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FIELD WELDING PROCEDURE METHOD

Process Sheet No. FW0007 Part No. R30555 Ver 01, 07-03

DESCRIPTION: This repair method is for the welding repair of the Tar Sands 138-inch crawler shoe.

PROCEDURE NO: FW0007 DRAWING NO: R30555

AUTHORIZED BY: L. Gunnell DATE: 1-10-2000

BASE METAL: P&H 28X WELD JOINT DETAIL:

WELDING PROCESS: FCAW, Flux Cored Arc

FILLER METAL SPECIFICATION: AWS A5.20

FILLER METAL CLASSIFICATION: E71T-5, E70T-5, E71T-1

ESAB Dual Shield T-5, and or ESAB Dual Shield 70T-12H4,

MANUAL or MACHINE Semi-Automatic

SHIELDING GAS: 75Ar/25CO2 for ESAB

FLOW RATE: 45-55 CFH

FLUX: NA

SINGLE OR MULTIPLE PASS: Multipass

WELDING CURRENT & POLARITY: DCRP

POSITION OF WELDING: (Flat for the T-5), E71T-1 all position

WELDING PROGRESSION: Backhand or Pull technique

PREHEAT TEMPERATURE INTERPASS TEMPERATURE

THICKNESS MINIMUM OF PREHEAT F MIN: (400 F ,D1&D2) MAX: 480 F on D1&D2

MIN. (500 .F on D3) MAX. 650 .F on D3

D1&D2 D3 POST HEAT TREATMENT

TO 400 . F 500. F TIME: 1 hour minimum

OVER TO 1-1/2 400 F 500. F TEMPERATURE: 400 deg. F. For 1 hour min on D1&D2

500 deg. F for 1 hour on D3

OVER 1-1/2 TO 2-1/2 400 F 500. F TECHNIQUE

OVER 2-1/2 400 F 500. F STRINGER (X) WEAVE ( )

IF NONE, AND BASE METAL IS BELOW BACKING MATERIAL: Mild steel ASTM A633 Gr. C&D

32, PREHEAT TO 70 AND MAINTAIN BACK GOUGE: YES ( NO (X )

BUTTERING: Along the side walls during welding

ADDITIONAL NOTES: INSPECTION: Visual and magnetic particle

METHOD:

This process sheet is FOR REFERENCE ONLY. Actual dimension to be taken from part print.
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FIELD WELDING PROCEDURE METHOD
Process Sheet No. FW0007 Part No. R30555 Ver 01, 07-03

WELDING PARAMETERS
PASS PROCESS ELEC- ELEC- AMPS VOLTS WIRE TRAVEL CURRENT OTHER
OR TRODE TRODE SPEED SPEED TYPE &
LAYER DIA. TYPE IPM IPM POLARITY
All FCAW 1/16 E70T-5, 250-500 28-32 226-369 14-16 DCRP FL,HZ

75/25

All FCAW 1/16 E71T-1 300-400 28-30 300-350 14-16 DCRP FL,HZ

75/25

All FCAW 1/16 E71T-1 170-210 21-25 135-150 4-10 DCRP VT,OH

75/25

WELDING INSTRUCTIONS:

1. On each of the face surfaces of the existing and broken piece preheat the part to 4 00 degrees F. on D1&D2 and on D3 to 500
degrees F. Use the air carbon arc process to form a 15 degree bevel on each section of the crawler shoe. The second option would
be to just bevel the one side to 30 degrees and the other side not beveled.

2. The preferred method for preheating would be with the Cooperheat electrical heating resistance blankets to maintain a constant
and thorough preheat.

3. After gouging grind the gouged surface smooth to clean base metal.

4. Check the gouged surface on each section with the magnetic particle to evaluate for any cracks or other defects.

5. If there are any cracks these will need to be repaired before proceeding.

6. Obtain a piece of the ASTM A633 Grade C&D, (3/8 inch thick by 1-1/2 - 2 inches) wide for the backup bar to be used on the
inside of the crawler shoe. The bar will need to be bent and formed to the inside of the crawler shoe to provide a tight fit against
the shoe.

7. The splices of the back up bar will need to be welded to each other with a full penetration weld joint.

8. Insert the backup bar on the inside of the existing shoe and tack to the shoe on the top surface only, not on the inside. The preheat
must be done prior to welding.

9. Next place the broken piece in to position so that there is a 3/8 inch root opening in forming the weld joint. It may be necessary
to have some strong back plates with a coped or half moon hole cut to go over the weld joint on each corner to maintain the
straightness and alignment during the welding operation. After or during welding remove the strong backs and grind smooth.

10. Again the tacking of the backup bar will be in the weld joint and not on the backside.

11. After the two pieces are tacked and aligned in with each other for straightness, then proceed with the welding.

12. The welding process will be with the flux cored arc process. The preferred wire to use would be with the ESAB Dual Shield T-5,
using the 75Ar/25CO2 shielding gas. This wire can only be welded in the flat and horizontal position.

13. Out of position welding will be done with the ESAB Dual Shield II 70T-12H4, also using 75Ar/25CO2 shielding gas.

14. During welding balance the welds around the shoe to minimize any twisting.

This process sheet is FOR REFERENCE ONLY. Actual dimension to be taken from part print.
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FIELD WELDING PROCEDURE METHOD
Process Sheet No. FW0007 Part No. R30555 Ver 01, 07-03

15. After welding maintain preheat on the weld joint for 1 hour. Then turn the blankets off and slow cool.

16. After cool down then check the completed weld with the magnetic particle test for any cracks of other defects.

This process sheet is FOR REFERENCE ONLY. Actual dimension to be taken from part print.
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FIELD WELDING PROCEDURE METHOD
Process Sheet No. FW0007 Part No. R30555 Ver 01, 07-03

This process sheet is FOR REFERENCE ONLY. Actual dimension to be taken from part print.
 Page 5 of 5
FIELD WELDING PROCEDURE METHOD
Process Sheet No. FW0007 Part No. R30555 Ver 01, 07-03

This process sheet is FOR REFERENCE ONLY. Actual dimension to be taken from part print.