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F L.SMIDTH

INSTRUKTIONER ANWEISUNGEN

INSTRUCTIONS INSTRUCCIONES

INSTRUCTIONS INSTRUCOES

18101-10

1/17

ROTARY KILN ERECTION

ARC WELDING, MANUAL

MGN:4E300

In this manual reference is made to the following instruction manuals:

Arc welding, manual, for erection and repairs

29261

Rotary kiln, erection. Covered electrodes for manual arc welding

18351

Contents: Page:
1. GENERAL INFORMATION 2
2. WELDING MACHINES 2
3. ELECTRODES 4
4. LIGHTING AND VENTILATION 10
5. PREHEATING 10
6. WELDING OPERATORS 12
7. SUPERVISION OF WELDING OPERATIONS 12
8. CHECKING OF WELDING OPERATIONS 13
9. WELDING QUALITY 14
10. SAFETY REGULATIONS 14 JRo

78.361

18101-10 2

NOTE!

The present instruction manual is concerned with the situations which, according to our experience, are the most likely to occur. An exhaustive enumeration of all conceivable situations which may occur during the operation of the plant cannot be provided.

Consequently, if a situation should arise, the occurrence of which is not foreseen in the instruction manual, and which the client is/or feels unable to handle, we would recommend that FLS is contacted without undue delay for advice on appropriate action.

1. GENERAL INFORMATION

FLS has forwarded a specification of the hand tools and erection tools needed for the erection of the kiln to the plant. Among other things, this specification indicates the scope of welding and cutting equipment and other tools which must be used in connection with the welding process.

2. WELDING MACHINERY

The welding machinery - generators or transformers - must be rated for an output of minimum 350A at 35V, 100% duty cycle.

Duty cycle is a measure usually given in percentage of a period for which the power source is capable of supplying a rated maximum current. The duty cycle rating is stamped on the rating plate of the machine.

DC welding machines should be used to maximum practicable extent.

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Use only welding rating below 100 (RMS value).

machines having a no-load voltage V DC (mean value) or 80 V AC

Voltage differences with more than 10% ripple are considered to be alternating voltage (AC).

When welding is performed inside the kiln where it is difficult to avoid physical contact between the welding operator and the object being welded, it is essential to use either a direct voltage (maximum 100 V) or an alternating voltage where the no-load voltage is limited to l2V.

In such conditions and under unfavourable circumstances, an alternating voltage of 80 V may be extremely dangerous.

For welding of a complete kiln, at least four welding machines must be available.

The machines must be mounted on travelling wheels.

The welding machines must incorporate remote-operation control so that the welding current can be regulated by the welding operator at the point of operation.

The welding machine must be connected to the mains by a local electrician, who must also determine the dimensions of the cables for the mains current.

The dimensions of the welding and return cables can be obtained from the following table:

Cross sectional
area 25 35 50 70 95 mm2
Max. welding
current 150 200 300 500 600 A 18101-10

4

These cross-sections will be sufficient to prevent heating of the cables.

If the length of the cables is more than 30 metres, it will be necessary to use a cross-sectional area being increased one step relative to the welding current indicated in the table.

The length of cables must be such that welding can also be performed inside the middle of the kiln.

3. ELECTRODES

3.1

Types

Electrodes with a thick covering of the acid or basic type must be used for site welding on kiln shells.

The basic electrodes must be used for tack-welding, bottom runs and repair work whereas the acid-covered electrodes are used for final runs and welds of minor importance.

The specific electrode type is indicated on the special electrode drawing for all welding operations in connection with kiln erection.

In connection with indicated in the list.

repairs, the electrode type is instruction manual or in the parts

See also instruction manual "Arc welding, manual, for erection and repair".

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3.2

Makes

The instruction manual "Covered electrodes for manual arc welding" contains a survey of recognized electrode makes, which corresponds to the material code (Mat. No.) used by FLS. This survey makes it easy to switch from one make to another where this is necessary because of local conditions.

FLS must always be informed about the type and make of the electrode being used. Electrodes of makes other than those listed in the survey must not be used unless prior permission has been obtained from FLS.

3.3

Handling and drying of welding electrodes

3.3.1

The electrodes must be absolutely dry in order to attain fault-free welding.

Ordinary basic electrodes are extremely sensitive to moisture pick-up. Since moisture in the coating of the electrodes has a highly undesirable effect on the mechanical properties of the molten weld material, it is a fundamental requirement that welding must only take place provided that correctly dried electrodes are used.

18101-10 6

3.3.2

Basic electrodes and moisture

The basic electrodes have a very low moisture content when they are supplied to the user. This will not only ensure favourable welding properties, but will also produce a weld metal having the lowest possible content of hydrogen under the given circumstances.

The content of hydrogen in the weld metal mainly stems from moisture in the covering of the electrodes. Hydrogen is undesirable in the weld material since an increased level of hydrogen in the weld metal will significantly increase the risk of crack formation.

In a humid climate, electrodes may, after the package has been opened, absorb moisture so quickly that the applicable requirements in respect of the maximum hydrogen level have been exceeded only a few hours after the package has been opened.

It is, therefore, necessary to keep and handle the electrodes in such a manner that the covering of the electrodes is always dry and so that the moisture content is minimized.

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The curve in Fig. 1 shows the mOistening rate for

ordinary basic electrodes. At a temperature and a relative air humidity of 70%, the requirement of max. 10 ml hydrogen per 100 metal will be exceeded within a period of 12

Fig. 1 MOISTENING RATE

Hdiff.

20 ml/100g (Glycerine method)

15

Ordinary basic electrodes

10

I I r

I I I I

0~~~1~~ __ ~ __ ~ __ =c~~ __ ~ __

o 10 20 0 60 70

5

Time of impact in hours at 32°C and 70% RH

of 32°C standard g weld hours.

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3.3.3

Storage and handling of welding electrodes

Since welding electrodes are used in all types of climatic conditions, it is impossible to predict any definitive time period during which the electrodes can be safely stored without being damaged by moisture.

Basic electrodes are always supplied in mOist-proof packaging, and, as long as the packaging is kept intact, the electrodes can be stored in a dry store room at 20-30°C for up to 6 months.

However, before the electrodes are put to use, they must always be placed in a heating cabinet at 150°C for a few hours before they are taken to the point of operation in a heat-insulated box, at a temperature of minimum 70°C.

Electrodes which have been
packaging must always be
by moisture and must never
the heating cabinet. stored in open or damaged considered as being damaged be put directly back into

Moist-damaged electrodes must be dried in a drying oven at a temperature of 350°C for 2 hours. After drying, the electrodes must be kept in a heating cabinet at 150°, up to the point where they are taken to the point of operation in a heat-insulated box.

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This method for handling the electrodes is shown in Fig. 2. It should be noted that the electrodes must not be kept in the heat-insulated box for more than 2 hours before they must be returned to the drying cabinet and that drying of electrodes must never be carried out more than maximum 5 times.

Drying procedure for ordinary ·basic electrodes

Packace i __ l Pack ace

undamaged ~ H . ~ damaged aln store

20 - 30°C

o

Fig. 2

SKOO 0

18101-10 10

4. LIGHTING AND VENTILATION

When welding inside the kiln shell, use only safety voltage for lighting purposes, i.e. the voltage rating must not exceed 50 V A.C. or 120 V D.C.

The transformers for lighting, and the associated feed cables, must be placed outside the kiln.

The kiln shell must be ventilated during welding.

The total air contamination at the point of welding must be as low as possible and the hygienic limit values must be observed. If air contamination cannot be sufficiently reduced by ventilation or extraction, the operating personnel must use respiratory protective equipment.

5. PREHEATING

Welding at low temperatures, i.e. temperatures lower than 5°C, will give rise to substantial and rapid temperature variations, and, as a consequence hereof, substantial stress levels in the materials.

Since, at the same time, the toughness of the mate-
rials is reduced at low temperatures, it is very
important that the rate at which the material is
heated and cooled is maintained at a moderate level in order to avoid crack formations in the welds.

It is a fundamental requirement for all the welding operations described that welding must not be carried out in any form if the temperature of the material is lower than 5°C. The temperature of the material to be welded must be raised to 20-50°C by preheating.

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Generally, the preheating temperature can be found by means of the carbon equivalent CE of the material, which can be determined from the following formula:

CE = C++ +

Mn Cr+Mo+V Ni+Cu

6 5 15

in which the different elements have been inserted as percentages in accordance with the material analysis of the steel.

If the carbon equivalent is greater than 0.41, the material must always be preheated.

Contact FLS with respect to the preheating temperatures. It is important that preheating is also carried out before tack welds are executed since these short welds involve a particularly high risk of crack formations.

The welds must be completely terminated when they are executed at low temperatures. Welding must not be interrupted, e.g. at the end of normal working hours. At low temperatures the stresses in semi-finished welds may well exceed the limit permitted by the notch impact strength of the material, hence causing cracks to be formed.

The welds must be allowed to cool off slowly, and, therefore, the-heating of the plates must be continued after welding until there is no longer any risk of substantial stresses in the material.

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Radiant heat

When the kiln shell is exposed to intensive and constant sunshine, or when the night and day temperatures vary greatly, it is preferable not to start welding operations until after sunset in order to prevent kiln warpage.

Unilateral exposure to radiant heat from an operating kiln may also cause warpage of a kiln shell during the welding operation. Therefore, it may be necessary to place protective shields between the kiln shell and the operating kiln.

6. WELDING OPERATORS

All welding operations on the kiln must be carried out by welding operators who have passed a welding qualification test according to an internationally recognized standard. (DIN, BS, AS ME or equivalent standard).

7. SUPERVISION OF WELDING OPERATIONS

It is the responsibility of the welding instructor/the chief erector to ensure that the welded seams are of a satisfactory quality and that they meet the requirements stipulated on the drawings.

When the necessary number of welding operators is provided by the client, the welding instructor must assist the client in all matters related to welding, and the welding instructor must conduct and supervise the welding operation and check that welding is performed in accordance with the requirements stipulated on drawings and in the instruction manuals.

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The welding instructor must take immediate action if unqualified welders are employed or if the quality of the welding operation is unsatisfactory.

In such cases, the welding instructor must contact. the plant management, and if the instructor's recommendations are not followed, he must immediately report to FLS.

In cases where the client has assigned the task of welding to the supplier who has manufactured the kiln shell sections or to a special erection or welding contractor considered to have the necessary experience, the status of the welding instructor will be that of an observer; however, the instructor must intervene immediately if the welding operations are not satisfactorily performed.

Special rules apply in the case of turnkey projects.

8. CHECKING OF WELDING OPERATIONS

It is essential to ensure that the finished seams have the desired quality.

Therefore, the welding instructor should inform the client about the advisability of letting a recognized institute, such as e.g. Lloyds or another classification company, examine the welded seams by ultrasonic testing.

The responsibility for the quality of welds, and for expenses in connection with these investigations, rests with the client.

Special rules apply in the case of turnkey projects.

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9. WELDING QUALITY

The requirements with respect to the quality of the welded seams must be as indicated on drawings and in instruction manuals. If these quality requirements are not met, the chief erector/the welding instructor must forward a report to FLS with a description of each single flaw.

10. SAFETY REGULATIONS

Under normal circumstances, the use of electrical welding equipment does not involve any risk to the welding operator.

The maximum voltage of 100 V DC is so low that the resistance in the welder's body and clothing will normally be sufficient to prevent the current to which the welding operator may be exposed from presenting any danger.

When welding is performed in a kiln shell where the welder may get into physical contact with the object being welded, the risk will be substantially higher.

Under unfavourable circumstances where the transition resistance between the welding circuit and the welder's body is substantially reduced, for example because the skin and clothing is wet or sweaty, electrical welding may involve extreme danger. Consequently, it is of paramount importance that the welding operator is isolated both from the object being welded, the welding circuit and earth while welding is being performed.

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For prevention of accidents, it is essential to ensure strict compliance with all rules governing the design and application of the welding equipment, and the safety regulations mentioned below must also be strictly observed:

l. 2.

Use only all-insulated electrode Never touch the electrode with Always use insulating gloves.

Any physical contact with the electrode may

holders. the hands.

3.

be extremely dangerous.

Never hold electrode or electrode holder in the armpit.

All cables and cable jOints and the insulation must be

must be insulated in perfect order

everywhere.

The cables must be lying freely. The welding operator must never roll the cable around his neck, over the shoulder etc ..

Return cable and earth terminal must always be fully functional. A bad connection will impede the electrical circuit.

The return cable shell proper and

must be connected on the kiln close to the pOint of welding.

4.

Stray currents may evolve Never move the welding cables.

The welding machines must never be placed inside

heat and cause fires. machine by pulling the

the kiln since, in event of cable fracture, the kiln shell may become a "live" conductor, and any contact with the kiln may prove fatal.

5. The cable and the mains plug of the welding machine must be intact and undamaged. Particular attention must be given to the insulation of the cable at the point where the cable enters the machine. Any leakage from the primary currrent cable to the steel cabinet of the machine will make the cabinet extremely dangerous.

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6. If AC transformers are employed, they must either be connected to earth or they must be doubleinsulated.

Double-insulated transformers must never be connected to protective earth on the primary side.

7. DC converters must be earthed.

8. Direct physical contact between the welding operator and the object being welded must never occur.

Therefore, the welder must wear a water-repellent, insulating suit and he must be standing on a water-repellent, insulating and non-inflammable base.

9. Effective ventilation must always be provided when welding is done inside the kiln.

10. Make sure that the welding shields are in proper working order. The protective glasses must have the correct degree of shading. First-aid treatment must be available for anyone who has been exposed to "flashes" from the welding arc.

For each plant, a number of warning labels are sent to the chief erector.

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ELECTRIC WELDING

WARNING

THE TERMINAL ON THE RETURN CABLE FASTENED TO THE WORKPIECE PROPER; AS POINT OF WELDING AS POSSIBLE.

MUST ALWAYS BE CLOSE TO THE

THE TERMINAL MUST NEVER BE PLACED SO THAT THE RETURN CURRENT IS FORCED THROUGH PARTS WHICH ARE SEPARATED FROM THE WORKPIECE, FOR EXAMPLE: MOVING PARTS, BEARINGS, ELECTRICAL INSTALLATIONS OR SIMILAR.

RETURN CURRENT THROUGH A BEARING MAY CAUSE WELD SCARS WHICH WILL RUIN THE BEARING.

A RETURN CURRENT THROUGH ELECTRICAL INSTALLATIONS MAY CAUSE DESTRUCTION OF THE PROTECTIVE EARTH WIRESHIGHLY DANGEROUS - OR EXPENSIVE ELECTRONIC EQUIPMENT.

The warning labels must be posted at appropriate points at site, primarily on the welding machines. Additional labels can be obtained from FLS.

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