Project Overview

GPX Engineering was appointed to deliver welding services, including inspection and certification. Welders used the Pandrol PLA one-shot crucible welding process.

Scope of Works

Innovations

The Pandrol Advanced process uses the smaller, CJ1 one-shot crucible, which is suitable for all standard gap and head wash repair welds (which account for 98.5% of all Pandrol welds cast in the UK in 2019). Pre-installed with a Startwel electronic ignition system, the CJ1 design makes it safer and easier to ignite the portion within the crucible. By using the CJ1 crucible as part of the Pandrol Advanced process, we were able to save on material waste, cost, and reduce manual handling risks. The CJ2 is 2kg heavier and its traditional igniter is classed as an explosive.
Further savings and efficiencies were achieved by:

1. the introduction of an improved cooling procedure that saves 10 minutes per weld
2. the use of a semi-automatic weld shearer to remove the excess weld, which has ergonomic lifting points for ease of use
3. changes to the internal mould design to create a fracture point so that the welder can simply hit off the vent riser with a hammer after 20 minutes, instead of having to use an angle grinder.

The whole Pandrol Advanced process is managed through the Pandrol Connect Welding app on the welder’s mobile phone. Rather than recording data by hand, the welder inputs data into the app before, during and after welding. This is then reviewed by welding controllers and monitored from the office.

Benefits / Project Outcome