Ontario ENGINEERING STANDARD SPECIFICATION 1/8 REV. SPECIALTY ENGINEERING MATERIALS ENGINEERING QA COPPER CLIFF SMELTER FLUID BED DRYER TUYERES

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1 SPEC /8 Rev Description Approved by Reviewed by Issue Date YYYY/MM/DD 1 Document format and number changed. Previous number QA-017 PB 2011/12/24 PB 2011/12/ /04/19 2 Modified sections 6 and 7 PB 2012/06/07 PB 2012/06/ /06/07 SPEC Reviewed 2016 Regional Approvals removed, no other changes P.Belzile A.Nadeau 2016/12/15

2 SPEC /8 1.0 PURPOSE This specification describes the minimum requirements for the supply of Tuyeres for the concentrate fluid bed dryers of the flash furnaces at the Copper Cliff smelter. 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..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. Standard Specification for Ductile Iron Castings ASTM A56-84 (reapproved 2004) Standard test method for evaluating the microstructure of ASTM A graphite in Iron castings Standard guide for magnetic particles testing ASTM E Standard practice for magnetic particle testing ASTM E ASME B&PV Code, Section VIII, Appendix 6 ASME B&PV code.1 PERSONNEL QUALIFICATIONS Non-destructive Evaluation (NDE) personnel performing the evaluation shall be certified in the appropriate method in accordance with one or more of the following: Natural Resources Canada CAN CGSB ISO ASNT recommended practice No. SNT-TC-1A ANSI/ASNT Standard CP-189:2001 Level II or III Level II or III Level II Level II

3 SPEC-8048 /8 4.0 DEFINITIONS Owner Supplier shall mean Vale and its authorized representatives with responsibility for the work being performed. shall mean the company, directly under contract with the Owner, which will supply the parts described in the Scope above. Manufacturer shall mean the foundry directly producing the parts. Inspector shall mean an inspector retained or employed by Vale with the mandate to perform site visits and witness the fabrication and testing of the parts. 4.1 CONFLICTING REQUIREMENTS In the event of conflict between this specification, the purchase order, the engineering drawings or the Manufacturer specification, the Supplier/manufacturer shall notify the Owner in writing of the basis of the conflict and justification for any deviations from this specification. This shall not delay in any way the delivery date agreed. This specification is provided to supplement the Supplier s own fabrication and design specifications. If the Supplier s specifications are more stringent and/or more complete for any of the sections of the present document or if any of the requirements of the present document are judged to be detrimental to the performance of the part, the Supplier shall notify the Owner, in writing, which sections of the present document should not be used and the technical/economical advantage of using the Supplier s specifications instead. 5.0 GENERAL REQUIREMENTS 5.1 SUPPLIER S REQUIREMENTS It is the responsibility of the Supplier to ensure that the requirements of this specification and of its own drawings and specifications are met and to perform all inspections necessary to ensure compliance prior to the inspections by the Owner. In addition to the Supplier s inspections, the Owner or its Inspector may perform any inspections necessary to verify compliance with this specification. Inspection may include

4 SPEC /8 any and all work, equipment, inspection equipment, materials, procedures and may be conducted at any time the Owner chooses. The Manufacturer shall provide accessibility to all fabrication and inspection work. The Manufacturer shall prepare an inspection and test plan (ITP) for the manufacture of the tuyeres. This shall be submitted to the Owner prior to commencement of fabrication. The Owner reserves the right to insert Review, Witness and Hold points at critical steps of the manufacture. 6.0 QUALITY ASSURANCE 6.1 MATERIALS The Tuyeres material shall meet the requirements of ASTM A 56 gr HEAT TREATMENT AND STRESS RELIEVING The Tuyeres shall be submitted to a full ferritizing anneal. Supplier shall provide copies of heat treatment reports and furnace chart recordings. 6. MECHANICAL PROPERTIES The mechanical properties of each batch of tuyere produced shall be tested per ASTM A56 sect. 6 for information only and the results of the mechanical tests will not be used for acceptance purposes. The mechanical properties of the tuyere should approach the following requirements: 60 ksi tensile strength 40 ksi yield strength 18% elongation hardness HB (000 kgf load) Three () additional test tuyeres (per batch of tuyeres) shall be poured for destructive testing (yield strength, tensile strength, elongation, hardness and microstructure). The first tuyere poured, the last one and one approximately in the middle of the batch shall be used for the testing.

5 SPEC /8 6.4 CHEMISTRY The Chemistry of the tuyere shall meet the following requirements: The total carbon shall be.00% min. The silicon shall be 2.50% max. The phosphorus shall be 0.08% max. The chemical analysis for total carbon shall be made from thin wafers approximately 0.8 mm thick cut from the three () test tuyeres cast. Drillings are not allowed. For each reduction in 0.01% below the maximum phosphorus content, an increase of 0.08% silicon above the specified maximum will be permitted up to a maximum of 2.75%. 7.0 MICROSTRUCTURE The microstructure of each of the test tuyeres should be fully ferritic (100%) and have approximately 90% Type I and Type II Graphite as evaluated by ASTM test method A247. One cross section taken from the shank (-5/8 OD) of each of the three () test tuyeres shall be used for examination. The results of the examination are produced for information only and shall not be used for acceptance purposes. The grain boundaries should be exempt of detrimental fine graphite particles. 7.1 DIMENSIONAL The tuyeres dimensions shall meet the requirements and tolerances specified on the engineering drawings. A complete dimensional analysis check must be done on each tuyere produced and recorded on an appropriate sheet. Each tuyere shall be properly identified/numbered. 7.2 NON-DESTRUCTIVE TESTING Each tuyere produced shall be submitted to the following inspection after machining: 100% visual inspection. 100% magnetic particles inspection (yoke method only). Magnetic particles inspection acceptance standards shall be per ASME sect. VIII appendix 6 with the following additional requirements:

6 SPEC /8 No rounded indication allowed on the bottom (-5/8 OD) half of the tuyeres including the fillet transition between the bottom (-5/8 OD) and top (5 OD) half. In addition, castings shall be free from adhering sand, scale, cracks and hot tears. 7. DEFECTS/REPAIRS When defects, which would prevent the piece from meeting the Owner s requirements, are found, a non-conformance report shall be issued. If it is decided to recover the piece, a written repair procedure shall be submitted to the Owner by the Supplier for approval. No repairs should be done on any tuyere without the prior written consent of the Owner. No welding repairs are allowed. 8.0 DOCUMENTATION The following documentation shall be provided: 4.1 PRIOR TO THE START OF CASTING: Supplier s Specifications Inspection and Test Plan Detail drawings 4.2 PRIOR TO DELIVERY Final inspection report including, but not limited to: Chemical analysis test report. Microstructure test report. Mechanical properties test reports. Non-destructive test reports. Dimensional inspection records. Heat treatment reports and furnace chart recordings. Non-conformance reports. Final version of drawings. Final QA document package. The final inspection report shall be supplied as one hard copy and one electronic copy in Acrobat format

7 SPEC /8 9.0 APPENDICES Appendix A: Revision and Transition Notes Appendix B: Keywords

8 SPEC /8 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 SPEC Reviewed 2016 Regional Approvals removed, no other changes Revision 2 Section 6 and 7 of the document were modified to reflect that the mechanical tests of section 6. and the microstructure examination of section 7.0 are produced for information only and will not be used for acceptance purposes. Refer to MOC This change was implemented with the purchase of Tuyeres for the 2012 September PMP. Revision 1 Document format and number changed due to Vale Engineering Document Program changes in Previous Standard number was QA-017 Rev 00. QA-017 Appendix B: Keywords