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Unique welding slag breaker system for improved occupational safety and sustainable efficiency in the fabrication of water wall panels for thermal boilers

Author

Listed:
  • D. Dinagaran
  • K.R. Balasubramanian
  • S.P. Sivapirakasam
  • N. Prasanna
  • Kuruva Gopanna
  • R. Yoganathan

Abstract

The current literature emphasises the use of submerged arc welding in water wall panel fabrication. However, the manual cleaning of welding slag presents challenges, prompting the development of an innovative slag breaker system within the submerged arc welding process. This manuscript describes the welding slag cleaning process, eliminate hazardous manual operations, and reduce environmental impact. The research further addresses the gaps in the literature by proposing an optimised cycle for water wall panel fabrication, integrating the slag breaker system. The manuscript highlights the benefits of reduced cycle time by 55.8%, enhanced occupational safety and minimised environmental concerns, contributing to sustainable manufacturing practices. The novel slag breaker system's design and integration into the submerged arc welding process are detailed, emphasising its practical application. Results demonstrate a streamlined cycle, significantly reducing manual labour, enhancing occupational safety, improving overall operational efficiency and reveals savings of INR 2,636,480/year emphasising the economic advantages.

Suggested Citation

  • D. Dinagaran & K.R. Balasubramanian & S.P. Sivapirakasam & N. Prasanna & Kuruva Gopanna & R. Yoganathan, 2026. "Unique welding slag breaker system for improved occupational safety and sustainable efficiency in the fabrication of water wall panels for thermal boilers," International Journal of Industrial and Systems Engineering, Inderscience Enterprises Ltd, vol. 53(3), pages 331-349.
    • Handle: RePEc:ids:ijisen:v:53:y:2026:i:3:p:331-349
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