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  • 1.High Productivity Welding Processes and AutomationA Look Ahead Matthew Yarmuch, MSc, PEng, IWE Program Leader Welding EngineeringAdvanced Materials Business Unit June 24, 2008

2. The Alberta Research Council

  • Canadas 1 stprovincial research organization
    • Established 1921; 500 employees; Not-for-profit corporation
  • Technical services, R&D and technology commercialization
  • Key market sectors: Energy, Life Sciences
  • Advanced Materials Business Unit
    • 29 employees (12 Ph.Ds & 7 P.Eng.)
    • Areas of Expertise:
      • Coatings and wear engineering
      • Corrosion engineering
      • Welding engineering
      • Polymer/composite materials
      • Materials testing and evaluation
    • Over 100 customers
    • 15 US Patents
    • 6 technologies commercialized

3. Welding Engineering Group

  • Development & implementation of high-productivity technologies
    • Wire-feed Processes
    • Automation
  • Productivity studies for Fabricators
    • On-site productivity monitoring
    • Consumable trials
    • Welding procedure trials
    • Training and consulting
  • Third-part assessments
  • Technical training programs
  • Mechanical & Metallurgical Testing
  • Consulting Services

4. Overview of the Advanced Welding Processes Study and Industry Survey High Productivity Welding Processes and AutomationA Look Ahead 5. Welding Study Background

  • Project Genesis January 2007
    • Welding Automation Forum - NAIT
    • Discussions with industry regarding productivity and automation
    • Funding contributions from ARC, AFE, and EEDC
  • Study Objectives:
    • Identify state-of-the-art in welding technology
    • Provide economic justification for modern processes
    • Identify road blocks and broad industry-wide issues
  • Study Outcomes:
    • Technologies and roadblock identified
    • In-shop comparisons of traditional vs modern processes
    • Economic case for implementation presented
    • Comparison of End User welding specifications
    • Identified industry-wide path forward initiatives

6. Welding Survey Participants Fronius Nardei Fabricators IPSCO Anonymous Fabricator Aecon Industrial CWB Group Anonymous Engineering Firm Melloy Industrial Services Lockerbie & Hole Euroweld Jacobs ATCO Pipelines Paintearth Energy Services KBR Dietech Automation Acuren Husky Energy GLM Industries Plasma Tech Industries ESAB Qualimet Imperial Oil Cessco Fabrication & Engineering Alco Miller Electric & Hobart Brothers Ludwig and Associates Fort Hills/Petro-Canada Dacro Industries Ledcor Air Liquide AMEC Americas TransCanada Pipelines Tornado Technologies Flint Energy Services Lincoln Electric Colt Worley Parsons Suncor Energy Plains Fabrication Willbros ARC Innovations SNC Lavalin Syncrude Canada Collicutt Energy Services PCL Industrial Constructors Roboweld Fluor Canada Ltd Shell Canada Fabricators Pressure Vessels Fabricators Pressure Piping Suppliers and Integrators Engineering Firms & Consultants End Users & Project Developers 7. Albertas Fabrication Industry

  • Demand exceeds supply of skilled labour in Alberta
    • Deficit of 400,000 skilled workers by 2010
    • 42% of companies facing production difficulties due to labour shortages (predicted to rise)
  • Higher Productivity Initiatives Required
    • Improved manufacturing (lean)
    • Wire-feed processes
    • Mechanization and Automation
    • Improved materials handling,
    • machining, prep, etc.

Unique opportunity for Province and Country to become a World Leader 8. Investigation of Welding Applications

  • Survey of End Users to determine current and futurepressure applications

9. Investigation of Future Applications

  • Survey of End Users to determine current and futurematerial requirements

10. Current Utilization of Wire Processes

  • Current process use for pressure piping, vessels, structural, pipeline and field applications
    • Based on responses from all industry sectors

Pressure Piping 11. Utilization of Wire Processes

  • Differences found inindustry perceptions
  • ( process piping )

Entire Industry End Users Fabricators 12. Investigation of Modern Technologies

  • Literature search and survey responses
  • Key technologies identified:
    • Modern Power Sources solid-state inverters
    • Software-based waveform control STT, RMD, CMT, pulse
    • Tubular (FCAW/MCAW) consumable manufacturing advancements
    • Overlay technologies hot-wire GTAW, PTAW, electro-slag
    • Advanced inspection techniques phased array
    • Utilization of mechanized welding and automation

Very few respondents attacked the technology Most concerned with the proper implementation of technology 13. In-Shop Productivity Studies

  • Comparisons of manual vs semi-automated processes
    • On-site studies, utilizing existing equipment, consumables, welders
    • Collaboration with Aecon Industrial, Plains Fabrication, Altex Industries and GLM Industries
  • Shop 1G (Roll) Scenarios:
    • 6NPS XS (0.432 wall) P1SMAW vs. GMAW-MSC/FCAW & MCAW
    • 12NPS XS (0.500 wall) P1 SMAW vs. GMAW-MSC/FCAW & MCAW
    • 24NPS S40 (0.688 wall) P1SMAW/SAW-DC vs GMAW-MSC/SAW-AC
  • Shop/Field 5G (Position) Scenarios:
    • 6NPS STD (0.280 wall) P1SMAW vs. GMAW-MSC/FCAW
    • 12NPS XS (0.375 wall) P1 SMAW vs. GMAW-MSC/FCAW

14.

  • Case Study 6NPS XS Shop Weld
  • Shop 12NPS & 24NPS improvements ranged from35% to 54%
  • 5G Position welds (6NPS & 12NPS) ranged from36% to 46%

Productivity Studies GMAW-MSC & FCAW SMAW 31% 41% 15.

  • Extrapolate data to typical piping module
    • Economic analysis by QGI Consulting, with ARC and Aecon Industrial
    • Welding cost reductions =29%
    • Increased welding labour productivity =36%
    • Net productivity improvement =14.4%

Topic 2 Productivity Study Improvements are expected to rise with further optimization of fabrication procedures 16. Barriers to Acceptance and Use

  • End User welding specification requirements
    • Requirements based on service experience
    • Identified conservative requirements that require new investigations
  • Insufficient welding-related training (all sectors)
    • Average welder not fabrication ready for modern processes
    • Technical workforce (inspectors, technologists and engineers) require more welding-related education
  • Industry Culture - bias against wire-feed & automation
    • Past repeated rejection of GMAW, FCAW and automation
    • Preconceived notion wire-processes unacceptable for pressure welding

17. Barriers to Acceptance and Use

  • Poor industry communication
    • Poor communication between end users, engineering firms, and fabricatorskey stumbling block
    • An industry-based Program required to promote collaboration
  • Lack of investment in modern technology
    • Fabricators are willing to invest, but are reluctant due to past rejection
    • End Users require proof of competency, training, equipment, etc
    • Due to the impasse, a collaborative industry-wide approach is required to spur investments and innovations.

18. Path Forward Strategies

  • Welding Productivity Program (WPP)
    • A collaboration of stake-holder