Welding of X80.NF.12.1 Welding of X80.NF.12.

1
Submerged arc welding for the future
a new generation of power sources
Nordic Welding Conference, Oct. 2012
Harm Meelker
Lincoln Smitweld B.V.
Welding of X80.NF.12.2 Welding of X80.NF.12.2
Overview
Introduction
Traditional SAW equipment
Process variables
Next generation SAW equipment
Procedure development
Energy savings
Features
Conclusions
Welding of X80.NF.12.3 Welding of X80.NF.12.3
Market Demands
Lower production costs
increased production
Increased quality
Higher strength materials
less total weight of construction
+ possible lower material costs
Greater flexibility
Welding of X80.NF.12.4 Welding of X80.NF.12.4
Conventional equipment
Welding of X80.NF.12.5 Welding of X80.NF.12.5
SAW process variables
Single arc
Single wire
Welding on DC minus
Tubular Cored Wire
Iron powder
Long Stick Out
Narrow gap
Semi-narrow gap
Multiple arc
Twin-arc
Tandem
Tandem twin
3 - 4 - 5 wires
Cold wire
Hot wire
Semi-narrow gap
Welding of X80.NF.12.6 Welding of X80.NF.12.6
125
145
190
225

Welding of X80.NF.12.7 Welding of X80.NF.12.7

Machined Grooves Offer Greater
Savings Potential
Welding of X80.NF.12.8 Welding of X80.NF.12.8
Narrow Gap or Narrow Grove
Narrow Groove:
Larger gap and radius
Larger sidewall bevel angles, up to 50
o
Compound bevels also typical
Typically <100mm
Narrow Gap:
Very small gap at the bottom:
20mm typical (10mm radius)
Same sidewall angle bevel
Sidewall bevel: 1.5
o
typical (1.2
o
min.)
Results in a narrow gap at the top
of the bead
Typically employed on wall thickness
greater than 100mm up to 350mm
Narrow Gap
Welding of X80.NF.12.9 Welding of X80.NF.12.9
Narrow Gap
Advantages:
Lower joint volume
Reduced consumables cost
Higher weld productivity
Disadvantages:
Very difficult to weld
More difficult to repair and
remove slag
Higher capital cost
PQR requalification cost
Precise weld joint fit-up very
critical
Need for machined joint
Welding of X80.NF.12.10 Welding of X80.NF.12.10
The next generation in Submerged
Arc Welding
State-of-the-Art in inverter technology
Highest capacity available on the
market
High efficiency inverter
Waveform Control Technology TM
Greatest control over the welding
process
Solid State Switching Technology
AC or DC Welding Process
Welding of X80.NF.12.11 Welding of X80.NF.12.11
Constant wire diameter and stick-out
Current [A]
constant voltage
and travel speed
Voltage [V]
constant current
and travel speed
Travel speed
[cm/min]
constant current
and voltage

Influence of current Voltage and Travel

Speed on penetration in SAW
Welding of X80.NF.12.12 Welding of X80.NF.12.12
AC/DC Submerged Arc Welding
Unique in the industry
Variable polarity for better process
control
High deposition
high-speed welding
thick section welding
Penetration profile
Arc stability in multiple-arc applications
Reduction in heat input
Technologically advanced
Waveform control technology
Digital communications technology
Welding of X80.NF.12.13 Welding of X80.NF.12.13
time
C
u
r
r
e
n
t
,

V
o
l
t
a
g
e

o
r

P
o
w
e
r

Negative
Current Level =>
DEPOSITION
Positive
Current Level =>
PENETRATION
Frequency
Cycle Balance =>
PENETRATION & DEPOSITION
Infinitely variable AC
The waveform can be varied to control penetration,
bead shape, electrode negative deposition eliminates
arc blow & arc-to-arc interaction by phase shirt control
Welding of X80.NF.12.14 Welding of X80.NF.12.14
Wave Balance
Typically run at 25% positive & 75% negative
Welding of X80.NF.12.15 Welding of X80.NF.12.15
DC Offset
Offset is a very
sensitive parameter
Typical range limited
to 0 to -10%.
8% offset => 25%
balance.
Large values of
current offset
interferes with
voltage regulation
causing system
instability
Welding of X80.NF.12.16 Welding of X80.NF.12.16
Waveform Control Technology
70% Positive
Penetration = 0.387
50% Positive
Penetration = 0.346
30% Positive
Penetration = 0.242
Positive = 835 Amps
Negative = 519 Amps
Penetration = .366
Positive = 450 Amps
Negative = 822 Amps
Penetration = .280
Wave Balance
Offset
Welding of X80.NF.12.17 Welding of X80.NF.12.17
Deposition rates
Welding of X80.NF.12.18 Welding of X80.NF.12.18
Power Wave

AC/DC 1000

SD
Inverter Power Source
Energy Efficient
DC+, DC- & AC (3 Phase)
CV and CC Modes
AC to DC Electronic Switch
Wave Balance Control
100% Duty Cycle
Frequency Control
Wave Shape Design
Production Monitoring 2

Weld History
Integrated Multi Arcs
Waveform Control
Technology
Welding of X80.NF.12.19 Welding of X80.NF.12.19
Systems
Welding of X80.NF.12.20 Welding of X80.NF.12.20
Arc configurations
Welding of X80.NF.12.21 Welding of X80.NF.12.21
Multiple Arc Welding
Welding of X80.NF.12.22 Welding of X80.NF.12.22
Company Herstaco Tube Welding B.V.
Adress Nijverheidsweg 24, Middelburg, The Netherlands
Type of business
Metal trading company
Tube/pile welding
Project team
Distributor Wagenvoorde Lastechniek, P.Keultjes, T. van Dorst, F, Meyer
Area of cost savings/target
Higher deposition rate by use of Powerwave AC/DC 1000
Target; 30% Cost Reduction
Procedure/Follow up
Introduce and demonstrate PW AC/DC 1000
Results
More than 33% reduction in labor costs
Sold SAW welding station, PW AC/DC 1000 with column & Boom
Consumables; L61/LW860
Deposition rate filling layers from 6 up to 9 Kg/Hr
Welding time per weld (1060x28mm) in a pile was 60 min., decreased to 40 min.
Practical example: Tube welding
Welding of X80.NF.12.23 Welding of X80.NF.12.23
Practical example: Tube welding
1060 x 35mm
Equipment
Fill
Cap
Travel speed
Welding time
Equipment
Fill
Cap
Travel speed
Welding time
Conventional
DC 1000
500/520 A - 31 Volt
= 6 kg/h
650/680 A - 34 Volt
= 7.6 kg/h
40 cm/min
60 min.
Conventional
DC 1000
500/520 A - 31 Volt
= 6 kg/h
650/680 A - 34 Volt
= 7.6 kg/h
40 cm/min
60 min.
Wave Control
PW AC/DC; with 40 Hz;
55% DC-; 5% offset
550 - 34 Volt
= 9 kg/h
720 A - 38/40 Volt
= 10.2 kg/h
60 cm/min
40 min.
Wave Control
PW AC/DC; with 40 Hz;
55% DC-; 5% offset
550 - 34 Volt
= 9 kg/h
720 A - 38/40 Volt
= 10.2 kg/h
60 cm/min
40 min.

Welding of X80.NF.12.24 Welding of X80.NF.12.24

Herstako cost reduction result based on
labor rate (35,-/hr
Project Humber UK; 350 Piles x 4 = 1400 Welds
Conventional process
Labor costs 1400 x 1hr x 35,-/hr = 49.000,-
Wave Control process
Labor costs 1400 x 0.67 hr x 35,-/hr = 32.830.-
Labor Cost savings for this project; 16.170,-
Energy savings are there too, but were not calculated, so the total cost saving is more than the calculated 33%. The investment of 1
machine is almost paid in 1 project.
Welding of X80.NF.12.25 Welding of X80.NF.12.25
A new procedure replaced a 9 pass single arc
approach with a 2 pass tandem arc
Cost Savings greater than 50% reduction in
weld time and consumable savings
70
36mm
2mm
BEFORE
36mm
6mm
50
AFTER
13mm Plate
19mm Plate
36mm Plate
Optimising procedures
Welding of X80.NF.12.26 Welding of X80.NF.12.26
Single V
Three Meter Diameter Can
Travel Speed Procedure 1(IPM)
27
Number of Passes 5
Deposition Rate (Lbs/hr) 43.24
Time to weld 1 Linear Foot of Weld (Min) 2.222
Time to weld Circumferential Weld (Min) 69.78
Welding Consumables per Joint (Lbs) 50.29
Double V Travel Speed Procedure 2 (IPM) 30
Number of Passes 2
Deposition Rate (Lbs/hr) 62
Time to weld 1 Linear Foot of Weld (Min) 0.8
Time to weld Circumferential Weld (Min) 25.12
Welding Consumables per Joint (Lbs) 25.96
Volume saved (24.32 Kg) 48 %
Time Saved (44.66 Min) 65 %
Optimising procedures
Welding of X80.NF.12.27 Welding of X80.NF.12.27
ORIGINAL PROCEDURES
Impacts: 27J @ -20C
Travel Speed = 530 mm/min.
4.0 mm 4.0 mm .
950 A 700 A .
30 V 34 V
AC
CC+
Deposition rate = 21,5 Kg/hr
Traditional procedure
Welding of X80.NF.12.28 Welding of X80.NF.12.28
Powerwave technology
TANDEM CAPABILITIES
Advantages:
CV & CC mode (CC is prefered).
Short distance between wires (one puddle).
Better duty cycle rating.
25-35 mm
Welding of X80.NF.12.29 Welding of X80.NF.12.29
Procedure development
Welding of X80.NF.12.30 Welding of X80.NF.12.30
Procedure development
Welding of X80.NF.12.31 Welding of X80.NF.12.31
Procedure development
Welding of X80.NF.12.32 Welding of X80.NF.12.32
Procedure development
Welding of X80.NF.12.33 Welding of X80.NF.12.33
Deposition rates
Summary;
Traditional tandem, 2x4.0mm -20 C and 21kg/hr
Powerwave 1x4.0mm/2x2.4mm -50 C and 35 kg/h
Powerwave 3x4.0mm -40 C and 45 kg/hr
Welding of X80.NF.12.34 Welding of X80.NF.12.34
Savings with the PW1000AC/DC
Welding of X80.NF.12.35 Welding of X80.NF.12.35
Idle consumption
Increased machine efficiency
Process efficiency
The power consumption of the PW1000AC/DC when the
machine is running but not welding.
The Inverter technology used in the PW1000AC/DC has a high
efficiency.
PW 1000AC/DC
400V 3Ph 50Hz
The Advanced AC Sub Arc process is showing higher deposition
and lower Heat input. The energy required to complete one joint is
reduced
Importance
Three ways to save energy
Welding of X80.NF.12.36 Welding of X80.NF.12.36
PW1000 AC/DC
Efficiency 86%
Power Factor 0.95
AC 1200
Efficiency 80%
Power Factor 0.81
DC1000
Efficiency 78%
Power Factor 0.73
Three machines running 600A 30V Comparison Three machines running 600A 30V Comparison
KW 20.9
KVA 22
Line current 32A
Idle Power 300W
KW 22.5
KVA 27
Line current 67A
Idle Power 2500W
KW 23.1
KVA 31.6
Line current 32A
Idle Power 2000W
Efficiency, line current and idle power levels are supporting savings Efficiency, line current and idle power levels are supporting savings
Commonly used in the
industry
PW1000AC/DC versus conventional inverter
Welding of X80.NF.12.37 Welding of X80.NF.12.37
50
Vessel fabrication
Material SA517 Grade 65
Wire LNS 133 2.4mm
FLUX 960
Vessel diameter 1250mm
DC1000
16mm
Layer Amps Volts TS (cm/min) HI (Kj/cm) KJ/layer
1 325 27 75 7.020 2.755
2 340 27 75 7.344 2.883
3 640 30 95 12.126 4.760
4 800 32 110 13.964 5.481
5 885 33 110 15.930 6.253
6 850 33 110 15.300 6.005
28.136
PowerWave 1000AC/DC
Layer Amps Volts TS (cm/min) HI (Kj/cm) KJ/layer
1 325 27 66 7.977 3.131
2 340 27 66 8.345 3.276
3 640 30 95 12.126 4.760
4 800 32 95 16.168 6.346
5 885 33 85 20.615 8.092
6 880 33 85 20.499 8.046
7 850 33 85 19.800 7.772
41.421
Total time per joint 26 minutes Total time per joint 34 minutes
Savings: 23.5% weld time per joint, 32% energy cost
The PW1000AC/DC is saving joint time + Energy
GMAWroot pass
Field experience Application: SA Twin 2.0mm
Welding of X80.NF.12.38 Welding of X80.NF.12.38
Quality Analysis
Advanced analysis tool for calculating overall
quality
of a weld based on deviation of wire deposition rate.

Lincoln Smitweld
Start Quality Analysis
Welding of X80.NF.12.39 Welding of X80.NF.12.39
Welding of X80.NF.12.40 Welding of X80.NF.12.40
Production Monitoring
Weld History
Diagnostics
Welding of X80.NF.12.41 Welding of X80.NF.12.41
Arc Link - TCP/IP
All components communicate via a network using Arc Link over
TCP/IP Protocol
Positioning Control &
Power Supply
Wire Drive Control &
Power Supply
Clock Signal
Wide Area Network
Monitor Application
Distributed system architecture
Welding of X80.NF.12.42 Welding of X80.NF.12.42
Application Pipe Mills
Longitudinal pipe welding
Conversion standard 3-
and 4-arc welding to
wave control 3- and 4- arc
welding
1.7m/min travel speed
increased to 2.3m/min
No change to weld bead
profile or mechanical
properties
35% increase in
production
Welding of X80.NF.12.43 Welding of X80.NF.12.43
Welding of X80.NF.12.44 Welding of X80.NF.12.44
STT powerwave MIG + SAW set-up
Welding of X80.NF.12.45 Welding of X80.NF.12.45
Welding of X80.NF.12.46 Welding of X80.NF.12.46
Shipbuilding with SAW robot
Welding of X80.NF.12.47 Welding of X80.NF.12.47
SAW robot
Welding of X80.NF.12.48 Welding of X80.NF.12.48
SAW robot
Welding of X80.NF.12.49 Welding of X80.NF.12.49
Conclusions
New technology for SA-welding was developed
Inverter technology
Waveform control
Cost savings
Energy
Higher deposition rage up to 30%
Pay-back time of equipment investment
Increasing quality
Superior parameter control
Diagnostics
Weld-log
Energy
Higher productivity
Fast responding
Welding of X80.NF.12.50 Welding of X80.NF.12.50
Conclusions/Benefits
Welding of X80.NF.12.51 Welding of X80.NF.12.51
Thank you! Questions?