Kumwell EXOTHERMIC WELDING Version 2007There are several main objectives for providing 2 welkdesigned ground system safety of personnal tops the list, followed by equipment protection, signal reference quality, return path for faults and/or surges and static dissipation, In order to meet these objectives, ground system interconnections must maintain a low contact resistance often under adverse conditions, for the expected life of the ground system, Connections in a ground network are subject to severe corrosion, high mechanical stress due to electromagnetic forces, and rapid thermal heating due to high current magnitudes during fault conditions, THE KUMWELL PROCESS ‘The KUMWELL exothermic welding process is a simple self contained method of forming high quality electrical conections,The compact process requires no external power or heat source making it completely portable, The KUMWELL exothermic welding is process in which an electrical connection is made by pouring superheated molten copper alloy on and around the conductors to be joined, The molten copper alloy contained and controlled within in a semi-permanent graphite mold causes the conductors to melt. When cooled the conductor are joined in a fusion weld. The superheated molten metal is created by a chemical reaction between aluminum and copper oxide, The process use finely divided aluminum particles as the reducing agent with copper oxide to produce the following chemical reaction 2A| + 3CuO mamnm—nm—mn 3Cu + AO, Version 2007 Kumwell Ccepro ets Wl Mota stestDse Top Hele Wee cory cette Cun Red [iss secTigi] This reaction generates a tremendous amount of heat |,e is exothermic is nature,with the molten metals reaching temperatues of approximately 4000 F Material Name Spec. Chemical Identity Copper Oxide CAS 1317-39-1 cuo Copper Oxide CAS 1317-38-0 uo Alumimun, CAS 7429-90-5 A Copper CAS 7440-50-68 Gu The majority of KUMWELL conections have at least twice the cross sectional area of the conductors being joined and equivalent or greater current carrying capacity Because the connection is a fusion of high conductivity high copper content alloy it will withstand repeated fault currents and will not loosen in the way that mechanical connectors can Corrosion resistance too, is exceptional, due to the alloy very high copper content (in excess of 90% ) Bs]Exothermic welding is a molecu- lar bonding of high conductivity high copper content alloy. (nexcess of 90 %) and high corrosion resistance . ine of curren mparision Metal A. Metal A. i Cctinped Connection Bxothemic Connecon Kum | Exothermic welding connection meet to standard as © UL 467 * (Grounding ond bonding equipment’) © [EEE std 837-2002 ‘(IEEE stan— dard for qualifying permanent connections used in substation grounding’). Kumwell’ Powder type kw exo thermic welded connections form a homogeneons mass of Copper-tin mixture to make a permanent grounding connec- tion between the copper wire to grounded components such as rebar, steel, pipe bus bor, and rail application grounding os power plant , substation, Transmission line, refinery plat, industrial, and com- mercial’ building telecomu- nication tower, etc. Kumwell Exothermic powder type KB. shall be free from Tin. Presence of metallic tin allow for wetting of pipe surface ond provides for unnecessary penatration that can lead to metaliugical demage to the pipe. Powder type KB and mould shall be test compliance to ANSI/ASME B914-1998 liquid hydrocarbons ‘and other liquids. kumw Exothermic welding powder type KR : shall be free from Tin. Presence of metallic tin callow for wetting of rail surface and provides for unnecessary penatration that can lead to metallurgical damage to the rail. Weld material shal provide a final joint with minimum — tensile strength of 40,000 psi tested using ASTM ES-94a (Test Methods for Tension Testing of Metalic Meti- tial ). KR Type application for Rafway signalling