EverSharp. Lip Cast Lip System Shroud Base Installation Instructions

Transcription

1 EverSharp Lip Cast Lip System Shroud Base Installation Instructions

2 Safety General Safety Information The safety practices described in this manual are meant as guidelines for safe operation under most conditions and are meant to supplement any safety rules and/or laws that may be in force in your area. Your safety and the safety of others results from putting into practice your knowledge of the correct operating procedures. Signal Words Throughout this manual are statements preceded by a special attention symbol:. The symbol is used with the following signal words to attract your attention to information of special priority. Read the paragraphs carefully and make sure you understand their significance, especially the possible causes of injury or death. WARNING: A statement preceded by WARNING is information that should be acted upon to prevent serious injury or death. CAUTION: A statement preceded by CAUTION is information that should be acted upon to prevent machine damage. Additional signal words that are not preceded by the attention symbol are: IMPORTANT: A statement preceded by the word IMPORTANT is information that possesses special significance. Tip: A statement preceded by Tip is information that is handy to know and may make your job easier. Personal Safety WARNING: When performing the work described in these instructions, always work safely and use proper safety equipment to help avoid injury. Always wear hard hat, gloves, safety shoes, eye protection, hearing protection and fall protection per regional, national and site requirements (e.g. OSHA, MSHA) when performing maintenance work. To avoid injury to others, keep bystanders well out of the way. 2

3 EverSharp Shroud Base Installation Instructions Section 1: Identifying EverSharp Cast Lip Bases ECC-BASE-2B ECC2-BASE-1 ECC-BASE-3 3

4 EverSharp Base Attachment Instructions Section 2: Base Installation 1. Position the base casting mounting base on the LIP, mid-way between adjacent teeth as shown in Figure Base casting must contact the LIP in the two zones shown in RED. Base may have a maximum gap of 2mm/0.08-inch in the BLUE regions. If gap exceeds this, weld build up the lip per the welding specifications detailed in ESCO document P6000GEN. Figure Contact of areas in RED must be confirmed with a 0.13mm/0.005-inch feeler gage. Contact coverage must be a minimum of 75% of the fit pad area. 4. Tack-weld the bases in place. Figure 2.2 Allowable Gap Contact Figure 2.3 4

5 Section 3: Base Welding Details 1. Refer to ESCO literature document P6000GEN for standard weld procedures, material, preheat instructions and interpass temperatures.* *ESCO facilities should refer to MII-4146 for weld preheat and interpass temperatures. 2. Weld the base casting using the standard ESCO weld procedures. a) First, make the initial root weld on the bottom leg of the base casting. b) Next, make the root weld on the top leg of the base casting (as detailed in Figures 3.1, 3.2 and 3.3). i. Continue welding the top leg, starting at front of weld joint and welding to half the width at the back of the leg. ii. Repeat for opposite side of base casting, completing initial weld layer. iii. Continue alternating weld passes, staggering starts and stops, until required weld geometry is attained. c) When the top leg is completely welded, switch to the bottom leg and weld out completely, as detailed in the following steps: i. For ECC2-BASE-1, start welding at center notch area first and then work out to end of the leg. Stagger starts and stops, welding until required weld geometry is attained. Next, weld the outside of the legs, alternating sides with each pass until complete. Refer to Figure 3.1 ii. For ECC-BASE-2B, alternate welding passes on the inside of each leg until complete. Next, weld the outside of the legs, alternating sides with each pass. Refer to Figure 3.2 iii. For ECC-BASE-3, weld the bottom leg the same as the top leg, as described in Step 2b. Refer to Figure 3.3 d) See Figure 3.4 for the weld finish profile guidelines. 5

6 Section 3: Base Welding Details (continued) Top Top Top Bottom Bottom Bottom ECC2-BASE-1 ECC-BASE-2B ECC-BASE-3 Figure 3.1 Figure 3.2 Figure 3.3 STARTING POINTS END POINTS BASE Figure 3.4 6

7 Section 4: Base Weld Finishing IMPORTANT: All grinding must be completed prior to toe peening. 1. Grind the areas of each weld as shown in BLUE in Figure 4.1 & Figure 4.2 below. Figure 4.1 Figure The surfaces of the base/lip fabrication welds shall be ground smooth according to the details listed below. a) The surfaces of the base/lip fabrication welds shall be ground smooth to [40mm]/1.5 inches from the end of each weld section. i. Grinding shall produce a smooth surface free of roughness and unevenness associated with the weld beads. ii. The toe of the welds shall merge smoothly with the lip and the base casting with a minimum radius of [4mm]/0.16 inch. iii. Grinding shall be performed using a high speed electric or pneumatic grinder with cone or plug grinding wheels no larger than [50mm]/2.00 inches in diameter. ANGLE HEAD OR DISK GRINDERS ARE NOT ALLOWED FOR THIS WORK. Grinding shall be done with the perimeter of the wheel and not the face. iv. The grinding direction must be perpendicular to the toe of the welds, as shown in Figure 4.3 and Figure 4.4a, 4.4b and 4.4c. IMPORTANT: Grinding the radii at the toe of the welds is facilitated by the use of cone-shaped grinding wheels. For final grinding, abrasive should be no coarser than 24 grit. 7

8 Section 4: Base Weld Finishing (continued) Base Figure 4.3: Proper grinding geometry at weld ends Base Figure 4.4a: Proper grinding directions Figure 4.4b: Correct weld end length Figure 4.4c: Correct weld end geometry 8

9 Section 4: Base Weld Finishing (continued) 3. Using a pneumatic hammer having the specifications shown in Table 1, toe peen, according to Figure 4.5, the weld toe along its full length as shown in BLUE in Figures 4.6 & 4.7. Air Pressure Air Consumption Stroke Length Blows per Minute 6.2 bar/90 psi 340 liters/minute 12ft 3 /hour [32mm]/1.13in 4600 Table 1: Toe Peen Pneumatic Hammer Specifications BASE Figure 4.5: Toe Peen Instruction Drawing 9

10 Section 4: Base Weld Finishing (continued) Figure 4.6 Figure 4.7 WARNING: Once the base has been fully installed, the lifting eye should be cut and ground smooth like shown in Figure 4.8. Failure to do so could result in injury from tripping or attempted lifting of anything other than the base. Figure

11 Section 5: Acceptance Standard 1. Welding shall be performed to the requirements of AWS D14.3 (or equivalent, as approved by ESCO engineering) except as modified in Table 2 below. 2. All unacceptable defects (crater cracks, gas holes, rollover, trapped slag, etc.) must be removed from the weld surface or groove side walls before welding Defect Acceptance Standard Linear Discontinuities Porosity Slag Undercut Rollover Weld Spatter No cracks, including crater cracks, are allowed in the welds or heat affected zones. Porosity shall not exceed four (4) holes in every [100mm]/4.0in of length of a single weld bead. No single void shall exceed [1.5mm]/0.06in in diameter. No visible slag in any layer is allowed. Undercut should be removed and repaired. Rollover or weld overlay shall not exceed [1.5mm]/0.06in beyond the fusion line of the weld. No bead of weld spatter shall exceed [0.8mm]/0.03in in diameter. The scatter density of beads of acceptable sizing shall not exceed 25 per [230cm 2 ]/36in 2. Table 2 11

12 P6041MIN01L ESCO Corporation. All Rights Reserved.