Submerged arc welding for the future

a new generation of power sources

Harm Meelker
Lincoln Smitweld B.V.
Nordic
Conference, Oct. 2012
WeldingWelding
of X80.NF.12.1

Overview

Introduction

Traditional SAW equipment

Process variables

Next generation SAW equipment

Procedure development

Energy savings

Features

Conclusions
Welding of X80.NF.12.2

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.12.3

Conventional equipment

Welding of X80.NF.12.4

SAW process variables

Single arc

Multiple arc

Single wire
Welding on DC minus
Tubular Cored Wire
Iron powder
Long Stick Out
Narrow gap
Semi-narrow gap

Twin-arc
Tandem
Tandem twin
3 - 4 - 5 wires
Cold wire
Hot wire
Semi-narrow gap

Welding of X80.NF.12.5

225
190
145
125

Welding of X80.NF.12.6

Machined Grooves Offer Greater

Savings Potential

Welding of X80.NF.12.7

Narrow Gap or Narrow Grove

Narrow Groove:
Narrow Gap

Larger gap and radius

Larger sidewall bevel angles, up to 50o
Compound bevels also typical
Typically <100mm

Narrow Gap:

Welding of X80.NF.12.8

Very small gap at the bottom:

20mm typical (10mm radius)
Same sidewall angle bevel
Sidewall bevel: 1.5o typical (1.2o 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
Advantages:

Lower joint volume

Reduced consumables cost
Higher weld productivity

Disadvantages:












Welding of X80.NF.12.9

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

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.12.10

Influence of current Voltage and Travel

Speed on penetration in SAW
Constant wire diameter and stick-out

Current [A]

Voltage [V]

constant voltage
and travel speed

constant current
and travel speed

Travel speed
[cm/min]
constant current
and voltage

Welding of X80.NF.12.11

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

Welding of X80.NF.12.12

Waveform control technology

Digital communications technology

Infinitely variable AC
Positive

Current, Voltage or Power

Current Level => PENETRATION

Cycle Balance => PENETRATION

& DEPOSITION

Frequency
time

Negative
Current Level => DEPOSITION

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.12.13

Wave Balance

Typically run at 25% positive & 75% negative

Welding of X80.NF.12.14

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.12.15

Waveform Control Technology

Offset

Wave Balance

Welding of X80.NF.12.16

Positive = 835 Amps

Positive = 450 Amps

Negative = 519 Amps

Negative = 822 Amps

Penetration = .366

Penetration = .280

70% Positive

50% Positive

30% Positive

Penetration = 0.387

Penetration = 0.346

Penetration = 0.242

Deposition rates

Welding of X80.NF.12.17

Power Wave AC/DC 1000 SD

Waveform Control
Technology
























Welding of X80.NF.12.18

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

Systems

Welding of X80.NF.12.19

Arc configurations

Welding of X80.NF.12.20

Multiple Arc Welding

Welding of X80.NF.12.21

Practical example: Tube welding

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 of X80.NF.12.22
Welding time per weld (1060x28mm) in a pile was 60 min., decreased to 40 min.

Practical example: Tube welding

1060 x 35mm
Equipment

Conventional

Wave Control

DC 1000

PW AC/DC; with 40 Hz;

55% DC-; 5% offset

Fill

500/520 A - 31 Volt 550 - 34 Volt

= 6 kg/h
= 9 kg/h

Cap

650/680 A - 34 Volt 720 A - 38/40 Volt

= 7.6 kg/h
= 10.2 kg/h

Travel speed 40 cm/min

60 cm/min

Welding time 60 min.

40 min.

Welding of X80.NF.12.23

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.12.24

Optimising procedures
BEFORE

70

36mm

2mm

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

AFTER

50

13mm Plate

36mm
6mm

Welding of X80.NF.12.25

19mm Plate

36mm Plate

Optimising procedures
Three Meter Diameter Can
Single V

Travel Speed Procedure 1(IPM)

Number of Passes

Double V

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

Travel Speed Procedure 2 (IPM)

Number of Passes

Welding of X80.NF.12.26

27

30
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 %

Traditional procedure
ORIGINAL PROCEDURES
Impacts: 27J @ -20C

Travel Speed = 530 mm/min.

CC+

AC

4.0 mm
950 A
30 V

4.0 mm
700 A
34 V

Deposition rate = 21,5 Kg/hr

Welding of X80.NF.12.27

.
.

Powerwave technology
TANDEM CAPABILITIES

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

Welding of X80.NF.12.28

25-35 mm

Procedure development

Welding of X80.NF.12.29

Procedure development

Welding of X80.NF.12.30

Procedure development

Welding of X80.NF.12.31

Procedure development

Welding of X80.NF.12.32

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.12.33

Savings with the PW1000AC/DC

Welding of X80.NF.12.34

Three ways to save energy

Idle consumption

The power consumption of the PW1000AC/DC when the

machine is running but not welding.
Importance

Increased machine efficiency

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

Process efficiency
The Advanced AC Sub Arc process is showing higher deposition
and lower Heat input. The energy required to complete one joint is
reduced

PW 1000AC/DC
400V 3Ph 50Hz
Welding of X80.NF.12.35

PW1000AC/DC versus conventional inverter

Three machines running 600A 30V Comparison

Commonly used in the
industry

AC 1200

PW1000 AC/DC

DC1000

Efficiency 80%

Efficiency 86%

Efficiency 78%

Power Factor 0.81

Power Factor 0.95

Power Factor 0.73

KW

22.5

KW

20.9

KW

23.1

KVA

27

KVA

22

KVA

31.6

Line current 67A

Line current 32A

Line current 32A

Idle Power 2500W

Idle Power 300W

Idle Power 2000W

Efficiency, line current and idle power levels are supporting savings

Welding of X80.NF.12.36

Field experience Application: SA Twin 2.0mm

16mm

Vessel fabrication
Material SA517 Grade 65
Wire LNS 133 2.4mm
FLUX 960
Vessel diameter 1250mm

50

GMAW root pass

PowerWave 1000AC/DC
Layer
1
2
3
4
5
6

Amps
325
340
640
800
885
850

Volts
27
27
30
32
33
33

TS (cm/min)

Total time per joint 26 minutes

Savings:

DC1000

75
75
95
110
110
110

HI (Kj/cm) KJ/layer
7.020
2.755
7.344
2.883
12.126
4.760
13.964
5.481
15.930
6.253
15.300
6.005
28.136

Layer
1
2
3
4
5
6
7

Amps
325
340
640
800
885
880
850

Volts
27
27
30
32
33
33
33

TS (cm/min)

66
66
95
95
85
85
85

Total time per joint 34 minutes

23.5% weld time per joint,

32% energy cost

The PW1000AC/DC is saving joint time + Energy

Welding of X80.NF.12.37

HI (Kj/cm) KJ/layer
7.977
3.131
8.345
3.276
12.126
4.760
16.168
6.346
20.615
8.092
20.499
8.046
19.800
7.772
41.421

Quality Analysis
Advanced analysis tool for calculating overall
quality
of a weld based on deviation of wire deposition rate.
Start Quality Analysis

Welding of X80.NF.12.38

Lincoln Smitweld

Welding of X80.NF.12.39

Production Monitoring

Weld History

Diagnostics

Welding of X80.NF.12.40

Distributed system architecture

Clock Signal

Arc Link - TCP/IP

Wire Drive Control &
Power Supply

Positioning Control &

Power Supply

Wide Area Network

Monitor Application

All components communicate via a network using Arc Link over

TCP/IP Protocol

Welding of X80.NF.12.41

Application Pipe Mills

Longitudinal pipe welding
Conversion standard 3and 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.12.42

Welding of X80.NF.12.43

STT powerwave MIG + SAW set-up

Welding of X80.NF.12.44

Welding of X80.NF.12.45

Shipbuilding with SAW robot

Welding of X80.NF.12.46

SAW robot

Welding of X80.NF.12.47

SAW robot

Welding of X80.NF.12.48

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.12.49

Conclusions/Benefits

Welding of X80.NF.12.50

Thank you! Questions?

Welding of X80.NF.12.51