KA_MN_SOP_Welding Procedure Hitachi Trucks EH3500, EH4000 PDF

C2 - INTERNAL MINING OPERATIONS PROCEDURE KA_MN_SOP_GENERAL CHASSIS WELDING PROCEDURE Issued by: Mobile Fleet Maintenance Page 1 of 19...

C2 - INTERNAL MINING OPERATIONS PROCEDURE KA_MN_SOP_GENERAL CHASSIS WELDING PROCEDURE Issued by: Mobile Fleet Maintenance Page 1 of 19 Eff. Date: 11/11/24 Rev: 1 Manager DOCUMENT TITLE CHASSIS WELDING PROCEDURE – EH3500, EH4000. PURPOSE To define the procedure for safe and effective welding repairs on cracks found in mobile equipment chassis and structural components, ensuring adherence to AWS D1.1/ D14.3 standards for structural integrity and safety. BRIEF DESCRIPTION OF CHANGE Change to Kansanshi Standard Uncontrolled if printed. Only up-to-date on the intranet. (Original, approved copy filed at the Safety Department)  C2 - INTERNAL MINING OPERATIONS PROCEDURE KA_MN_SOP_ GENERAL CHASSIS WELDING PROCEDURE Issued by: Mobile Fleet Maintenance Page 2 of 19 Eff. Date: 11/11/24 Rev: 1 Manager 1 Revision table DATE PREPARED BY NATURE OF REVISION REV.NO. APPROVED 0 New Procedure Miguel Rodriguez 1 Scheduled Review 2 Change to procedure Uncontrolled if printed. Only up-to-date on the intranet. (Original, approved copy filed at the Safety Department)  C2 - INTERNAL MINING OPERATIONS PROCEDURE KA_MN_SOP_ GENERAL CHASSIS WELDING PROCEDURE Issued by: Mobile Fleet Maintenance Page 3 of 19 Eff. Date: 11/11/24 Rev: 1 Manager Contents 1 Revision table................................................................................................................................2 2 Purpose.........................................................................................................................................4 3 Scope............................................................................................................................................4 4 Safety Requirements......................................................................................................................4 4.1 Site Safety Precautions..............................................................................................................4 4.2 Personal Protective Equipment (PPE)........................................................................................5 5 Welding Standards and Repair Procedures....................................................................................5 6 Responsibility and Qualifications....................................................................................................5 7 Welding Procedure Specification (WPS).........................................................................................5 8 Technical Requirements.................................................................................................................9 8.1 Parts Cleaning and Inspection.......................................................................................................9 8.2 Excavation and weld preparation.................................................................................................10 8.3 Backing strips..............................................................................................................................11 8.4 Welding Process.........................................................................................................................12 8.5 Tack Welding...............................................................................................................................13 8.6 Welding of run-off tabs................................................................................................................13 8.7 Welding Positions........................................................................................................................14 8.8 Welding Technique......................................................................................................................14 8.9 Grinding Procedures....................................................................................................................17 8.10 Final weld Inspection...................................................................................................................18 8.11 Paint............................................................................................................................................19 9 Documentation............................................................................................................................19 10 Repair Standards and References...............................................................................................19 Uncontrolled if printed. Only up-to-date on the intranet. (Original, approved copy filed at the Safety Department)  C2 - INTERNAL MINING OPERATIONS PROCEDURE KA_MN_SOP_ GENERAL CHASSIS WELDING PROCEDURE Issued by: Mobile Fleet Maintenance Page 4 of 19 Eff. Date: 11/11/24 Rev: 1 Manager 2 Purpose To define the procedure for safe and effective welding repairs on cracks found in chassis and structural components, ensuring adherence to AWS D1.1/D14.3 and OEM specification (KO-111- 01, Hitachi – Repair welding manual). 3 Scope This procedure applies to welding crack repairs on the chassis and other structural components of Trucks EH3500 and EH4000. 4 Safety Requirements 4.1 Site Safety Precautions  Safety is the responsibility of all employees. Always follow the site policies and regulations.  Before starting repair work, sufficiently study and understand the repair drawings, and select tools and auxiliary equipment necessary (For example: Scaffold, protectors, cylinder rod protection, etc.).  Only carry out welding, drilling, firing and grinding work on the machines with express authorization from site operation management. Follow the mine-specific lock-out/tag-out procedures.  Prior to commencing gouging, cutting or welding, a detailed assessment of the task shall be made by the supervisor and team members. This is to assess risk and to confirm both the sequence and method to be used, including any specific controls.  Position fireproof barriers around the work area and clear all flammable materials from the vicinity.  Verify the availability of fire extinguishers and ventilation to control fumes.  Do not carry out repair and welding work in the rain and in the presence of strong winds. Uncontrolled if printed. Only up-to-date on the intranet. (Original, approved copy filed at the Safety Department)  C2 - INTERNAL MINING OPERATIONS PROCEDURE KA_MN_SOP_ GENERAL CHASSIS WELDING PROCEDURE Issued by: Mobile Fleet Maintenance Page 5 of 19 Eff. Date: 11/11/24 Rev: 1 Manager 4.2 Personal Protective Equipment (PPE)  Ensure all welding personnel wear PPE, including welding helmets, gloves, safety glasses, silicon mask with filter 2097, ear protection, face shield, and fire-resistant clothing (Apron, spats, sleeves, and jacket). 5 Welding Standards and Repair Procedures All welding repairs must be conducted following the AWS D1.1/D14.3 and OEM specification. 6 Responsibility and Qualifications  Qualified Welding Technician: D1.1, 3G/4G, groove weld qualification, Unlimited (Plate thickness Qualified).  Welding repair supervisor: Five years of experience as a welding Supervisor.  Condition Monitoring/NDT Inspector: SNT-TC-1A – Level II. 7 Welding Procedure Specification (WPS)  Welding shall follow the parameters outlined in the approved WPS. o Welding Process: FCAW. o Electrode: AWS 5.29, E81T1N1-H4 and E111T1- H4, gas mix 75%-25% Argon/Co2, or as indicated on the wire/consumable specification sheet. o Preheat: When ambient temperature is lower than 10 °C (50 °F) and/or presence of humidity, be sure to preheat base metal to 30-50 °C (86-122°F). Material Thickness Preheating Temperature Welding Process/Filler Material/Wire diameter/Gas flow rate High Tensile Steel T< 25 mm 50-100 °C FCAW-G: E81T1N1 – H4 25