0079-3340 ordering data.docx

Mechanized Clad Welding Machine Doc# 0079-3340

· Package must include the following:

Roll build up gantry Horizontal Beam w/ 150in (3.8m) travel Fixed Beam, approx. 59in (1.5m) above platform Programmable Step Over SAW Welding Head (156:1) Motorized Vertical Slide, L=28.7in (730mm) Motorized Horizontal Slide, L=13in (330mm) 1500 Amp SAW Torch, L=15.7in (400mm) Based Control System Display and Navigate System Programed Surface Speed Joint tracking (automatically tracks the shaft surface and raises/lowers the welding head to maintain constant electrical stickout) DC Power Source Flux feed and recovery system with dust Collection Heated Flux Tank Flux Tank Low Level indicator Technical Service Support for Installation (3 days max) Equipment Training Support for Training (3 days max)

· Must be able to do buildup of shafts with diameters of 20-40” (508-1016mm), weld lengths of 12’ (Max) (3660mm). Along with maximum preheat temperature of 450°F and a max interpass temperature of 525°F.

· Base frame must be made of heavy-duty framing that will support the complete station with a platform for power supply, flux system etc.

· Power source must be able to be placed on platform

· Beam must be in fixed position, vertically approx.59in (1.5m) above platform

· Must have gear racks on one side of the boom for a motorized carriage with a horizontal travel length of approx. 150in (3.8m)

· Beam must have heat shielded motorized boom carriage with cable chain.

· Motorized carriage must be controlled by integrated control system for jogging/stepping/spiraling

· Welding head must be for a single wire submerged arc welding

· Submerged arc welding head must be able to be attached to the motorized boom carriage

· Must have wire feed speed 8-157ipm (0.2-4.0 m/min) with cooling gun

· Submerged arc welding head must include a 2-Axis HD Wire Straightener

· Submerged arc welding head must include flux hopper 10 liter

· Submerged arc welding head must be motorized with a vertical slide of 28.7in (730mm) stroke

· Submerged arc welding head must have a manual horizontal slide of 13in (330mm) stroke for over the hill adjustments

· Submerged arc welding head must have a flux support on flexi-arm

· Submerged arc welding head must have a 15.7in (400mm) long contact device with Maximum 1,500 Amps.

· Wire feeding system must include one wire spool of 30kg that will be able to be mounted on top of welding head

· Must have control system with graphical user-friendly touch screen interface that has a 12” screen and switch for rotation control

· Control system must be able to control the welding process parameters, interface and step functions (step on same position of the circumference)

· control system must be designed with totally integrated functions; welding head manipulation and operation of the column and boom which all controlled by the operator using a remote control that has a complete set of internal control cables

· The remote control must have the following functions:

-Start and Stop of welding

- Inching of wire -Welding head movement, vertical slide -Travelling boom carriage movements -Manual Joint tracking with Joystick.

-Selection of GMH Automatic tracking modes -Flux supply and recovery -High /Low speed -Emergency stop

· Automatic joint tracking must have air cooled inductive sensors for height control

· Joint tracking must have Manual slide adjustment and Vertical joint tracking operation modes

· The welding power source must be able to be monitored from the front panel of the process controller, which permits easy adjustment of all welding parameters for the welder

· The welding power source must be able to connect to another power source in parallel for demanding applications

· The power source must be a Thyristor-controlled 3-phase, fan-cooled DC power source that is designed for high productivity mechanized submerged arc welding

· Power source must have a duty cycle of 1250 Amps at 100%

· Flux Feed and Recovery System which uses dry and clean compressed air only must include:

Flux recovery unit (be placed on top of flux hopper) Flux Delivery Tank Flux Dust Filtration Unit

· The flux recovery system must have a max working pressure of 87psi (0.6MPa), Air supply of 20.5cfm (580 l/min), Airflow of 20.5cfm @ 87psi (580l/min @ 0.6MPa) and max suction height of 55in @ 87psi (1.4m @ 0.6MPa)

· Flux feeder must consist of a pressure tank with filling funnel, a slag screen and a flux valve which closes when the flux feeder is under pressure

· Compressed air must be fed to the unit via a pressure regulator with an automatic moisture trap and a nipple for 10 mm compressed air hose

· Flux feeder must have a connection for 1” (25.4mm) outlet hose at the bottom of the tank with a safety valve and a tap for decompression of the tank

· Must have dual heating elements installed at the bottom of the flux pressure tank for keeping the flux dry inside the tank (not for preheating of flux)

· Must have low level indicator for the flux (low level sensor indicating when it is time to refill the tank)

· Dust filter unit must have two stages:

1) The cyclone inlet where the larger particles are separated

2) The finer particles is separated in a cleanable fine filter of polyurethane-coated polyester

· The polyurethane coating must be able to separate the dust on the filter's surface for easy cleaning

· Cleaning of dust filter must be able to be done manually with a lever