Roxtec GmbH
Neuer Höltigbaum 1-3, 22143 Hamburg GERMANY Tel +49 (040) 657398-0, Fax +49 (040) 657398-50 EMAIL [email protected], www.roxtec.de
D o k u men t : R o x te c -G K W e ldin g in s tr u c tion S te e l+A lu R e v .2 4 .0 6 .2 0 1 5 ; C h n a g e s a n d Mi s ta k e s r e s e rv e d . R e v : J u n i. 2015
Welding instructions
for
GK packing system
Foreword:
The GK packing system is a safety-related component in shipbuilding.
This safety system is of decisive importance on board a ship. For this
reason, all necessary tests according to the latest IMO resolution
A.754(18) have been carried out on the GK packing system and
successfully passed.
In the event of a fire, a collision, or if a leaking medium has to be held
back, you will be dependent on the reliable sealing off of compartments
for the protection not only of the life and health of persons on board
but also for preventing greater damage to the ship itself or even its
loss.
Only when all work on or with the GK packing system has been
carried out with care can the high expectations be satisfied which
are placed on the packing system with regard to fire resistance,
water- and gas-tightness.
All
of
the
information
which
follows
is
intended
as
recommendations which the person carrying out the work should
check for their appropriateness in the individual case.
D o k u men t : R o x te c -G K W e ldin g in s tr u c tion S te e l+A lu R e v .2 4 .0 6 .2 0 1 5 ; C h n a g e s a n d Mi s ta k e s r e s e rv e d . R e v : J u n i. 2015
Table of contents
Section
Page:
Foreword
2
Table of contents
3
Scope of validity
4
Types of frames
4
1. Welding method
5
1.1 Design
1.2 Welding current
1.3 Welding materials
1.3.1 Stick electrode
1.3.2 Welding wire
1.3.3 Shielding gases
5
6
6
6
7
7
2. Cut-out
8
2.1 General information
2.2 Size of the cut-out
2.3 Cut edge of the cut-out
2.4 Shape of the cut-out
8
12
13
13
3. Fitting the frame into bulkhead or deck
14
4. Tacking the frame
15
4.1 Number and position of tacks
15
5. Welding the frame
16
5.1 Checking the welding
17
5.2 Checking dimensional tolerances
17
6. Finishing
6.1 Finishing aluminium structures
18
18
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Welding instructions
Scope of validity:
GK packing system (frame):
Single frames and group frames made of
- S 235 JR / 1.0037 (St37-2)
- S 355 J2G3 / 1.0570 (ST52-3N)
to be welded into suitable / compatible steel plates.
In addition frames made of aluminium AlMg3, mat. no.:
3.3535, EN AW5754 for welding into aluminium panels made of
compatible aluminium.
(As regards other materials please consult ROXTEC-Hamburg)
Types of frame:
SPK/SPR-60
sizes 2 to 8
SPK/SPR
sizes 2 to 8: single and group frames
SPK-S30
sizes 2 to 8: single and group frames
SPK-S50
sizes 2 to 8: single and group frames
SPKh-120/180
sizes 2 to 8
RM connection piece
sizes 50 to 200
Information about other types of frame or materials / material
combinations may be obtained from:
ROXTEC GmbH
Neuer Höltigbaum 1-3
22143 Hamburg
Tel:
040-657 398-0
Fax:
040-657 398-50/51
Email:
[email protected]
D o k u men t : R o x te c -G K W e ldin g in s tr u c tion S te e l+A lu R e v .2 4 .0 6 .2 0 1 5 ; C h n a g e s a n d Mi s ta k e s r e s e rv e d . R e v : J u n i. 2015
1. Welding method
A suitable welding method should be used for welding
GK
single and group frames.In principle there is no different in the welding method between frames without a flange (SPK, SPR) and frames with a flange (SPK-F, SPR-F).
1.1 Design
The connection between the frame and the plate takes the form of a single or a
double fillet weld (depending on design requirements).
Fig. 1.1 Weld details
Minimum and maximum thickness of fillet weld a
Table 1.1
Fillet weld thickness a
Plate thickness t amax [mm] amin [mm]
---
6 4.2 3.0
8 5.6 3.0
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1.2 Welding current
An amperage should be selected which will ensure sufficient fusing of the base
material. In addition, it should be selected such that there is as little heat input as possible in order to avoid unnecessary thermal stress and deformation.
1.3 Welding materials
1.3.1 Stick electrode
With steel structures
One suitable stick electrode is:
Type E 425 B 32 H5 * DIN 1912
Key:
E 425 B 32 H5
H2 content 5 ml / 100 g weld metal
PA and PB weld position
type of current: AC/DC
covering: basic (rebaking at 300 °C; 2 h)
minimum impact energy: 47 J at -50 °C
tensile strength: Rm 420 N/mm²
manual arc welding
or
Type E 4343 RR (B)7 * DIN 1912
Key:
E 4343 RR(B) 7
covering: thick rutile basic
minimum impact energy: 47 J at -20 °C
minimum impact energy: 28 J at -30 °C
tensile strength: Rm 430 N/mm²
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1.3.2 Welding wire
With steel structures
I. A suitable type of welding wire (MAG welding) is:
(1) Type EMK 6D; 1.2 mm; material no.: 1.5125 * DIN 8559 SG 2
or
(2) Type SG3 C Y46 4 3 * Key:
SG3 C Y46 4 3
minimum impact energy: 47 J at -20 °C
minimum impact energy: 28 J at -30 °C
Rm = 530-680 N/mm² RP = 460 N/mm²
shielding gas CO2
. mechanical quality class 3
With aluminium structures
II. A suitable type of welding wire (MIG welding) is:
AlMg 5; dia. 1.2 mm *
The wire feed should be adapted to the conditions prevailing.
1.3.3 Shielding gases
With steel structures
I. A suitable type of shielding gas for welding (MAG) is: For (1) M 2.1 (Corgon 18) shielding gas DIN 32526 - M21 * For (2) C1 (carbon acid) shielding gas DIN 32526 - C1 *
Consumption of shielding gas is given as approx. 15 l/min. *
With aluminium structures
II. A suitable type of shielding gas for welding (MIG) is:
Argon 4.6 *
* All data are recommendations whose suitability should
be verified in the individual case by the company
D o k u men t : R o x te c -G K W e ldin g in s tr u c tion S te e l+A lu R e v .2 4 .0 6 .2 0 1 5 ; C h n a g e s a n d Mi s ta k e s r e s e rv e d . R e v : J u n i. 2015
2. Cut-out
2.1 General information
The location of the cut-out for the
GK
clamping frames should be chosencarefully. The cut-out should be laid out such that the cables, bundled tubing and pipes to be routed straight through the packing frame. In particular the position of the cable racks in front of the frame should be taken into consideration.
The cables and pipes should have a bending radius R2 which in area A (see Fig. 2.1) allows the cables or pipes to be routed at right-angles in parallel through the
packing frame.
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Furthermore, it should be ensured that the frames have sufficient clearance from deckheads, adjacent bulkheads, HP profiles or other components.
A minimum distance of 25 mm is recommended.
Type SPK
(see Fig. 2.2)Fig. 2.2 Minimum distances with frames of type SPK
The frame can also be mounted flush to the bulkhead or deck on one side and there welded with a I-weld seam.
Type SPR
(see Fig. 2.3)Caution! With frames of type SPR it is also important to ensure that the
pressure bolt can be operated.
The threaded hole should also be protected against welding residues
during welding-in.
The maximum possible plate thickness into which a frame of this type can be welded is 8 mm. If plates are thicker a type SPR frame with additional depth should be used.
D o k u men t : R o x te c -G K W e ldin g in s tr u c tion S te e l+A lu R e v .2 4 .0 6 .2 0 1 5 ; C h n a g e s a n d Mi s ta k e s r e s e rv e d . R e v : J u n i. 2015
Fig. 2.3 Minimum distances with frames of type SPR
Type RM sleeve
(see Fig. 2.4)Fig. 2.4 Minimum distances with frames of type RM sleeve
The frame can also be mounted flush to the bulkhead or deck on one side and there welded with a I-weld seam.
If cables and pipes are not routed at right angles through deck or bulkhead it is possible to fit the
GK
frame at an angle in the opening. Here it should be noted that the cut-out dimensions become larger.D o k u men t : R o x te c -G K W e ldin g in s tr u c tion S te e l+A lu R e v .2 4 .0 6 .2 0 1 5 ; C h n a g e s a n d Mi s ta k e s r e s e rv e d . R e v : J u n i. 2015 Fig. 2.5 Fig. 2.6 GK frame at GK frame at an angle up to 5.4° an angle up to 28.35°
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2.2 Size of the cut-out
Type SPK frame:
The size of the cut-out should be such that
an air gap not exceeding 2 mm runs all the way round the
GK
frame which is to be used. In each case the dimension Z = 2-4 mm should be added to the width and height of the packing frame to give the cut-out dimensions.Alternatively, in aluminium structures the air gap will not exceed 1 mm. In each case the dimension Z = 1-2 mm should be added to the width and height of the packing frame to give the cut-out dimensions.
Fig. 2.7
Size of the cut-out
To prevent cracks from forming the corners of the cut-out
should always be rounded
.
Table 2.1 in Section 2.3 gives the radii for the individual types.
Type Rm sleeve:
The size of the cut-out for a sleeve should be such that an air gap not exceeding
2 mm runs all the way round the
GK
sleeve which is to be used. In each case the dimension Z = 1-2 mm should be added to the external diameter of the pipe to give the cut-out dimensions.D o k u men t : R o x te c -G K W e ldin g in s tr u c tion S te e l+A lu R e v .2 4 .0 6 .2 0 1 5 ; C h n a g e s a n d Mi s ta k e s r e s e rv e d . R e v : J u n i. 2015
2.3 Cut edge of the cut-out
A cut-out of sufficient size should be created in the plate for mounting
GK
single or group frames. The cut edges should be vertical (90°) to the surface of the plate.Fig. 2.8
Cut edge of the cut-out
The cut edges must be smooth and without burr in
order to prevent problems in the weld seam.
2.4 Shape of the cut-out
The outline of the cut-out should have rounded corners. The straight cut edges of the openings must be parallel and at right angles to each other.
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Radii for the most important types of frame:
Table 2.1 Cut-out radii
GK
frame types:SPK-60 sizes 2 to 8 R = 12 mm
SPK/SPR sizes 2 to 8: single and group frames R = 12 mm SPK-S30 sizes 2 to 8: single and group frames R = 32 mm SPK-S50 sizes 2 to 8: single and group frames R = 52 mm
SPKh-120 sizes 2 to 8 R = 72 mm
SPKh-180 sizes 2 to 8 R = 102 mm
3. Fitting the frame into bulkhead or deck
The
GK
frame can be installed in any position. They can be installed anywhere space permits and the minimum clearances are observed (see Section 2.1).Fig. 3.1
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4. Tacking the frames
Before being tacked, the frame should be fixed in its installation position such that a constant air gap runs around the entire frame. Tacking should ensure that welding is as distortion-free as possible.
4.1 Number and position of tacks
Tacking should fix the frame in its ideal position. Tacking points should be located as shown in Fig. 4.1. DIN EN 1090-2 should be taken into account when laying out the weld seams. Unnecessary tacks should be avoided if a good weld seam is to be achieved.
Fig. 4.1
Location and number of tacking points
The air gap should not be larger as otherwise the deformation expected after the frame is welded in will exceed permitted values (see Section 5.1.2).
In all cases tacking should be only from one side since
every tack disturbs the structure in the weld seam and
incomplete weld fusion may occur.
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5. Welding the frames
Welding-in is done in several steps (see Fig. 5.1) in order to achieve an even input
of heat. Welding is continued at the opposite position.
Under no circumstances should welding-in be done in just one single
operation. This would result in impermissible deformations of the
frame which would endanger the impermeability of the packed
opening.
Fig. 5.1
Welding sequence
- if welding is required on both sides, welding can be done in fewer steps on the
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5.1 Checking the welding
No breaks are permitted in the weld seams, weld starting points must be carefully
executed and must be impermeable without any gaps so that the packing frame is
watertight and gastight.
5.2 Checking dimensional tolerances
After welding-in and after cooling, the internal dimensions of the frame should be checked:
Table 5.1
Maximum values of the internal dimensions
GK
type D H [mm] [mm] SPK-/SPR-60 60.0 - SPK/SPR 120.0 - SPK-S30/S50 120.0 - SPKh-120 - 120.0 SPKh-180 - 180.0 Fig. 5.2Designation of internal dimensions
These values have a tolerance of ± 1.0 mm.
In the event of a deviation from these values, please contact
ROXTEC
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6. Finishing
The weld seams must be cleared of welding residues.
6.1 Finishing steel structures
Any paint residues (burnt paint) caused by the welding must be completely
removed from the inner surfaces of the frame.
