CONE FABRICATION

1. Welding of strake. The strake has the function of keeping the hollow structure
stable and acting as a heat sink for any heat-affected zone due to welding/ cutting.
2. Tracing of outer diameter and positioning of cone segments to cross check and
for assembly
3. See dumpy level at the back. This was used to check if the cone was to level
and straightness
4.

Marking and cross checking of dimension on one of the cone segment

5. Comparing measured dimension (measured at 4 above) with already preassembled part of cone
6. In this case, the cone segment had an excess that needed to be cut off. The
boilermaker is tracing with a scriber the length through which the excess need to be
cut
7. The boilermaker punched throughout the length to be cut. This was done so that
the welder who would proceed with flame cutting of that length of segment could
easily identify through his goggle what path is to be followed and as such yield a
good and uniform length of cut.
8.

The cone completely assembled and tack welded

9.

Welder proceeding with full welding of the cone

TUBE SHEET
Used in evaporators
Circular shape divided into 4 parts
`

Submerged arc welding at solid lines

At dashed line, welded on site. Only tack welded in workshop

Tolerance of a hole checked with go-no-go tool

use pilot drill
Pilot drill!
A small drill to start a hole to ensure that a larger drill will run true to center.
This is done, in the workshop, by first using a drill of smaller diameter than the hole
to be made for a preliminary hole, then using the required diameter of the drill to
make the hole.
WELDING TYPES

Types of Welding
Welding. So you think it's as simple as
grabbing the gun and pulling the trigger,
eh?
Tell me this then - what types of welding
are there? Not completely sure? read on...
Arc Welding
Arc welding is a process utilizing the concentrated heat of an electric arc to
join metal by fusion of the parent metal and the addition of metal to joint
usually provided by a consumable electrode. Either direct or alternating
current may be used for the arc, depending upon the material to be welded
and the electrode used.
Electroslag Welding

Fluxed-Core Arc-Welding

Electroslag Welding (ESW) deposits the

weld metal into the weld cavity
between the two plates to be joined.
This space is enclosed by water cooled
copper dams or shoes to prevent
molten slag from running off. The weld
metal is produced from a filler wire
that forms an initial arc with the
workpiece until a sufficient pool of
liquid metal is formed to use the
electrical resistance of the molten slag.

Click to view larger JPEG. FluxedCore Arc-Welding (FCAW) uses a

tubular electrode filled with flux
that is much less brittle than the
coatings on SMAW electrodes while
preserving most of its potential
alloying benefits.

Gas Metal-Arc Welding

Gas Tungsten-Arc Welding

Click to view larger JPEG. Gas MetalArc Welding (GMAW), also called Metal
Inert Gas (MIG) welding, shields the
weld zone with an external gas such as
argon, helium, carbon dioxide, or gas
mixtures. Deoxidizers present in the
electrode can completely prevent
oxidation in the weld puddle, making

Click to view larger JPEG. Gas

Tungsten-Arc Welding (GTAW), also
known as Tungsten Inert Gas or
TIG welding, uses tungsten
electrodes as one pole of the arc to
generate the heat required. The gas
is usually argon, helium, or a
mixture of the two. A filler wire

The emissive fluxes used shield the

weld arc from surrounding air, or
shielding gases are used and
nonemissive fluxes are employed.
This process requires special
The higher weld-metal deposition
equipment used primarily for
rate of FCAW over GMAW (Gas
horizontal welds of very large plates up Metal Arc Welding) has led to its
to 36 inches or more by welding them popularity in joining relatively
in one pass as in large machinery and heavy sections of 1" or thicker.
nuclear reactor vessels.
Another major advantage of FCAW
There are also variations of ESW where is the ease with which specific
shielding is provided by an appropriate weld-metal alloy chemistries can be
gas and a continuous arc is used to
developed. The process is also
provide weld metal. These are termed easily automated, especially with
Electrogas Welding or EGW machines. the new robotic systems.

multiple weld layers possible at the

joint.

provides the molten material if

necessary.

GMAW is a relatively simple, versatile,

and economical welding apparatus to
use. This is due to the factor of 2
welding productivity over SMAW
processes. In addition, the
temperatures involved in GMAW are
relatively low and are therefore
suitable for thin sheet and sections
less than inch.

The GTAW process is especially

suited to thin materials producing
welds of excellent quality and
surface finish. Filler wire is usually
selected to be similar in
composition to the materials being
welded.

Plasma Arc Welding

Shielded-Metal Arc Welding

Click to view larger JPEG. Plasma Arc

Welding (PAW) uses electrodes and
ionized gases to generate an
extremely hot plasma jet aimed at the
weld area. The higher energy
concentration is useful for deeper and
narrower welds and increased welding
speed.

Click to view larger JPEG. ShieldedMetal Arc Welding (SMAW) is one of

the oldest, simplest, and most
versatile arc welding processes. The
arc is generated by touching the tip
of a coated electrode to the
workpiece and withdrawing it
quickly to an appropriate distance
to maintain the arc. The heat
generated melts a portion of the
electrode tip, its coating, and the
base metal in the immediate area.
The weld forms out of the alloy of
these materials as they solidify in
the weld area. Slag formed to
protect the weld against forming
oxides, nitrides, and inclusions
must be removed after each pass to
ensure a good weld.

Atomic Hydrogen Welding (AHW) is

similar and uses an arc between
GMAW may be easily automated, and two tungsten or carbon electrodes
lends itself readily to robotic methods. in a shielding atmosphere of
It has virtually replaced SMAW in
hydrogen. Therefore, the work
present-day welding operations in
piece is not part of the electrical
manufacturing plants.
circuit.

The SMAW process has the

advantage of being relatively
simple, only requiring a power
supply, power cables, and electrode
holder. It is commonly used in
construction, shipbuilding, and
pipeline work, especially in remote
locations.
Submerged Arc Welding
Click to view larger JPEG. Submerged
Arc Welding (SAW) shields the weld
arc using a granular flux fed into the

weld zone forming a thick layer that

completely covers the molten zone and
prevents spatter and sparks. It also
acts as a thermal insulator, permitting
deeper heat penetration.
The process is obviously limited to
welding in a horizontal position and is
widely used for relatively high speed
sheet or plate steel welding in either
automatic or semiautomatic
configurations. The flux can be
recovered, treated, and reused.
Submerged Arc Welding provides very
high welding productivity....4-10 times
as much as the Shielded Metal Arc
Welding process.
MIG Welding
MIG (Metal Inert Gas) or as it even is called GMAW (Gas Metal Arc Welding)
uses an aluminium alloy wire as a combined electrode and filler material.
The filler metal is added continuously and welding without filler-material is
therefore not possible. Since all welding parameters are controlled by the
welding machine, the process is also called semi-automatic welding.
The MIG-process uses a direct current power source, with the electrode
positive (DC, EP). By using a positive electrode, the oxide layer is efficiently
removed from the aluminium surface, which is essential for avoiding lack of
fusion and oxide inclusions. The metal is transferred from the filler wire to
the weld bead by magnetic forces as small droplets spray transfer. This
gives a deep penetration capability to the process and makes it possible to
weld in all positions. It is important for the quality of the weld that the
spray transfer is obtained.
There are two different MIG-welding processes, conventional MIG and
pulsed MIG:
Conventional MIG uses a constant voltage DC power source. Since the
spray transfer is limited to a certain range of arc current, the conventional
MIG process has a lower limit of arc current (or heat input). This also limits
the application of conventional MIG to weld material thicknesses above 4
mm. Below 6 mm it is recommended that backing is used to control the
weld bead.
Pulsed MIG uses a DC power source with superimposed periodic pulses of
high current. During the low current level the arc is maintained without
metal transfer. During the high current pulses the metal is transferred in the
spray mode. In this way pulsed MIG is possible to operate with lower
average current and heat input compared to conventional MIG. This makes
it possible to weld thinner sections and weld much more easily in difficult
welding positions.
TIG Welding
TIG-welding (Tungsten Inert Gas) or GTAW-welding (Gas Tungsten Arc

Welding) uses a permanent non-melting electrode made of tungsten. Filler

metal is added separately, which makes the process very flexible. It is also
possible to weld without filler material.
The most used power source for TIG-welding generates alternating current
(AC). Direct current can be used, but due to high heat generation on the
tungsten electrode when DC-EP (electrode positive) welding, that particular
polarity is not feasible. In some cases DC-EN (electrode negative) is used,
however, this requires special attention before welding, due to the arc's
poor oxide cleaning action.
AC TIG-welding usually uses argon as a shielding gas. The process is a
multi purpose process, which offers the user great flexibility. By changing
the diameter of the tungsten electrode, welding may be performed with a
wide range of heat input at different thicknesses. AC TIG-welding is possible
with thicknesses down to about 0,5 mm. For larger thicknesses, > 5 mm,
AC TIG-welding is less economical compared to MIG-welding due to lower
welding speed.
DC TIG-welding with electrode negative is used for welding thicknesses
above 4 mm. The negative electrode gives a poor oxide cleaning compared
to AC-TIG and MIG, and special cleaning of joint surfaces is necessary. The
process usually uses helium shielding gas. This gives a better penetration in
thicker sections. DC TIG-welding is applicable for welding thicknesses in the
range 0,3 - 12 mm. More and more popular is also pulsed DC TIG-welding,
which makes it possible to weld uniform welds with deeper penetration at
the same heat input. Pulse frequency is usually in the range 1 - 10 Hz.

MMAW
SMAW
GTAW
ROLLING OF A CONE
Between rollers for curvature
HAND HELD POWER TOOLS
Some hand held power tools that I encountered in the tool room were:
Grinder 9 , 5 , 4.5
Drilling machine hand
Drilling machine magnetic
Chop saw cutting machine
HEALTH + SAFETY HAZARDS

Signs above in blue background and in a circle Mandatory

Safety Helmets to be worn
Eye protection
Protective footwear
Hearing protection in site/ workshop
Hot works
Working with high Voltage
Working at heights permit of works to be given
Other Hazards:
Dangerous machinery chop saw blades exposed parts on motion use guards

rotating reciprocating reverse movements trapped in, entangled or crushed

Falling hazards
Cylinders of oxygen, acetylene wrongly positioned collision
Chains, ropes, lifting tables
Noise + vibration vibration causes carpal tunnel + white finger syndrome
IMPROVE!
REGROOVING MILL ROLLER
Submerged arc welding is used to recover lost thickness

Shell fitted to shaft

regrooved
MILL SHELL ATTACHED TO SHAFT
Cylindrical Casting heated for six hours or more.
The casting then expands.
ABOUT TYPES OF FIT

Basic terms.
It is necessary that the dimensions, shape and mutual position of surfaces of
individual parts of mechanical engineering products are kept within a certain accuracy
to achieve their correct and reliable functioning. Routine production processes do not
allow maintenance (or measurement) of the given geometrical properties with
absolute accuracy. Actual surfaces of the produced parts therefore differ from ideal

surfaces prescribed in drawings. Deviations of actual surfaces are divided into four
groups to enable assessment, prescription and checking of the permitted inaccuracy
during production:

Dimensional deviations
Shape deviations
Position deviations
Surface roughness deviations

This toll includes the first group and can therefore be used to determine dimensional
tolerances and deviations of machine parts.

As mentioned above, it is principally impossible to produce machine parts with

absolute dimensional accuracy. In fact, it is not necessary or useful. It is quite
sufficient that the actual dimension of the part is found between two limit dimensions
and a permissible deviation is kept with production to ensure correct functioning of
engineering products. The required level of accuracy of production of the given part is
then given by the dimensional tolerance which is prescribed in the drawing. The
production accuracy is prescribed with regards to the functionality of the product and
to the economy of production as well.
A coupling of two parts creates a fit whose functional character is determined by
differences of their dimensions before their coupling.

where:
d=D ... basic size
Dmax , Dmin ... limits of size for the hole
dmax , dmin ... limits of size for the shaft
ES ... hole upper deviation
EI ... hole lower deviation
es ... shaft upper deviation
ei ... shaft lower deviation

Depending on the mutual position of tolerance zones of the coupled parts, 3 types of
fit can be distinguished:

1.7 Type of fit.

Depending on the mutual position of tolerance zones of the coupled parts, 3 types of
fit can be distinguished:
A. Clearance fit
It is a fit that always enables a clearance between the hole and shaft in the
coupling. The lower limit size of the hole is greater or at least equal to the
upper limit size of the shaft.
B. Transition fit
It is a fit where (depending on the actual sizes of the hole and shaft) both
clearance and interference may occur in the coupling. Tolerance zones of the
hole and shaft partly or completely interfere.
C. Interference fit
It is a fit always ensuring some interference between the hole and shaft in the
coupling. The upper limit size of the hole is smaller or at least equal to the
lower limit size of the shaft.

shaft fitted inside