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  • Electrode Guide

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    jayasimha
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    The document discusses various problems that can occur during the electrode melting process such as electrode socket breakages, nipple breakages, and slippages. It lists probable causes for each problem including non-conducting charge, electrode quality issues, machining tolerance errors, nipple prefitting issues, and column vibrations. It then provides ways to confirm the root causes such as examining run time graphs for current and voltage changes and observing gaps in joints. Finally, it recommends actions that can be taken to address each problem such as adjusting overcurrent settings, reducing joining torque, and stopping water cooling for a period of time.

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    electrode handling

    Original Title

    Electrode Guide

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    The document discusses various problems that can occur during the electrode melting process such as electrode socket breakages, nipple breakages, and slippages. It lists probable causes for each problem including non-conducting charge, electrode quality issues, machining tolerance errors, nipple prefitting issues, and column vibrations. It then provides ways to confirm the root causes such as examining run time graphs for current and voltage changes and observing gaps in joints. Finally, it recommends actions that can be taken to address each problem such as adjusting overcurrent settings, reducing joining torque, and stopping water cooling for a period of time.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    Download as pdf or txt
    10 views1 page

    Electrode Guide

    Uploaded by

    jayasimha
    The document discusses various problems that can occur during the electrode melting process such as electrode socket breakages, nipple breakages, and slippages. It lists probable causes for each problem including non-conducting charge, electrode quality issues, machining tolerance errors, nipple prefitting issues, and column vibrations. It then provides ways to confirm the root causes such as examining run time graphs for current and voltage changes and observing gaps in joints. Finally, it recommends actions that can be taken to address each problem such as adjusting overcurrent settings, reducing joining torque, and stopping water cooling for a period of time.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    Download as pdf or txt
    of 1

    Sr Problem Probable Cause Confirmation-1 Confirmation-2 Confirmation-3 Confirmation-4 Action -1 Action -2 Action -3

    Breakage occurred during See Run Time Graph. Sudden See Run Time Graph. Sudden Regulation Check for Overcurrent
    Heavy Scrap Collapse Initial few minutes Of Rise in Currents just before Drop in Voltage just before Setting and Column Speed during
    Melting Breakage Breakage Arcing
    Run Time Graph of Currents
    Breakage occurred during Run Time Graph of Hyd Operation Practice ,
    1 Electrode Socket Breakages Non Conducting Charge for sudden reduction & Electrode Saver Alarm
    Initial few minutes Of Pressure for sudden Fall just Check Electrode Saver Setting Change in Arcing
    / Skull Voltage for sudden Rise just before Brk
    Melting before Breakage Pattern
    before Breakage
    Comparitively Higher No. of Breaks with LOW AD (<1.67)
    Electrode Quality Lot Specific / Plant Specific
    Breakages Stocks
    Reduce the Joining Torque by 15 -
    Transition Joint Centre Shear
    20% during Transition
    Gap in Joint confirmed by
    Stop Water Cooling
    Within initial 2 -3 Heats after Molten Pitch , Water Oxidation Gap in Middle / Lower Joint of
    Machining Tolerances Prefit Nipple loosening for 2 Hours after New
    2 Nipple Breakage Addition , Arcing on Faces of Broken Broken Column
    Addition
    Electrodes
    Grind Broken Nip
    Within initial 2 -3 Heats after Broken Nipple Sample to be sent
    Nipple Quality Even in Flat Bath Lot Specific / Plant Specific Sample to see
    Addition to Nsk for Testing
    Lamination / Coring
    If Inter-Plant
    Within initial 2 -3 Heats after Reduce the Joining Torque by 15 -
    Transition Joint Transition, consult
    Addition 20% during Transition
    Plant
    In Flat Bath Dip E-1, Current in
    Clock-wise Phase Gap in Middle / Lower Joint of Cos-F between Request Customer for Changing
    3 Slippage Without Nipple Clockwise Flat Bath Rotation E1 & E-3 should rise, E2 should
    Rotation Slipped Column 0.7 to 0.85 the Phase Sequence
    remain constant
    Stop Water Cooling
    Within initial 2 -3 Heats after Gap in Middle / Lower Joint of
    Machining Tolerances Last 3 -4 Threads intact Prefit Nipple loosening for 2 Hours after New
    Addition Slipped Column
    Addition
    Gap in Middle / Lower Joint Nipple Lossening during End
    4 Slippage With Nipple Nipple Prefittig Lot Specific / Plant Specific Prefit Niple Tightening
    of Slipped Column Cap Removal
    Gap in Joint confirmed by
    Machining Tolerances + Match Mark Reverse Error Column Severe
    Some times Nipple Breakages & Molten Pitch , Water Gap in Middle / Lower Joint of Regulation Testing , Electrode
    5 Column Vibrations during usage after 10 - 12 Vibrations during Initial
    Some times Slippages Oxidation , Arcing on Faces Slipped Column Arcing Speed will be much Higher
    (E+M) Heats Period of Arcing
    of Broken Electrodes
    Long & Deep Cracks upto Cracks more with Low AD Change in Melt Profile to use
    Short Arc Operation Increrase in DRI %
    Joint Stocks Higher Voltage Tap
    6 Tip Cracks
    Cracks below and Above Reduce the Joining Torque by 15 Increase in Water
    Higher Electrode CTE(L) UHP-LF / HP-Dp Stocks
    Lower Joint % Cooling Qty.

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