One Shot Crucible Instructions

Transcription

Wide Gap One Shot
Crucible Weld Kit
Wide Gap Weld Kit
Components
CJ One Shot Crucible
Page 1
PI022 WGW 68 CJ Oxy-LPG REV1 070208
Railtech Australia Limited
Wide Gap Process LPG
CJ - One Shot Crucible
Instructions
The Al l New Rail tech
Wide Gap welding process
designed for Australian
conditions and
incorporating the CJ - One
Shot Crucible
The Railtech Wide Gap Weld is
designed and manufactured to gain
maximum control over the following
aspects:
Chemical analysis of the metal.
Control over the heat affected zone
Mechanical characteristics of the
weld. (Brinell hardness).
Major
quality
improvements
are
achieved by using the CJ - One Shot
Crucible.
Safety
Using a CJ - One Shot Crucible compared
to a Standard Crucible greatly reduces the
risk of the welding personnel incurring
injuries since the weight of the crucible is
only 10kg + Portion.
A Standard
Crucible (new) complete with hardware is
49kg + Portion. When we consider the
average weight of a portion is 18kg then it
is clear there are advantages.
The CJ - One Shot Crucible does not
require preheating and therefore the
welder is handling a cold crucible for most
of the procedure.
Metallurgical Improvements:
There are fewer sand inclusions in the
weld metal.
Less risk of slag inclusions from a dirty
crucible.
2
Instructions
Less risk of porosity in the weld since
each crucible is new and there is
virtually no risk of moisture.
Weld Installation Improvements:
There is considerably less hardware for
the welder to carry.
No crucible hardware is required.
Preheating the crucible prior to
commencing work is no longer required
and therefore there is less risk of bad
welds.
Welders can be ready to start welding
as soon as the work site is safe and
clear of trains.
Far less risk of operator error.
Preheating is achieved with the use of
an approved Oxy-LPG (Refer Note 1, Page 17)
preheat torch.
Preheating time is determined by the
size of the rail.
ADVANTAGES
Prefabricated moulds allow:
Defined short preheat time.
Eliminates the need to evaluate rail end
temperature.
Takes less time to complete a weld.
The CJ - One Shot Crucible is supplied
with the automatic self-tapping thimble
fitted and has the following advantages:
There is no requirement to install the
automatic thimble and closing portion
with less risk of possible weld problems.
3
Instructions
There is no risk of the operator burning
himself when placing the thimble into a
CJ. (As with Standard Crucible).
Weld Kit Advantages:
Complete weld in a box, eliminates risk
of not having all components on the
weld site.
Less risk of using the wrong portion for
the rail to be welded.
Good protection for the mould and
portion during transit.
The WGW-CJ kit box is easily identified
with the packaging displaying a CJ One Shot Crucible on the box. This
identifies that the weld kit requires a CJ
- One Shot Crucible. (This is very
important, as a weld kit designed for use
with a standard crucible MUST not be
used in a CJ - One Shot Crucible and a
portion designed for a One Shot must
not be used in a standard crucible.
Advantages of the CJ Crucible:
The material used as in the refractory is
waterproof, thus allowing the crucible to be
used without any drying preparation. The CJ
Crucible is positioned on top of the mould for
pouring, and the close proximity to the
pouring reduces the washing of sand from
the mould deflection plug into the mould.
Thus producing a “Metallurgically Cleaner
Weld.”
“WARNING” The Wide Gap-CJ Weld
is designed for use with a “One
Shot” CJ Crucible. Type CJ2-F1,
Part Number: 83450113.
4
Instructions
NEVER attempt to use a standard
crucible with a weld kit carrying the
marking “CJ”.
The above may result in serious injury or
damage to property and can result in
defective welds.
A.
ADJUSTMENT OF THE RAILS
(Please note that any Rail Authority specifications for
alignment should be adhered to as directed)
The gap between the rail ends must be
68.0mm +/ 3.0mm. If it is necessary to recut
the rail ends, the cut should be performed
with a mechanical rail saw or an alternative
gas cutting method.
In the case of long welded rails, this process
must be performed at the releasing
temperature.
B.
RAIL ALIGNMENT
1. Visual alignment at a distance of 4 to 5
metres from the rail joint.
2. Lifting the rail ends to set the joint is
required to eliminate dipped welds during
the cooling process of a weld.
The
process depends on the type of rail and
track condition.
The adjustment is
checked with a steel straight-edge of 1.0
metre placed half on each rail so as to
have the same clearance on each side
between the straight-edge and the rail
head. The clearance must be 2.0 to
2.5mm. To carry out this adjustment, the
sleeper fastenings are removed 2 or 3
sleepers on each side of the joint. It may
also be necessary to remove the sleeper
pads and slew the sleepers to allow
enough space to insert the mould. In
curves, due to the flexibility of the rails,
alignment is also achieved over a length
of one metre by means of tie rods
adjusted on the foot of the opposite rail.
5
Instructions
3. In plan view, the gauge faces of the rail
are aligned accurately over a length of at
least one metre. For this adjustment,
wedges can be inserted between the rail
and the sleeper plates. If the two rails are
twisted, one or both of them must be
corrected with wedges and by adjusting
the corresponding sleeper fastenings. In
curves, due to the flexibility of the rails,
the alignment is also achieved over a
length of one metre by means of tie rods
adjusted on the foot of the opposite rail.
4. Re-check the alignment and welding gap
before proceeding.
5. Similar care should be taken with web and
foot alignment.
Using alignment equipment to set up rails is a
good practice to eliminate misalignment of
the rails during welding.
The Railtech “A Frame Aligner” is a tool,
which is designed to perform this operation.
Railtech “A Frame Aligner” (P/N 11111005)
Use a 1.0 Metre straight edge (Railtech
Australia Limited P/N 78203200) to set the
vertical alignment of the rails.
The amount of peak is as advised by the
Railway to suit the rail section and local
conditions.
Measure the peak approximately 50mm from
each end of the 1 Metre straight edge.
C.
ATTACHING THE PREFABRICATED
MOULDS
1. Check the moulds to see that they are the
correct size and there are no cracks or
other damage likely to cause an
unsuccessful weld.
6
Instructions
2. Before assembling, the moulds are to be
fitted to the rail shape by rubbing along
the rail.
3. Fit each mould half into the respective
steel mould jacket and ensure that the
slag overflow on the mould corresponds
with the lip in the mould jacket. (Note:
The mould must fit over the locating dowel
in the mould jacket.)
4. Fit the base plate of the mould into the
steel base plate.
Place a seam of Clay Cement in the
grooves on each side of the mould
baseplate. (Railtech Australia Limited
Clay Cement Part No. B82662100).
Place the mould and base plate under the
rail foot, position centrally in the gap, and
tighten with the two adjusting screws, then
tap under the base plate lightly, to ensure
good seal, and retighten screws by hand
only.
Take care when positioning the base plate
onto the rail that the Clay Cement does
not contact the foot until correctly aligned,
as the paste may stick and it will be
necessary to re-apply Clay Cement.
5. Place the two side moulds into position
using the locating guides on the mould
jackets onto the base plate guides to
ensure correct alignment.
6. Position the moulds clamp and tighten,
taking care not to damage the moulds by
over tightening.
7. To prevent the risk of dropping paste into
the mould during the next step, please
cover the mould with a piece of cardboard
from the kit box. Apply Stemming Paste to
seal the clearance between moulds and
7
Instructions
rail. Pack it firmly into the space between
the flat part of the steel jackets and the
rail, pressing it with the fingertips to force
it into the clearance. Make a 'smoothing'
movement to ensure a perfect adherence
of the paste. Apply Stemming Paste to
the pouring lip on the mould cover.
(Railtech Australia Limited Stemming
Paste Part No. 78203700).
8. It is a good idea to apply Stemming Paste
to the thread on the mould clamp, to
ensure that any spillage of slag or metal
will not damage the thread.
9. Place the slag basin with a quantity of dry
sand covering the bottom of it in position
on the mould clamp; be careful that it is
placed under the slag pouring lip.
D.
PREPARING THE CHARGE
During the preheat procedure, open
the portion bag and pour the portion
into the CJ - One Shot Crucible. Take
care that the entire portion is emptied
from the bag. You may put an UNLIT
fuse in the top of the portion,
(alternatively, this can be placed in the
portion when ready to ignite it). Place
the lid on the CJ Crucible, and place in
a safe area until ready for use.
E.
PREHEATING
WITH
OXY-LPG
TORCH (Refer Note 1, Page 17)
Use a preheat torch as recommended
by Railtech,
(Railtech Australia
Limited P/N 78217300) equipped with
Harris accessories as specified.
Ensure that a 22 hole rectangle
preheat tip is used when welding
WGW-CJ - One Shot Crucible
Process.
8
Instructions
IT IS NECESSARY TO USE A RAILTECH/HARRIS LPG
REGULATOR FITTED WITH AN ACCURATE GAUGE FOR
MEASURING GAS PRESSURE.
(RAILTECH AUSTRALIA LIMITED P/N: 78201100 IS THE ONLY
APPROVED REGULATOR FOR WELDING PLK PROCESS.
USE HARRIS OXYGEN REGULATOR (RAILTECH AUSTRALIA
LIMITED P/N 78201200) OR ANY SUITABLE OXYGEN
REGULATOR.
WORKING PRESSURE AT TORCH
Oxygen:
3.0 Bar - 300 KPa. Measured at the
Oxygen regulator
LPG:
0.5 Bar - 50 KPa. Measured at the
pressure check gauge located on the
Preheat Torch, with flame burning, and
LPG tap fully open.
WORKING PRESSURE SHOULD BE READ AT THE
LPG CHECK GAUGE (RAILTECH AUSTRALIA
LIMITED P/N 78202300) FITTED TO THE HARRIS
HANDLE (PART NUMBER 78200200).
PREHEATING
1.
Fit the preheating torch support to the rail,
and locate the torch onto the support.
2.
Adjust the preheat torch inside the mould
and secure the torch support on the head
of the rail by tightening screw on the side
of the torch support.
ENSURE THAT THE TORCH SUPPORT IS
ON THE HIGHER SETTING
It should be 60mm from the end of the tip to
the head of rail.
3.
Unlock the screw on the torch and remove
the torch. (Do not remove the support
clamp)
4.
Open the LPG valve approx. ½ a turn and
ignite the torch using the correct tools.
9
Instructions
Increase the LPG and oxygen until the
flame is established.
Continue to
increase the LPG until the tap is fully
open. Adjust the oxygen until the cone of
the flame is between 10-12 mm long with
a bright blue colour. The LPG gauge must
read: 0.5 Bar - 50 KPa. At the torch.
You must read this pressure from the
LPG Check Gauge located on the
handle.
5.
Place the torch on its support in the
mould opening. Now carefully close
the OXYGEN tap until the flame starts
'popping'. Increase the oxygen flow ¼
to ½ turn, until the 'popping' stops.
This ensures a good neutral flame.
6.
Place the sand deflection plugs on top of
the mould during preheat to be sure it
contains no moisture. Ensure the bottom
of the plug is preheated in preference to
the top of the plug.
7.
The following preheating times should be
adhered to:
8.
Rail Size
Preheat Time
68kg
60kg
53kg
50kg
47kg
41kg
31kg
5.0 Minutes
4.0 Minutes
3.0 Minutes
3.0 Minutes
3.0 Minutes
3.0 Minutes
3.0 Minutes
Use a stopwatch to accurately adhere to
the above times.
10
Instructions
SAFETY PRECAUTIONS
GAS
Before fitting regulators to gas bottles, open
the tap on the bottle slightly to clean. Bottles
should be located well clear of the work area.
HOSES
Use only 10 mm I.D. Hoses.
Inspect hoses regularly for damage and note
the following:
LPG hose is ORANGE
Oxygen hose is BLUE.
HEATING TORCH
To light the torch, Open the LPG valve
slightly and light torch using the correct tool.
(Do NOT use a cigarette lighter as injury can
occur)
F.
REACTIONS AND POURING
1. When preheating is complete, remove the
heating torch and place the mould
deflector plug in the mould using tongs
and gently push firmly into position.
2. Place the CJ Crucible on top of the mould
and align it.
3. Place the ignition match into the portion (if
not done at time of putting portion in
crucible) and light it using the preheat
torch.
4. Place the lid on the crucible.
5. The reaction will now take place.
6. There is a delay of between 15 and 25
seconds before the automatic thimble
releases the molten metal.
11
Instructions
7. When the pour is complete, wait a
minimum of 1.0 minute at which time the
crucible should be removed using a
crucible fork. (Railtech Australia Limited
P/N 82631410)
8. When the slag in the slag tray has cooled
to form a skin, remove the slag tray and
place clear of working area in a safe
place.
NOTE: Do not empty hot slag onto wet
ground, concrete or into water, as
an
explosion will occur.
F.
REMOVING
TRIMMING
MOULDS
AND
1. After the pour wait a minimum of 5.0
minutes before removing the mould clamp
and mould jackets.
2. At 8.0 minutes after the pour is complete
and using a large hammer, the top of the
mould may be pushed over onto a shovel
and removed.
3. At 10.0 minutes weld can be dressed,
using a weld shear or cold chisel cutting
set.
4. The base plate is
completion of shearing.
H.
removed
after
GRINDING
Grind the rail profile according to Rail
Authority’s specifications.
Based on information acquired from testing
and from outside sources, the weld should be
allowed to cool to 350o C before allowing
traffic to pass over the weld.
12
Instructions
I.
STORAGE
Ensure moulds and portions are stored in a
dry place, and do not open packages until
ready to use.
J.
HARDWARE
Use only Railtech hardware and keep it in
good clean working order.
K.
PORTIONS.
DO NOT use portions if bag has been broken
in transit
Note:
The Wide Gap One-Shot has been designed
to utilize the original Wide Gap hardware.
No Water
Please!!!
Keep Dry
13
Instructions
Torch Suit
22 Hole tip
Part 78217300
Torch Nipple Harris
Part 78201600
22 Hole
Preheat Tip
Part 78208700
Flash – Guard
Reverse Flow Check
Valves
Oxy P/n 78207200
LPG P/n 78207100
Propane Check
Gauge
Part: 78202300
Adaptor for
22 hole
Preheat Tip
Part 78208800
Railtech Harris
Propane Regulator
Part 78201100
WG68 Process
LPG Preheat Torch, Regulator & Check
Gauge.
Oxygen Single Stage 825Z106 Regulator
Part number: 78201200
14
Instructions
82090605
82180210or
82180310
82631410
83450113 or
83450121
15
Instructions
Mould Jackets - Pairs
Part Numbers:
82090605
41-70kg WGW-68
Base Plates
Part Numbers:
82180310
41-52kg WGW-68
82180210
53-70kg WGW-68
Mould Clamp C3
Part Number:
82250200
Slag Tray
Part Number:
82532000
Stemming Paste - Box
Part Number:
78203700
Clay Cement - Tube
Part Number:
B82662100
16
Instructions
17

One Shot Crucible Instructions

Transcription

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