18101-11

Note!

This instruction manual describes the situations which,

according to our experience, are most likely to occur. An
exhaustive enumeration of all conceivable situations which
may occur during welding of the kiln cannot be provided.
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 therefore,
recommend that FLS be contacted without undue delay for
advice on the appropriate action.

1. GENERAL

Welding of the kiln shell is carried out mainly by

automatic welding in the form of submerged arc welding
(SAW), i.e. mechanical welding with continuous supply of
welding rod and welding powder.
Automatic welding gives both a more uniform weld quality
and a smoother surface of the welded seams than manual
welding.

2. WELDING MACHINERY

The power source for submerged arc welding must have a

constant voltage characteristic (CV) and a capacity of at
least 800 A at 44 V and 100 % operating factor. DC is used
for welding and the electrode is connected to the (+)
terminal (DCEP).

2.1
Fi11er material
A filler material consisting of unalloyed rod and a
manganese-alloy welding powder is used for submerged arc
welding of kiln shells during erection.
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The molten material must have mechanical properties

corresponding to those of the kiln plates.
FLS recommends the following electrode make:

ESAB OK Autrod 12.10, 4mm (unalloyed rod)

ESAB OK Flux 10.81 (manganese-alloy welding powder)

If another make is selected, the qualities of rod and

welding powder must be adjusted mutually as regards analysis
as both rod and welding powder will affect the analysis of
the weld metal.
Instructive values are given below for mechanical
properties and analysis:

Weld metal analysis in %:

C Mn Si
0,07 1,0 0,8

Mechanical properties:
Tensile strength 550 Mpa
Yield point 460 Mpa
Elongation >22%
Charpy-V, 0C 40 J

The hydrogen content (H2) in the weld metal increases the

risk of crack formations and as the hydrogen content of the
weld metal originates mainly from moisture in the welding
powder, it is important that the supplier's directions for
storage of electrodes and welding powder should be observed.
When supplied, the welding powder has a very low hydrogen
content and should be stored in a dry place in the unopened
original packaging.
The copper-coating of the weld rod is thin and gives only
partial protection against rust.
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Before use, the welding powder must be dried at 300 C for

at least 2 hours. A silo as shown in Fig. 1 with a volume
of 200 litres and a heating element of 2 kW makes it easy
to handle the welding powder and reduces any waste, and at
the same time the welding powder is kept warm and dry.

Fig. 1

A consumption of approx. 1.2 kilo welding powder can be

expected per kilo welding rod.
We1ding powder damaged by moisture can normally be dried.
Directions for drying temperature and keeping time will be
given by the supplier.

3. WELDING OF KILN SHELL

The kiln shell is welded partly on the ground (on tra-

velling wheels), partly on the foundations when the kiln
shell sections have been placed on the supports, clamped
together and aligned (erection welding). Radiant heat
Where the kiln shell is exposed to intensive and con-
stant sunshine, or when the night and day tem-
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peratures vary greatly, it will be best not to start

welding operations until after sunset in order to prevent
kiln warpage.
Unilateral radiant heat from a kiln in operation may also
cause warpage of a kiln shell during the welding
operation. It may, therefore, be necessary to place
protective shields between the kiln shell and the
operating kiln.

3.1
Welding on travelling wheels
For transport purposes the kiln is delivered in short
belts which are welded together on site to form kiln shell
sections of a suitable erection length.
The erection length of the kiln shell sections is shown on
the shipping drawing.
The kiln belts are welded together on the ground supported
by travelling wheels, and this work can be carried out
concurrently with the installation of the support
components.
It will be necessary to arrange part of the erection area
especially for welding on travelling wheels. Such an area
is shown to the right of fig. 6 on enclosure I. It
consists of two concrete floors for the travelling wheels
and a gantry crane for loading and unloading of the kiln
belts.
Figs. 7 - 11 on enclosures I-III show how reception,
unloading and parking of kiln belts can be arranged.
Fig. 12 on enclosure IV shows a welding set-up. The two
kiln belts to be welded together are placed on a set of
travelling wheels. The automatic welding machine is placed
on a gantry across the belts. Tarpaulins over the place of
welding provide weather protection.
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The set of trave11ing whee1s in fig. 12 are made on site.

Fig. 13 shows a set of trave11ing whee1s which have a
load-bearing capacity of 80 tons and can be remote-
controlled from the place of we1ding.
The trave1ling whee1s must be ab1e to turn the ki1n be1ts
at an even periphera1 speed which matches the we1ding
speed, i.e. 1ies within an adjustment range of 15-25 m/h
corresponding to 250-420 mm/min.

3.2
Erection welding
3.2.1
Barring
When the kiln shell sections have been placed on the
supports and the kiln gearing has been equipped with a
gear unit and a barring gear unit, erection welding can be
started.
The kiln must be barred continuously at a speed matching
the welding speed which is 250-420 mm/min. as mentioned.
To this end, it will be necessary to connect an infinitely
variable electric motor (or infinitely variable gear unit)
to the high-speed shaft of the barring gear.
It must be possible to remote-control barring from the
place of welding, both when circular seams, guide blocks
and cooler supports are to be welded. It may be done e.g.
by mounting a remote-control cable and a control box with
push-buttons.
The kiln gearing has one or two drives. Fig. 2 shows an
example of how the speed of the high-speed shaft of the
barring gear unit can be calculated. For automatic welding
it will suffice to use one drive, and the calculation,
therefore, applies to both gearings.
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Gear ratio up to the high-speed shaft of the barring gear unit:

Gear rim/pinion = 196/19 = 1:10.32
Main gear unit = 750/14.08 = 1:53.27
Barring gear unit = 1440/45 = 1:32

Total gear ratio = 1:10.32x53.27x32 =

1 : 17592

Example:

Kiln belt diameter D = 6000 mm

Required welding speed = 250 420 mm/min.

nT min = 250 x 17592 = 233 ver/min

x 6000

nT max = 420 x 17592 = 392 ver/min

x 6000

Normal motor rating for barring at welding speed is from 2 -3.5 kW. At low
speeds/high gear ratios the barring gear may easily be overloaded if too
large a motor is used.
If the kiln has a hydraulic barring motor, it can be used for barring during
welding when the yield of the pump unit is changed.
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3.2.2
Scaffolds for external erection welding
It is not possible to give a general description of the
construction of scaffolds as it will depend an the
scaffold material available in every single case.
Fig. 14 an enclosure V shows an example of haw to
construct a welding platform for performance of the
external erection welds.
The platform can be built up of tubes or light sections to
be mounted in the travelling erection crane in frames
which are welded to the crane. A number of hales in the
frames make it possible to raise or lower the platform in
order that the automatic welder can be placed at the
correct distance from the kiln shell.
Other types of scaffold are described in the welding
programme in section 7, sub-section 7.3.2.1.

3.2.3
Internal erection welds
Figs. 15 and 16 on enclosure VI show the welding machinery
for internal welds. The set-up is the same for travelling
wheel welding and erection welding.
The automatic welding machine is run in as follows: The
trolley of the automatic welding machine must run directly
on the bottom of the kiln shell. Clamp a not too sensitive
spirit level to the automatic welding machine to check its
position. Select a suitable barring speed for the kiln and
start barring. Set the speed control of the automatic
welding machine trolley until barring speed and trolley
speed coincide and the spirit level bubble is stationary,
i.e. the trolley moves on the kiln shell at the same speed
as the shell, but in the opposite direction. When this is
so, welding can be started.
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4. PRIHEATING

Welding at low temperatures, i.e. temperatures below 5C,

will give rise to large and rapid temperature variations
and thus substantial stress levels in the materials.
Since, at the same time, the toughness of the materials is
reduced at low temperatures, it is important that the rate
at which the material is heated and cooled is maintained
at a moderate level in order to prevent crack formations
in the welds.
It is a fundamental requirement for all welding operations
that welding must not be carried out in any form if the
temperature of the material is below 5C. The temperature
of the material to be welded must be raised to 20-50C by
preheating.
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:

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 should also be carried out
before tack welds are ma de since these short welds
involve a particularly high risk of crack formations.
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10

5. SAFETY REGULATIONS FOR AUXILIARY MACHINERY

Under special working conditions, e.g. welding during kiln

erection or repair, it is difficult to avoid getting into
touch, or in electrically conductive connection, with the
part on which work is being carried auto
Therefore, special regulations apply to extra protection
of the electric connections to hand tools and welding
machinery under these working conditions.

Hand lamps must under special working conditions be

secured by the use of a safety voltage, i.e. the rated
voltage must not exceed 50 V AC or 120 V DC.

Hand tools and other portable devices (except hand lamps)

which are used under special working conditions must be
secured by the use of a safety voltage as mentioned above
or a secondary circuit (a double- winding transformer).

As regards welding machinery used under special working

conditions it applies that the no-load voltage (OCV) must
not exceed 100 V DC or 12 V AC. Voltage differences with
more than 10 % pulsation are regarded as alternating
voltage (AC).

DC machinery is normally considered the safest machinery.

The kiln shell must be ventilated during welding. The

total air pollution on the welding site must be as low as
possible, and hygienic limits must be observed. If air
pollution cannot be reduced sufficiently by ventilation or
suction, the crew will have to use respirators.
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11

Transformers for auxiliary and welding machinery as well

as feed cables to such machinery must be placed outside
the kiln.

6. AFTERTREATMENT OF WELDED SEAMS

6.1
All welded seams must be ground and cleaned of weld
splashes, among other reasons because of the subsequent
ultrasound testing.

6.2
In UNAX kilns the circular seam A above the heavy belt for
the 'movable' UNAX cooler supports (see fig. 3) is exposed
to a very high dynamic load.

Fig. 3

It is, therefore, very important that this welded seam

should be completely without micro-cracks, without a top
bead and have a completely filled throat.
Very serious welding flaws as shown in fig. 4, i.e. an
undercut and insufficient filling, will result in stress
concentrations in the dynamically loaded structure which
will again reduce the fatigue strength and useful lifetime
and may give rise to crack formations.
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12

Fig. 4

The following after treatment of the said circular seam

should, therefore, be carried out on the inner and outer
sides of the kiln shell:
Grind the welded seam and its transition to the base
material as shown in fig. 5. Check the grinding with a
gauge R = 200 mm.
The grinding characteristic must correspond to the use of
emery cloth no. 60.
The direction of grinding must be at right angles to the
circular seam.

Fig. 5
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13

Examine the welded seam 100 % by means of magnetic

particle flaw detection (MPl) on the entire ground
surface.
If flaws are found, they must be remedied by careful weld
repair and subsequent ultrasound testing and dimension-
checking in order to satisfy the quality requirements of
weld class QC. (See general workshop instruction manual
520531).
The welded seam must be photographed before and after the
repair, and the photos be sent to FLS as documentation.

7. EXAMPLE OF A COMPLETE KILN WELDING OPERATION

7.1
General
7.1.1
A 4.5 x 75 m UNAX kiln is chosen as basis for the
example.
Planning is divided into two tables as shown in en-
closures VII and VIII.
The table on enclosure VII represents the total kiln
erection and shows the individual welders' positions in
the course of welding.
The table on enclosure VIII deals with details of the
welding of the kiln and the welding together of the burner
tunnel. The example is based on automatic welding of the
circular seams of the kiln shell and that the tube girder
is welded on the ground and is not mounted until the kiln
has been finish-welded.
The table on enclosure VII also includes the welding work
to be done in connection with the UNAX cooler supports.
This work is described in a separate instruction manual.
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14

7.1.2

The welding programme described may only be regarded as a

guiding example.
It is a condition in order that the welding programme can
be carried out that the welding work will be coordinated
with the other erection work in a way which is
satisfactory to the welders.
During the periods of welding the welders must have full
disposal of the kiln. That is, it will only be possible to
carry out other work on the kiln if it can be done in such
a way as not to disturb the welding operations.

7.1.3
When the erection joints of the kiln shell have been
welded inside and out, final alignment of the tyres must
be carried out and the tyres be secured with stop blocks
in the longitudinal direction of the kiln. This work will
have to be carried out on the welding team's days off as
it cannot be done concurrently with the welding
operations.
The final fine alignment of the gear rim must not be
carried out until the kiln welding work, including welding
of the tyre guide blocks, has been completed. The
alignment work may be carried out together with welding of
the cooler supports when this is done on the second shift
because all welders will be working on the day shift
during this period.

7.2
Crew
It is anticipated that six certified welders will be
required for the welding work, three of whom must be
certified for both manual and automatic welding.
In addition, a number of assistants varying in numbers
from two to tive during the entire process.
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15

Besides, an average of four scaffolders will be required

during the entire process.
The six welders are divided into three teams, each with
its own assistants. Some of the time the teams will have
to work shifts in order to adapt the welding work to the
periods during which the kiln is at full disposal for
barring.
The programme is based on a 72-hour work week dis-
tributed an six days of 12 hours.
This applies to all personnel participating in the welding
work.
Beside the crew listed in the tables, it will be necessary
to reckon with a welding foreman during the entire
process.

7.3

Comments on the individual items of the planning tables

7.3.1
The following items of this text deal with the in-
dividual items in the two planning tables on enclosures
VII and VIII. The last two digits of the item numbers
correspond to the numbering on the planning forms.

7.3.2
Enclosure VIII, welding of kiln shell A. Kiln sections
7.3.2.1
Erection of scaffolds for welding machine
To be able to carry out the welding operations con-
tinuously it will be necessary to have two scaffolds. The
scaffolds must be able to bear the welding machine and its
crew and be so steady that the movements of the crew will
not set up vibrations which may interfere with the welding
operations.
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16

The scaffolds may be composed of two strong bottom parts

and a common top part which is slightly lighter. During
welding of a circular seam the free scaffold bottom part
can be mounted at the next circular seam. When welding of
the first circular seam is completed, the top part of the
scaffold can be moved directly to the other bottom part by
means of a mobile crane, and welding of the next circular
seam can be started.
The manually welded bottom run which has to be laid before
automatic welding can be started e.g. from a trolley
placed on top of the kiln controlled by a wire. A mobile
crane can rapidly move the trolley from one joint to the
next.

7.3.2.2 and 7.3.2.3

Preparation of machinery for automatic welding and welding
of bottom runs
Check machines and cables. Repair or renew defective
cables. Make a test specimen to check the welding machine
and the operator. Check that all necessary consumer goods
to be used for the welding operations are available on
site.

7.3.2.4
Tack-welding and manual welding of bottom run
Two runs have to be made at a time, with one welder on
either side of the kiln. Complete all bottom runs and
inspect them visually before automatic welding is started.

7.3.2.5
External welding including grinding of welded seams
These welds are made by two welders on the day shift. Note
that the welding time of some seams is longer than a
normal work day for the day shift, and so the night shaft
will have to finish the seams.
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17

All the welded seams must be ground and cleaned of weld

splashes, among other reasons because of the subsequent
ultrasound testing. See sub-section 6.2 for the special
conditions relating to welding of circular seams at
'movable' cooler supports.

7.3.2.6
Dismounting of stiffening crosses, mounting bolts, angle
irons and locking pieces
Remove the mounting bolts during the external welding
operation. Removal of stiffening crosses, mounting irons
and adjusting irons ('horses') must be carried out by the
use of carbon arc chipping.
This work will be done by the night shift.
Gouging of stiffening crosses, mounting irons and
adjusting irons will leave scars on the kiln shell. It is
very important that the kiln shell should be repaired by
welding and subsequent grinding.
This work will also be done by the night shift.

7.3.2.7
Back-grooving of welded seams inside the kiln shell
Gradually as the external welded seams are finished, they
will have to be back-grooved from the inside until the
throat of the weld is clean and without cracks and slag
inclusions.
This work will also be done by the night shift.
After internal back-grooving, the throat must be ground
absolutely clean with a high-speed angle grinder.
This work will also be done by the night shift.
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7.3.2.8
Automatic welding of internal welded seams
Automatic welding of the internal seams is carried out by two welders
on the day shift. After welding, the seams are to be ground and all
weld splashes removed. Do not forget ventilation!

7.3.2.9
Ultrasonic NDT (Non Destructive Testing) of the welded seams
This work will have to be done by an NDT expert in compliance with
the instruction manual for this work.

7.3.2.10
Repair of defective seams
Defective welded seams are repaired by back-grooving with a carbon
arc or angle grinder and subsequent manual welding. The work will be
done concurrently with the NDT on the day or night shift as required
and in such a way that it will not interfere with the automatic
welding inside the kiln.

7.3.2.11
Removal of scaffolds for external welding
See sub-section 7.3.2.1

B. Guide blocks
7.3.2.13
Scaffolds for welding of guide blocks
Scaffolds will have to erected at all tyres so that the guide blocks
can be welded flat-downhand (2F).
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19

7.3.2.14
Fine alignment of tyres, tack-welding and welding of guide
b1ocks
When the erection joints have been welded inside and out,
the guide blocks must be aligned and placed correctly
relative to the supporting rollers before welding can be
started.
The alignment will have to be co-ordinated with the
erection programme.
The work of tack-welding and welding the guide blocks is
done by two welders on the night shift.

C. Gearing
7.3.2.16
Scaffold at gear rim
The purpose of the scaffold at the gear rim is to allow
flat-downhand welding (2F) of the gear rim springs.
The gear rim must be aligned prior to welding and
inspected as described in the instruction manual for this
work.
The work must be co-ordinated with the erection programme.

7.3.2.17
We1ding of gear rim springs
This work is done by two welders on the day shift.

D. Burner tunnel
7.3.2.19
Scaffold for welding
The necessary scaffolds must be erected for external and
internal welding of the joints.
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20

7.3.2.20
Welding of burner tunnel
This work is done by two welders. When welding has been
carried out from one side, the seams are chipped from the
other side until a clean weld metal appears. Stiffening
crosses, mounting and adjusting irons must be gouged and
all scars be removed by welding and subsequent grinding.

7.3.2.21
NDT control
The NDT control is to be carried out by an NDT expert in
compliance with the directions on the drawing.

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