C Case History on itioning of TATA Hita itachi 470 cket ... · the EDP 550 EWAC Tiles ss) ... iced at project site: Work area to be properly i ... SERVICE REPORT Page 14 . Reconditioning

Reconditioning of TATA HITACHI 47

C“Reconditio

Excavator Buck

Ferro Scrap

Prepared By:-

ARGHOJYOTI DEY

EASE - Asansol

[email protected]

470 Ex Bucket at FSNL, Burnpur

Case History on itioning of TATA Hitacket with EDP 550 EW

At rap Nigam Limited, B

ail.com

Page 1

itachi 470 EWAC Tiles”

, Burnpur.


SL No.

1. Abou

2.

3. E

4. P

5.

6.

7.

8.

9.


INDEX

DESCRIPTION

out Ferro Scrap Nigam Limited

Activities at FSNL

Excavator Bucket details

Problem & Wear analysis

EWAC Solution

Safety & Equipments

Welding Procedure

Do’s & Don’t

Service Report

Page 2

PAGES

3

4

5-6

7

8

9

10-12

13

14


About: Ferro Scrap N

FSNL is a Government of Ind

up share capital is Rs 200 Lak

FSNL has over the years evol

The company at present opera

very competitive price and wi


Nigam Limited

ndia Company under Ministry of Steel. The

akhs and it is a wholly owned subsidiary of

olved as a pioneer organization in the field

rates in ten steel plants in the country & off

with technology comparable to other world

Page 3

he authorized and paid

of MSTC ltd.

ld of Steel Mill Services.

offers services at a

ld leaders.


Major Activities

Ferrous scrap recovery is a process

iron & steel making which was con

crores worth of metallics recycled a

Over a period of time, it has been e

to considerable savings in energy a

Operations & elements of activities

� Cooling, digging, loading and

pit available for current dumpi

� Separation of iron & steel scra

of scrap.

� Processing of thimble skulls, l

� Recovery and processing of iro

� Collection, processing, loading

� Collection, processing and seg

� Processing of moulds and bott

� Transportation of processed sc

� Crushing & screening of LD s

� Transportation of worked trou

� Handling of solid waste like sl


s at FSNL

ss that reclaims ferrous metallics from muck an

onsidered as a waste, was started in an effort to

d annually thereby saving precious raw materia

established that usage of ferrous scrap to prod

and natural resources.

ies include:

d transporting BF & SMS slag dumped in slag

ping.

rap from slag through magnetic separator and r

, ladle skulls and jams by lancing and subseque

iron and steel scrap from dump.

ing and transportation of maintenance scrap.

egregation of mill rejects.

ottom plates by balling.

scrap to SMS, blast furnace and sintering plant

slag to be used in sinter plant, blast furnace an

ough slag from operation site after Metallic reco

sludge & ash.

Page 4

and debris arising out of

to gain for the country

rials.

oduce steel leads

ag pits and making slag

d recovery and processing

uent balling.

nt.

and as Rail Ballast.

ecovery to a marked place.


EDP 550 EWAC Tiles Ins

Excavator Bucket Details:

Machine: TAT

Component: Exc

Capacity: 2.5 C

Base Material: Man

Material Handled: Stee

Input size: +300

Present Life:

The bucket is presently new in operat

exposed to the surrounding scrap m

frequently. As per the current practice

/ spring plates in every 2-3 months.


nstallation on TATA Hitachi 470

At

FSNL, Burnpur

ATA Hitachi 470 Excavator

xcavator Bucket

5 Cu Mtr

anganese Steel

eel Scraps, Slag etc

00mm

ration. However its inner loading area as well a

material during operation thus resulting in

ices followed, these buckets are reconditioned w

Page 5

70 Excavator Bucket

ll as both the outer walls is fully

n damage of parent material

d with normal mild steel plates


Detailed Drawing:

(Note: The dimensions are for general refer

Working Parameters: The bucket is of 2.5CuMtr capacity. H

These buckets are used to load steel sc

in hot scrap area where slag is cooled

buckets from one place to other.


ference only. It may vary from one model to another)

. However the capacity may vary depending on

l scraps from scrap area to the dumpers. Someti

ed & then these semi cooled slag in scrap form

Page 6

on Excavator machine capacity.

etimes these buckets also work

m is loaded through these


Problem Due to continuous operation in slag &

etc, these buckets comes under heav

This results in gradual loss of origina

foreign objects & hence ultimately re

maintenance & reconditioning which

production.

Wear Factor Analysis

1) Abrasion: As we know St

excavator bucket which exca

abrasion. As a result of this b

and tear takes place.

2) Impact & Pressure : Duri

pressure and in some cases he

Due to this wear takes place.


g & scrap area in steel plant for loading of iron

avy abrasion accompanied by mild impact &

inal parent metal of bucket body which directly

esults in damage of bucket body. As a result

ich forces the excavator for shutdown. This

Steel scraps, slag etc are abrasive in nature.

cavate the scraps and operation during dum

base material & loading area of bucket expos

uring excavation of scraps, bucket excavate t

heavy objects comes in direct contact with the

Page 7

ron scraps, digging of solid slag

& pressure of big solid objects.

tly comes in contact with these

lt bucket will require repetitive

is will finally result in loss of

e. In scrap yard & dump yard,

umping is subjected to severe

ose to sever abrasion and wear

the objects against the severe

the body causing severe impact.


EWAC SOLUTION In order to combat this problem EW

at the maximum wear prone area o

Product : EDP550 EWAC

Size : 100mm x 100mm

Thickness : 10mm ( 6mm Ba

� Coating Alloy

Chrome Carbide containing ha

moderate impact.

� Base Plate

The base plate of tile comprise

normal mild steel grade weldin

� Weld Deposit Chemistry

Iron Base, alloyed with Cr,

uniformly distributed primary

� Abrasive Wear resistanc

At least 40 times superior to M

� Bulk Hardness

52-58 Rockwell C

� Surface Finish

Welded surface with stress rel

Note: Only Mild steel base plate

bucket and no welding to be don


EWAC Alloys Limited suggested to install

of the bucket.

C Tiles

m

ase Plate + 4mm Cladding Thickness)

hard phase in tough Iron base matrix, to resist

ises of IS:2062 grade plate or ST37 grade plate

ding alloy.

ry

r, C, Mn, Si and reinforced with proprietary

ry Chrome Carbides in Fe based eutectic matrix

nce

Mild steel in laboratory testing (ASTM G 65 –

relief cracks, generally perpendicular to welding

te part of EWAC tiles should be welded

one on hard faced side of EWAC Tiles

Page 8

the EDP 550 EWAC Tiles

ss)

Severe abrasive wear and

tes suitable to be welded with

ary micro alloying addition to

rix .

–Practice A)

ing direction.

d with the mother plate of


Safety

Before starting on-the-job dem

Training imparted on:-

1) Personal Protective Equip

2) Welding safety: Welding S

fumes and proper earthling cab

3) Precautions to be practice

site work; adjacent & nearby a

4) Work Permit:

Involves equipment isolatio

Approval from equipment f

Materials & Machines U

Material : EDP 5

Tile Thickness : 10 mm

Tile Size : 100mm

Quantity : 180 No

Welding Alloys : E7018

Machine & Tools:

1) Welding Machine- R

2) Grinding machine, c

3) PPE


emonstration, a safety training program was he

ipment: Helmet, Safety Shoes, Safety belts, H

g Screen, Gas mask, Welding gloves, safety fro

cables to be used for earthing.

iced at project site: Work area to be properly i

y areas to be accident free, other work groups to

tion

t from the concern person through “permit -to-w

s Used

550 EWAC Tiles

m ( 6mm Base Plate + 4mm Cladding T

m x 100mm

Nos

18

Rectifier (400 amps)

, chipping hammer, wire brush

Page 9

held by FSNL, Burnpur.

, Hand Gloves, Face mask.

from arc, spatters, heat, &

y inspected and approved for

to be at safe distance.

work form”

Thickness)


Welding Procedure

• Weld Process : MM

• Electrode Diamete

• Polarity: DC +

• Current: 120-135 A

• Welding technique

• Welding angle : El

• Before Welding: Su

(Wire brush, chippi

Installation process o

1. Identifying the wear pro

Both inside & outside side wa

outer face is also subjected to

OEM.


re

MMAW

eter : 4.00 mm

5 Amperes (Minimum current to be used

ue: Stringer bead.

Electrode angle to be 10° to the Normal t

Surface preparation to be done. Tools &

ping hammer, etc.)

of “EDP550 EWAC TILES”

rone area of bucket.

alls of bucket & Loading area face is subjected

to heavy wear but the outer face is already equip

Page 10

ed)

al to the base

& Tackles to be ready

ted to heavy wear. The bottom

uipped with Hardox Plates by


2. Cleaning the surface & m

3. Placing of EDP EWAC T

suitable gap between Til

4. Tack welding of Tiles at


making it free from dirt/contaminati

Tiles ( With Hard faced area facing u

iles both horizontally & vertically.

at all the corners.

Page 11

tion for welding of tiles.

g upwards) maintaining


5. Final full welding (maint

Tiles with bucket body.

Fig: Buket eq

Total 180 Nos * of EDP 550 E

70 Nos Tiles welded on Loadi

20 Nos each on both the Inner

35 Nos each on both the Outer

*Note: The Quantity of Tile m

a) As per Bucket s

b) As per OEM de

c) As per worn ou

d) & As per the ga


intaining all welding parameter & pro

equipped with EWAC Tiles after 1 month of operation

EWAC Tiles were welded on various faces of

ding surface area of bucket.

er side walls of bucket.

ter side walls of bucket.

e may vary -

t size to size

design for same capacity.

out areas & wear affected areas.

gap maintained between two tiles.

Page 12

rocedure as mentioned) of

of bucket.


Do’s & Don’ts :

Sl No. Do

1. Before starting we

PPE’s & set welding

waste work piece.

2 Using E7018, set m

per range given in in

3 Only MS Parts of E

with mother material

4 Electrode angle to b

perpendicular.

5

Make stringent bead

6 Chip slags, peen w

hot.

7 Maintain inter pass t


Do’s D

welding, check your

ng parameters on

Don’t neglect safe

current directly on

minimum current as

instruction.

Don’t use high cu

Welding.

EDP 550 to be weld

ial.

Don’t weld hard f

with mother mate

be 10° to the normal/ Don’t neglect reco

angle.

ad. Don’t weave.

weld bead when red Don’t peen when

heat, its of no use

temperature. Don’t overheat

gaps between tw

chipping & peenin

Page 13

Don’t

afety, don’t set

on actual job.

current for easy

d faced side

terial.

ecommended

en the bead has lost its

se

t the job, have time

two weld beads by

ning.



SERVICE REPORT

Page 14



Page 15

Documents

C Case History on itioning of TATA Hita itachi 470 cket ... · the EDP 550 EWAC Tiles ss) ... iced at project site: Work area to be properly i ... SERVICE REPORT Page 14 . Reconditioning