Kiln Shell Auto Welding Process

After aligning kiln shell : 

• Manual welding(MMAW) at root run from outside
• Grinding done from outside
• DP taken
• Welding tractor is installed
• Preheating of joint up to 120 deg °C
• Saw welding is performed
• Simultaneous grinding is done

Process during Welding :

• Automatic flux delivery system
• Job grinding and dust removal by wire brush
• Continue heating with burner

OD WELDING PROCEDURE :

• The root of the bevels is welded by the welder manually
• Taken DP after welding and found ok
• The remaining outside bevel is welded using the submerged arc welding (saw) process with continuous job heating and grinding

MACHINE SETUP FOR OD WELDING :

• We don’t need to give any motion to carriage. Just have to place above structure. Torch has to be adjusted for proper arc gap by x-y axis

ID WELDING PROCEDURE :

• Back gouging is done at joint followed by grinding
• DP test and local fill-up at larger depth
• Saw machine installation and setting and job heating and grinding.

MACHINE SETUP FOR ID WELDING :

• Track installation- 6mm rod has to be welded on id circumference 250mm away from joint.
• Wheel of machine has to placed on this track
• Run the welding tractor opposite to kiln rotation.
• Speed of tractor and kiln should be equal so that displacement with respect to each other is zero.