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DamodaDURGAPUR STE
“Coal Cr
DVC
Prepared By:-
ARGHOJYOTI DEY
EASE - Asansol
Coal Crusher H
dar Valley CorporationEEL THERMAL POWER S
Andal , West Bengal
Case History on
oal Crusher Hard-FacingAt
DVC-DSTPS, Andal.
mail.com
rusher Hard-Facing 1
ion STATION
acing”
TerocoatingDVC
Machine
Component
Numbers of components
Base Material
Machine capacity
Material Handled
Input size
Output Size
Present life
Problem:
Wear out of suspension arm
Coal Crusher H
rocoating on coal crusher of CHP
DVC-DSTPS, Andal
: Coal Crusher
: Suspension Arm & End Disc
: Suspension Arn-19 nos, End Disc- 2
: Manganese steel
: 1500 TPH
: Coal
: -300 mm
: -25 mm
: 90-120 days
arms & end discs due to impact and abra
rusher Hard-Facing 2
of CHP
2 Nos.
rasion.
Wear Factor analysis
1) Abrasion :
Coal is abrasive in nature. Whe
the crusher components becaus
since the crushing which takes
have the grinding effect on the
2) Impact:
Impact comes into picture beca
These lumps when crushed by
The output size post crushing i
SOLUTION
In order to combat this problem
concerned components with ou
TRIBO TUF 6517 AC/DC+ (
Unique Martensitic Ti-C alloy
components, subjected to high
conditions
Typical applications:
Clinker Breaker Hammers, Blo
Scraper Blades
Outstanding Features:
• Finely dispersed titanium
• Crack free multilayer d
• Consistency in hardness
• High resistance to impa
• Ideal for thick, multi-pa
Coal Crusher H
hen the crusher is put into operation, the coal
ause of abrasion. Here, abrasion is termed as g
es place between the crusher & impactor / bea
he components leading to abrasive wear.
ecause of big lump sizes of coal in the range of
by rotor hammers put impact before breaking
g is -25mm.
lem EWAC Alloys Limited suggests Terocoati
our super rich weld alloys TRIBOTUF 6517.
+ (Hardness: 52-60HRc)
oy designed for terocote of carbon steel and ma
gh impact combined with severe pressure and a
low Bars, Roller Press Rolls, Shovel Buckets
itanium carbide in martensitic matrix.
r deposit.
ess irrespective of number of layers.
pact, pressure & abrasion.
pass, protective coatings.
rusher Hard-Facing 3
al tends to wear out
grinding abrasion
eater plate tends to
of 250-300 mm.
g into smaller sizes.
ating of
7.
manganese steel
d abrasion in service
ts, Shredders, Augers,
Materials & Machines U
Material : TriboTuf 6517 ( 4.0
Machine : 1) Welding Machine
2) Grinding machin
3) PPE
Welding procedure
Weld Process : MMAW
Electrode Diameter : 4.00 mm
Polarity : DC +
Current : 120-135 Amperes (M
Welding technique : Cladding
Welding angle : Electrode ang
No. of welding layers : Three
Electrode Angle:
Before Welding Surface preparation to be done
(Grinding, cleaning, heating)
Coal Crusher H
s Used
4.00 mm )
ine- rectifier (400 amps)
ine, chipping hammer, wire brush
m
(Minimum current to be used)
g & Chequering-Dot patterns, staggered
ngle to be 10° to the Normal to the base
ne > Tools & Tackles to
(Wire brush, chippi
rusher Hard-Facing 4
to be ready
ping hammer, etc.)
WELDING TECHNIQ
Welding Technique:
1) Cladding : 3 layers (
2) Chequering-Dot : 3 layers (
Chequering-Dot pattern saves 2/3
Coal Crusher H
QUE ( Pictorial Representation)
(Primary wear area)
s (Secondary wear area)
2/3rd of alloy deposition. It should be done in seco
rusher Hard-Facing 5
condary wear areas only.
Cladding
Chequering –Dot
Coal Crusher H
rusher Hard-Facing 6
End Disc Terocote-ing
Circumference to be hard-face
• Side walls to be hard-face
• Tie-rod holes to be enc
• Dots in the chequered
Coal Crusher H
ced as shown (2-3 layers)
faced as shown (2-3 layers)
ncircled with hard-facing weld beads
ed blocks to be same or more in height than
rusher Hard-Facing 7
n that of weld bead
On-site demonstration pho• Welders working at two op
Coal Crusher H
hotographs t two opposite ends of coal crusher
rusher Hard-Facing 8
Pic: Showing Half cladding, H
Pic: Dots pattern being done
Coal Crusher H
, Half chequering
rusher Hard-Facing 9
Pic: showing welding in proc
Coal Crusher H
ocess, stub end after burning of electrode
rusher Hard-Facing 10
Pic: Showing Chequered- Do
Coal Crusher H
ot pattern being carried out on end disc
rusher Hard-Facing 11
Do’s & Don’ts :
Sl No. Do’s
1. Before starting weld
PPE’s & set welding pa
waste work piece.
2 Using Tribotuf 6517
current as per range giv
3 Only MS Parts of EDP
with mother material.
4 Electrode angle to be 1
perpendicular.
5
Make stringent bead.
6 Chip slag, peen weld b
7 Maintain inter pass tem
Coal Crusher H
’s Don’t
lding, check your
parameters on
Don’t neglect safety, d
current directly on actu
17, set minimum
given in instruction.
Don’t use high cur
welding.
DP 550 to be weld
Don’t weld hard fa
mother material.
e 10° to the normal/ Don’t neglect recomm
angle.
Don’t weave.
bead when red hot. Don’t peen when the b
heat, its of no use
emperature. Don’t overheat the j
gaps between two w
chipping & peening.
rusher Hard-Facing 12
’t
, don’t set
ctual job.
urrent for easy
faced side with
mended
e bead has lost its
job, have time
weld beads by
Points to be Noted:-
1. The use of EWAC make sp
reduces the chances of HAZ
2. Combination of cladding &
3. In comparison to cladding,
4. It must be noted that for cru
wear prone areas only. Prim
5. Tribotuf 6517 should be ap
should be avoided. Howeve
hard-facing can be done. Th
6. DC welding machines shou
Coal Crusher H
special weld alloys like TriboTuf 6517 reduce
AZ and helps in prolonging the life of compon
& Chequering–dot pattern reduces alloy cons
g, Chequering & dot pattern consumes only 1/
crusher like equipment, Chequering pattern to
rimary wear area to be completely weld cladde
applied on base material. Application on alrea
er, if previous hard-facing was done with Tri
This electrode is capable of multi-layer build
ould be preferred for optimum results.
rusher Hard-Facing 13
ces heat input & hence
onents.
nsumption by 40-45%.
1/3rd of weld alloy.
to be done in secondary
ded.
eady hardfaced surface
Tribotuf 6517 then re-
ld up without any crack.
Purc
Coal Crusher H
rchase Order Copy for reference
rusher Hard-Facing 14
Coal Crusher H
SERVICE REPORT
rusher Hard-Facing 15
Coal Crusher H
rusher Hard-Facing 16
