SPEC-83055 - Engineering Standards

North
Atlantic
ENGINEERING STANDARD SPECIFICATION
TITLE
VALE #
PAGE
SPEC-83055
1/19
SPECIALTY ENGINEERING
MATERIALS ENGINEERING
NDE – ARTICULATING BOOM CRANE (IN SERVICE
EQUIPMENT)
REV.
1
REVISIONS
Rev Description
1
New inspection standard
per CSA Z150.3-11
Rev’n
by
App
Sud
SV
PB
2013/12/12
2013/12/12
App
PC
App
Thom
App
VB
App
LH
App
Clyd
App
Act
Pending Pending Pending Pending Pending Pending
Issue Date
YYYY/MM/DD
2014/01/22
Sud = Sudbury, Ontario, PC = Port Colborne, Thom = Thompson, Manitoba, VB = Voisey’s Bay, LH = Long Harbour, Act = Acton, England,
Clyd = Clydach, Wales, N/A = Not Applicable
ENGINEERING STANDARD SPECIFICATION
TITLE
North
Atlantic
VALE #
PAGE
SPEC-83055
SPECIALTY ENGINEERING
MATERIALS ENGINEERING
NDE – ARTICULATING BOOM CRANE (IN SERVICE
EQUIPMENT)
1.0
2/19
REV.
1
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.
This standard covers the inspection of in-service articulating boom cranes (other mobile
cranes are covered in the Z150-11), but this standard does not cover the daily pre-shift
inspections which are required to be done by the equipment’s operator.
NDE Type I (MAJOR - STRUCTURAL) – All items evaluated after disassembly. The need
for disassembly of any critical component shall be determined by the manufacturer or an
Engineer. The manufacturer or the engineer shall approve the crane for continued use when
operated in accordance with the manufacturer’s instructions. Frequency as specified by the
manufacturer or a maximum of 5 years.
- Or after any actual, suspected or potential damage, sustained during an incident, that could
affect the structural integrity or stability of the platform.
NDE Type II (PINS and LOAD BEARING VISUAL) – All items evaluated in place without
disassembly.
- 12 months frequency for articulating cranes
HDET Periodic inspection – All items evaluated in place without disassembly
- 200h frequency for articulating boom cranes
2.0
APPLICATION
This specification, applies at any Vale locations indicated with approval on the cover page,
with the following exceptions:
2.1
EXCEPTIONS
None.
3.0
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.
ENGINEERING STANDARD SPECIFICATION
TITLE
North
Atlantic
VALE #
PAGE
SPEC-83055
SPECIALTY ENGINEERING
MATERIALS ENGINEERING
NDE – ARTICULATING BOOM CRANE (IN SERVICE
EQUIPMENT)
ASTM E269
ASTM E709
ASTM E114
ASTM E317
ASTM E500
ASTM E587
CSA Z150.3-11
CSA W59
SPEC-83021
4.0
3/19
REV.
1
Magnetic particle examination – Definitions
Magnetic particle examination
Ultrasonic examinations - General
Ultrasonic examinations – Evaluating performance characteristics
Ultrasonic examinations - Definitions
Ultrasonic angle-beam examination by the contact method - Standard
practice
Articulating boom cranes
Welded steel construction
NDE - Ultrasonic and Magnetic Particle examinations of Round Bar
Stock
HDET INSPECTION REQUIREMENTS
The heavy-duty equipment technicians are responsible to conduct a periodic inspection and
an annual inspection.
All deficiencies shall be carefully examined and it shall be determined whether they
constitute a hazard.
Hooks with cracks, or having more than the normal throat opening or any twist out of the
plane of the unbent hook, shall be removed from service and destroyed.
Periodic inspection
The periodic inspection shall be performed after 200H of use or as recommended by the
OEM whichever comes first. It shall include the requirements of the daily pre-use check and
items such as, but not limited to, the following:
(a) deformed, cracked, or corroded members, in the crane structure and carrier
(b) loose bolts, particularly mounting bolts;
(c) cracked, worn or deformed sheaves and drums;
(d) worn, cracked, or distorted parts, such as pins, gears, rollers, and locking devices;
(e) excessive wear on brake and clutch system parts and linings;
(f) crane hooks inspected for cracks;
(g) travel steering, braking, and locking devices, for malfunction;
(h) excessively worn or damaged tires and crawler undercarriage;
(i) hydraulic and pneumatic hose, fittings, and tubing inspection for
ENGINEERING STANDARD SPECIFICATION
TITLE
North
Atlantic
VALE #
PAGE
SPEC-83055
SPECIALTY ENGINEERING
MATERIALS ENGINEERING
NDE – ARTICULATING BOOM CRANE (IN SERVICE
EQUIPMENT)
4/19
REV.
1
(i) evidence of leakage at the surface of the flexible hose or its junction with the metal end
fitting sand couplings;
(ii) blistering or abnormal deformation of the outer covering of the hydraulic or pneumatic
hose;
(iii) leakage, at threaded or clamped joints, that cannot be eliminated by normal
tightening or recommended procedures; and
(iv) evidence of excessive abrasion or scrubbing on the outer surface of a hose, rigid
tube, or fitting. Steps shall be taken to eliminate the interference from elements in contact or
to otherwise protect the components;
(j) hydraulic and pneumatic pumps and motors for
(i) loose bolts or fasteners;
(ii) leaks at joints between sections;
(iii) shaft seal leaks;
(iv) unusual noises or vibration;
(v) loss of operating speed;
(vi) excessive heating of the fluid; and
(vii) loss of pressure;
(k) hydraulic and pneumatic valves for
(i) crack in valve housing;
(ii) improper return of spool to neutral position;
(iii) leaks at spools or joints;
(iv) sticking spools;
(v) failure of relief valves to attain correct pressure setting; and
(vi) relief-valve pressures as specified by the manufacturer;
(l) hydraulic and pneumatic cylinders for
(i) drifting caused by fluid leaking across the piston;
(ii) rod seals leakage;
(iii) leaks at welded joints;
(iv) scored, nicked or dented cylinder rods;
(v) dented case (barrel); and
(vi) loose or deformed rod eyes or connecting joints;
(m) hydraulic filters for
(i) evidence of rubber particles on the filter element which may indicate deterioration of
hose, O-ring, or other rubber component;
(ii) metal chips or pieces on the filter that could denote failure in pumps, motors, or
cylinders; and
(iii) further checking as necessary to determine the origin of the problem before
corrective action
can be taken; and
(n) other items as specified by the manufacturer.
ENGINEERING STANDARD SPECIFICATION
TITLE
North
Atlantic
VALE #
PAGE
SPEC-83055
SPECIALTY ENGINEERING
MATERIALS ENGINEERING
NDE – ARTICULATING BOOM CRANE (IN SERVICE
EQUIPMENT)
5.0
5/19
REV.
1
PRE NDE REQUIREMENTS (CLEANING AND PREPARATION)
Magnetic particle & visual inspections - all items to be free of grease, rust scale and loose
paint.
Clean all pins removed during disassembly.
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.
Ultrasonic inspection – clean all pins removed during disassembly. Ensure ends of pins are
flat & true. If required, grind ends.
Areas of cleaning and inspection. See sketches (Section 13 NDE report) for typical
articulating crane assembly and identification of areas to be cleaned and inspected.
6.0
RESPONSIBILITY
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.
7.0
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).
CGSB Level I personnel performing the inspection are to work in strict accordance with a
written instruction prepared by a CGSB Level II or III and are to have the results reviewed by
a Level II or III.
North
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ENGINEERING STANDARD SPECIFICATION
TITLE
VALE #
PAGE
SPEC-83055
SPECIALTY ENGINEERING
MATERIALS ENGINEERING
NDE – ARTICULATING BOOM CRANE (IN SERVICE
EQUIPMENT)
8.0
6/19
REV.
1
MAGNETIC PARTICLES INSPECTION (MT)
Magnetic particle inspection is to be carried out in accordance with ASTM E709 using the
following:
.1
.2
.3
AC yoke with lifting force of 10 lbs.
Dry or wet magnetic particles.
Continuous magnetization.
Area of inspection
.1
In place inspection: All accessible welds, edges and change of sections.
Magnetization
.1
9.0
Each part must be magnetized in at least two directions approximately at right
angles to each other.
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 crosssection 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.
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.
10.0
VISUAL INSPECTION (VT)
Direct visual inspection is to be carried out using white light.
North
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ENGINEERING STANDARD SPECIFICATION
TITLE
VALE #
PAGE
SPEC-83055
SPECIALTY ENGINEERING
MATERIALS ENGINEERING
NDE – ARTICULATING BOOM CRANE (IN SERVICE
EQUIPMENT)
7/19
REV.
1
Annual inspection of load-bearing components
An inspection of the load-bearing components of the crane shall be performed by a
competent person and supervised by an engineer, as follows:
(a) Visual weld inspection shall be performed in accordance with CSA W59 (refer to CSA
W59, as applicable) and shall be documented. The inspection shall be performed by a
person qualified to the requirements of CSA W178.2.
(b) Critical, suspect areas, and other inconsistencies identified by the manufacturer, the
supervising engineer, the competent person, or the qualified visual inspector shall be further
examined by an appropriate non-destructive test method by a person(s) qualified to meet the
requirements of CAN/CGSB 48.9712/ISO 9712.
11.0
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.
12.0
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
TITLE
North
Atlantic
VALE #
PAGE
SPEC-83055
SPECIALTY ENGINEERING
MATERIALS ENGINEERING
NDE – ARTICULATING BOOM CRANE (IN SERVICE
EQUIPMENT)
13.0
8/19
REV.
1
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 use.
North
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ENGINEERING STANDARD SPECIFICATION
TITLE
VALE #
PAGE
SPEC-83055
SPECIALTY ENGINEERING
MATERIALS ENGINEERING
NDE – ARTICULATING BOOM CRANE (IN SERVICE
EQUIPMENT)
REV.
1
Vale Inspection Form for yearly and major Inspections
ITEM
NO.
ITEM
Major inspection
Yearly inspection
1
Hook
MT
MT
2
Cap Screw (2)
MT
MT
3
Link (2)
MT
MT
4
Link pin
MT & UT
MT and UT
5
Swivel link
MT
MT
6
Swivel link pin
MT & UT
MT and UT
7
Extension boom
MT & VT
VT
8
Outer boom
VT-MT
9
Inner boom
VT-MT
10
Pin
MT & UT
11
Cylinder pin
MT & UT
12
Hollow pin
MT
13
Main pivot pin
MT & UT
14
Boom cylinder
VT
15
Pedestal cylinder
VT
16
Pedestal cylinder pin
MT & UT
17
Pedestal cylinder pin
MT & UT
18
Pedestal
VT-MT
19
Slewing housing
20
Three point bridge
21
Outrigger beam
MT & VT
22
Outrigger brackets (2)
NEW
UT
UT
MT
UT
VT
VT
UT
UT
VT
MT & VT
VT
NEW
24
Slewing housing bolts (6)
NEW
25
Outrigger beam mounting bolts (8)
NEW
26
Extension boom cylinder pin
NEW
Remarks
VT
VT
Outrigger brackets bolts (8)
REMARKS
VT
MT & VT
23
9/19
VT
VT
For a major, replace with new.
VT
For a major, replace with new.
VT
For a major, replace with new.
VT
For a major, replace with new.
VT
For a major, replace with new.
1 – Items inspected during major inspection 5Yrs. Requires disassembly.
North
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ENGINEERING STANDARD SPECIFICATION
TITLE
VALE #
PAGE
SPEC-83055
SPECIALTY ENGINEERING
MATERIALS ENGINEERING
NDE – ARTICULATING BOOM CRANE (IN SERVICE
EQUIPMENT)
REV.
1
Figure 1
6
4
1
3
12
9
8
10
7
13
17
14
16
11
15
18
19
22 & 23
21
20
24
10/19
25
26
ENGINEERING STANDARD SPECIFICATION
TITLE
North
Atlantic
VALE #
PAGE
SPEC-83055
SPECIALTY ENGINEERING
MATERIALS ENGINEERING
NDE – ARTICULATING BOOM CRANE (IN SERVICE
EQUIPMENT)
14.0
APPENDICES
Appendix A: Revision and Transition Notes
Appendix B: Keywords
Appendix C: Crane Nomenclature
Appendix D: Example OEM Inspection Criteria
Appendix E: Sample Crane Log
11/19
REV.
1
North
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ENGINEERING STANDARD SPECIFICATION
TITLE
VALE #
PAGE
SPEC-83055
SPECIALTY ENGINEERING
MATERIALS ENGINEERING
NDE – ARTICULATING BOOM CRANE (IN SERVICE
EQUIPMENT)
12/19
REV.
1
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 0
New standard Specification
Appendix B: Keywords
310-11, Articulating crane, Z150.3, recertification,
ENGINEERING STANDARD SPECIFICATION
TITLE
North
Atlantic
VALE #
PAGE
SPEC-83055
SPECIALTY ENGINEERING
MATERIALS ENGINEERING
NDE – ARTICULATING BOOM CRANE (IN SERVICE
EQUIPMENT)
Appendix C: Crane nomenclature
13/19
REV.
1
ENGINEERING STANDARD SPECIFICATION
TITLE
North
Atlantic
VALE #
PAGE
SPEC-83055
SPECIALTY ENGINEERING
MATERIALS ENGINEERING
NDE – ARTICULATING BOOM CRANE (IN SERVICE
EQUIPMENT)
Appendix D: Example OEM inspection criteria
14/19
REV.
1
ENGINEERING STANDARD SPECIFICATION
TITLE
North
Atlantic
VALE #
PAGE
SPEC-83055
SPECIALTY ENGINEERING
MATERIALS ENGINEERING
NDE – ARTICULATING BOOM CRANE (IN SERVICE
EQUIPMENT)
15/19
REV.
1
ENGINEERING STANDARD SPECIFICATION
TITLE
North
Atlantic
VALE #
PAGE
SPEC-83055
SPECIALTY ENGINEERING
MATERIALS ENGINEERING
NDE – ARTICULATING BOOM CRANE (IN SERVICE
EQUIPMENT)
16/19
REV.
1
ENGINEERING STANDARD SPECIFICATION
TITLE
North
Atlantic
VALE #
PAGE
SPEC-83055
SPECIALTY ENGINEERING
MATERIALS ENGINEERING
NDE – ARTICULATING BOOM CRANE (IN SERVICE
EQUIPMENT)
Appendix E: Sample Crane Log
17/19
REV.
1
ENGINEERING STANDARD SPECIFICATION
TITLE
North
Atlantic
VALE #
PAGE
SPEC-83055
SPECIALTY ENGINEERING
MATERIALS ENGINEERING
NDE – ARTICULATING BOOM CRANE (IN SERVICE
EQUIPMENT)
18/19
REV.
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ENGINEERING STANDARD SPECIFICATION
TITLE
North
Atlantic
VALE #
PAGE
SPEC-83055
SPECIALTY ENGINEERING
MATERIALS ENGINEERING
NDE – ARTICULATING BOOM CRANE (IN SERVICE
EQUIPMENT)
19/19
REV.
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