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Tank Agw I Single Side

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0% found this document useful (0 votes)
19 views15 pages

Tank Agw I Single Side

Uploaded by

onder doganci
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 15

AUTOMATIC GIRTH WELDERS

Single and Double Sided Models Features

♦ Effectively cuts welding time


up to 40%

♦ Adjustable frame for plates 6ft


to 10ft tall (1.8m-3m)

♦ Unlimited tank diameters


down to 15’ in diameter

♦ High / low rapid travel select


controls

♦ Self propelled at speeds from


4 to 105 IPM

♦ Plates up to 2” thick

♦ Single and Double sided


Energia Red-D-Arc / Ransome’s AGW Automatic Girth Welder is operation
an automatic system that speeds up construction of field-erected
storage tanks. It straddles the shell plates riding on adjustable flanged
wheels at operator controlled speeds of 4 to 105 IPM (.10—2.67 M
/min). It can handle plates as thick as 2 inches and tank diameters
from 15 feet and up. Available as dual or single sided machines.
Each is equipped with welding heads, controls, flux support belts and
recovery units so that 3 and 9 o’clock welds can be made
simultaneously. The Lincoln NA-3 solid
state control and welding head fitted with nozzles, wire feed rolls,
straighteners and 50 Lbs. (22.7Kg) wire reels for either single or
Twin-arc wire are standard. Submerged arc flux belt mechanism
ensures retention of the flux at the joint, and efficient recycling of flux.
Open arc models are available upon request.
Adjustable Frame for Plates 6’ to 10’ Tall
Specifications
AUTOMATIC GIRTH WELDERS
Notes
Includes ♦ NA-5 Controls Available
♦ CE-Mark Compliant Models Available
Operator's Platform with seat ♦ Custom Engineered Models Available
Lincoln NA-3 Wire Feeder and Control
Lincoln DC-600 or DC-1000 Power Source
Vertical Adjuster Adjustable tubular frame for plates 6ft to 10ft tall (1.8m-3.05m)
Horizontal Adjuster Min. 20ft(6. 1m) to an Unlimited tank diameter range
Flux Belt Assembly Travel speeds 4-105 ipm(.10-2.67 m/min)
Flux Recirculating System Speed, direction and rapid travel select controls (Master side)
Lincoln Tiny Twin Wire Kit
Pre-Heat Torch
Service Skid with Disconnect Average welding speed is approximately 30 ipm(.762 m/min)
Tropicalized Controls. with a deposition rate of 11# per hour. (per side)
Weather Curtains
200 feet of Control Cable Assembly
Loading Safety Wheels
Operator Communication System (AGW-II Only)
Operators Manual
Tool Kit
Page 2 of 14
SUBMERGED ARC INTRODUCTION
The submerged arc welding (SAW) process was developed in the early 1940s. This process is
different from other electric arc welding methods. The arc is submerged under the powdered fusible
granulated material, commonly called flux, is used to shield the arc and protect the molten metal.
Since the arc is completely covered by the granulated flux the weld is produced without the visible arc.
The nature of the arc and flux coverage is such that very little smoke or visible fumes are developed.
The flux is fed by either a gravity system or by a pressurized method into the arc zone through a
concentric nozzle or applied in advance of the arc through a hose or fitting.

During the welding operation, the heat of the arc melts some of the flux along with the tip of the
continuously fed electrode and a portion of the base metal. As the electrode progresses along the joint,
the lighter liquefied flux rises above the molten metal and solidifies in the form of slag. The weld
metal solidifies while the slag above it remains molten, later solidifying over the newly deposited
weld metal, thereby protecting the arc and molten metal from contamination by the atmospheric
oxygen and nitrogen. The unfused particles of granulated flux are normally picked up manually or
with a vacuum system and re-fed into the flux holding system. The solidified slag is removed and
normally discarded. A schematic representation of the SAW process is shown in the diagram.
Amongst the available arc welding processes for joining steel, submerged arc welding is probably the
most commonly used mechanized process.

Page 3 of 14
DIMENSION

SPECIFICATIONS
A: 6.9’
B: 13.8’
C: 17.5’
D: 5.9’ to 10.5’ adjustable
E: 13.6”
F: 13.6”
G: 3’
H: 4.2’

Height increment: 11.8” (300mm).


Travel speed: 3.9” ipm to 113.4” ipm
Input Power: 110VAC/50hz/1ph. (alternative 400vac 50Hz/3ph)
Carrying Pay load: 300Kg each side.
Flux hoist capacity: 70kg
Shell height: 5.9’ (1.8M) to 9.8’ (3M).
Shell thickness: 0.375”(9.5mm) min to1.96” (50mm) max.
Page 4 of 14
SHELL PLATE REQUIREMENT HEIGHT

PLATE
HEIGHT 1 2 3 4
6’ 6’(1828.8mm) 5.3’(1628.8mm) 7.9”(200mm) 3’(921mm)
8’ 8’(2438.4mm) 5.3’(1628.8mm) 3.96’(809.6mm) 3’(921mm)
10 10’(3048mm) 5.3’(1628.8mm) 4.65’(1419.2mm) 3’(921mm)

Note: For 12’ and above shell plate can be done. Consult factory the detail shell plate requirement.

Page 5 of 14
AUTOMATIC GIRTH WELDER LAYOUT

System consist of:


A-Frame carriage assembly
Platform & handrail
All weather curtains
Collapsible LNG rack
Main Controller console
Wire feed control system
Weld head motor assembly
Wire reel assembly
Flux hopper assembly
Flux belt and roller assembly
Flux recovery system
6” X-Y slide adjuster
Flux recovery system
Electric hoist
Auxiliary power
Page 6 of 14
Power Pack assembly

Romar AGW-2 is a double sided, self-propelled automatic girth welder complete with fully
integrated submerged arc welding system. It is a system that is designed for construction of field-
erected storage tank that can speed up the horizontal welding process up to 40 over percent versus the
manual stick application. It rides on the edge of the tank diameter from 15’ (4.6m) to unlimited
diameter. Travel speed is controlled by operator from minimum 3.9 inches per minute to 113.4 inches
per minute maximum. With the telescopic column design it can handle shell plate height from
5.9’(1.8m) to 13’(4m) and thickness from 0.375”(9.5mm) min to1.96” (50mm) max.
The system consist of

Carriage
Powered by 1 hp DC motor through gear
reducer. Solid-state electronic unit control
the carriage travel speed range from 3.9
inches per minute to 113.4 inches per
minute.

Platform
Includes handrail, weather curtains,
operator-seat and ladder for operator to
access.

Cylinder rack
A collapsible LPG rack located on the side
of the carriage. Heating torches and
cylinder bottle will NOT supply with the
machine.

Auxiliary box
Includes 1 out-put power of 110 VAC or
220 VAC 1ph/13amps

Page 7 of 14
Wire feeder controller
Wire feeder Controller ability to perform on CC/CV
applications. Function includes wire feed speed, start &
carter fill, volt & amperes meter. Interface with main
control box to provide an auto start with carriage travel and
flux recovery function.

Controller Console
Includes on/off selector switch, Travel manual/auto
mode, forward/reverse selector switch, travel speed
potentiometer, flux recovery manual/auto mode, flux
on/off switch, main fuse and digital display meter.

Flux belt
4” width flux belt self-
driven mechanism holds the
flux and convey the flux to
the flux recovery pick-up
nozzle during operation.

Cross slide adjuster


A set of X-Y slide adjuster
4” stroke supported the
weld head movement.
Make easy for operator to
fine-tune the position of
the nozzle before or during
welding.

Wire drive assembly


115V heavy-duty motor drive
assembly with gear reducer
built in. Speed ranges 0-400
inches per minute comes with
a one size drive roll, wire
straightener and 180o nozzle.

Page 8 of 14
Flux recovery system
A 3 watts /110VAC Electric driven flux
recovery unit designed to resist the abrasive
nature of the flux comes with a primary
separator tank and butterfly valve. Manual
release the flux and channel it to a 25lbs
capacity flux hopper. A 2 x 2OD heavy-duty
rubber hose with pick-up tools is also provided.

25lbs flux hopper


Separator tank

Power Pack Electric hoist


Hydraulic power pack operates the cylinder The electric hoist is operated at 110VAC manual
straddling across the top platform for the purpose push button. Lifting capacity of 70kg.
of opening and closing the A-frame.
Optional item
Pre-heating torches
Operators phone set.

Page 9 of 14
CONSOLE LAYOUT

This console provides the electrical component for the function of the AGW except the welding
process, which is controlled via the Wire feeder. The main Panel allows the distribution of incoming
supply to the transformer so that AGW operate at 110V.

Function
Power: ON / OFF selector switch
Travel: Start / Stop Selector
Travel: Left / Right Selector
Travel: Speed adjustment
Flux: Recovery Mode Hand / Auto Selector
Flux: Recovery ON / OFF Selector
Fuse: Main fuse
Digital: Displaying figure that related to the speed desired by operator.
Page 10 of 14
SET-UP GUIDELINES

Flux belt should be positioned approx ¾” below of


the bottom plate. As shown on the left.

Made a slight hump to exert pressure against the


belt to assure maximum contact with the shell
plate to prevent spillage of the flux.

This belt is a continuous belt running over two


rollers. It is essential that this belt be held tightly
against the side of the tank to stop spillage of the
flux. If spillage does occur, the weld profile will be
destroyed.

Flux recovery nozzle should be tilted slightly


backward to allow a proper pick up the unused flux
efficiently.

The two wires must never be place opposite each


other. Ideally 2” to 3” away.

The flux tube (feeding) should set about 1” away


from the tip
40” flux belt on the outer side
32” flux belt on the inter side

Nozzle Angle.
Nozzle pointed downward at 25 to 30 degree for
plate thickness .5” to .68 plates.

10 to 15 degree drag angle to keep the molten slag


from running ahead of the weld pool at all times.

Page 11 of 14
Nozzle Angle.
Nozzle pointed downward at 30 to 35 degree for
plate thickness ¾ to 1” plates.

15 to 20 degree drag angle to keep the molten slag


from running ahead of the weld pool at all times.

Page 12 of 14
Welding Guidelines
Outside Inside

Plate Thickness: Volt: 25 to 27 Volt: 25 to 27


6 & 8 mm Amps: 400 to 440 Amps: 400 to 440
Electrode Size: 1/8” T/S: 26 /26IPM T/S: 26 /26IPM
Passes: 1 Passes: 1

Plate Thickness: Volt: 26 to 27 Volt: 26 to 27


8 & 10 mm Amps: 420 to 480 Amps: 420 to 480
Electrode Size: 1/8” T/S: 26/26IPM T/S: 26IPM
Passes: 2 Passes: 1

Plate Thickness: Volt: 25 to 27 Volt: 25 to 27


10 & 13 mm Amps: 450 to 470 Amps: 450 to 470
Electrode Size: 1/8” T/S: 26/26IPM T/S: 26/26IPM
Passes: 2 Passes: 2

Plate Thickness: Volt: 25 to 27 Volt: 25 to 27


13 & 16 mm Amps: 480 to 520 Amps: 450 to 520
Electrode Size: 1/8” T/S: 26/35 IPM T/S: 26/35 IPM
Passes: 2 Passes: 2

Plate Thickness: Volt: 26 to 27 Volt: 26 to 27


16 & 18 mm Amps: 530 to 570 Amps: 480 to 600
Electrode Size: 1/8” T/S: 27/30 IPM T/S: 27/30 IPM
Passes: 2 Passes: 2

Plate Thickness: Volt: 26 to 29 Volt: 26 to 29


18 & 22 mm Amps: 480 to 570 Amps: 480 to 660
Electrode Size: 1/8” T/S: 26/35/35 IPM T/S: 26/35/35 IPM
Passes: 3 Passes: 3

Plate Thickness: Volt: 26 to 29 Volt: 26 to 29


22 & 25 mm Amps: 480 to 520 Amps: 480 to 550
Electrode Size: 1/8” T/S: 22/22/28 IPM T/S: 22/22/28 IPM
Passes: 3 Passes: 3

This parameter is supplied as a guide for establishing a welding procedure.


For more detail information consult consumables manufactures.

Page 13 of 14
Note:
For thick sections a manual root pass is firstly put in to stop the chances of root bead cracking.
Minimum root gap is 2mm for thin material and 4mm for 1” thick material.

Page 14 of 14

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