SIGN IN YOUR ACCOUNT TO HAVE ACCESS TO DIFFERENT FEATURES

FORGOT YOUR PASSWORD?

FORGOT YOUR DETAILS?

AAH, WAIT, I REMEMBER NOW!
QUESTIONS? CALL: +9120 - 66308333 Or Mail: enquiry@rakhoh.com
  • LOGIN

Boilers and Steam Boiler Manufacturer In Maharashtra, PuneBoilers and Steam Boiler Manufacturer In Maharashtra, Pune

Boilers and Steam Boiler Manufacturer In Maharashtra, Pune

BOILER ACCESSORIES, THERMIC FLUID HEATERS & SPECIALTY FABRICATION.

+9120 - 66308333
Email: enquiry@rakhoh.com

RAKHOH BOILERS
S-11, T Block, M.I.D.C.,Bhosari, PUNE - 411 026. Maharashtra, India

Open in Google Maps
  • Home
  • About Us
  • Products
  • EPC projects
    • Water Filtration Plant EPC
    • Wastewater and Effluent Treatment Plant
    • Wind Energy projects
    • Captive Power Plant projects
    • Our Presence
  • Technology
    • QUALITY
    • MANUFACTURING FACILITY
  • Services
    • BOILER RETROFIT AND UPGRADES
    • PLANT MAINTENANCE
    • TAILORED SPARES AND MACHINING
    • CAREFUL COMMISSIONING AND HANDOVER
    • EPC
  • Clients

    SOME OF OUR RECENT CLIENTS

    VIEW ALL
    • Projects

      Elliott Group

    • Projects

      NOCIL LTD

    • Projects

      Mapro

    • Projects

      Nilons

  • Media
  • Blog
    VIEW ALL -
    • Steam Boiler Manufacturer In Maharashtra
      19 October 2022 by bullweb, in Steam Boiler,Steam Jackets
      Steam Jackets in Boilers | Definition, Types, and Applications
      Steam is integral to meet various process operational requirements in manufactur...
      READ MORE +
    • Optipac Boiler
      17 October 2022 by bullweb, in Boiler,Steam Boiler
      Signs that indicate replacement for steam boilers
      Steam boilers are vital equipment for steam generation in the process and manufa...
      READ MORE +
    • huskon bolier
      15 October 2022 by bullweb, in Boiler,Steam Boiler
      Role of Steam Boilers in Textile Industries
      Most manufacturing industries require steam boilers for accomplishing process op...
      READ MORE +
  • Careers
FREEQUOTE
  • Home
  • BLOG & STORIES
  • Boiler
  • Importance of Welding for Steam Boiler Manufacturing
 

Importance of Welding for Steam Boiler Manufacturing

Importance of Welding for Steam Boiler Manufacturing

by bullweb / Friday, 16 September 2022 / Published in Boiler, Steam Boiler

Industrial steam boilers are irreplaceable in almost every industry throughout the world. The energy holding capacity and safety in using steam is a major cause of steam boilers being an ideal choice for process operations. Therefore, industries consider every factor while selecting a steam boiler manufacturer. The quality of the steam boiler is a crucial aspect in deciding on a boiler company. The precision and utilization of high-tech machinery play a vital role in ensuring the superior quality of steam boilers. A steam boiler is manufactured of three primary components i.e. a cylinder, a base, and a cover. Rakhoh Boilers, as a leading steam boiler manufacturer, ensures that the steam boilers are fabricated with utmost safety and precision with excellent welding.

Welding in Steam Boilers:

Welding is a process involving fabrication that joins materials, usually metals or thermoplastics, through fusion, varying from lower temperature metal-joining techniques like brazing and soldering that do not melt the base metal. Combined with melting the base metal a filler material is usually added to the joint, forming a pool of molten material to cool and form a joint. It is generally stronger than the base material. Pressure may also be used jointly with heat or by itself for producing a weld.

Contrary to brazing and soldering that do not involve the melting of base metal, welding includes a high heating process that melts the base material by usually adding filler material. As a result, the high heat causes a weld pool of molten material. Pressure is also used for producing a weld along with the heat or by itself. It also utilizes a shielding gas for protecting the melted and filler metals from contamination or oxidation. A weld joint in a steam boiler is designed for withstanding the subjected forces during its lifespan. Therefore, the design of the joint is decided by the type and load magnitude on the weld.

The welding process is generally categorized as:

Gas welding: Gas welding includes oxy-acetylene gas welding and hydrogen gas welding.

Arc welding: Arc welding includes metal arc welding (SMAW ), submerged arc welding (SAW ), gas metal arc welding (MIG, MAG), electrode slag metal arc welding, tungsten inert gas welding (TIG), flux-cored arc welding(FCAW ), etc.

Resistance welding: Resistance welding includes percussion welding, seam welding, and spot welding.

Thermit welding: Thermit welding involves producing heat by exothermic chemical reactions.

Solid-state welding: Solid-state welding involves friction welding, forge welding, pressure welding, etc.

Special welding process: Special welding processes include electron beam welding, diffusion welding, plasma arc welding, underwater welding, ultrasonic welding process, etc.

Requirements of Tube Welding in Steam Boilers:

The characteristics of boiler tube welding include,

  • Large quantity of tubes
  • Radial and axial clearances
  • Tubes made of carbon steel or other metal with a high strength-to-weight ratio
  • Thick boilerplates of up to 900 mm
  • The strength and consistency of the weld are pivotal considerations in determining the ideal way to weld the pressure vessel tubes as the tubes carry high-pressure steam or liquids in a flowing pattern that can cause a loss in efficiency due to turbulence or distortion.

    One of the most crucial aspects of welding boiler tubes is to determine the ideal option between orbital welding and manual welding. Factors like industrial application tube quantity and safety should be the paramount priority. Therefore, manual welding is the least likely option because of the lack of accessibility.

    Additionally, the welder must decide the best technique to apply. As gas-shielded welding processes are more consistent than other techniques, MIG and TIG are the ideal alternatives. However, MIG leads to the spattering of filler that negatively impacts the weld quality and bead appearance. On the other hand, TIG uses tungsten electrodes, producing the highest purity welds. Narrow Groove TIG or Thick Wall welding processes are best suited for the thick wall boiler applications found commonly in power plants.

    Tungsten Inert Gas Welding with tungsten electrodes results in the highest-quality and consistent welds. Implementing an orbital welding process reduces the lack of accessibility, making it easier for consistency throughout the welding. However, attributes like good heat control, process stability, and fixed position tube welding capability with automated controls should be considered by steam boiler manufacturers for welding machines.

    Common Hazards with Welding:

    Welding leads to hazardous consequences for both welders and those working in the vicinity. Therefore, it is essential to ensure precautions to prevent accidents and injuries.

    Electric Shock:

    As a welder touches two metal objects with a voltage difference leads to the electric shock that can cause severe injuries or death. It is further classified as,

    Primary shock:
    It ranges from 230 to 260 volts that occur by having direct contact with the inside of welding equipment and other grounded metals. Primary shock is extremely hazardous

    Secondary shock:
    It is the most common type of shock occurring while touching the electrode circuit that ranges from 20 to 100 volts

    Prevention for Electric Shock:

  • Avoid touching the metallic parts of the electrode holder with damp skin or clothing.
  • Rubber mats or other insulation for welders.
  • Wear dry gloves.
  • Only qualified technicians should handle welding equipment.
  • Proper inspection of welding equipment and electrode holder.
  • Fire Hazards:

    Welding sparks spray up to 35 feet and may cause fire hazards, severely impacting the workers with grease on their clothing.

    Prevention for fire hazards:

  • Ensure the availability of fire extinguishers.
  • Ensure spacious working space.
  • Store combustible substances and flammable chemicals away from the working space.
  • Use fire-resistant shields.
  • Dusty locations can generate additional risks when welding.
  • Fumes and Gases:

    Welding introduces the personnel to gaseous fumes like ozone, nitrogen, and carbon monoxide that may cause asthma, pneumonia, or cancer.

    Prevention for Fumes and Gases:

  • Minding the head from the fume plume.
  • Ventilation and local exhaust for harmful gases.
  • Use approved respiratory devices.
  • Monitor contaminant levels to determine air quality
  • Physical Hazards:

    Various physical hazards are involved in welding activities like burns, cuts, crushed fingers, and eye damage.

    Prevention for physical hazards:

  • Welding helmets with side shields for protection against UV radiation, particles, debris, and chemical burns.
  • Respirators for protection against gases and fumes.
  • Fire-resistant clothing for preventing burns caused by heat, fire, and radiation.
  • Ear protection for preventing workplace noise hazards and vibration.
  • Boots and gloves to protect welders from hazards like an electric shock and falling objects.
  • Conclusion:

    Rakhoh Boilers is a leading steam boiler manufacturer since its inception in 1983. We are a trusted name in over 26 countries for delivering efficient steam boilers, waste heat recovery systems, thermic fluid heaters, boiler accessories, and boiler services of world-class quality.

    For more details, visit www.rakhoh.com

    Tagged under: "boiler manufacturer in India"

    About bullweb

    What you can read next

    An Overview of Combustion Problems of Biomass Boilers and Its Solutions
    Importance of Heat Exchanger and Tips to Increase its Efficiency
    Boiler Automation System in Process Industries with PLC and SCADA

    Leave a Reply Cancel reply

    Your email address will not be published. Required fields are marked *

    Latest News

    • Steam Boiler Manufacturer In Maharashtra

      Steam Jackets in Boilers | Definition, Types, and Applications

      Steam is integral to meet various process opera...
    • Optipac Boiler

      Signs that indicate replacement for steam boilers

      Steam boilers are vital equipment for steam gen...
    • huskon bolier

      Role of Steam Boilers in Textile Industries

      Most manufacturing industries require steam boi...
    • Prevention of Steam Leakage in Boilers

      Steam Boilers are of utmost importance in the p...
    • Role And Types Of Soot Blowers In Steam Boilers

      Steam Boilers are essential for operational pro...

    Contact Us

    GET IN TOUCH
    T +9120 - 66308333/ 66308340

    Mr. Yogesh Kharde (Sales Manager)

    Mobile no : +91 97654 92017
    Email: enquiry@rakhoh.com

    GET A FREE QUOTE

    Please fill this for and we'll get back to you as soon as possible!

    Explore

    • Home
    • Products
    • EPC Projects
    • Contact Us
    • Sitemap
    • About Us Rakhoh Industries Pvt Ltd

    Products

    • Solid Fuel Fired Bi-Drum Boiler
    • Combo X Boiler
    • Membrane X Boiler
    • Optipac Boiler
    • MINIPAC – SMALL INDUSTRIAL BOILER (SIB BOILER)
    • Huskon Boiler
    • Bi-Drum/D Type/Power X Boiler

    Contact

    GET IN TOUCH
    +9120 - 66308333 +91 97654 92017
    Email: enquiry@rakhoh.com

    RAKHOH BOILERS
    S-11, T Block, M.I.D.C.,Bhosari, PUNE - 411 026. Maharashtra, India

    • Dashboard
    • GET SOCIAL
    Boilers and Steam Boiler Manufacturer In Maharashtra, Pune

    © 2015 All rights reserved. Rakhoh Industries Pvt Ltd.

    TOP