Manufacture of Lead Processing Kettles

SPECIFICATION FOR THE MANUFACTURE OF LEAD PROCESSING KETTLES

Contents

1) Introduction

2) Standard Steel specifications

3) Plate Forming

4) Preparation of Welded Joints

5) Welding Equipment

6) Testing

7) Heat Treatment

8) Painting and Marking

9) Documentation

10) Kettle Inspection Check List

1) Introduction.

This specification is intended to represent the minimum manufacturing specification of any

kettle manufactured by Wefco. Care should be taken to consider the clients specification to
ensure that any additional requirements are met.

2) Standard Steel Specifications.

Wefco lead kettles are normally supplied manufactured from the following materials, specially
rolled to give low Aluminium, Silicon and Manganese contents.

a) ASTM A285 Grade A (Modified)

Carbon 0.17 % Max

Manganese 0.80 % Max

Phosphorous 0.03 % Max

Sulphur 0.03 % Max

Silicon 0.20 % Max

Aluminium 0.01 % Max

b) BS 2858 (Modified)

Carbon 0.100 % Max

Manganese 0.490 % Max

Phosphorous 0.030 % Max

Sulphur 0.036 % Max

Silicon 0.030 % Max

Aluminium 0.050 % Max

Before delivery all plate shall be ultrasonically tested to BS EN 10160:1999

Note:-

The above are Wefco standard material specifications, these can be substituted to meet client
requirements as necessary.
3) Plate forming.

Kettle plate may be formed by either of the following two methods subject to the clients
specification.

a) Cold Forming

After cold forming the plates shall be normalised

b) Hot Forming

The plate temperature during forming shell be above the minimum normalising
temperature.

4) Preparation of Welded Joints.

Preparation of the joint faces shall be accomplished by one or more of the following methods.

Thermal cutting

Chipping

Grinding

Machining

The preparation method used must produce a clean smooth surface to the profile required. The
joint faces and immediately adjacent surfaces shall be free from heavy scale, moisture, oil paint
or any other substance, which may affect the quality of the weld or impede the welding process.

Non Destructive Testing may be carried out on cut edges to ensure they are free of defect prior
to welding.

5) Welding Equipment and Operation.

5.1 Welding Process and Consumables.

All welding, where practical, shall be carried out using the submerged arc process with
resulting welds having the following chemical composition.

Carbon less than 0.10 %

Manganese 0.9 % to 1.2 %

Silicone 0.1 % to 0.2 %

5.1 continued.....

Wire size to be a maximum of 3.2 mm dia.

5.2 Storage and Care of Welding Consumables

The care and storage of all welding consumables shall be in accordance with the
manufacturers recommendations so to avoid damage or deterioration.

Filler wires and electrodes which show any sign of damage or deterioration shall not be
used.

Storage of consumables shall be arranged so that they are stored in a heated area to the
manufacture recommendations.

5.3 Welding Equipment

All welding plant, cables, instrumentation and accessories shall comply with all current
regulatory standards.

All welding equipment shall have current calibration certificates and per our ISO 9001
procedures.

5.4 Welding Procedures and Approvals.

Welds shall be carried out in accordance with written procedure which are approved by
a Third Party Inspector (Lloyds Register). Weld procedures are to comply with the
specification requirements of individual contracts but likely ISO 15614 and/ or ASME IX.

All welders are qualified and tested to relevant standards and endorsed by a Notified
Body.

5.5 Weld Joint Geometry.

Joint geometry, together with acceptable tolerances, shall be shown on the appropriate
drawing and weld procedure. No deviations are permitted without prior approval.
 5.6 Alignment of Butt Joints / Temporary Attachments

Alignment of the plate surfaces should be within 3 mm. To facilitate construction the use
of temporary attachment for the use of clamps, dogs, wedges etc is permitted.
Temporary attachments shall be carefully removed by cutting or shipping, not
hammering. Any damage of the surface shall be restored by welding and / or grinding
and checked for surface cracks by dye or magnetic particle inspection.

5.7 Stray Arcing

Precautions should be taken to avoid accidental stray arcing on the work piece. If any
stray arcing has occurred grinding of the scar is required followed by dye or magnetic
particle inspection.

6) Testing.

All joints are to be subject to 100 % radiography examination according to specification

requirements both pre and post heat treatment. The purchase specification shall be checked for
the inclusion of additional test as required by the client.

7) Heat Treatment.

All kettles shall be heat-treated to normalising temperatures in accordance with the below;

0degC to 250degC at open rate

250degC to 910degC (+/- 10deg) at max 150degC/hr
Soak time minimum 1 hr
Cool in still air.

Note: Client requirements are to be checked to ensure they do not deviate from the above.

8) Painting and Marking.

The kettle shall be wire brushed and/or shot blasted to remove all loose rust and millscale, then
given one coat of red oxide primer externally (or system required by specific client
requirement). The Wefco Job No. is to be marked on the outside in figures approx. 200 mm high
by welding along with all information required by the purchaser.
9) Documentation.

The client shall be provided with a full documentation pack consisting of, but not limited to;

Drawings
Material certificates including consumables
Welding procedures, & Procedure Qualifications
Welder qualifications
Heat treatment records
NDT test reports
Conformity Certificate
Third Party Inspection Certificate (if applicable)