Aluminum Welding Wire For Heavy Duty Applications
When it comes to high production aluminum welding, not all aluminum welding wires are created equal. In demanding welding environments, standard aluminum wire can result in inconsistent wire feeding and poor arc characteristics resulting in costly downtime. IndalcoÂŽ welding wire was developed to address those common problems and make the aluminum welding process easier.
Standard Aluminum Wire
Indalco
Even in the most demanding aluminum applications, Indalco ensures smooth and trouble-free wire feeding without wire shavings. When it comes to the most demanding aluminum applications, let Indalco do the heavy lifting. Authorized Distributor: Cotmac Industrial Trading Pvt. Ltd. www.cotmactrading.com Contact Person: Arjun Sirur Mobile: +91 98231 20220 Email: arjun.sirur@cotmac.io
Wire shavings during the feeding process with standard aluminum wire versus Indalco
EDITOR'S DESK
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E-Market Launched!!! Dear Readers, The Oct-Nov. 2018 Issue has been published with collection of interesting articles like Welding in Subsea Project-Inconel 625 Cladding over C-Steel Forging; Micro plasma arc welding in small scale welding process; oil & gas segment overview; etc. The topics covered would again satiate your hunger for Welding Knowledge. Just in case, our readers have missed reading past Issues, please visit WFTT website (www.weldfabtechtimes.com). Enjoy the digital version anytime – anywhere. Some good news for the welding and fabrication segment! You can now sell your products online, through the E-MARKET portal of WeldFab Tech Times Discounted Rates. We believe that the E-MARKET space seems to be a great
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4
WELDFAB TECH TIMES | OCT - NOV 2018
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www.weldfabtechtimes.com
CONTENTS 6
INDEPTH
16
TIP-TIG welding for submarines
ARTICLE
20
WELDING TIPS
34
Micro plasma arc welding in small scale welding process
Welding in Subsea ProjectInconel 625 Cladding over C-Steel Forging
INNOVATIONS
46
WELDFAB TECH TIMES | OCT - NOV 2018
42 Good looks aren’t everything - especially in welding
INTERVIEW
38
Local Vacuum technology EBFLOW
We are investing in getting new technologies to India
www.weldfabtechtimes.com
CASE STUDY
30
Belarusian NPP on progress
LAUNCHES
WOMEN IN WELDING
28
56
XMT 350 FieldPro system with Polarity Reversing
EVENTS UPDATE
08 50 52
TENDERS
58
BULLETIN PRODUCTS UPDATE
www.weldfabtechtimes.com
“I aim to always learn and grow as a welder and educator”
Sector Watch OIL & GAS
62 OCT - NOV 2018 | WELDFAB TECH TIMES
7
BULLETINS
IIW organizes 1st National Skill Competition on Best Welders (Woman) in Chennai
I
ndia is ranked 121st out
Engineering Ltd., Amreli, R. K.
of 131 countries in female
Dutt Concerns, Thane, C. V.
workforce participation
Raman College of Engineering,
and it is therefore widely
Bhubaneswar and Pundit Din
believed that if gender parity
Dayal Petroleum University,
in workforce is achieved, India
Gandhinagar. This event was definitely
can increase its GDP by 16 per cent which in turn can
a milestone in the history of
go a long way to boost the
Welding in INDIA. It was a very tough
stagnating economy. Today, women in India are striving for equal participation
Many dignitaries were
Chairman, IIW-India Chennai
competition in four categories
Branch and Shri Rituraj Bose,
viz., Best Structural Welder
in every sphere of industrial
present during the event,
Chairman, National Skill
(Woman) in SMAW Process,
activity and Welding is no
to make the day even more
Competition – Best Welder,
Best Structural Welder
exception. To encourage the
historical and memorable in
IIW-India; were also present
(Woman) in GMAW Process,
Women to make their career in
the lives of all women who
among other dignitaries.
Best Pipe Welder (Woman) in
Welding, The Indian Institute
had put all their heart to
Significant number of
GMAW Process and Best Pipe
of Welding (IIW) had organized
prove themselves and add on
contestants from various
Welder (Woman) in GTAW
the ‘Best Welder’ competition
pride to their lives. Dr. Arun
sectors who are engaged
Process.
exclusively for women at the
Kumar Bhaduri, Distinguished
in manufacturing through
National Level, for the first
Scientist & Director, IGCAR,
welding had participated in
Prakash Patole of Mahindra &
time, on 12th October 2018,
and President of IIW-India
categories like: Shielded Metal
Mahindra in Best Structural
at Kemppi India premises,
inaugurated the occasion
Arc Welding, Gas Metal Arc
Welder (Woman) in SMAW
Chennai.
through lighting of the lamp.
Welding & Gas Tungsten Arc
Process and Ms. Rasika Prakash
Dr. Shaju K. Albert, Vice
Welding.
Lokhande of Mahindra Vehicle
The event was supported
8
systems.
The participants include
The winners are – Ms. Arati
Manufacturers Ltd. in Best
by M/s Kemppi India Pvt.
President, IIW-India; Shri
Ltd., Chennai – a 100% owned
Rashmi Ranjan Mohapatra,
18 from IGCAR, Kalpakkam,
Structural Welder (Woman) in
subsidiary of leading Finnish
Managing Director, Kemppi
Integral Coach Factory,
GMAW Process.
company manufacturing
India Pvt. Ltd.; Shri Devasis
Chennai, Mahindra &
Digitally Controlled Welding
Paul, Director, Nextgen Plasma
Mahindra Ltd., Mumbai,
Women Welders for their
Equipment and M/S Nextgen
Pvt. Ltd.; Shri Somenath
Mahindra Vehicle
future welding career.
Plasma Pvt. Ltd., Kolkata –
Ghosh, Assistant Director, Skill
Manufacturers Ltd., Pune,
manufacturers & integrators of
Development Programme,
GE India Industrial Pvt.
For more information please
automated welding and cutting
IIW-India; Shri T.V. Prabhu,
Ltd., Pune, Reliance Naval &
visit: www.iiwindia.com
WELDFAB TECH TIMES | OCT - NOV 2018
Best wishes to all of the
www.weldfabtechtimes.com
BULLETINS
Panasonic Welding Systems India supports AOTS (Japan) & CII (India) to organize Technical Seminar and Workshop on ‘High Precision Arc Welding Technology in India’
A
OTS, Japan (Association for Overseas
Technical Cooperation and Sustainable Partnerships) and Confederation of Indian Industry, India (CII) organized a Technical Seminar and Workshop on ‘High Precision Arc Welding Technology’ at Ahmedabad on 23-24 Oct 2018. The seminar was organized at Hotel Hyatt Regency, Ahmedabad and the practical demonstration
(welding consumables) and
(Group Executive Director,
India’ vision, this initiative is
of Japanese latest welding
Iwatani Corporation, Japan
Kataria Automobiles Pvt
expected to foster the growth
technology was conducted
(shielding gas).
Ltd) , Mr Masafumi Himeno
of personnel engaged in the
The seminar served as
(Divisional Director-SFS
manufacturing sector, Welders
University (GTU), Ahmedabad
an opportunity to promote
Division, Panasonic India
and Welding Technologists in
on both the days. This training
welding technology which
Pvt Ltd) and Prof (Dr) S.D.
particular.
program at Ahmedabad
remains the most critical for
Panchal ( Registrar, GTU)
Expressing his views on
was funded by Ministry of
industrial sectors required to
.The seminar served as a
the occasion, Mr Masahide
Economy Trade and Industry,
assure long-term reliability
platform to promote Japan’s
Sato referred to Japanese
Japan (METI).
across applications such
latest high-precision welding
Prime Minister Mr Abe’s visit
at Gujarat Technological
as Fabrication of Building,
technology into India. The
to India on 13-15 Sept 2017
and last such METI supported
Bridges, Process Plant
eminent faculty included Prof.
& re-iterated Japan’s strong
training program will be
Equipment, Manufacturing of
Fumiyoshi Minami (Joining
support for initiatives such
scheduled on 13 – 14 Dec,
Automobiles, Railways, Ships,
& Welding Research Institute
as “Make in India”, “Digital
2018 in Jamshedpur. First
etc.
–JWRI, Osaka University,
India”, “Skill India”” and
Japan),who delivered
“Start-up India”. He also said
Besides, the upcoming 3rd
program in this series was
Some of the key dignitaries
held at Chennai (22-23 Aug
present at the occasion were
valuable lecture on “Welding
“Strong India benefits Japan
2018). Panasonic Welding
(Chief Guest) Mr. Masahide
Mechanics and Design for
and Strong Japan benefits
Systems was an Industry
Sato (Dy Chief of Mission,
Smart Manufacturing”.and
India”. Japan has already
Partner by providing lecture
Consulate General of Japan in
Mr Masaharu Sato, (Japan
started taking significant
and practical demonstration
Mumbai), Mr Rajendra Shah
Welding Engineering Society-
measures to improve the
on latest welding Equipment
(Vice Chairman-CII Gujarat
JWES ,Japan), who covered
human resource in India and
and Robot technology to
State Council & Chairman,
topics on “Importance of
we shall continue to support
improve productivity of Indian
Harsha Engineers Ltd), Mr
International Standards on
such kind of initiatives in
metal fabrication industry.
Hisashi Kanda (General
welding quality control and
India.”
Other industry partners were
Manager, AOTS-India),
qualification of welders”.With
Kobelco Welding, Japan
Mr Dharmendra Mishra
an aim to support ‘Make in
www.weldfabtechtimes.com
Mr Hisashi Kanda, AOTS, India stated “AOTS
OCT - NOV 2018 | WELDFAB TECH TIMES
9
BULLETINS
to welding called –National welding month which is April month .Welding is an essential part of everyday life. From cars to high rise office buildings, airplanes to rockets, pipelines to highways, none of it would be possible without welding.” This Technical workshop and seminar is attended Japan promotes technical
that we truly acknowledge
supports the concept of “Make
by more than 130 nos. of
cooperation of Japan
the contribution of welding
in India”. It means India need
participants from many sectors
with other countries and
to manufacturing sector.
to be able to increase export
like Automotive Industry,
despatches experts from Japan
This workshop is 2nd in the
of India manufactured goods
Energy sector, Plant assembly,
to these countries in order
series of 3 such workshops
and for which latest Japanese
Oil upstream and Downstream,
to upgrade human resources
funded by METI. Japanese
technology Welding machines
Transformer manufacturing,
there. AOTS is already actively
manufacturing technology
and Robots can support
General fabrication etc
working in 43 countries having
is far ahead that of India. We
Indian industry to upgrade to
and Educational institutes
offices there and has plans
acknowledge the support
international level.
like Gujarat Technological
to expand in many other
of Japanese experts to
countries. For this workshop
support upgrade Indian
added that “Welders build
University ,International
also AOTS has arranged to
manufacturing.
the world we live in. Many of
Automobile Centre for
you may know that America
Excellence, Japan India
has dedicated one full month
Institute of Manufacturing etc .
send experts from Japan. Mr. Rajendra Shah spoke
Masafumi Himeno said that this training program
University, PDPU, Rai
ESAB acquires Gas Control Equipment
HFT develops leaktight argon gas feed hose
E
Control Equipment (GCE).
well as cutting and welding
H
With headquarters in Malmö,
equipment," says Shyam
hose assemblies with leaktight
Sweden, GCE is a leader in
Kambeyanda, President,
fittings. They provide welders
European gas equipment,
ESAB. "The opportunities
with a method to feed non-
offering full solutions for
created by combining GCE
contaminated argon gas into
general industrial, healthcare,
with ESAB's global presence
their welding zone.
high-purity, as well as science
and continuous improvement
and research applications. GCE
culture will drive both
hose comes with an argon
argon gas regulator, while the
employs more than 900 people.
businesses to achieve new
regulator that connects
prefitted other end joins up
heights of success."
directly to an inflatable tube
with all HFT Argweld® weld
brands and a rich tradition.
and pipe weld purging system
purging systems.
GCE businesses have more
at one end and to the gas
than 100 years of experience
source at the other.
SAB Welding & Cutting
and distributing equipment
Products announced
for pressure and flow control
that it has acquired Gas
of high pressure gases, as
"GCE offers industry-leading
developing, manufacturing
10
Prof (Dr) S.D. Panchal
WELDFAB TECH TIMES | OCT - NOV 2018
Source: www.esabindia.com
untingdon Fusion Techniques (HFT) manufactures
tailor-made argon gas feed
The natural rubber feed
A selection of adapters is
provided for attaching the
Source: www.canadianmetalworking.com
www.weldfabtechtimes.com
BULLETINS
GMR Group setting up Defence Manufacturing Hub at GKSIR in Krishnagiri, TN
T
Source: www.gmrgroup.in
he GMR Group, India’s
as its key nodes and aims to
Major Defence Public Sector
manufacturing hub can
leading infrastructure
provide impetus to the defence
Undertakings (DPSUs) like
potentially be a game changer
company, is setting
production industry in the
Hindustan Aeronautics Ltd
for the region. We will be
up an 'Aerospace & Defence
country and in the region,
(HAL), Bharat Electronics Ltd
providing all the necessary
Manufacturing Hub' at its
in particular. The proposed
(BEL), Bharat Earth Movers
infrastructure facilities to attract
Special Investment Region,
defence manufacturing hub
Ltd (BEML) and Defence
global majors to set up their
Hosur (GKSIR), Krishnagiri
at GKSIR, Hosur is a step in
Research and Development
manufacturing facilities here.
district in Tamil Nadu,
making this vision a reality.
Organization (DRDO) are
GKSIR Hosur is keen to set
only 50 – 60 km. The hub also
an international benchmark.
to encourage indigenous
The project is a Joint Venture
production of defence
(JV) between GMR Group and
benefits from the established
GMR Group is world renowned
equipment in the country.
the Tamil Nadu Industrial
industrial ecosystem in Hosur,
infrastructure developer and
Development Corporation
700+ MSMEs engaged in
we already have an excellent
initiative, the government has
(TIDCO). Under this project,
precision engineering in the
track record of creating mega
recently announced setting
approximately 600 acres of
region. Proximity to Bangalore
infrastructure projects in India
up of a Defence Industrial
prime industrial land has been
ensures ready access to skilled
and abroad”.
Production Corridor (DIPC) in
made ready for immediate
manpower.
Tamil Nadu. The corridor will
occupation.
Under the ‘Make in India’
The GKSIR team will be taking potential investors
BVN Rao, Business
connect Hosur and Chennai –
The proposed hub is an
Chairman-Transportation &
through the salient points of the
with Kattupalli port, Chennai,
ideal location for defence
Urban Infrastructure, GMR
project and discuss potential
Tiruchi, Coimbatore and Hosur
related manufacturing.
Group said, “This defence
opportunities for investments.
www.weldfabtechtimes.com
OCT - NOV 2018 | WELDFAB TECH TIMES
11
BULLETINS
EC launches antidumping investigation for imports
T
Kuka aims to grow subcontract welding services
antidumping investigation
N
into imports of hollow
Kuka’s subcontract friction
sections, welded tube and
welding facility in Halesowen
he European
ew technical sales
Commission
engineer Rob Wilkes
has launched an
and technical services
manager Jayne Shimwell at
pipe steel from Macedonia,
Friction welding specialist
Russia and Turkey. The
Kuka Systems UK has signalled
Source: www.pesmedia.com
complaint was lodged in
in drilling for oil or gas. The
its ambition to grow its
treatment and metallurgical
August 2018 by the Defence
products concerned currently
subcontract operation with
analysis and testing services.
Committee of the welded
fall under CN codes 7306 61
the appointment of a new
steel tubes Industry of the
92 and 7306 61 99.
technical sales engineer.
boosted with the addition of
New technical sales
a refurbished friction welding
European Union on behalf
The investigation of
The facility has also been
of producers representing
dumping and injury will cover
engineer, Rob Wilkes has
machine specifically for joining
more than 40% of the total
the period from 1 July 2017 to
joined the Halesowen-based
piston rod components. There
Union production of hollow
30 June 201. The examination
company with a brief to win
are nine machines at the site
sections.
of trends relevant for the
new business for Kuka’s
for handling a wide variety
assessment of injury will
in-house services which
of rotary and linear friction
investigation is welded tubes,
cover the period from 1
include joining components
welding process applications.
pipes and hollow profiles of
January 2015 to the end of the
for manufacturers in the
Plans are already underway
square or rectangular cross-
investigation period.
aerospace, automotive and
for the operation to move into
construction machine sectors.
larger premises near its existing
The product subject to this
section, of iron other than
Provisional measures
cast iron or steel other than
may be imposed no later
stainless, but excluding line
than seven months from the
for promoting Kuka’s facility,
Kuka’s ongoing investment
pipe of a kind used for oil
initiation of the investigation.
one of the largest in Europe,
programme in its advanced
which offers subcontract
welding systems and services
friction welding, induction heat
in the UK.
or gas pipelines and casing and tubing of a kind used
Source: www.steelguru.com
Mr Wilkes will be responsible
site later this year as part of
Airgas opens welding, packaged gas store in Dacono
A
a retail store at 4016
from the company, the staff
Joe Collier Drive in
relocated from Airgas’ former
Dacono. The branch sells
location in Boulder and have
welding supplies, gases and
a combined 50-plus years
irgas recently opened
According to a news release
safety protection, as well as
Source: www.greeleytribune.com
propane tank exchange and
Regional distribution, at 4016 Joe Collier Drive in
counties. Regular operating
account, fill plant and
Dacono, will fill nitrogen and
hours are 7 a.m. to 5 p.m.
eBusiness managers work with
and industrial companies in
propane cylinders on site.
Monday-Friday. Six people
district and area management
northern Colorado, the new
The branch will also make
are staffed at the branch, near
to provide additional support
10,000 sq ft location, located
deliveries in Weld and Boulder
Colo. 52 and Interstate 25.
to the branch.
food-grade CO2 tanks. Located near manufacturing
12
experience in the industry.
WELDFAB TECH TIMES | OCT - NOV 2018
www.weldfabtechtimes.com
BULLETINS
TSTC welding technology ranks 7 in the nation is off to a good start
T
TSTC’s Welding Technology
for one program at
program will learn hands-
Texas State Technical College
on about arc welding, gas
in Harlingen which was just
tungsten arc welding, layout
named one of the top 10 in the
and fabrication and multiple
nation.
process welding.
he Fall 2018 semester
Students who graduate from
Welding Technology was
Once the program is
recently ranked number seven
successfully completed,
in 2018 as one of the best
Welding Technology graduates
welding programs in the U.S.
can find work throughout
by Washington Monthly, a bi-
the state in manufacturing without too much debt.
monthly nonprofit magazine
www.WashingtonMonthly.
based in Washington, D.C. that
com, the magazine rates
focuses on the United State
schools based on three
offers two certificate tracks:
and steel erection operations
Government.
equally weighted criteria:
Structural Welding and
as pipefitters, steamfitters,
social mobility, research and
Structural and Pipe Welding,
welders, cutters, solderers
2018 Washington Monthly,
public service, and awards
and an associate degree track.
and brazing machine setters,
“Introduction: A different kind
colleges based on the number
It takes approximately three
of college ranking,” by Kevin
of students they accept, help
to four semesters to complete a
Carey, which can be found at
graduate and earn a good living
certificate or associate degree.
Based on an article in the
shops, maintenance shops,
Welding Technology
ship building yards or oil fields
operators and tenders. Source: www.valleymorningstar.com
Phoenix Announces ABS Class A Wet Welding Approval
LLCC - Taylorville hosts open house for updated welding lab
P
hoenix International Holdings, Inc. (Phoenix) announces it
has received American Bureau of Shipping (ABS) approval of a Class A wet underwater fillet Welding Procedure Specification for ASTM A 131 and Group II steels of the
Source: www.foxillinois.com
American Welding Society
L
new flooring and welding
D1.1 structural welding code.
Community College-
project was funded through an
curtains, and energy efficient
With this procedure, Phoenix
Taylorville hosted an
anonymous gift combined with
ventilation and lighting
can now perform permanent
open house to showcase its
LLCC Foundation and college
systems. It has 12 machines,
underwater weld repairs to
newly updated & renovated
funds. The project includes
wherein each perform MIG,
Classed vessels and structures.
welding lab.
new welding lab equipment,
TIG and stick welding.
incoln Land
www.weldfabtechtimes.com
The $275,000 welding lab
Source: www.maritime-executive.com
OCT - NOV 2018 | WELDFAB TECH TIMES
13
BULLETINS
3D welding simulators secure jobs for future Ivy Tech, Toyota
T
he Palaszczuk
training simulators at a total
go to deliver the $5 billion
Government is
cost of up to $800,000.
landmark LAND 400
securing jobs of
defence deal which will see
enable TAFE SkillsTech
Queensland playing the
new equipment to train
to increase the speed at
leading role manufacturing a
Queenslanders faster in
which students can become
new generation of vehicles for
welding qualifications which
qualified to the ISO 9606
the Australian Army,” he said.
are in high demand by
welding standard.”
defence and manufacturing industries.
“More Queenslanders
I
vy Tech Columbus and Toyota Industrial Equipment Manufacturing
(TIEM) unveiled a new opportunity for manufacturing
The investment would help
achieving ISO 9606 level
students. The new Toyota
address a national shortage of
welding qualifications in
Industrial Equipment Welding
ISO 9606-qualified welders as
faster timeframes means
Lab opened its doors during
Development, Manufacturing,
identified by Weld Australia.
more Queenslanders eligible
Sept, 2018, thanks to a
Infrastructure and Planning
ISO 9606 qualifications
to get involved in delivering
$350,000 donation from the
Cameron Dick joined with
represent the international
on this major contract, and
company.
Minister for Training and
standard required for
more Queenslanders able to
Skills Development Shannon
precision welding of materials
access high-skilled, well-
tripled the current size of the
Fentiman at Parliament
needed in industries such
paid careers in the defence
college’s lab at the Columbus
House to demonstrate new
as defence, maritime and
manufacturing industry more
campus from 890 to 2,450
3D augmented reality systems
advanced manufacturing.
broadly.
sq ft. It features 20 metal
Minister for State
for training welders.
Training with the
“This is an important
The expansion nearly
welding booths with individual
augmented reality system
part of our journey as a
ventilation systems, precision
welders to have the
is considerably faster
government, as we continue
and multi-process welding
technology and coursework
than traditional welding
to position Queensland as
machines, plus an assortment
to meet the international
training, enabling us to get
the nation’s defence and
of accessories, including
welding standard increasingly
experienced welders to the
advanced manufacturing
a virtual reality welding
being required for major
ISO 9606 level in reduced
powerhouse and create the
simulator. TIEM also donated
defence and commercial
time and cost over traditional
jobs of the future.”
19 engines to the college,
projects, so we are planning
training methods.
“We want Queensland
Five welding simulator
enabling students to train and
for the future,” said Mr. Dick.
The technology is also
units will be based at
learn about engine engineering,
“Skilling Queenslanders
mobile, allowing it to move
SkillsTech in Acacia Ridge,
components, and repair.
with the right qualifications
where the training demand is
with the remaining five to
Graduates of the welding
desired for these projects
in support of major projects,
be based in regional areas
program can earn a certificate
will make Queenslanders
including industry sectors
such as North and Far North
in Welding Technology in
more competitive in securing
such as maritime and broader
Queensland.
one year or a certificate in
this work and strengthen
manufacturing.
Queensland’s chances of
Mr Dick said Rheinmetall
Minister for Training and
Structural Welding in eight
Skills Development Shannon
months. American Welding
winning contracts which
Defence Australia has
Fentiman said the Palaszczuk
Society certificates in Shielded
deliver economic benefits to
identified a need for ISO
Government provides funding
Metal Arc Welding, Gas Metal
our whole state,” he added.
9606 qualified welders as
to assist more Queenslanders
Arc Welding, and Gas Tungsten Arc Welding are also available.
part of its recruitment for its
to get the skills they need
Queenslanders to keep
new Military Vehicle Centre
to get a job in high priority
pace with industry demand
of Excellence, as well as its
industries.
for qualified welders by
future supply chain.
“Our government is helping
purchasing 10 state-of-the-art augmented reality welding
14
“These simulators will
the future by funding
open new welding lab
for welders is forecasted by the
“We want Queenslanders trained up and ready to
WELDFAB TECH TIMES | OCT - NOV 2018
Ivy Tech reports that a 10 per cent increase in demand year 2024.
Source: www.miragenews.com
Source: www.localnewsdigital.com
www.weldfabtechtimes.com
INDEPTH
TIP-TIG welding for submarines Source : www.asc.com.au
T
he Australian builder and
ASC’s partnerships with subject matter
maintainer of the Collins Class
experts and research organisations are a
Submarine, ASC, had signed
high priority,” said Mr Whiley.
a strategic cooperation agreement with Australia’s Defence Science
continued collaboration with DST
and Technology (DST), renewing a
and look forward to further benefits
relationship that has produced successful
for Australia’s operational submarine
collaboration and innovation across
fleet, the Collins Class, across
Australia’s submarine fleet.
ASC’s responsibilities in submarine
ASC Chief Executive Officer, Stuart Whiley said that the collaboration with
maintenance, sustainment, upgrades and
technique this year; • Materials, including main motor banding refurbishment; • Hydrodynamics, including assessing changes to sonar fairing designs; • Signatures, including radar absorbing materials on submarine masts; • Diesel engines (performance improvements, condition monitoring).
life-of-type extension.” ASC and DST have worked together
TIP-TIG welding for submarines
defence research organisation was
for many years. Since ASC and DST last
ASC has successfully passed explosive
critical to the company’s commitment to
formalised the collaboration in 2013, the
tests for an advanced new welding
continuous improvement.
organisations have delivered positive
technique for submarine hull steel in a
Australia’s leading government sector
outcomes for Australia’s Submarine
development that opens the way to more
maintainer of the Collins Class fleet,
Enterprise in the following areas:
efficient and reliable welds for Australian
which will be in service into the 2040s,
• Submarine structures, including the
submarines.
“As the builder, design authority and
16
“I’m delighted to secure ASC’s
certification of a new hull-welding
WELDFAB TECH TIMES | OCT - NOV 2018
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INDEPTH
The newly approved TIP-TIG welding method is a more consistent and improved welding process and is expected
submarine hull fabrication and welding capability. “Proving this advanced application of
to lead to increased efficiencies for
TIP-TIG welding for the high tensile, low
submarine sustainment while retaining a
carbon steel used in the Collins Class
safe environment for submarine crews.
submarine pressure hulls means we will
To gain Commonwealth approval, ASC-
achieve even higher quality and reliability
welded test specimens of the hull steel
in our future work on Australia’s fleet of
had to pass repeated explosive bulge tests
Collins Class submarines,” Whiley said.
at a facility in Victoria. The tests involved
“And it demonstrates our ongoing “Today, those same disciplines and
a one square metre specimen of Collins
capability in ‘build like’ skills, leveraging
Class hull steel, made up of two sections
our long history as a submarine builder,
dedication are part of the current
that had been welded together.
maintainer and design authority in
team that works on the fleet. The next
Australia. This is a result of ASC retaining
generation of welders, and all the trades,
blown up until the “bulge” in the steel
more than 40 per cent of its submarine
are very capable and committed to
produced a thinning of the hull of a
workforce with skills and experience from
achieving a world class product for the
certain specified per cent. The tests were
the original Collins Class build in the
Navy.”
conducted with the specimens held at
1990s and 2000s.”
The test specimen was repeatedly
a temperature significantly below zero
Peter Whyte, who welded the first hull
The news follows the recent announcement that ASC is the first
degrees, simulating the most demanding
sections for the build of HMAS Collins in
Australian defence company to receive
under-sea conditions.
1989 and is now a senior project manager,
the international corporate certification
says ASC retains and applies the highest
for excellence in procurement by the
welding standards.
Chartered Institute of Procurement and
Careful examination of the weld showed that cracks did not grow or break through, successfully passing the test.
“As the first welder on the Collins
Supply (CIPS).
build I’m proud of what the team at ASC
“This achievement will guide our
Whiley said the successful explosive tests
achieved in the build of the fleet,” Whyte
future work in procurement -- a critical
demonstrate ASC’s continued expertise in
said.
role as Australia’s largest locally owned
ASC Chief Executive Officer Stuart
defence prime contractor, supporting the Government’s Naval Shipbuilding Plan,” Whiley said. ASC built and maintains the Collins Class submarine fleet, employing more than 1,200 submarine personnel in SA and WA. In recent weeks, the company has signed on with asset management experts to strengthen its life-cycle management execution of the Collins fleet under a new partnership with the Asset Management Council of Australia. It has also a signed a renewed strategic cooperation agreement with Defence Science and Technology Group for Collins. For More Info: www.australiandefence.com.au
18
WELDFAB TECH TIMES | OCT - NOV 2018
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Needs Special Products
brings Technically Advanced Welding Products to Indian Industry from Global Leaders
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ARTICLE
Micro plasma arc welding in small scale welding process high input resulting in greater distortion is a major drawback of GTAW welding [2]. Plasma arc welding (PAW) is known to its greater energy concentration than GTAW process, deep penetration with greater arc stability and better control of the process [1]. PAW technique has lower equipment cost and adopts large tolerance between gaps and misalignment than highly focused laser beam or electron beam [1-2]. Swagat Dwibedi, Associate Professor, Department of Mechanical Engineering, Indian Institute of Technology Guwahati
Swarup Bag, Associate Professor, Department of Mechanical Engineering, Indian Institute of Technology Guwahati
Therefore, PAW is good alternative and cost effective than laser or electron beam welding in industrial application. Recent development on constricted
Abstract
used for holding and manipulating the
and regulated arc even at low current in
With miniature of components, the
small components play an important
micro plasma process makes it possible
demand for small scale products is ever
role for successful development of small
to apply in micro scale welding process
increasing. Hence the downscaling of
scale welding process.
which is more advantageous than GTAW process. However, the application
the conventional welding process is
20
utilized to develop several microwelding
Introduction
of µ-PAW is not explored for a wide
processes. The concentrated and well
The plasma arc welding (PAW) is one
range of materials. The positioning
controlled power density is the primary
of the variants of arc welding processes
of the electrode brings the difference
requirement for small scale welding
where the joining of the materials is
between GTAW and PAW where the
process. Hence, apart from laser or
mainly achieved through transferred
constriction of plasma arc is possible
electron beam, the development of
arc. The non-transferred arc is mainly
rather than the open type of arc for
arc welding find a place in small scale
used for chemical vapour deposition,
GTAW (~ approximately 3 times power
welding application. Production of low
plasma spraying, waste treatment, and
density than GTAW). Also, the plasma
amperage current in continuous mode
production of ultra-fine powders [1].
arc can be separated from the shielding
as well as well-regulated pulse mode
Three different modes of current are
gas envelope. Hence the controlled and
makes it possible for micro plasma arc
mainly used in PAW process: micro-
regulated arc in case of PAW is possible
to apply in small scale welding process.
plasma, melt-in mode, and keyhole
to generate which is considered as the
The current below 15 A is used for
plasma. The downscaling of PAW
advancement over GTAW process. The
micro plasma arc welding (µ-PAW)to
process where the current ranges from
µ-PAW can create deep penetration and
join several metallic materials like low
0.1 to 15 A is mainly used for small scale
even run in keyhole mode. Since the
carbon steel, stainless steel, maraging
welding process. Welding of thin sheets
electrode is protected, it offers longer
steel, titanium alloy and even nickel
is significant in several engineering
life. It creates stable arc and may run
based super alloy. The development of
field where dimensional tolerances and
in low amperage current (~ 0.05 A). It
µ-PAW process for these materials can
residual distortion of the weld joint is
is observed that lots of research work
be considered as an alternative for laser
major concern. One of the common
has come up on the establishment of
welding in terms of equipment cost.
welding methods of thin sheet is gas
small scale welding process using laser
However, the fixture and backing plate
tungsten arc welding (GTAW). However,
system. However, very limited work has
WELDFAB TECH TIMES | OCT - NOV 2018
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ARTICLE
found in esteemed literature on small
is termed as non-transferred arc. In
to maintain the arc. The low current or
scale welding using μ – PAW process
transferred arc, as the workpiece forms a
base current level is set at a value just
although it is one of the low cost systems,
part of the electrical circuit, high energy
sufficient to maintain an arc without
at least, as compared to laser welding
density, and high penetration is achieved
causing significant plate melting. The
process. Therefore, establishment of
as compared to non-transferred arc.
ideal pulse current level is determined
μ – PAW system for different materials
Transferred arc finds application in the
by the thermal properties of the material
has significance in current scenario of
area of welding where as non-transferred
and should be set at a level which will
miniature components. The analysis on
arc is used mainly for thermal spraying
ensure that the weld pool can propagate
comparative mode between different
and joining of non-conductive
at a rate that is fast enough to ensure
materials is useful to establish the
workpiece. Fig. 1 depicts difference
the maximum thermal efficiency.
parameters for welding of dissimilar
between transferred and non-transferred
Another variant of PAW is variable
materials. The range of parameters
arc in PAW [3].
polarity plasma arc welding (VPPAW).
(current, voltage, speed) or a combined
VPPAW finds application in welding
of parameters (heat input per unit
of aluminium alloys, because surface
length) is important to know to develop
oxide film formed, should be cleaned up
successful weld joint for a specific
by cathode atomization effect without
material.
damage the tungsten tip. In VPPAW, AC square wave current is used; the
Recent Advancement
amplitude and duty cycle of the current
To initiate the arc in PAW, a low current
waveform can be freely adjusted. When
pilot arc is obtained between the
the electrode is positive, workpiece acts
electrode and the constricting nozzle first, which ionizes the plasma gas flowing through the nozzle. The plasma gas flowing through the constriction
Fig. 1 : Concept of (a) transferred and (b) non-transferred arc in PAW [3]. Many variants of PAW processes have
as the cathode, oxide film on the surface can be cleaned up. The current waveform is optimized to avoid the consumption of tungsten. In the electrode negative
reaches a very high temperature, and
been developed, i.e. pulsed plasma
duration, workpiece acts as the anode
provides a low resistance path to initiate
arc welding (P-PAW), variable polarity
and more heat is deposited into the weld
the plasma arc between the electrode
plasma arc welding (VPPAW), double
pool to melt the workpiece. Fig. 2 depicts
and the workpiece; this is termed as a
sided arc welding, ternary gas plasma
square-waveform of pulsed welding
transferred arc. The transfer arc flows
arc welding, laser-assisted plasma arc
current and variable polarity current
through the nozzle and extends its path
welding, PAW-MIG hybrid welding
waveform [4].
to reach the base metal, forming a low
process, soft plasma arc welding, plasma
resistance path of current between the
spot welding process, manual pulse
tungsten electrode and the base metal.
keyhole PAW and increased power
The plasma arc is with high temperature
density PAW [4]. Table 1 shows the
and velocity due to the restriction by
comparison between different variants
the orifice, fusing and joining the metal
of PAW.
pieces as desired. The plasma gas itself
One of the variant of plasma arc
is not sufficient to protect the weld
welding is its pulse mode, in which there
metal and therefore, a large volume of
are two current levels, peak current (Ip)
inert shielding gas is allowed to flow
and base current (Ib). Peak current is
through an outer gas nozzle surrounding
the maximum value of pulse current
the inner nozzle. The shielding gases
during pulse-on time and it must be
generally use inert type gases like argon,
sufficient enough to melt the material
or helium and may be similar of plasma
and base current is the minimum value
producing gas. The arc formed between
of the pulsed current during pulse-off
the electrode and the constricting nozzle,
time and it must be sufficient enough
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Fig. 2 : Square-waveform of pulsed current and variable polarity current waveform [4].
OCT - NOV 2018 | WELDFAB TECH TIMES
21
ARTICLE
Table 1 : Comparison of different variants of PAW [4]. Increased power density PAW
In Technische University Delft, the traditional PAW torch was modified to increase the power density of the arc by additional radial constricting gas flow in the orifice nozzle.
Manual pulse keyhole PAW
Dr. Li from University of Kentucky designed a control system to stabilize the keyhole behaviour. The control system can overcome small disturbance of the welding speed and torch offset.
Plasma spot welding process
Developed by English and Japanese researchers for auto manufacturing. torch head of PAW is relative small in size and weight, the spot PAW process hence has much better operation flexibility.
Soft PAW
VPPA welding process was proposed in Harbin Institute of Technology. Helps to stabilize the flow field of the liquid in the weld pool, high quality welds.
PAW-MIG hybrid welding process
Cleans up the oxide film on the workpiece surface, but also gives the protection to the droplet and weld pool. In this efficient welding process, arc temperature is significant increased, wire fusion is accelerated, and the welding quality is improved.
Laser-assisted PAW
Enhances the melting efficiency of the base metal, the welding speed can reach is increased and the weld quality is improved as well.
Ternary gas PAW
NASA developed the ternary gas plasma arc welding.In ternary gas plasma arc welding process, penetration is increased, weld width and heat affected zone are reduced.
Double sided arc welding
Plasma arc is further compressed, energy is more concentrated, penetration ability greatly increased and the ratio of depth to width of the weld is further increased.
Variable polarity PAW
Finds application in welding of aluminium alloys, because surface oxide film formed, should be cleaned up by cathode atomization effect without damage the tungsten tip
Pulsed PAW
Lowers the amount of heat input, resulting in higher cooling rate.
Discussions
moves at constant speed (controlled with
provision for purging gas flow is essential
It is apparent that the complexity
speed knob) with the help of a rail guided
for welding of titanium alloy. It helps to
for fusion welding process increases
motor (PUG machine) powered platform.
reduce the problem of oxidation due to
with decrease in geometric size. The
The use of proper fixture is an essential
high rate of heat transfer through copper
dimensional mismatch intensifies
requirement for producing a good weld
with increase in geometric sizes of the
joint. A suitable fixture is designed and
substrate materials. Table 2 depicts the
constructed for the operation of welding
review of research work carried out in
procedure in open air to prevent both
Advanced Welding Lab, IIT Guwahati,
oxygen contamination and distortion
India.
of the workpiece. The backing plate of
Fig 3 depicts the experimental set-up
the fixture is also made of copper which
used to conduct the experiments. The
results in high cooling rate, yielding
welding torch is fixed while the workpiece
low angular distortions of the joint. The
Table 2 : Review of research work carried out in Advanced Welding Lab, IIT Guwahati. Material
Thickness (mm)
Current (A)
Voltage (V)
Speed (mm/s)
Reference
Titanium alloy
0.5
Butt
8-13
24
2.33-6.67
[4]
Low carbon steel
0.5
Butt
10-14
24
2.5-6
[5]
Stainless steel
0.5
Butt
10-14
24
2.5-6
[5]
Butt
7-15
24
2.80, 3.63 [7]
Inconel 718
0.7
Butt
14-15
24
3.6-5
[9]
Dissimilar SS316L/SS310
0.8/0.6
Butt
8-13.5
24
2.25-3.18
[10]
Maraging steel
22
Joint geometry
WELDFAB TECH TIMES | OCT - NOV 2018
Fig. 3 : Schematic of experimental set-up for Âľ-PAW used at IIT Guwahati.
Fig. 4 : Arrangement for provision of purging gas.
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ARTICLE
as well as heat convection by the purging
the higher side during welding of low-
current (PC) micro-plasma arc welding
gas [4]. Secondary process parameters
carbon steel, due to the fact that higher
process. Microstructure at the weld zone
used for µ-PAW is depicted in Table 3.
thermal conductivity and diffusivity of
indicatethe dendrites for the PC mode of
low-carbon steel cause the deposited
welding is very fine and equiaxed at the
heat to diffuse away more rapidly. A
weld interior whereas the microstructure
low melting point as well as high heat
is coarser and columnar for CC mode
Stand-off distance (mm)
1.2-1.7
Electrode diameter (mm)
1.2
Plasma gas flow rate (lpm)
0.4-0.7
capacity of SS304 (1723 K, 530 J/Kg K)
of welding. Figure 5 depicts the
Shielding gas flow rate (lpm)
7-8
makes the domain of the feasible weld
microstructure at the weld interior for (a)
Torch Position
Vertical
narrow as compared to low carbon steel
PC mode and (b) CC mode. With decrease
(1773 K, 510.78 J/Kg K). It is also observed
in welding heat input due to current
that the weld bead of low-carbon steel is
pulsating, the cooling rate enhances
smaller for the same welding condition,
resulting in a reduction in weld metal
investigated to find out the effect of
but the total heat-affected zone is higher
columnar dendrite arm spacing and size
heat input on thermal and mechanical
because low-carbon steel has very high
of the deleterious laves phase. PC mode
aspects. The micro scale butt joint by
thermal conductivity (43 W/mK) which
weldments also show improvements
plasma arc at optimal parameters is of
causes most of the heat to dissipate
in hardness and tensile properties as
very high quality, without any internal
away, whereas SS304 has lower thermal
compared to the CC mode welding
imperfections and with regular fusion
conductivity (16.2 W/mK) and the heat is
which is attributed due to reduce heat
zone. The maximum joint efficiency of
highly concentrated (due to low thermal
input and as a result the average cooling
the weld joint found to be more than
diffusivity- 4.2 µm2/s) in the weld zone
rate increases which further refines the
100% in most of the cases. The weld bead
causing it to form a wider bead [7].
fusion zone microstructure. This refined
Table 3 : Process parameters used for µ-PAW. Microwelding of titanium alloy is
increases with current up to a certain
microstructure minimizes Nb segregation
limit after which burn out of the material
changes of Maraging 300 steel (0.5 mm
in the grain boundary and further
occurs(beyond 9.5 A at welding speed
thick) weldments has been performed.
diminishes the amount of laves phase.
of 2.33 mm/s and 2.75 mm/s, beyond
The weldability of maraging steel with
Nb-rich laves phase in the microstructure
11.5 A at welding speed of 4.2 mm/s,
µ-PAW is accomplished by finding a set
of weld fusion zone is undesirable
beyond 12.5 A at welding speed of 5.62
of suitable primary variables of welding
because it results in detrimental effect on
mm/s).The temperatures are well below
current (7-14 A) and welding speed (2.8-
the mechanical properties [9].
the vaporization temperature of the
3.7 mm/s). The HAZ is extended over a
materials and hence it can be concluded
large area as compared to FZ. However,
that the conduction mode heat transfer
the structure of base material (BM) is not
prevails against keyhole formation
affected by diffusional heat transfer since
within this power density range used for
the maximum temperature in this zone
microwelding of 0.5 mm thick plate. It is
does not create any phase transformation.
also obvious that the heat affected zone
It clearly indicates the FZ and HAZ with
is confined in small area due to effect of
long solidified grains at the boundary,
copper fixture. The distortion increases
which is the characteristic boundary
with increase in heat input due to greater
condition for almost all kind of steels.
manufactured by welding together sheets
amount of heat available at a specific
The microstructure in the weld zone is
of different grades or thicknesses. TWBs
area.The maximum measured deflection
primarily decided by the solidification
are used to reduce the weight, which
for the same welding condition of 4 mm/s
behavior that critically assesses the
results in increase in fuel efficiency
and 11 A at a point 5 mm from end point
size and distribution of grains, any
and reduction in cost due to use of
along the weld line is about 3.45 mm
segregation, porosity and hot-cracking
less material. SS 316L (0.8 mm) and
[5-6].
behavior of the alloy [8].
SS 310 (0.6 mm) is successfully joined
SS 304 and low-carbon steel is
24
A detailed study on themicrostructural
Inconel 718 sheets of thickness 0.7
Fig. 5 : Microstructure at the weld interior for (a) pulse mode and (b) continuous current mode welding [9]. Tailor welded blanks (TWBs) are
in butt configuration to form a TWB
successfully joined using µ-PAW process.
mm welded joints is prepared using
joint. SS 316L is a variant of SS 316
The range of welding current shifts at
constant current (CC) and pulsed
with an extra low carbon that restricts
WELDFAB TECH TIMES | OCT - NOV 2018
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ARTICLE
detrimental precipitation of carbides. SS 316L finds applications in exhaust
lower than that of the parent material. • A comparative analysis is performed
minimizes the amount of brittle intermetallic laves phase in the weld
manifolds, evaporators, heat exchangers,
based on the physical properties
zone, leads to significant improvement
furnace parts, jet engine parts, chemical
between SS304 and low-carbon
in the micro hardness value and tensile
equipment and parts exposed to marine
steel. The behavior of the weld pool
atmospheres. SS 310 is a grade (highly
shape and size is mainly influenced
alloyed) of austenitic stainless steel
by the thermal property whereas
formed by µ-PAW process indicates
developed for high temperature services.
the residual distortion is decided by
that a weld joint with high quality,
Presence of high chromium and nickel
the solidification and mechanical
regular fusion zone and no visible flaw
composition allows this highly alloyed
constraints. The range of the current
is obtained under controlled process
steel to withstand oxidation while in
shifts at the higher side during welding
parameters. Microstructure and
service at high temperatures (up to
of low-carbon steel (8-10 A for SS 304
solidification of the weld pool is a direct
1,200°C) in absence of reduced sulphur
whereas 8-12 A for LCS at welding
function of amount of heat input, which
gases. SS 316L-SS310 joints enables to
speed of 2.75 mm/s), (10-15 A for SS
in turn dictates mechanical property of
benefit of both the materials and enhance
304 whereas 10-18 A for LCS at welding
the resulting weld joint. Thus, selection
the property of the resulting structure [10].
speed of 4.2 mm/s) and (11-18 A for
of heat input value plays an important
SS 304 whereas 11-20 A for LCS at
role for achieving sound weld joint.
Conclusions
welding speed of 5.26 mm/s) i.e., for
Micro-hardness of the weld zone is
The present article aims to summarize the
a similar condition, more current can
found to be higher than that of the base
research work carried out in Advanced
be employed to obtain a successful
material and HAZ. This is attributed to
Welding Lab, Indian Institute of
joint. This is due to the fact that higher
the presence of fine grains in the weld
Technology Guwahati. Following are the
thermal conductivity and diffusivity of
zone which results in high value of joint
major conclusions from the present article:
low-carbon steel cause the deposited
strength and hardness but low value of
• Effect of heat input on micro-plasma
heat to diffuse away more rapidly.
arc weldments on Ti6Al4V alloy with
• Joining of maraging steel experiences
properties of the welded joint. • Experimental analysis of TWB butt joint
ductility. • The most influencing parameters are
500 µm sheet thickness is studied
broad metallurgical transformation
welding current and speed whereas
extensively. Optimum value of heat
that leads to welding distortion and
plasma gas flow rate, stand-off distance,
input results in joint efficiency
transformation of austenite into
shielding gas flow rate, and electrode
comparable to base metal. Deformation
martensite at very low temperature with
diameter are secondary parameters
behavior of the weldments at moderate
significant increase in specific volume;
that influence the weld bead geometry
heat input (~45-90 J/mm) is found to
that can be controlled by finding
and heat-affected zone. The combined
be relatively better than other welding
feasible range of process parameters.
effect of the parameters such as welding
conditions. This is attributed to low
The microstructural study of maraging
current and speed is represented by
value of heat input resulting in high
300 steel welded samples provides
heat input per unit length (welding
cooling rate(683 K/s)thus enhancing
the physical changes occurred during
power/ speed). Too low heat input
the microstructural properties, which
welding, and it provides the reasons for
causes incomplete fusion or partial
results in improved mechanical
typical hardness profiles generated in
penetration that result in improper
properties, yielding high joint strength.
the weld sample.
joint strength. If heat input is very high,
• Use of proper fixture is made to
• Inconel 718 weldments in butt
the over-penetrated weld holds a large
minimize oxidation and reduce
configuration are prepared using
molten pool that may result in greater
distortion to considerable extent. Due
micro-plasma arc welding in pulse
shrinkage and distortion. Therefore,
to use of copper as fixture, high cooling
mode and continuous current mode.
the optimum combination of process
rate (683 K/s) is achieved that lead
Further study on weld microstructure
parameters is necessary to achieve a
to the formation of hard martensitic
and mechanical behavior reveals
sound weld joint.
structure in micro-plasma weldments
that pulse mode results in
of Ti6Al4V alloys. As a result, the
significant refinement of fusion zone
Acknowledgement
fracture toughness of the weld was
microstructure. Grain refinement
The present investigation is a result
www.weldfabtechtimes.com
OCT - NOV 2018 | WELDFAB TECH TIMES
25
ARTICLE
of research work carried out by past
microstructure and pitting corrosion of
influence on mechanical properties in
and present researchers in Advanced
AISI 316L stainless steels in heavy LiBr
plasma microwelding of Ti6Al4V alloy,
Welding Laboratory, Department of
brines, Corrosion Science, 53(8) (2011)
Journal of Materials Engineering and
Mechanical Engineering, Indian Institute
2598-2610.
Performance, 25(11) (2016) 4718-4728.
of Technology Guwahati. The authors
7. M. Baruah and S. Bag: Characteristic
Zhang: Plasma arc welding: Process,
difference of thermo-mechanical
of these researchers. The authors also
sensing, control and modeling, Journal
behavior in plasma microwelding of
gratefully acknowledge the experimental
of Manufacturing Processes, 16(1)
steels, Welding in the World, 61(4)
facility provided by the department
(2014) 74-85.
(2017) 857 - 871.
4. L. Z. Ming, S. L. Cui, Z. Luo, C. Z. Zhang,
8. T. Saikia, M. Baruah and S. Bag: On
Workshop and Central Instrument Facility
Z. M. Wang and Y. C. Zhang:Plasma
the effect of heat input in plasma
(CIF) at IIT Guwahati, Assam.
arc welding: process variants and
microwelding of maraging steel,
of Mechanical Engineering, Central
its recent developments of sensing,
Proceedings of IMechE, Part B: Journal
References
controlling and modelling, Journal of
of Engineering Manufacture, DOI:
1. H. P. Li and X. Chen: Three-
Manufacturing Processes, 23 (2016)315-
dimensional modelling of a dc nontransferred arc plasma torch, Journal
327. 5. M. Baruahand S. Bag: Influence of heat
of Physics D: Applied Physics, 34 (2001)
input in microwelding of titanium
L99–L102.
alloy by micro plasma arc, Journal of
2. R. Sánchez-Tovar, M.T. Montañés, and J. García-Antón: Effect of the microplasma arc welding technique on the
26
3. C. S. Wu, L. Wang, W. J. Ren, and X. Y.
thankfully acknowledge the contribution
WELDFAB TECH TIMES | OCT - NOV 2018
10.1177/0954405417731470. 9. A. Sahu and S. Bag: Micro-plasma arc welding of Inconel 718 thin sheets (under review). 10. S. Dwibedi, S. Bag, D.K. Lodhi and A.
Materials Processing Technology, 231
Kalita: Joining of different thickness
(2016) 100 - 112.
dissimilar materials SS 316L/SS 310 by
6. M. Baruah and S. Bag:Microstructural
µ-PAW process (under review).
www.weldfabtechtimes.com
LAUNCHES
XMT 350 FieldPro system with Polarity Reversing Quick-Select technology automatically selects correct polarity, lead outputs & weld parameters.
The system’s optimized stick and TIG arc performance is specifically designed for open root pipe welding — including process pipe and modular assembly applications — to help improve weld quality. Arc starts maintain the root opening and prepared edge, while stops limit arc marks outside the heataffected zone. The XMT 350 FieldPro system with Polarity Reversing also includes Miller
M
ArcReach® welding technology, which iller Electric Mfg. LLC,
swaps leads or cables to change welding
gives welders complete control at the
a leading worldwide
processes.”
wire feeder or remote — even hundreds
manufacturer of Miller brand ®
of feet from the power source. This
interface, Quick-Select technology
minimizes the non-value-added time
the new XMT 350 FieldPro system with
automatically selects the correct polarity,
spent walking to and from the power
Polarity Reversing. The system’s industry-
lead outputs and weld parameters. This
source to make parameter adjustments
leading technology eliminates the need
prevents operators from inadvertently
and maximizes arc-on time, weld quality
to manually swap leads between welding
welding in the wrong polarity, reducing
and jobsite safety.
processes — saving time and money and
the risk of weld rework that results
improving safety on the jobsite.
from incorrect cable connection. Quick
compatible with all ArcReach accessories,
XMT 350 FieldPro power sources are
process changeover also eliminates the
which include multiple feeder and
jobsite to make changes with outdated
setup time spent switching cables and
remote options, to help efficiently meet
welding equipment, the more money
gas hoses.
evolving project needs on the jobsite. The
“The more welders have to walk on the
it costs,” says Ken Stanzel, Product
“There is no guessing and no need
accessories provide maximum flexibility,
to check — welders get exactly the
delivering remote control capabilities for
“The XMT 350 FieldPro system with
results they want,” Stanzel says. “The
stick, MIG, TIG and flux-cored welding.
Polarity Reversing eliminates the need to
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Manager, Miller.
28
With the push of a button on the
arc welding equipment, has introduced
WELDFAB TECH TIMES | OCT - NOV 2018
www.weldfabtechtimes.com
CASE STUDY
Belarusian NPP on progress
Introduction
Manpower Involved
Belarus will soon be gifted with its first
As many as 41 subcontractors, including
approximately 8,000 jobs during the
nuclear power plant. The Belarusian
23 Belarusian ones and 18 Russian ones,
peak construction period and 1,000 new
nuclear power plant is currently under
are busy building the Belarusian nuclear
permanent jobs, when it starts operations.
construction and is expected to be
power plant. The number of construction
operational from 2019. The project is
workers is close to 7,000 people, BelTA
Welders Training
financed by Russia, and Atomstroy export
learned from Press Secretary of the
The Russian company OAO NIKIMT
is building the 2,400 MWe plant, with
Belarusian Energy Ministry Zhanna
Atomstroy had trained and certified
two VVER-1200 reactors. ASE Group,
Zenkevich during a media tour of the
welders for the Belarusian enterprises
a Rosatom's engineering division, acts
nuclear power plant for Belarusian and
involved in building the Belarusian
as the general designer and the general
Russian reporters on 28 March.
nuclear power plant. As many as 20
contractor as part of the project to
30
The project will further generate
specialists have completed the training
build the Belarusian nuclear power
Project Benefits
course and have passed the exam. “The
plant. The Belarusian nuclear power
The project will address the power
construction of any nuclear power plant
plant is being built using the Russian
demand in Belarus, which has scarce
requires a considerable volume of welding
standard Generation III+ design AES-
domestic fuel resources. It aims to diversify
operations. The Belarusian nuclear power
2006 near Ostrovets, Grodno Oblast. The
energy resources, replace the import of
plant is built in line with Russian norms
Generation III+ design is fully compliant
natural fossil fuels (five million tonnes of
and requirements, which means that all
with international safety norms and
fuel-equivalent a year), reduce electric
the welding operations are to be carried
recommendations of the International
power production costs, and increase the
out in accordance with Russian rules for
Atomic Energy Agency (IAEA).
country’s capacity to export electric power.
the nuclear power engineering industry,”
WELDFAB TECH TIMES | OCT - NOV 2018
www.weldfabtechtimes.com
CASE STUDY
stressed Vladimir Popov, Deputy Director
for the hydraulic testing of the reactor
in Ostrovets in Belarus. Each 330-tonne
General for Manufacturing of OAO
unit depends on the date the welding
steam generator was lifted onto the
NIKIMT Atomstroy. The training course
process is finished. The welding of the
ramp extension and moved on rails via
has allowed the Belarusians to fully
main circulation line is one of the first
the equipment airlock into the reactor
prepare for welding operations at the
civil engineering projects of Rosatom's
building, news agency BelTA said. Then a
reactor.
best practices system. The system was
polar crane placed the steam generators
first used to weld the main circulation line
into position. The Belarusian nuclear
Work in Progress
of the fourth unit of the Kalinin nuclear
power plant is being built using the
General construction operations are nearly
power plant in 2010. Over 70 proposals
Russian VVER-1200 AES-2006 design.
finished at the first unit of the Belarusian
to improve various practices had been
nuclear power plant. Electric installation
taken into account before the welding of
operations and heat systems installation
the main circulation line of the second
operations are in full swing. The reactor
unit of the Belarusian nuclear power plant
AEM-technology welded the upper half of the reactor vessel VVER-1200 for Unit 2
pressure vessel of the first unit was fully
began. The main circulation line connects
Volgodonsk branch of AEM-technology,
installed on 1 April 2017. The welding of
the primary coolant equipment: the
(part of machine building division of
the main circulation line was finished on
reactor pressure vessel, steam generators,
ROSATOM - JSC Atomenergomash)
7 September 2017. A turbine unit, process
and main circulation pumps. The main
welded the upper half of the reactor vessel
equipment, and pipelines are being
circulation line is designed to enable the
installed in the turbine building.
flow of the heat transfer agent — water
Work is in progress to build the internal protective shell in the reactor building of
as hot as 350C under pressures as high as 17.6MPa.
the second unit of the Belarusian nuclear the second unit was installed in December
Steam generators installed at second Belarus unit
2017. Steam generators were installed in
All four steam generators was installed
their designated positions on 12 January.
during January 2018 at unit 2 of the
Work to install equipment is in progress in
nuclear power plant under construction
power plant. The reactor pressure vessel of
One of the four steam generators being lifted into place at second Belarus unit.
the turbine building of the second unit.
Main circulation line of the plant’s second unit welded The welding process took 70 days and became a new reference point for fulfilling similar operations at future nuclear reactors. All the 28 joints of the main circulation line were welded in this period of time. The seams were overlaid with austenitic stainless steel to protect them against corrosion. Sergei Olontsev, ASE Group Senior Vice President for Managing Russian projects, said that the most complicated operation had been finished in a record short period of time thanks to proper organization of the process and step-by-step audit of all the operations. The welding of the main circulation line is important because the schedule
32
WELDFAB TECH TIMES | OCT - NOV 2018
Reactor.
www.weldfabtechtimes.com
CASE STUDY
austenitic stainless steel within days. The operation will protect the seams from the aggressive environment. The main circulation line is 850mm in diameter and is over 130m long. Its walls are 70mm thick. The line connects the main equipment in the primary coolant circuit: the reactor, steam generators, and main circulation pumps. The main circulation line is designed to enable the flow of the heat transfer agent — water as hot as 350C under pressures as high as 17.6MPa. Second unit.
Safety at Site Main circulation line of the plant's first reactor welded
The safety of the construction of
operation to assembly of parts of the half reactor vessel (two shells of nozzle and
One of the most important stages of
is constantly monitored. The safety
flange zone) took place before the welding
the project — the welding of a main
depends on every person involved in
operation. Uniqueness of such operation
circulation line — has been finished
building it. It is a broad notion, and thus
is that the allowed high difference for all
in the reactor compartment of the first
relies on the technological solutions
parts installed relative to each other was
unit of the Belarusian nuclear power
made by the designer and on every
only 0.5mm. The operation to automatic
plant. The installation of the main
bricklayer and welding operator. Any
welding of circumferential rings started
circulation line began on 4 June to end
poor-quality welding seam can lead to
after the half reactor assembling. Welding
on 21 August. Specialists welded all
violations of the technology. Therefore,
process of two welds carried out over
the 28 butts over the course of 78 days.
a special interagency working group has
15 days with the continuing heating of
The operations were controlled step by
been created. It unites representatives
weld joint zone. The heat temperature
step. The welding of the pearlitic part
of all the regulatory agencies. Matters of
was above 200°C. After welding, the
of the main circulation line over the
quality and safety are discussed at every
structure was then placed to furnace for
period of 78 days instead of the standard
session.
heat treatment at a temperature of 300°C
84 days confirms that one of the most
to obtain the required properties of the
complicated stages in building a nuclear
Challenges
metal. Welded joints of upper half of the
power-generating unit is now virtually
As per the reports from belsat.eu, the
reactor was inspected and prepared for
automated, stressed Dmitry Romanets,
circle of potential buyers of electricity
inner anti-corrosion overlay welding.
director for building the Belarusian
from the Belarusian NPP is shrinking.
The reactor is a vertical cylinder with an
nuclear power plant at ASE Group. The
Recently, the Ministry of Foreign Affairs
elliptical head inside of which the reactor
main circulation line of the second unit
of Finland spoke about the lack of
core and the Internals are located. Reactor
of the second Novovoronezh nuclear
interest in electricity from Belarus. The
was hermetically sealed with the lid in
power plant was welded within 72 days.
first power unit of the Belarusian NPP is
which the actuators and reactor control
That time was used as a reference point
planned to start operation in a year. But
and protection mechanisms are installed.
for the welding operation in Belarus. In
the government still doesn’t say where
The lid also included nozzles used to
essence Rosatom's engineering division
the electricity produced in Belarus will
feed cables from internal reactor control
has set a new industry standard, which
be sold. Almost all western neighbors of
sensors. The attachment of lid to casing
provides for completing this operation
Belarus have refused to buy it. Finland
was carried out with the studs. The upper
within less than 80 days. Specialists of the
joined them the other day, claiming that
part of casing has coolant inlet and outlet
Russian company Energospetsmontazh
they plan to finish the construction of
nozzles as well as emergency coolant inlet
intend to complete overlaying the seams
their own NPP Olkiluoto in the coming
nozzles in case of cladding failure.
inside the main circulation line with
years.
VVER-1200 for Unit 2 of the plant. The
www.weldfabtechtimes.com
the nuclear power plant in Belarus
OCT - NOV 2018 | WELDFAB TECH TIMES
33
ARTICLE
Welding in Subsea Project-Inconel 625 Cladding over C-Steel Forging sitic stainless steels, duplex stainless
material) is bonded, mechanically/
steels or the more complex high nickel
metallurgical or through some other
chromium alloys, must be considered
high pressure and temperature process
The advances of clad welding of
Dr. M. K. Sharma, AequitasVeritas Industrial Services, Oslo/Vadodara
corrosion resistance, durability, strength
industry to optimize the cost effecting
or appearance. The majority of clad
solution to offshore/subsea industry.
products made today used carbon steel as
Oil industry looks various ways of
the substrate and Inconel (625/715 nickel
advancement in welding by cladding
alloys) and SS as the clad materials to be
over carbon steel components / Flanges
bonded. Seawater is naturally corrosive
specifics in piping systems. The material
but the internal reservoir fluids can also
grade of flange depends upon the type
add to this corrosion. The contents of
of fluid involved and environment
the piping typically contain aggressive
where the pipe is supposed to be used.
elements such as chlorides, sand, organic
Generally, those types of flanges are
acids, carbon dioxide (sweet crude),
eld overlay cladding in
preferred which can be incorporated
and hydrogen sulfide (sour crude).
offshore oil and gas projects
with low cost optimization and multiple
Coated tubing, inhibitors, and corrosion
ensure steady demand
subsea applications using the advance
resistant alloys (CRA's) are commonly
for high-performance alloys for years
technology in overlay& clad welding.
used to combat corrosion in these areas.
to come. Corrosion and corrosion
Cladding is the metallurgical process of
Corrosion due to sour crude, increases
prevention costing the subsea industry
welding or coating a metal onto another
with temperature and with increasing
billions of dollars every year, the selection
metal under high temperature / pressure,
sulfur content. Chromium based alloys
of materials to ensure the safe long-term
in order to protect the inner material from
are commonly used for resistance to
operation of equipment such as pipelines
high corrosion. The cladding process
sulfur compounds. Low cost optimization
& accessories and valves is vital, especially
over carbon steel flange is a cost effective
solution to carbon steel flange cladded
in deep sea operations. Hydrogen sulfide,
method to other corrosion resistance
with 625 is discussed in this article.
dissolved carbon dioxide and various
materials like CRA (Corrosion resistance
chlorides are all present in fossil fuels
alloys) or duplex or bare Inconel flange
Inconel 625
delivered from subsea fields. A sour
used in highly corrosive environment.
Nickel Alloy 625 is used both for its
W
service at high temperature is more
34
onto another substrate to enhance its
low C-steel flange used in Oil & Gas
high strength and outstanding aqueous
corrosive, while the same service at high
Introduction
corrosion resistance base material or or
pressure is more erosive. A combination
In offshore projects or subsea piping,
as an welding filler. The strength of Nickel
of the two is potentially hazardous and
the corrosion resistance requirement
Alloy 625 is primarily a solid solution
has serious implications on decisions
is exceptionally undebatable. Cladding
effect from molybdenum and columbium.
such as whether to manufacture from
is better way to prevent corrosion of
Nickel Alloy 625 has excellent weldability.
high-cost corrosion resistant alloys,
the low alloy material involved in the
The matching filler metals are often used
or to coat low-cost carbon steels using
flange forging. Cladding over carbon
for dissimilar metal joining and to weld
techniques such as weld overlay cladding.
steel pipes is cheaper than using
the aqueous corrosion steel.Welding
Where maximum protection is needed,
duplex stainless steel or Ni base alloy.
INCONEL alloy 625 is readily joined by
corrosion-resistant alloys (CRAs),
Cladding refers to a process where a
conventional welding processes and
including austenitic and ferritic / marten
metal, CRA or composite (the cladding
procedures.
WELDFAB TECH TIMES | OCT - NOV 2018
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ARTICLE
Typical Applications for the Nickel Alloy
as covered electrodes, coiled electrode
625 include:
wire, and strip electrodes.
GMAW weld process is used to clad Inconel 625 alloy over low carbon steel flange as shown in Fig.2. Gas metal arc
• Chemical process equipment handling mixed acids both oxidizing and
Weld Overlay and Process Used
welds were made with 1.2 mm diameter
reducing
Eventually the clad welding in this project
welding wire, argon + 2% oxygen
• Flue gas desulfurization scrubbers
for North sea was conducted using
shielding gas and heat inputs ranging
• Evaporators for wet-process
GMAW process and after a number of
from 0.67 KJ/mm. The chemistry and
phosphoric acid containing H2SO4, HF
tests i.e. cladded flange was qualify for
mechanical properties of filler wire used
and ferric salts
the subsea application and approved
in this welding are shown in another
as per requirement. The flanges had
paper.
• Weld Overlay
grooves which were prone to wear and
Metallurgy
corrosion and hence were required to be
Inconel alloy 625 is a solid-solution matrix
welded with corrosion resistance material
Welding Procedure : According to ASME Specifications IX
stiffened face-centered-cubic alloy. The
(625). The welding was carried out by
Welding process
alloy may contain carbides, which are
automated GMAW process in the grooved
: GTAW/Automatic/ Hotwire
inherent in this type of alloy. Carbides
as shown in drawing (Fig.1), cladded
Parent Metal
: F52 ASTM A694
that can be found are MC and M6C (rich
region was machined to the required
Filler Wire
in nickel, niobium, molybdenum, and
dimension, inspected & tested.
: AWS A5.14: ERNiCrMo-3 (1.2mm)
carbon). In addition M23C6, a chromium-
Wire Type
: INCONEL 625
rich carbide, appears in solution-treated
Shielding Gas
: Argon + 2% O2
material exposed at lower temperatures.
: Horizontal
The hardening effect that takes place in
Welding Positioning
the material on exposure in the range
Joint Type
: Overlay, Cladding
centered around 1200°F is due to sluggish
Heat Input
: 0.6 KJ/mm
Heating Method
: Propane (preheat)
Preheating Temperature min.
: 136°C
Inter-pass Temp. Max.
: 250°C
precipitation of a nickel-niobium-rich phase, gamma prime.
Weld Cladding
Fig.1: Flange drawing (Material: ASTM A694 F52, Job: Forged flange 22” size). The subsea forging is made in
The term weld cladding usually denotes
accordance with the requirement of
the application of a relatively thick layer
North seaproject specification, and the
(3 mm or more) of weld metal for the
necessary tests were done in order to
Non Destructive Examination
purpose of providing a corrosion-resistant
identify its chemical and mechanical
The visual examination, LPT and MPT is
surface. Typical base metal components
properties requirements (Table-1).
carried out on cladded flange after final
that are weld-cladded include the internal
The steel melting is done in electric arc
machining. Qualified NDT operators as
surfaces of carbon and low-alloy steel
furnace, under vacuum degassing which
per European norms conducted NDT
flanges, pressure vessels, reactors, tube
improves the properties of the resulted
who are minimum PCN LV-2, for the
sheets, nuclear reactor containment
billets or ingots to be used in forging.
NDT testing. The surfaces of forged items
vessels, and hydrocrackers. The cladding material is usually an austenitic stainless steel or a nickel-base alloy (625 or 715). Weld cladding is usually performed using GMAW process, Laser process or submerged arc welding. However, fluxcored arc welding (either self-shielded or gas-shielded), plasma arc welding, and electro-slag welding can also produce weld claddings. Filler metals are available
www.weldfabtechtimes.com
Table-1: Chemistry and mechanical properties of F52 Forging. Chemistry F52
C
Mn
Si
P
S
0.26 max
1.60 max
0.15 to 0.35
0.025 max
0.025 max
V
Al
B
N
Ceq
0.08 max
0.015- 0.055
0.0005 max
0.010 max
0.43 max
Mechanical Properties
Y.S 0.2% [MPa]
T.S [MPa]
E [%]
CVN J (-20°C)
Room T
360 min
455 min
20 min
27 Min
OCT - NOV 2018 | WELDFAB TECH TIMES
35
ARTICLE
ASTM D7091-Magnetic Induction Method Manual Accuracy: Up to 0.1mm - ± 0.0015mm and Precision: Up to 0.1mm - ± 0.0003mm Fig.2: Weld cladding over carbon steel forged flange.
ISO 2178:Non-magnetic coatings on magnetic substrates - Measurement of coating thickness
cleaned to BS 7079 before inspection
procedure. No special procedure
performed. NDT inspection was carried
qualification test is required. Acceptance
out in accordance with DNV OS-F101
criteria:
Thickness acceptance criteria: Defined in
App-D.
Crack-like indications: not permitted.
project specification which is min 3mm.
Visual Examination
Linear indications with length more
Conclusions
All flanges in the finished condition
than 2 mm or three times the width: not
Based on the above experience during
were 100% visually inspected for surface
permitted.
this project, following conclusion can be
finishes and to ensure compliance with
drawn.
visual and dimensional tolerances. Visual
Linear indications with length < 1.5 mm
examination shall in general comply
may be deemed irrelevant.
with DNV OS-F101 Appendix D C400 and
1. Cladding of Inconel 625 over C-steel by GMAW is cost effective solution. 2. Automation of clad welding in
B800 for welds. Fig.3 asshows the casting
Rounded indication: Diameter < 3 mm,
defect observed during visual inspection
accumulated diameter in any 100x150
at 5X magnification. Porosity in weld
mm area < 8mm.
offshore project is useful for better welding quality. 3. Defect probability can be minimized
after cladding 2.99mm is also observed
using hot wire in GTAW process.
which is very close to reject but less than
Cladding Thickness
the 3.0 mm acceptable criteria, therefore
Cladding thickness measurements was
minimized by clad welding
it was accepted. Acceptance criteria: No
carried out using Fischer Deltascope
automation.
visible defects.
FMP30/FGB2. The equipment accuracy
4. Welding consumption can be
5. Failure risk /leakage in flange could be
& precision which is important of the
minimized using GTAW automation
Dye-Penetrant Examination
Deltascope is mentioned below. The
process.
All flanges were examined by DPI over
equipment measurement principal
100% of their external and accessible
by magnetic method is in accordance
Acknowledgement:
internal surfaces including bevel ends in
to ISO2178. The cladding thickness
KristensenStål & Metallverksted
accordance with DNV OS-F101 Appendix
measured value is shown in Fig.3 above.
AS, Vestfossen is acknowledged for
D C222 (and B600 for welds). Dye penetrant testing is shown in fig.3and no
conducting cladding at their Clad Deltascope FMP30: DIN EN ISO 2178/
Technology Center, Norway.
defects were observed.
Magnetic Particle Examination All flanges were examined by MPI over 100% of their external and accessible internal surfaces excluding cladded bevel groove (Non-magnetic) in accordance with DNV OS-F101 Appendix-D, D200 or ISO 17638 as per following testing
36
WELDFAB TECH TIMES | OCT - NOV 2018
Fig.3 : Defect in Forging.
DPT Examination
MPI Examination
Cladding Thickness
www.weldfabtechtimes.com
INTERVIEW
We are investing in getting new technologies to India Rohit Gambhir, Managing Director, ESAB India
38
Q1. ESAB India Ltd started its operations in 1987 by acquiring the welding business of Peico Electronics & Electricals Ltd (now Philips India Ltd). How has been the journey so far?
improve productivity, quality and cost
which will soon be the third largest
competitiveness of Industrial users.
in the world.
We have a 75-person-strong Global R&D
Q2. How has been the Indian market for ESAB as compared to other international markets?
The journey has been very exciting
Center in India catering to both Indian
Indian market has been growing at a
for ESAB, as we have helped the
and global needs. India is a major focus
faster pace for us then rest of the world.
industrial growth in India by bringing
market for ESAB, and we look forward to
We do think that India, with its higher
in new technologies. We have focused
further investments in India. We are the
growth and embracing new technologies,
on being a full welding and cutting
market leaders in India and are working
will be a major growth driver to rest of
solutions company that can help
to increase our share in this great market,
the world.
WELDFAB TECH TIMES | OCT - NOV 2018
During this time, we have acquired many other companies globally and are working to bring their technology to India as well.
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INTERVIEW
Q3. During 2017, Larsen and Toubro Ltd (L&T) had agreed to sell unit EWAC Alloys Ltd to ESAB Holdings Ltd. What is the current status?
is in the process of being integrated
This has been bought globally and works
We have the full range of Welding and
as an independent entity in India. They
Cutting products covering:
have strong robust plans to increase
• Automation
share in India and globally as well.
• Cutting machines
Q10. What challenges do you come across and how did you manage to cope up with the same?
• Industrial gas equipment
The challenge for us is majorly
Q4. What is your say on the Indian welding market? Also brief us on your company’s presence in India. Any expansion plans?
• Consumables (Electrodes, Solid Wire,
on introducing new products and
globally.
Q6. Can you quickly take us through your product line?
Flux Cored wire, Fluxes and Tig Rods)
Q9. We have known that Boeing had selected ESAB as a partner in the manufacturing of fuel tank structures for SLS. This was a global order taken in the USA.
technologies to India. The initial cost
• Arc welding equipment
of product and training is very high.
• Hard facing products
However, we look at it as our investment
The Indian welding market is based on
• Personal Protection Equipment
in making the Indian Fabrication market
the strong focus by the government on
• Service and process support
a world class market and growing our
manufacturing and infrastructure, and
With this, we provide a full range of
share in the same.
is expected to do very well in the next
products, both made in India and ESAB
few years. Major policy improvements
worldwide.
significantly increased the possibility
Q7. Any recent developments?
of growth. In the first six months of the
The recent developments are in bevel
calendar year, we have grown by more
cutting machines (made in India); new
Q11. Availability of skilled manpower in one among the major challenges. Your say. What is ESAB’s role to cope up with the same?
than 25% in almost all segments in India.
high-production arc welding equipment,
We have two training centers in India
ESAB is present in all sectors and have
high-end gas regulators, and improved
wherein we train workers from across
a strong sales, service and distribution
stainless steel electrodes. Besides, there
industry segments. Apart from this,
network across the country. We are
are many other applications being
we also help in providing automated
investing in getting new technologies
developed in ESAB India R&D.
solutions that can help the industry.
Q8. Could you please share some of the interesting projects you work upon?
Q12. Safety at work is one of the key considerations. What is company’s effort towards health and safety?
We are working with large manufacturing
This is a major focus from ESAB globally.
units to bring global Friction Stir
We have a strong EHS culture and
Welding and Laser Plasma Welding
training to ensure that every employee is
solutions to India.
safe, healthy and aware at all times.
(like GST) have made business easier and
to India, major expansion in R&D and production capabilities.
Q5. ESAB India had acquired the welding business of Sandvik Asia Pvt Ltd, Pune somewhere during Feb 2018. Please elaborate. This is a relatively new acquisition and
www.weldfabtechtimes.com
OCT - NOV 2018 | WELDFAB TECH TIMES
39
WELDING TIPS
The difference between Quality Assurance and Quality Control They focus on different areas of the value chain, but both are needed to keep customers happy. Quality assurance is involved in almost every phase of fabrication. Quality control ensures all final checks meet customer specifications. Both are needed to keep customers satisfied. QC do share some commonalities in the
on what projects are going through the
way they are treated in metal fabrication
QA process at any given time. This means
environments.
that no two days are exactly alike. One
The role of QA is more about quality
for new parts before releasing them to
issues are prevented, rather than just
the shop floor as per the new product
correcting problems that have already
checklist; handling reviews of customer
occurred. Of course, when quality issues
returns or rejections; or analyzing internal
do arise, quality personnel implement
rejections and disposition of rejections
corrective action as well.
with the materials review board.
QA specialists also review customer
C Sridhar, Director-Technical, Advance Institute of Welding Technology, Chennai, Tamilnadu
Q
uality Assurance team members
The next day might necessitate the
returns and handle internal rejections,
initiation of corrective and preventive
all with an eye toward continuous
actions as required on a customer return
improvement and achieving the goals set
or because of an internal rejection;
up in the Quality Management System
coordinating quality-related issues
(QMS). The Quality Assurance team
with customers and vendors; or
also works with vendors on quality-
reviewing the performance of the QMS
related issues, so they are able to make
to make any changes that may be needed
improvements.
to achieve goals.
stay on top of daily production
On the other hand, the role of QC is
efforts. Dashboards that bring
skewed more toward the back end of the
together information such as rework rates
fabrication process, including in-process
for certain manufacturing processes are
inspections, final inspections, receiving
helpful tools in this task.
inspections, calibration, and first-article
If you Google “QA vs. QC,” it returns
day might involve reviewing sales orders
planning and ensuring potential quality
inspections. In other words, QA is more
thousands of results. While that’s only
about prevention, while QC focuses
slightly more than half the number of
more on post-fabrication inspection and
search results as “Taylor Swift” produces,
remediation when necessary. Both are
it illustrates how much confusion exists
important and are concerned with quality,
around the differences between Quality
but they have sharply different focuses and
Assurance (QA)and Quality Control (QC).
immediate objectives.
While not every company defines QA
42
and QC in the exact same way and the
How Do QA and QC Roles Differ?
departments and areas might overlap in
The QA role requires juggling a lot of
some manufacturing facilities, QA and
different details and objectives, depending
WELDFAB TECH TIMES | OCT - NOV 2018
Figure 1
www.weldfabtechtimes.com
WELDING TIPS
level, review of jig requirements during
and ultimately made for one happy
are no less complex. They may spend
spot welding, and welding process and
customer.
an entire day performing first /lastpiece
postmortem after first-build to address
approval for each order during each stage
issues or make changes.
The QC team’s daily responsibilities
receiving inspections for purchased
ensuring quality goals are achieved with
Challenges, Continuous improvement, and the Future of Quality
items; an afternoon calibrating measuring
each production order. A check of part
With years of combined experience in the
equipment; or most of a day handling final
dimensions on a coordinate measuring
fabrication and machining job sectors,
inspection of a product before it’s released
machine is one way they do just that.
QA & QC has to work in tandem. For
In other words, QA is involved at
instance, customer requirements for
of fabrication and finishing; a morning
for shipment.
Quality Control plays a huge part in
just about every stage of fabrication,
cosmetic finishes generally are not well-
start. Modern manufacturing projects
from product design to the setup of
documented when they are handed over to
require QA standards be built directly
job processes to the management of
quality. In fact, most customers’ drawings
into design plans from the beginning.
production flow (see Figure 1). QC
are generated with software that assigns
QA team is involved with the fabrication
then takes over, ensuring all of the final
closed tolerances on all features.
process from the job’s kickoff, working
measurements meet the specs set out at
alongside the engineering team to ensure
the beginning (see Figure 2).
QA is involved with a job from the very
design-for-manufacturability factors
So when they are not feasible for the price a customer is able to pay, QA team works to find creative ways to make that
are considered upfront at the same
QA + QC: The Dream Team
customer’s fabrication dreams come true.
time that customer specifications and
QA team have to tackle complex
The company’s quality team takes into
other project requirements are being
projects. By keeping a close eye on
account bottom-line job requirements &
reviewed. QA assists in determining
the manufacturing process stipulated
expectations, so they are able to markup
the many criteria necessary for
by QA from the start of fabrication to
internal documents & make design changes
efficient, cost-effective, and quality
final inspection, the QC team ensured
that allow the customer to get its expected
fabrication. This can include the design
the final product met the customer’s
tolerances without the additional cost.
of manufacturing sequences, definition
requirements. This will help to prevent
of critical dimensions at the component
any issues during the on-site integration
In terms of the industry overall, however, one of the biggest challenges the company’s quality team faces is change. It’s absolutely a constant and keeping up with the latest trends can be a job in and of itself. Whether playing a part in instituting new applications of Six Sigma and lean methodologies, tracking regulatory updates, or analyzing a QMS for additional potential efficiencies across business processes, continuous improvement simply never ends. QA and QC may not be the same, but both play very important parts in the most central issue of maintaining overall product quality. From design to deployment, a quality team ensures that every job meets the requirements set out at each stage of the manufacturing process, so that the end result is the same every time - products that meet, if not exceed, customer expectations, each and every time.
44
WELDFAB TECH TIMES | OCT - NOV 2018
www.weldfabtechtimes.com
INNOVATIONS
Local Vacuum technology -
EBFLOW L
EBFLOW system - inside.
ocal Vacuum technology EBFLOW offers the possibility of eliminating the need for a vacuum
chamber and has been developed by CVE for the joining of large structures particularly aimed at the renewable energy generation sectors. This technology has been demonstrated to weld thick sections up to 250 mm in steels and light alloys.
EBFLOW main advantages: • Achieving the fastest thick section welding rates ever • Facilitating very high joint completion rates in thick section steels • A coarse vacuum is established and maintained only where it is needed
46
WELDFAB TECH TIMES | OCT - NOV 2018
EBFLOW is a new technology designed specifically for large structure welding. • Pre-heating is not necessary and consumables are not required during the weld • Quality and reliability are improved
with immediate post weld inspection possible • 20 to 30 times faster than conventional submerged arc welding,
www.weldfabtechtimes.com
INNOVATIONS
100mm per minute in 150mm thick
Specifications
steel have been achieved
• Typically 90 meters long, 9 meters in
• Using a system of sliding seals and
diameter with 100mm wall thickness,
precision handling enables fast
weighing 1,200 tonnes.
longitudinal and circumferential
• EBFLOW process particularly suited
welds on large work pieces
for wall thickness above 40mm and up
• There is no filler wire, the autogenous weld can be heat treated and the weld
to 200mm. • 3,300 hrs Sub Arc Weld: 60 meters
rendered invisible. It cannot be found
long x 6 meters diameter, 80mm thick
using most methods of QC.
section.
EBflow flanges.
• 110 hrs EBFLOW system: 60 meters
EBFLOW system
long x 6 meters diameter, 80mm thick
The Local Vacuum nature of EBFLOW
section.
use of large tubular structures to contain
is particularly suitable for large tubular
high pressure water for cooling and for
thick section material. Welds can be
Wind Tower flanges
long term storage of waste.
made in a fraction of the time - over 20
EBFLOW Technology is being deployed
Specifications
times quicker than conventional arc
to manufacture flanges from sections
• These forgings can also be welded
welding methods is not unusual.
rather than forging the whole flange in
with no filler wire, the autogenous
Specifications
one piece.
weld can be heat treated and the weld rendered invisible. It cannot be found
S355 Steel
EBFLOW
SAW
FCAW
"Stick"
Linear seam 1.3meters x 60mm WT
6.0 mins
8.3hrs
31 hrs
41 hrs
Circular seam 711mm dia x 40mm WT
3.5 mins
5.0 hrs
47 hrs
63 hrs
using most methods of QC. • High integrity autogonus welds and near parent metal strength. • Production is quicker, more cost
Tubulars - Wind Farms and Oil/Gas exploration
effective and less reliant on a small
Technological innovation in this sector
production bottleneck.
number of manufacturers so easing a
is being driven by the desire to reduce the costs and increase the manufacturing
EBFLOW Vs Submerged Arc
rate of large tubular structures used in
Multiple Submerged Arc Welds (SAW) Vs
tower foundations and offshore rigs of
a single pass EBFLOW.
Tubes for wind.
all types.
Specifications
EBFLOW Nuclear.
• Towers for wind energy are made from tubulars joined end on end. • Flanges added to the ends of the tubulars are used to join them together.
Specifications • No joint "V" preparation required just clean metal to metal. • Wide range of materials can be successfully welded. • Single pass weld compared to a multi pass conventional arc weld.
• Forgings can be welded and, because there’s no filler wire, the autogenous weld can be heat treated and the weld rendered invisible. It cannot be found using most methods of QC.
For More Details: Cambridge Vacuum Engineering
48
WELDFAB TECH TIMES | OCT - NOV 2018
Nuclear - Power Generation and Waste Containment
Tel: +44 (0) 1223 863481
Modern nuclear power plants rely on the
Email: Sales@camvaceng.com
Fax: +44 (0) 1223 862812
www.weldfabtechtimes.com
PRODUCTS UPDATE
SAW Systems
Cladding Systems
• Single / Twin Wire and
• Cap Seal / Shell
Tandem • Power Source capacity up to 1600A
Cladding
cladding of 90
- Cladding with
deg elbow with
30 / 60 / 90 /
auto-pass
120mm strips
• Single Wire SAW Systems
•
with ESW
- Operating Mode: CC/CV Gouging and Electro Slag • In-built protections
- Wide mains voltage
- Over / Under Voltage
tolerance: ±20% (Inverter)
- Single Phasing
Complete
systems with Column
• Small Pipe Cladding
- Suitable for SAW, Welding (ESW)
- Sector wise
& Boom, Positioner,
- Cladding of pipes with
Cladding Head, Cooling
diameter starting 38mm
System, Flux Recovery
using TIG
System etc. are available as
• 90 Deg Elbow Cladding
per requirement.
For More Info: KAIYUAN WELDING & CUTTING AUTOMATION INDIA PVT. LTD. Survey No. 255/1/8, Hinjawadi, Taluka Mulshi, Pune – 411057, Maharashtra, India Contact No. +91 7755900921, 7755900873 - Web: www.kaiyuan.in - E-mail: info@kaiyuan.in
SHARP ELECTRODES PVT LTD – Manufacturers of Manual Arc Welding Electrodes
S
harp Electrodes Pvt
Our Managing Director
Ltd was established
Dr.(Mrs.) J. Mohanasundari
in the year 1984. The
who is a well known Women
Company has excellent
Entrepreneur is a recipient
manufacturing facilities
of INTERNATIONAL AWARD
with accreditation of ISO
namely International Women
9001:2008 quality system
Entrepreneurial Challenge was established in 1992
we are continuously
Award (IWEC Award - 2013)
with accreditation of ISO
bagging award from EEPC
organised by Barcelona
engaging mostly women
9001:2008 quality system
(Engineering Export
Chamber of Commerce in
employees, reliable quality
from DNV, The Netherlands.
Promotion Council,
partnership with Chamber
SHARP brand Welding
The electrodes manufactured
Government of India) under
of Commerce of Manhattan
Electrodes, Dry Flux
are marketed in India from
various categories like Star
(New York) and FICCI - FLO
Powder and EQ Cut Wire
1984 and also exported to
Performance, Highest Export
held at LIMA, PERU, South
rods of various ranges. The
various countries including
and Export excellence award.
America.
electrodes are approved by
U.A.E, OMAN, QATAR,
Lloyd's Register, London,
MAURITIUS, AUSTRALIA,
UK and TUV Sud, South
BAHRAIN, NEPAL, U.S.A,
Asia. Our sister concern
U.K & ANGOLA.
from DNV, The Netherlands. The unit manufactures,
KAYJAY SHARP TRENDYS
www.weldfabtechtimes.com
For the past 16 years,
For More Info: SHARP ELECTRODES PVT. LTD. Website: www.sharpelectrodes.com www.sharptrendys.com
OCT - NOV 2018 | WELDFAB TECH TIMES
49
PRODUCTS UPDATE
7500 Series FiberStar Welding System FiberStar Fiber Laser Welding Machines (CW and/or Pulse Fiber Engine Output)
F
iberStar Fiber Laser
is that very little
safety, all
Laser Welding Machines
Welding Machines
heat is generated
FiberStar manual
are ideal for a wide range
offer a significant
at the weld
laser welding
of complex alloys and
competitive advantage
point allowing
systems offer a
applications including:
for today’s aerospace,
users to easily
factory sealed,
Medical Device Components,
electronics, medical device
weld > 0.025mm
maintenance-
300 Series Stainless Steel,
and micro component
from complex,
free laser source
Aerospace and Electronics,
assembly marketplace
heat sensitive,
designed for more
Nitonol, Titanium, Platinum,
subject to stringent quality
intricate parts
than 30,000 hours
Automotive and Micro
requirements.
while providing
of operation.
Components, and Many
Fiber laser welding
unparalleled
technology produces a
parameter flexibility from 0 –
sharp, focused light beam
100% duty cycle. Designed to the highest
that consistently melts a very small area of metal. The
standards of reliability,
benefit of the technology
repeatability, and user
FiberStar Fiber
Complex Alloys.
For More Info: LaserStar Technologies Corporation Tel: 401-438-1500, Fax: 866-516-3043 Email: sales@laserstar.net
Selco Weld –Genesis
Welding Innovation Efficiency & Technological Excellence iPanel
Green Welding Genesis are equipped with green@wave® patented technology for extremely high efficiency in mains current absorption (PF=1), according to European Standard EN61000-3-12
Weld@Net System Selco’s exclusive Weld@Net® Production Control Monitor software lets you control a number of power sources simultaneously from your PC, as Genesis power sources are equipped with Selco iPanel control
well as display and adjust all their welding parameters. Weld@
panels incorporating graphic displays and an intuitive user
net® PCM also lets you calculate and verify the quality and
interfaced that are unique in their field.
productivity of automatic and manual welding systems using an advanced production and cost reporting system.
Robot Ready Selco Genesis can be used in automatic and/or robotised welding systems by installing the dedicating operating software. Selco’s automatic welding power sources are complete with all the hardware and software components needed for use in any application.
50
WELDFAB TECH TIMES | OCT - NOV 2018
For More Info: Sumant Corporation Authorised Distributor +91 9011680001/8275879963. Web – www.sumantcorporation.com / www.selcoweld.com E-Mail – sumantcorporation@gmail.com
www.weldfabtechtimes.com
PRODUCTS UPDATE
1000-1250 AMPS INVERTER TYPE ARC WELDING MACHINE (MODEL: INARC - 1000I & INARC - 1250I) Model
INARC-1000 I
Rated Input Voltage Rated Input Power (KVA) Welding Current Range (A)
INARC-1250 I
Three Phase 380 ~ 440 Volts 50 Hz Supply 54.6
68
60 ~ 1000
Duty Cycle
60 ~ 1250 100%
Efficiency
89%
89%
Power Factor
0.95
0.95
Weight (Kg) Over all dimensions (mm)
T
hese machines are
95
100
765X352X757
765X352X802
and 1250 amps
and arc force control.
heavy duty IGBT soft switching inverter
Features:
type DC welding power
• 100% Duty cycle
sources, which can be used
• High Efficiency, Small
for MMA as well as for AirArc ouzing applications. Models: Available in 1000
• Easy arc striking facility
Size & Light Weighting. • Designed for heavy duty industrial applications.
For More Info: Warpp Engineers Pvt. Ltd. Tel: (+91)-8551817868 / 69 Email: salessupport@warpp.co.in
250i2 EV CNC Battery Welding System
A
n all-new design
capable of welding highly
joined to either similar
and performance.
conductive metals such
or dissimilar materials to
This latest update
as copper and aluminum.
facilitate the electric current.
takes all of the great features
Inside a lithium-ion battery
If the joint is not made
from our previous model
are various copper and/or
properly, there is a potential
and adds to it with a new
aluminum components that
for voltage drops due to the
motorized weld head adding
carry the electrical current
resistance between the two
greater control, precision,
(such as buss bars). These
pieces.
and uniformity to every weld.
components are commonly
Manufacturers can produce lighter, more compact battery packs without
One of the biggest
compromising power or
challenges when welding EV
capacity.
Batteries is finding a welder
www.weldfabtechtimes.com
For More Info: Tel: +1-(801)-658-0015 Email: sales@sunstonewelders.com www.sunstonewelders.com
OCT - NOV 2018 | WELDFAB TECH TIMES
51
EVENTS UPDATE
NATIONAL Event
Date
Address
Organiser
BAUMA CONEXPO INDIA
11 - 14 December, 2018
Delhi
Messe München GmbH
Engiexpo 2019
05th - 07th January 2019
AES University Ground, Ahmedabad
Engi Expo
India Steel 2019
22nd - 24th January, 2019
Bombay Exhibition Center
FICCI
Tooltech Bengaluru
24th - 30th January, 2019
BIEC Bengaluru International Exhibition Centre in Bengaluru
Indian Machine Tool Manufacturers' Association
IMTEX 2019
24th - 30th January, 2019
BIEC Bengaluru International Exhibition Centre, Bengaluru
Indian Machine Tool Manufacturers' Association
MESSE Cutting & Welding
21st - 23rd March, 2019
Hitex Exhibition Centre, Hyderabad
Indmesse Trade Fairs
BLECH INDIA 2019
25th - 27th April, 2019
Bombay Convention & Exhibition Centre (BCEC)
Inter Ads - Brooks Exhibitions (India) Pvt. Ltd
CWE 2019
20th - 22nd September, 2019
Bombay Exhibition Center
ITEI
th
th
INTERNATIONAL
52
Event
Date (2018)
Location
Organiser
Welding Eurasia
14th - 17th Mar 2019
Tuyap Exhibition and Convention Center, Büyükçekmece, Turkey
Hannover Fairs Turkey Fuarcilik A.S.
Metalworking Welding Monitoring and Diagnostics
20th – 22th Mar 2019
IEC Ekaterinburg-Expo (Ekaterinburg-ekspo), Yekaterinburg, Russia
Perm Fair
Welding
26th - 28th Mar 2019
Targi Kielce, Kielce, Poland
Targi Kielce
Welding & Cutting
09th – 12th Apr 2019
Minsk Marriott Hotel, Minsk, Belarus
Minsk Expo
Welding Incheon Korea
22nd – 23rd May 2019
Songdo Convensia (Songdo ConvensiA), Incheon, South Korea
Metal Network Korea Company
Beijing Essen Welding & Cutting Fair
25-28 Jun 2019
Guangdong Modern International Exhibition Center, Dongguan, China
Chinese Mechanical Engineering Society
INA WELDING
28th - 30th August 2019
JIExpo Kemayoram, Jakarta Indonesia
GEM Indonesia
Philweld
28th – 31st August 2019
World Trade Center Metro Manila, Pasay, Philippines
Environmental XPRT
Hi Welding & Production Equipment
01st – 03rd Oct 2019
MCH Messecenter Herning, Herning, Denmark
Messecenter Herning
Weldex
15th – 18th Oct 2019
Sokolniki Exhibition and Convention Centre, Moscow, Russia
ITE Moscow
WELDFAB TECH TIMES | OCT - NOV 2018
www.weldfabtechtimes.com
Lasting Connections
THE BEST FOR THE BEST Wherever and whatever you have to weld, Bรถhler Welding has the best stick electrode for the job. We supply any type you may need and our electrodes are always easy to handle, with fine arc ignition and stability.
voestalpine Bohler Welding India Pvt. Ltd. B-206, Universal Business Park, Chandivili Farm Road, Off Saki Vihar Road, Sakinaka, Mumbai - 400 072, India T. +91 / 22 42284400, E. welding.india@voestalpine.com www.voestalpine.com/welding
Scan for more information
WOMEN IN WELDING
â&#x20AC;&#x153;I aim to always learn and grow as a welder and educatorâ&#x20AC;? accepted into Local 5 Boilermaker Union, where I worked during 2017.
Pauline L Badamo, CEO, The Welding Workshop AWS Certified Welder
Q3. Could you quickly take us through your qualification background?
One of the memorable project was
I am an AWS Certified Welder 3G and 4G
Coeymans, NY during 2017.
welding the steam headers and ACC units for HRSG Boilers for PSEG at Port of
Unlimited Thickness in SMAW Process. I am proficient in SMAW, GMAW, GTAW
Q7. Your current project?
and FCAW. I have received my F60
Currently, I am working on small to
Q1. What made you choose welding as a career, which is a highly male dominated segment?
(Fireguard for Torch Operations), G60
medium scale art projects to sell at a few
(Torch use of flammable gases) and OSHA
upcoming local festivals.
My introduction to Welding and
sites. I have 2 years of teaching experience
Construction happened by chance.
into SMAW, GMAW and GTAW to women.
10 safety training to work on construction
Somewhere during 2014, I found a flyer
Q8. When on site, what are the key points you follow during welding for any project? Any suggestions. One key component to be successful in
I had never welded or worked with metal
Q4. How much of total experience do you hold?
before, but I was aware that I will enjoy
I have 4 years of Professional Welding and
metal, being sure to have all your tools
this nature of work, especially when it is a
Fabrication experience, and 2 years of
organized and ready, properly fine tuning
challenging task. Thus, I thought it would
teaching.
in the machine to the proper heat and
advertising the Local 28 Sheetmetal Union.
be a great and a good fit.
Welding is preparation. Cleaning the
electrode setting for the work, and of
Q5. Your strengths?
course to use proper PPE in order to
Q2. Could you brief us on your journey so far into welding?
I would say my strongest processes are
work safely.
I first learned welding, fabrication and
as much as possible.
SMAW and GMAW, but I continue to learn
working for Brett Fence and Contracting
Q9. Please share some of the interesting anecdotes during your career?
Corporation of Franklin Square NY from
I still remember the period while working
2015 to 2017. During 2016, I attended
on the repair and installation of steel
a Formal 3 month program at CUNY
handrails for FEDEX Company along with
Brooklyn City Tech where I learned the
the owner of my company. Over the 2
further techniques in SMAW, GMAW and
days, I was amazed to receive waves and
GTAW. After much practice, I appeared
thumbs up even from the truck drivers as
for Structural Welding exam, earning my
they passed us back and forth. During the
AWS (American Welding Society) Welder
last day, my boss told me that even the
Certification in D1.1 Unlimited Thickness
female drivers stopped to ask and confirm
in 3G and 4G. Thereafter, I completed
that I was indeed a female welding. All
the 6G schedule 120 pipe test, and was
were impressed and glad to see a woman
installation of steel structures, while
56
Q6. Could you please share your experience of some of the mega project you worked upon?
WELDFAB TECH TIMES | OCT - NOV 2018
www.weldfabtechtimes.com
WOMEN IN WELDING
welding. Hearing that, made me feel very
bend and be manipulated and I find that
to do as a woman is to stay focused, work
happy and proud.
if there is a will, there is a way. When
hard and always be professional.
following blueprints or engineering
Q10. What is your say on health and safety in welding? How do you consider the same when on job?
drawings, it is helpful to refer it, if
Q13. What are your future plans?
necessary.
My future plan is to continue growing The
Health and Safety is extremely important
and women to fabricate and weld. I aim
in either a shop setting or out in the field.
Q12. Have you anytime faced gender discrimination on site, as the stream is male dominated?
I have worked in both shop and field
When I go to work in the morning, I only
funds to produce a figurative sculpture
settings. It is vital to wear all necessary
think about doing the best that I can on the
project that has been in gestation for quite
PPE to protect your hearing, eyes, lungs
given project I have and to work well with
a few years.
and overall health. If these steps are
my peers to complete that task. Of course, I
taken, you can avoid injury throughout
have worked with people that have varying
your career.
negative and positive opinions on Women
Q14. Closing message, especially to the female.
working in Welding and Construction,
Whatever it is that interests you, pursue
but that has never bothered me. Over
it to the fullest capacity. If it is welding
the years, half of my best teachers and
or anything else, do not let anyone ever
mentors have been men. The best thing
change your mind or make you believe you
while welding, fabricating and working
Q11. What kind of challenges do you come across and how do you manage to cope up with the same?
Welding Workshop, where I teach girls to always learn and grow as a welder and educator. One personal goal is to gather
In Welding, Fabrication & Construction,
cannot do it. You must realize who you are,
you must always be able to solve
what you want, set goals and take steps
challenges and creatively come up with
to walk in the direction of your vision.
solutions. I find that if I am having an
It usually doesnâ&#x20AC;&#x2122;t happen overnight, be
issue that may be frustrating or I am
patient with the process and yourself.
being challenged, taking a short break
When you accept failure as your best
and returning to the problem with a fresh
friend and teacher, success is right around
mind is helpful. Fortunately, metal can
the corner. Good luck!
www.weldfabtechtimes.com
OCT - NOV 2018 | WELDFAB TECH TIMES
57
TENDERS
58
LOCATION
NATURE OF WORK
START DATE
CLOSING DATE
TENDER VALUE EMD (Rs.) (Rs.)
CONTACT
Multi State
Tender For Comprehensive Annual Maintenance Contract Of One Robotic Welding Machine ( M / S Kuka / Make ) Of Bmf / Budge Budge For 03 Years At Bmf / Budge Budge, Eastern Railway
09/11/2018
21/12/2018
84.96 Lakhs
1,69,920
Government Departments Railways
Andhra Pradesh
Providing Of Individual Equipment And Structure Earthing Replacement Of Damaged Ms Pipes And Seperate Earth Mat 50X8 100X16 Mm Ms Flat At 132 Kv Ss Kurnool655 ( Inr )
31/10/2018
04/12/2018
18.48 Lakhs
-
Government Departments Power
Chandigarh
tender for Providing And Laying 800Mm I / D Ms Pipe Line Made Out Of Hr Coil With Inside Epoxy Coating From Sewage Treatment Plant Diggian Upto Site Of Tertiary Water Storage Reservoirs In Sector 28 / 29 Chandigarh
12/11/2018
01/12/2018
22.72 Crore
45,50,000
Local Bodies - Public Administrative Department
Tamil Nadu
Tender For SEAMLESS COPPER TUBE 12.7 mm OD x 2.03 mm WALL THICKNESS x RL 5.5 TO 6.00 MTR (BSEN 1057-1996-R-220 ANNEALED)
12/11/2018
17/12/2018
-
1,05,500
Government Departments Railways
West Bengal
Tender For Hand tube bending tube size : 6mm. Make/ Brand for all the above items : Inder, Ridgid, Swagelok, Gedore
12/11/2018
03/12/2018
-
-
Government Departments Railways
West Bengal
Tender For INSTALLATION COMMISSIONING OF HEAVY DUTY MANUAL METAL ARC WELDING RECTIFIER. DETAILS SPECIFICATION ENCLOSED ANNEXURE-"A" MAKE WELDTHERM MODEL NO: EASY ARC-400 OR ESAB MODEL NO-LHJ425 OR SAEE ARC MODEL NO-410M.
09/11/2018
12/12/2018
-
-
Government Departments Railways
Tamil Nadu
Tender For SUBMERGED ARC 31/10/2018 WELDING PLANT, CAPACITY 1200 AMPS. ( AS PER SPECIFICATION ENCLOSED ).
03/12/2018
20,200
Government Departments Railways
WELDFAB TECH TIMES | OCT - NOV 2018
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TENDERS
60
LOCATION
NATURE OF WORK
START DATE
CLOSING DATE
TENDER VALUE EMD (Rs.) (Rs.)
CONTACT
Delhi
Tender For MANNUL METAL ARC WELDING ELECTRODE UNDER IRS CLASS NI TO SPECIFICATION NO.-IRS:M 28-12, SIZE 4 MM X 350 MM. NB-THE LOT SHOULD NOT HAVE MANUFACTURING DATE OLDER THAN THREE MONTHS. DSL/AMV Uttar Pradesh 792.00 Kg
12/11/2018
17/12/2018
-
-
Government Departments Railways
Uttar Pradesh Corrigendum - Supply Of Ms 20/09/2018 Pipes, Bends, Valves, Flanges Etc, 449 / Epd-I / Btps / 2018-19
12/12/2018
6.80 Lakhs
7,000
Boards / Undertakings / PSU - Power
Chhattisgarh
Construction of Hot Metal Sand Pit on item rate basis for 3.0 MTPA Integrated Steel Plant at Nagarnar near Jagdalpur, Chhattisgarh State
14/11/2018
05/12/2018
-
4,45,000
puneetgupta@ nmdc.co.in
Trombay, Mumbai
Works Contract for “Design, Fabrication, Supply, Testing, Installation and Commissioning of Ultrasoniccum-Water Jet-Cleaning Tank with accessories as per specifications, at AFD”.
14/11/2018
03/12/2018
-
-
Email: hsharma@barc. gov.in Tel: (022) - 25594927
Karnataka
Architectural and structural Design, Supply, Fabrication, Erection & Commissioning of Pre- Engineered Building – 4 along with civil, PH, Electrical works at SMF, Challakere, Chitradurga, District, Karnataka.
19/11/2018
10/12/2018
1,200 Lakhs
22 Lakhs
natarajj@barc. gov.in Tel: 0821 240 6644/6779
Kharagpur West Bengal
Supply Of Plasma Cutting Machine Specification Plasma Cutting Machine Capacity-22 Mm Clean Cut Technical Specification Attached As Annexure-A Make - Mogora Cosmic Or Modern Machine Tools Or Miller Or Ador Welding Terms & Conditions 1 Tc & Gc Of Original Equipment Manufacturer Are Must. 2 2. Authorized Distributor Certificate For Oem Is To Be Submitted. 3 Commisssioning Require At Consignee Premises. 4 Rites Inspection Required.
13/11/2018
04/12/2018
-
-
Central Government
WELDFAB TECH TIMES | OCT - NOV 2018
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Sector Watch OIL & GAS
Credit -www.pawelding.com.au
SECTOR WATCH: OIL & GAS
Oil & Gas On Rise crore (US$ 2.73 billion) on drilling oil and gas wells in 2018-19. • During Oct 2018, India presented a wide range of investment opportunities in the upstream oil and gas sector, citing strong interests in the ongoing USD 2.86 billion investment underway to double gas production and drill more than 120 exploration wells over the next four-five years. The USD 2 billion investment will nearly double the
Market Outlook:
Promotion (DIPP), the petroleum and
natural gas production to 60 billon
The oil and gas sector is among the
natural gas sector attracted FDI worth
cubic metres (bcm) a year by 2022
eight core industries in India and plays
US$ 7.00 billion between April 2000 and
from the current 33 bcm a year.
a major role in influencing decision
June 2018. Following are some of the
making for all the other important
major investments and developments in
Government Initiatives
sections of the economy.
the oil and gas sector:
Some of the major initiatives taken by
• In September 2018, the Government
the Government of India to promote oil
India’s economic growth is closely related to energy demand; therefore the
of Gujarat selected Energy
and gas sector are:
need for oil and gas is projected to grow
Infrastructure Limited (EIL), a
• In September 2018, Government of
more, thereby making the sector quite
subsidiary of the Netherlands-based
India approved fiscal incentives to
conducive for investment.
Energy Infrastructure Butano (Asia)
attract investments and technology
BV, to set up a Liquefied Petroleum
to improve recovery from oil
several policies to fulfil the increasing
Gas (LPG) terminal at Okha with
fields which is expected to lead to
demand. The government has allowed
an investment of Rs 700 crore (US$
hydrocarbon production worth Rs 50
100 per cent Foreign Direct Investment
104.42 million).
lakh crore (US$ 745.82 billion) in the
The Government of India has adopted
(FDI) in many segments of the sector,
• World's largest oil exporter Saudi
next twenty years.
including natural gas, petroleum
Aramco is planning to invest in
products, and refineries, among others.
refineries and petrochemicals in India
investments worth Rs 723 crore (US$
Today, it attracts both domestic and
as it looks to enter into a strategic
111.30 million) in Uttar Pradesh to
foreign investment.
partnership with the country.
improve the liquefied petroleum
As per the IBEF reports, the Oil
• Foreign investors will have
• State-run oil firms are planning
gas (LPG) infrastructure in a bid to
imports rose sharply to US$ 87.37 billion
opportunities to invest in projects
promote clean energy and generate
in 2017-18 from US$ 70.72 billion in
worth US$ 300 billion in India, as
employment, according to Mr
2016-17. Gas pipeline infrastructure in
the country looks to cut reliance
Dharmendra Pradhan, Minister
the country stood at 16,771 km at the
on oil imports by 10 per cent by
of Petroleum and Natural Gas,
beginning of September 2018.
2022, according to Mr Dharmendra
Government of India.
Pradhan, Minister of Petroleum and
Investments According to data released by the Department of Industrial Policy and
www.weldfabtechtimes.com
Natural Gas, Government of India. • Oil and Natural Gas Corporation (ONGC) is going to invest Rs 17,615
• A gas exchange is planned in order to bring market-driven pricing in the energy market of India and the proposal for the same is ready
OCT - NOV 2018 | WELDFAB TECH TIMES
63
SECTOR WATCH: OIL & GAS
to be taken to the Union Cabinet,
The Barauni-Guwahati pipeline will
Sudan to launch over 30 oil bids in 2019
according to Mr Dharmendra
connect to the 'Indradhanush' gas grid
www. sudantribune.com
Pradhan, Minister of Petroleum and
network, which is being developed by
Sudan is preparing to launch over 30 oil
Natural Gas, Government of India.
GAIL along with joint venture partners
exploration bids next year in an attempt
Indian Oil Corp(IOC), Oil India Ltd,
to lure western companies to reinvest
CNG (compressed natural gas) plants
Numaligarh Refineries Ltd (NRL) and
in its petroleum industry after the left of
and allied infrastructure at a cost of
Oil and Natural Gas Corp (ONGC) to
economic sanctions, the Financial Times
Rs 7,000 crore (US$ 1.10 billion) to
provide uninterrupted supply of natural
reported. Sudan has proven gas reserves
promote the use of clean fuel.
gas across all the North Eastern states.
of 3 trillion cubic feet, but development
• The Oil Ministry plans to set up bio-
has been limited. It also does not have
Sector News
Govt plans selling 149 fields of ONGC to
the pipelines or the port terminals to
$10-billion clean air drive set to boost
private & foreign co.
bring in gas or liquefied natural gas,
Indian pipe makers
www.economictimes.indiatimes.com
according to the U.S. Energy Information
www. economictimes.indiatimes.com
The government is mulling selling as
Administration in 2014. Sudan currently
Steel pipe makers are set to become
many as 149 small and marginal oil
produces 133,000 barrels of oil per
beneficiaries of India’s $10 billion
and gas fields of ONGCNSE -0.22 % to
day (bpd). The country’s production
push to expand its natural gas network
private and foreign companies and allow
is stationed mainly in the Heglig area
to more of its urban masses and cut
the state-owned firm to focus only on
and its surroundings, as well as western
pollution.
big fields. On the anvil is some kind of
Kordofan.
India has just completed its biggest
extension of the Discovered Small Field
city gas distribution auction that would
(DSF) bid round where discovered and
Total SA in talks with multiple Indian
extend coverage to more than half of its
producing fields of Oil and Natural Gas
firms for stake in LNG terminals
1.3 billion people across a third of the
Corp (ONGC) are auctioned to firms
www.economictimes.indiatimes.com
nation’s area. This project aims to see
offering the maximum share of output to
French energy giant Total SA said it
10 million homes linked to gas grids by
the government, sources said.
is in discussions with multiple Indian companies to acquire a stake in LNG
2020 and bring relief to smog filled cities. India, Nepal agree for LPG and natural
import terminals and city gas distribution
GAIL contracts pipes for Barauni-
gas pipelines
projects and is also interested in setting
Guwahati gas pipeline
www.newsonair.com
up petrol pumps in the world's fastest
www. energy.economictimes.
Petroleum Minister Dharmendra Pradhan
growing energy consuming nation. Total is
indiatimes.com
has said that India and Nepal have agreed
in talks to buy up to half of Adani Group's
State-owned gas utility GAIL (India) Ltd
to explore the possibilities of laying
stake in LNG projects in Gujarat and
has purchased steel pipes worth Rs 1,100
pipelines for LPG and natural gas for
Odisha, a under-construction LPG import
crore for laying the Barauni-Guwahati
fertilizer plant and industries in Nepal.
facility and in the firm's city gas projects.
gas pipeline, putting on fast track the
The Indian Oil Corporation and Nepal
implementation of the project that will
Oil Corporation will work together on
Brookfield to acquire Ambani gas
connect the north-east with the national
these projects. These companies have
pipeline
gas grid.
agreed to complete pipeline work from
www. economictimes.indiatimes.com
Motihari in Bihar to Amelkhgunj in Nepal
Canadian investor Brookfield is set to buy
will act as a branch line from the
at an early date. The 69-kilometre long
the lossmaking East West Pipeline Ltd
prestigious Pradhan Mantri Urja Ganga
Motihari-Amelkhgunj pipeline is being
(EWPL), earlier known as Reliance Gas
pipeline project, will commence from
laid by India. It will ensure a smooth,
Transportation Infrastructure Ltd, for an
December 2018 the company said in a
cost-effective and environment-friendly
enterprise valuation of Rs 14,000 crore ($2
statement.
supply of petroleum products to Nepal.
billion).
Work on the 729-km pipeline, which
64
WELDFAB TECH TIMES | OCT - NOV 2018
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PIPELINE DOER’S
Triple L
F
or over 35 years, Triple L
the northern Rockies.
after mile – the company’s crews do what it takes to get the job done while
has been in business to help
Triple L provides comprehensive energy solutions like:
keeping safety as top priority. Quality,
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» Pipeline
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- bringing values-minded business
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Through the decades of boom and
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bust in the energy market, Triple L
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consistency, and transparency is
For More Info: Tel: (307) 332-4617
have kept on going with the team, growing its list of successful projects,
Welding and Fusing
Email: office@triplelinc.com
services and customers throughout
Bead after bead, fuse after fuse, mile
www.triplelinc.com
P&A Welding Pty Ltd
E
stablished in 1993, P&A Welding Pty Ltd utilises many years of
industries. P&A Welding Pty Ltd offers the services
construction and piping projects as a single source.
of specialised welding, pipefitting,
P&A Welding Pty Ltd currently has 2
offering specialist services in piping,
boiler-making and machining. All
Workshops; Workshop 1 being utilised
mechanical, construction, maintenance
available personnel have experience
for the fabrication of carbon steel
and engineering to projects throughout
of in-service welding on gas pipelines,
pipework and structural assemblies and
Australia. With its wealth of knowledge
facility fabrication and installation
Workshop 2 for non-ferrous pipework
and experience, P&A Welding has gained
of pipe spooling in carbon steel and
and fabrication.
significant recognition for the quality of
exotic materials. P&A Welding Pty Ltd
its services, reliability and expertise in a
can provide experienced trades and
wide range of diverse contracts within
supervisory personnel and all relevant
For More Info:
the construction, oil and gas and mining
equipment for the total completion of
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diverse welding experience,
Magnatech LLC
M
agnatech's primary focus is
by welding personnel in the harsh
ease-of-use, the company strive to meet
the design and manufacture
welding environment. The company’s
its customers’ needs and expectations.
of equipment for orbital
compact digital power supplies provide
Magnatech provides a complete product
welding applications. The company’s
precise control of the welding process,
solution for any type of tube or pipe
proprietary line of orbital pipe welding
yet are tough enough to withstand field
welding application.
systems is the most compact available
use. Magnatech continuously improve
in the world today. Magnatech is expert
existing tools, while designing new
For More Info:
in miniaturizing complex mechanisms
products for the pipe welding industry.
Tel: 860-653-2573
which must be rugged enough for use
By emphasizing simplicity, reliability and
Fax: +1 860.653.0486
www.weldfabtechtimes.com
OCT - NOV 2018 | WELDFAB TECH TIMES
65
OIL & GAS PIPELINE: CASE STUDY
Inline Isolation Provides Safe Decommissioning Benefits at UK Gas Terminal Use of T.D. Williamson SmartPlug® inline isolation tool alleviates the need for pipeline depressurization during onshore decommissioning activities.
W
hen a multinational Energy and Services company planned to decommission an onshore
gas terminal in northwest England, they required a fast, total solution that would avoid depressurizing and blowing down a 40 km (25 mi), 36-inch gas pipeline. The pipeline runs from an offshore field through north and south sub-terminals prior to feeding into the United Kingdom’s gas transmission network. A key concern was to complete the line decommissioning safely and quickly, to minimize potential
tool configured to provide a
signals from the built-in
disruptions to the supply schedule.
single block isolation as a risk
SmartPlug transponder. After
mitigation measure. The single
both tools were set, TDW
The solution was the proprietary SmartPlug inline isolation tool from T.D.
module SmartPlug tool acted
monitored the integrity of
Williamson (TDW). The SmartPlug tool is
as a pipe end barrier to contain
each isolation during the
a remotely controlled, piggable pipeline
the pipeline contents once the
pressure isolation device that allows
pipeline was cut. As time was
pipeline sections to be isolated at or close
of the essence, extreme focus
to their operating pressure. Not only does
and effort were required to
this reduce downtime during both planned
deliver the designed, assembled, & tested
were pigged back to the receiver using
maintenance and unexpected repairs, it
second single module SmartPlug tool on
residual gas pressure from the pipeline.
also keeps pipeline inventory in place.
site within three days.
®
The operator initially contracted TDW to
The operation at the south sub-terminal
According to Thomas Idland, TDW Senior Manager, Operations Offshore,
provide isolation services using a 36-inch
began by launching, pigging, and setting
the nature of the operation required
SmartPlug tool, providing double-block
the first SmartPlug tool to create double-
careful design, attention to detail, and risk
isolation against the gas pressure in the
block isolation against the 16 bar (232 psi)
mitigation during tool launch, set, and
pipeline. This would enable the safe
gas pressure in the pipeline. Once the first
retrieval. “TDW engineers were available
removal of a 36-inch full bore tee as part
SmartPlug tool was set against full line
on site at all times during the operation
of the decommissioning process. During
pressure, the line was depressurized. The
to provide any additional support to the
operational discussions, however, the
second SmartPlug tool was then launched
client and TDW operating crew,” Idland
operator requested a pipe end barrier. The
and pigged to the designated location
said. “The out-of-box solution engineered
goal was to provide a safe vapor barrier
approximately 40 m (131.23 ft.) upstream of
by TDW and the high quality of execution
behind cutting and welding near 1 km
the primary isolation tool. This tool acted
in the field were recognized and well-
(0.62 mi) of open, water-filled pipeline
as a vapor barrier to the pipeline from the
appreciated by the client.”
potentially containing a low content of
north terminal. Both SmartPlug tools were
dissolved hydrocarbons.
tracked and remotely activated by the
For More Info:
proprietary TDW SmartTrack™ system,
Phone: 918-447-5000
which uses extremely low-frequency
www.tdwilliamson.com
After considering the options, TDW delivered a second 36-inch SmartPlug
66
full decommissioning work SmartPlug™ tool activity. Upon completion isolating pipeline section of the decommissioning at 16 bar (232 psi). activities, the SmartPlug tools
WELDFAB TECH TIMES | OCT - NOV 2018
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