Harm Melker, Lincoln Submerged Arc Welding ...

8/11/2019 Harm Melker, Lincoln Submerged Arc Welding ...

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Welding of X80.NF.12.1Welding of X80.NF.12.1

Submerged arc welding for the futurea new generation of power sources

Nordic Welding Conference, Oct. 2012

Harm MeelkerLincoln Smitweld B.V.


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OverviewIntroductionTraditional SAW equipment

Process variables

Next generation SAW equipmentProcedure development

Energy savingsFeatures

Conclusions


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Market DemandsLower production costs

increased productionIncreased qualityHigher strength materials

less total weight of construction+ possible lower material costs

Greater flexibility


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Conventional equipment


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SAW process variablesSingle arc

Single wireWelding on DC minus

Tubular Cored WireIron powderLong Stick Out

Narrow gapSemi-narrow gap

Multiple arc

Twin-arcTandemTandem twin3 - 4 - 5 wiresCold wireHot wireSemi-narrow gap


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125

145

190

225


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Machined Grooves Offer Greater

Savings Potential


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Narrow Gap or Narrow GroveNarrow Groove:

Larger gap and radius

Larger sidewall bevel angles, up to 50o

Compound bevels also typicalTypically


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Narrow GapAdvantages:Lower joint volume

Reduced consumables costHigher weld productivity

Disadvantages:

Very difficult to weldMore difficult to repair andremove slagHigher capital cost

PQR requalification costPrecise weld joint fit-up verycriticalNeed for machined joint


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The next generation in Submerged

Arc WeldingState-of-the-Art in inverter technology

Highest capacity available on themarketHigh efficiency inverter

Waveform Control Technology TMGreatest control over the welding

process

Solid State Switching Technology

AC or DC Welding Process


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Constant wire diameter and stick-out

Current [A]

constant voltageand travel speed

Voltage [V]

constant currentand travel speed

Travel speed[cm/min]constant currentand voltage

Influence of current Voltage and Travel

Speed on penetration in SAW


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AC/DC Submerged Arc Welding Unique in the industry Variable polarity for better process

control High deposition

high-speed weldingthick section welding

Penetration profile Arc stability in multiple-arc applications Reduction in heat input

Technologically advanced Waveform control technology Digital communications technology


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time

C u r r e n

t , V o

l t a g e o r

P o w e r

NegativeCurrent Level => DEPOSITION

PositiveCurrent Level => PENETRATION

Frequency

Cycle Balance => PENETRATION & DEPOSITION

Infinitely variable AC

The waveform can be varied to control penetration,bead shape, electrode negative deposition eliminatesarc blow & arc-to-arc interaction by phase shirt control


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Wave Balance

Typically run at 25% positive & 75% negative


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DC Offset Offset is a verysensitive parameter

Typical range limitedto 0 to -10%.8% offset => 25%

balance.

Large values ofcurrent offset

interferes withvoltage regulationcausing systeminstability


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Waveform Control Technology

70% Positive

Penetration = 0.387

50% Positive

Penetration = 0.346

30% Positive

Penetration = 0.242

Positive = 835 Amps

Negative = 519 Amps

Penetration = .366

Positive = 450 Amps

Negative = 822 Amps

Penetration = .280

Wave Balance

Offset


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Deposition rates


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Power Wave

AC/DC 1000

SD

Inverter Power SourceEnergy EfficientDC+, DC- & AC (3 Phase)

CV and CC ModesAC to DC Electronic SwitchWave Balance Control100% Duty CycleFrequency ControlWave Shape DesignProduction Monitoring 2 Weld HistoryIntegrated Multi Arcs

Waveform ControlTechnology


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Systems


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Arc configurations


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Multiple Arc Welding


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Company Herstaco Tube Welding B.V.Adress Nijverheidsweg 24, Middelburg, The Netherlands

Type of businessMetal trading companyTube/pile welding

Project teamDistributor Wagenvoorde Lastechniek, P.Keultjes, T. van Dorst, F, Meyer

Area of cost savings/targetHigher deposition rate by use of Powerwave AC/DC 1000Target; 30% Cost Reduction

Procedure/Follow up

Introduce and demonstrate PW AC/DC 1000

ResultsMore than 33% reduction in labor costsSold SAW welding station, PW AC/DC 1000 with column & BoomConsumables; L61/LW860Deposition rate filling layers from 6 up to 9 Kg/HrWelding time per weld (1060x28mm) in a pile was 60 min., decreased to 40 min.

Practical example: Tube welding


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Practical example: Tube welding

1060 x 35mm

Equipment

Fill

Cap

Travel speed

Welding time

Equipment

Fill

Cap

Travel speed

Welding time

Conventional

DC 1000

500/520 A - 31 Volt

= 6 kg/h650/680 A - 34 Volt= 7.6 kg/h

40 cm/min

60 min.

Conventional

DC 1000

500/520 A - 31 Volt

= 6 kg/h650/680 A - 34 Volt= 7.6 kg/h

40 cm/min

60 min.

Wave Control

PW AC/DC; with 40 Hz;55% DC-; 5% offset550 - 34 Volt

= 9 kg/h720 A - 38/40 Volt= 10.2 kg/h

60 cm/min

40 min.

Wave Control

PW AC/DC; with 40 Hz;55% DC-; 5% offset550 - 34 Volt

= 9 kg/h720 A - 38/40 Volt= 10.2 kg/h

60 cm/min

40 min.


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Herstako cost reduction result based on

labor rate (35,-/hr

Project Humber UK; 350 Piles x 4 = 1400 Welds

Conventional process

Labor costs 1400 x 1hr x 35,-/hr = 49.000 ,-

Wave Control process

Labor costs 1400 x 0.67 hr x 35,-/hr = 32.830.-

Labor Cost savings for this project; 16.170,-Energy savings are there too, but were not calculated, so the total cost saving is more than the calculated 33%. The investment of 1machine is almost paid in 1 project.


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A new procedure replaced a 9 pass single arcapproach with a 2 pass tandem arcCost Savings greater than 50% reduction inweld time and consumable savings

70

36mm2mm

BEFORE

36mm6mm

50

AFTER

13mm Plate 19mm Plate 36mm Plate

Optimising procedures


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Single V

Three Meter Diameter Can

Travel Speed Procedure 1(IPM) 27

Number of Passes 5Deposition Rate (Lbs/hr) 43.24

Time to weld 1 Linear Foot of Weld (Min) 2.222

Time to weld Circumferential Weld (Min) 69.78

Welding Consumables per Joint (Lbs) 50.29

Double V Travel Speed Procedure 2 (IPM) 30

Number of Passes 2

Deposition Rate (Lbs/hr) 62

Time to weld 1 Linear Foot of Weld (Min) 0.8Time to weld Circumferential Weld (Min) 25.12

Welding Consumables per Joint (Lbs) 25.96

Volume saved (24.32 Kg) 48 %

Time Saved (44.66 Min) 65 %

Optimising procedures


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ORIGINAL PROCEDURES

Impacts: 27J @ -20C

Travel Speed = 530 mm/min.

4.0 mm

4.0 mm .950 A 700 A .30 V 34 V

AC

CC+

Deposition rate = 21,5 Kg/hr

Traditional procedure


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Powerwave technology

TANDEM CAPABILITIES

Advantages:

CV & CC mode (CC is prefered).Short distance between wires (one puddle).Better duty cycle rating.

25-35 mm


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Procedure development


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Deposition rates

Summary;

Traditional tandem, 2x4.0mm -20 C and 21kg/hrPowerwave 1x4.0mm/2x2.4mm -50 C and 35 kg/hPowerwave 3x4.0mm -40 C and 45 kg/hr


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Savings with the PW1000AC/DC


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Idle consumption

Increased machine efficiency

Process efficiency

The power consumption of the PW1000AC/DC when themachine is running but not welding.

The Inverter technology used in the PW1000AC/DC has a highefficiency.

PW 1000AC/DC400V 3Ph 50Hz

The Advanced AC Sub Arc process is showing higher depositionand lower Heat input. The energy required to complete one joint isreduced

Importance

Three ways to save energy


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PW1000 AC/DC

Efficiency 86%

Power Factor 0.95

AC 1200

Efficiency 80%

Power Factor 0.81

DC1000

Efficiency 78%

Power Factor 0.73

Three machines running 600A 30V Comparison

KW 20.9

KVA 22

Line current 32A

Idle Power 300W

KW 22.5

KVA 27

Line current 67A

Idle Power 2500W

KW 23.1

KVA 31.6

Line current 32A

Idle Power 2000W

Efficiency, line current and idle power levels are supporting savings

Commonly used in theindustry

PW1000AC/DC versus conventional inverter


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50Vessel fabricationMaterial SA517 Grade 65Wire LNS 133 2.4mmFLUX 960Vessel diameter 1250mm

DC1000

16mm

Layer Amps Volts TS (cm/min) HI (Kj/cm) KJ/layer

1 325 27 75 7.020 2.7552 340 27 75 7.344 2.8833 640 30 95 12.126 4.7604 800 32 110 13.964 5.4815 885 33 110 15.930 6.2536 850 33 110 15.300 6.005

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PowerWave 1000AC/DC

Layer Amps Volts TS (cm/min) HI (Kj/cm) KJ/layer1 325 27 66 7.977 3.1312 340 27 66 8.345 3.2763 640 30 95 12.126 4.7604 800 32 95 16.168 6.3465 885 33 85 20.615 8.0926 880 33 85 20.499 8.0467 850 33 85 19.800 7.772

41.421Total time per joint 26 minutes Total time per joint 34 minutes

Savings: 23.5% weld time per joint, 32% energy cost

The PW1000AC/DC is saving joint time + Energy

GMAW root pass

Field experience Application: SA Twin 2.0mm


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Quality AnalysisAdvanced analysis tool for calculating overall

quality

of a weld based on deviation of wire deposition rate.

Lincoln Smitweld

Start Quality Analysis


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Production Monitoring

Weld History

Diagnostics


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Arc Link - TCP/IP

All components communicate via a network using Arc Link overTCP/IP Protocol

Positioning Control &Power Supply

Wire Drive Control &Power Supply

Clock Signal

Wide Area NetworkMonitor Application

Distributed system architecture


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Application Pipe Mills

Longitudinal pipe welding Conversion standard 3-

and 4-arc welding towave control 3- and 4- arcwelding

1.7m/min travel speedincreased to 2.3m/min

No change to weld beadprofile or mechanical

properties 35% increase inproduction


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STT powerwave MIG + SAW set-up


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Shipbuilding with SAW robot


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SAW robot


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SAW robot


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Conclusions New technology for SA-welding was developed

Inverter technology

Waveform control Cost savings Energy Higher deposition rage up to 30%

Pay-back time of equipment investment Increasing quality

Superior parameter control Diagnostics Weld-log Energy Higher productivity

Fast responding


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Conclusions/Benefits


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Thank you! Questions?

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