC SP14 Industrial Blast CleaningCSA W59 Welded Steel ConstructionCSA W47.1 Fusion Welding of Steel Company Certification



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7.0 REVISION AND TRANSITION NOTES

Revision notes describe: what was changed, and if applicable, why it was changed, and the plan toimplement the change, including whether changes are retroactive.Note: The revision notes are a summary of the changes and may not necessarily be a complete list.

A risk code is entered for each revision and if applicable, the revision notes will describe how riskwas addressed for the revision.RiskCode Risk Category

A This revision is a minor change and/or introduces no risk.

B Risk has been addressed for this revision by the reviewer and approver. Low risk or no new hazards identified.

C For this revision, a PHR or other risk management tool has been used to address risk and minimize hazards. Thisrisk assessment has been documented and is available through Central Engineering.

Rev Revision Notes RiskCode

Approvedby

Reviewedby

Issue DateYYYY/MM/DD

1 Document format and number changed. Previousnumber QA - 008 A P. Belzile P. Belzile 2012/05/01

2 SPEC Reviewed 2016 – Regional Approvals removed, noother changes A P. Belzile A. Nadeau 2016/12/15

3 Moved to new format and corrections made to sectionsreference and reference standard. A K.L. Robin P. Belzile 2018/02/06

Documents

ENGINEERING STANDARD SPECIFICATION Ontarioextportal.vale.com/eng/Sud/standards/pdf/SPEC-83044.pdfWeld acceptance criteria shall conform to CSA W59 section 12. ... Undercut is not more