THermit Rialtech - Instruction

8/10/2019 THermit Rialtech - Instruction

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PI022 WGW 68 CJ Oxy-LPG REV1 070208

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Wide Gap Weld KitComponents



Railtech Australia LimitedWide Gap Process LPGCJ - One Shot Crucible

Instructions

PI022 WGW 68 CJ Oxy-LPG REV1 070208 2

The A l l New Ra i l techWide Gap we ld ing processdes igned for Aust ra l i ancondi t ions andincorpora t ing the CJ - OneShot Cruc ib le

The Railtech Wide Gap Weld isdesigned and manufactured to gain

maximum control over the followingaspects:

Chemical analysis of the metal.

Control over the heat affected zone

Mechanical characteristics of theweld. (Brinell hardness).

Major quality improvements areachieved by using the CJ - One ShotCrucible.

Safety

Using a CJ - One Shot Crucible comparedto a Standard Crucible greatly reduces therisk of the welding personnel incurringinjuries since the weight of the crucible isonly 10kg + Portion. A StandardCrucible (new) complete with hardware is49kg + Portion. When we consider theaverage weight of a portion is 18kg then it

is clear there are advantages.The CJ - One Shot Crucible does notrequire preheating and therefore thewelder is handling a cold crucible for mostof the procedure.

Metallurgical Improvements:

There are fewer sand inclusions in theweld metal.

Less risk of slag inclusions from a dirtycrucible.




Instructions


Less risk of porosity in the weld sinceeach crucible is new and there isvirtually no risk of moisture.

Weld Installation Improvements:

There is considerably less hardware forthe welder to carry.

No crucible hardware is required.

Preheating the crucible prior tocommencing work is no longer requiredand therefore there is less risk of badwelds.

Welders can be ready to start weldingas soon as the work site is safe andclear of trains.

Far less risk of operator error.

Preheating is achieved with the use ofan approved Oxy-LPG (Refer Note 1, Page 17)

preheat torch.

Preheating time is determined by thesize 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 suppliedwith the automatic self-tapping thimblefitted and has the following advantages:

There is no requirement to install theautomatic thimble and closing portionwith less risk of possible weld problems.




Instructions


There is no risk of the operator burninghimself when placing the thimble into aCJ. (As with Standard Crucible).

Weld Kit Advantages:

Complete weld in a box, eliminates riskof not having all components on theweld site.

Less risk of using the wrong portion forthe rail to be welded.

Good protection for the mould andportion during transit.

The WGW-CJ kit box is easily identifiedwith the packaging displaying a CJ -One Shot Crucible on the box. Thisidentifies that the weld kit requires a CJ- One Shot Crucible. (This is veryimportant, as a weld kit designed for usewith a standard crucible MUST not beused in a CJ - One Shot Crucible and a

portion designed for a One Shot mustnot be used in a standard crucible.

Advantages of the CJ Crucible:

The material used as in the refractory iswaterproof, thus allowing the crucible to beused without any drying preparation. The CJCrucible is positioned on top of the mould forpouring, and the close proximity to thepouring reduces the washing of sand from

the mould deflection plug into the mould.Thus producing a “Metallurgically CleanerWeld.”

“WARNING” The Wide Gap-CJ Weldis designed for use with a “One

Shot” CJ Crucible. Type CJ2-F1,Part Number: 83450113.




Instructions


NEVER attempt to use a standardcrucible with a weld kit carrying the

marking “CJ”. The above may result in serious injury or

damage to property and can result indefective welds.

A. ADJUSTMENT OF THE RAILS(Please note that any Rail Authority specifications foralignment should be adhered to as directed)

The gap between the rail ends must be68.0mm +/ 3.0mm. If it is necessary to recutthe rail ends, the cut should be performedwith a mechanical rail saw or an alternativegas cutting method.In the case of long welded rails, this processmust be performed at the releasingtemperature.

B. RAIL ALIGNMENT

1. Visual alignment at a distance of 4 to 5metres from the rail joint.

2. Lifting the rail ends to set the joint isrequired to eliminate dipped welds duringthe cooling process of a weld. Theprocess depends on the type of rail andtrack condition. The adjustment ischecked with a steel straight-edge of 1.0metre placed half on each rail so as to

have the same clearance on each sidebetween the straight-edge and the railhead. The clearance must be 2.0 to2.5mm. To carry out this adjustment, thesleeper fastenings are removed 2 or 3sleepers on each side of the joint. It mayalso be necessary to remove the sleeperpads and slew the sleepers to allowenough space to insert the mould. Incurves, due to the flexibility of the rails,alignment is also achieved over a lengthof one metre by means of tie rodsadjusted on the foot of the opposite rail.




Instructions


3. In plan view, the gauge faces of the railare aligned accurately over a length of atleast one metre. For this adjustment,wedges can be inserted between the railand the sleeper plates. If the two rails aretwisted, one or both of them must becorrected with wedges and by adjustingthe corresponding sleeper fastenings. Incurves, due to the flexibility of the rails,the alignment is also achieved over a

length of one metre by means of tie rodsadjusted on the foot of the opposite rail.

4. Re-check the alignment and welding gapbefore proceeding.

5. Similar care should be taken with web andfoot alignment.

Using alignment equipment to set up rails is agood practice to eliminate misalignment ofthe 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 thevertical alignment of the rails.

The amount of peak is as advised by theRailway to suit the rail section and localconditions.Measure the peak approximately 50mm fromeach end of the 1 Metre straight edge.

C. ATTACHING THE PREFABRICATEDMOULDS

1. Check the moulds to see that they are thecorrect size and there are no cracks orother damage likely to cause anunsuccessful weld.




Instructions


2. Before assembling, the moulds are to befitted to the rail shape by rubbing alongthe rail.

3. Fit each mould half into the respectivesteel mould jacket and ensure that theslag overflow on the mould correspondswith the lip in the mould jacket. (Note:The mould must fit over the locating dowelin the mould jacket.)

4. Fit the base plate of the mould into thesteel base plate.Place a seam of Clay Cement in thegrooves on each side of the mouldbaseplate. (Railtech Australia LimitedClay Cement Part No. B82662100).Place the mould and base plate under therail foot, position centrally in the gap, andtighten with the two adjusting screws, thentap under the base plate lightly, to ensuregood seal, and retighten screws by handonly.Take care when positioning the base plateonto the rail that the Clay Cement doesnot contact the foot until correctly aligned,as the paste may stick and it will benecessary to re-apply Clay Cement.

5. Place the two side moulds into positionusing the locating guides on the mould

jackets onto the base plate guides toensure correct alignment.

6. Position the moulds clamp and tighten,taking care not to damage the moulds byover tightening.

7. To prevent the risk of dropping paste intothe mould during the next step, pleasecover the mould with a piece of cardboard

from the kit box. Apply Stemming Paste toseal the clearance between moulds and




Instructions


rail. Pack it firmly into the space betweenthe flat part of the steel jackets and therail, pressing it with the fingertips to forceit into the clearance. Make a 'smoothing'movement to ensure a perfect adherenceof the paste. Apply Stemming Paste tothe pouring lip on the mould cover.(Railtech Australia Limited StemmingPaste Part No. 78203700).

8. It is a good idea to apply Stemming Paste

to the thread on the mould clamp, toensure that any spillage of slag or metalwill not damage the thread.

9. Place the slag basin with a quantity of drysand covering the bottom of it in positionon the mould clamp; be careful that it isplaced under the slag pouring lip.

D. PREPARING THE CHARGE

During the preheat procedure, openthe portion bag and pour the portioninto the CJ - One Shot Crucible. Takecare that the entire portion is emptiedfrom the bag. You may put an UNLIT fuse in the top of the portion,(alternatively, this can be placed in theportion when ready to ignite it). Placethe lid on the CJ Crucible, and place ina safe area until ready for use.

E. PREHEATING WITH OXY-LPG

TORCH (Refer Note 1, Page 17) Use a preheat torch as recommendedby Railtech, (Railtech AustraliaLimited P/N 78217300) equipped withHarris accessories as specified.Ensure that a 22 hole rectanglepreheat tip is used when welding

WGW-CJ - One Shot CrucibleProcess.




Instructions


IT IS NECESSARY TO USE A RAILTECH/HARRIS LPG REGULATOR FITTED WITH AN ACCURATE GAUGE FORMEASURING GAS PRESSURE.(RAILTECH AUSTRALIA LIMITED P/N: 78201100 IS THE ONLY APPROVED REGULATOR FOR WELDING PLK PROCESS.

USE HARRIS OXYGEN REGULATOR (RAILTECH AUSTRALIALIMITED P/N 78201200) OR ANY SUITABLE OXYGENREGULATOR.

WORKING PRESSURE AT TORCH

Oxygen:3.0 Bar - 300 KPa. Measured at theOxygen regulator

LPG:0.5 Bar - 50 KPa. Measured at thepressure check gauge located on thePreheat Torch, with flame burning, andLPG tap fully open.

WORKING PRESSURE SHOULD BE READ AT THELPG CHECK GAUGE (RAILTECH AUSTRALIALIMITED 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 mouldand secure the torch support on the headof the rail by tightening screw on the sideof the torch support.

ENSURE THAT THE TORCH SUPPORT ISON THE HIGHER SETTINGIt should be 60mm from the end of the tip tothe head of rail.

3. Unlock the screw on the torch and removethe torch. (Do not remove the supportclamp)

4. Open the LPG valve approx. ½ a turn andignite the torch using the correct tools.




Instructions


Increase the LPG and oxygen until theflame is established. Continue toincrease the LPG until the tap is fullyopen. Adjust the oxygen until the cone ofthe flame is between 10-12 mm long witha bright blue colour. The LPG gauge mustread: 0.5 Bar - 50 KPa. At the torch.

You must read this pressure from theLPG Check Gauge located on thehandle.

5. Place the torch on its support in themould opening. Now carefully closethe OXYGEN tap until the flame starts'popping'. Increase the oxygen flow ¼to ½ turn, until the 'popping' stops.This ensures a good neutral flame.

6. Place the sand deflection plugs on top ofthe mould during preheat to be sure it

contains no moisture. Ensure the bottomof the plug is preheated in preference tothe top of the plug.

7. The following preheating times should beadhered to:

Rail Size Preheat T ime

68kg 5.0 Minutes

60kg 4.0 Minutes

53kg 3.0 Minutes

50kg 3.0 Minutes47kg 3.0 Minutes

41kg 3.0 Minutes

31kg 3.0 Minutes

8. Use a stopwatch to accurately adhere tothe above times.




Instructions


SAFETY PRECAUTIONS

GAS

Before fitting regulators to gas bottles, openthe tap on the bottle slightly to clean. Bottlesshould be located well clear of the work area.

HOSES

Use only 10 mm I.D. Hoses.

Inspect hoses regularly for damage and notethe following:

LPG hose is ORANGE

Oxygen hose is BLUE.

HEATING TORCH

To light the torch, Open the LPG valveslightly 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 theheating torch and place the moulddeflector plug in the mould using tongsand gently push firmly into position.

2. Place the CJ Crucible on top of the mouldand align it.

3. Place the ignition match into the portion (ifnot done at time of putting portion incrucible) and light it using the preheattorch.

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 thimblereleases the molten metal.




Instructions


7. When the pour is complete, wait aminimum of 1.0 minute at which time thecrucible should be removed using acrucible fork. (Railtech Australia LimitedP/N 82631410)

8. When the slag in the slag tray has cooledto form a skin, remove the slag tray andplace clear of working area in a safeplace.

NOTE: Do not empty hot slag onto wetground, concrete or into water, as anexplosion will occur.

F. REMOVING MOULDS ANDTRIMMING

1. After the pour wait a minimum of 5.0

minutes before removing the mould clampand mould jackets.

2. At 8.0 minutes after the pour is completeand using a large hammer, the top of themould may be pushed over onto a shoveland removed.

3. At 10.0 minutes weld can be dressed,using a weld shear or cold chisel cuttingset.

4. The base plate is removed aftercompletion of shearing.

H. GRINDING

Grind the rail profile according to RailAuthority’s specifications.

Based on information acquired from testingand from outside sources, the weld should beallowed to cool to 350o C before allowing

traffic to pass over the weld.




Instructions


I. STORAGE

Ensure moulds and portions are stored in adry place, and do not open packages untilready to use.

J. HARDWARE

Use only Railtech hardware and keep it ingood clean working order.

K. PORTIONS.

DO NOT use portions if bag has been brokenin transit

Note:

The Wide Gap One-Shot has been designed

to utilize the original Wide Gap hardware.

No WaterPlease!!!Keep Dry




Instructions


22 HolePreheat TipPart 78208700

Propane CheckGauge

Part: 78202300 Railtech HarrisPropane Regulator

Part 78201100

WG68 ProcessLPG Preheat Torch, Regulator & Check

Gauge.

Torch Suit22 Hole tipPart 78217300

Flash – GuardReverse Flow Check

Valves

Oxy P/n 78207200LPG P/n 78207100

Torch Nipple HarrisPart 78201600

Oxygen Single Stage 825Z106 RegulatorPart number: 78201200

Adaptor for22 holePreheat TipPart 78208800




Instructions


82631410

82090605

82180210or

82180310

83450113 or83450121




Instructions


Mould Jackets - PairsPart Numbers:82090605 41-70kg WGW-68

Mould Clamp C3Part Number:82250200

Slag TrayPart Number:82532000

Stemming Paste - BoxPart Number:78203700

Clay Cement - TubePart Number:B82662100

Base PlatesPart Numbers:82180310 41-52kg WGW-6882180210 53-70kg WGW-68




Instructions

PI022 WGW 68 CJ O LPG REV1 070208 17

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THermit Rialtech - Instruction