High Productivity High Productivity Welding Processes Welding Processes

and Automation and Automation A Look AheadA Look Ahead

Matthew Yarmuch, MSc, PEng, IWEProgram Leader – Welding Engineering

Advanced Materials Business Unit

June 24, 2008

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The Alberta Research Council• Canada’s 1Canada’s 1stst provincial research organization provincial research organization

– Established 1921; 500 employees; Not-for-profit corporation

• Technical services, R&D and technology Technical services, R&D and technology commercializationcommercialization

• Key market sectors: Energy, Life SciencesKey market sectors: Energy, Life Sciences• Advanced Materials Business UnitAdvanced Materials Business Unit

– 29 employees (12 Ph.D’s & 7 P.Eng.)– Areas of Expertise:

• Coatings and wear engineering • Corrosion engineering • Welding engineering• Polymer/composite materials• Materials testing and evaluation

– Over 100 customers – 15 US Patents– 6 technologies commercialized

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Welding Engineering Group

• Development & implementation of high-Development & implementation of high-productivity technologies productivity technologies – Wire-feed Processes

– Automation

• Productivity studies for FabricatorsProductivity studies for Fabricators– On-site productivity monitoring

– Consumable trials

– Welding procedure trials

– Training and consulting

• Third-part assessments Third-part assessments • Technical training programsTechnical training programs• Mechanical & Metallurgical Testing Mechanical & Metallurgical Testing • Consulting ServicesConsulting Services

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Overview of the Advanced Overview of the Advanced Welding Processes Study and Welding Processes Study and

Industry SurveyIndustry Survey

High Productivity Welding High Productivity Welding Processes and Processes and

Automation Automation A Look AheadA Look Ahead

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Welding Study Background

• Project Genesis – January 2007Project Genesis – January 2007– Welding Automation Forum - NAIT– Discussions with industry regarding productivity and automation– Funding contributions from ARC, AFE, and EEDC

• Study Objectives:Study Objectives:– Identify state-of-the-art in welding technology– Provide economic justification for modern processes– Identify road blocks and broad industry-wide issues

• Study Outcomes:Study Outcomes:– Technologies and roadblock identified– In-shop comparisons of traditional vs modern processes– Economic case for implementation presented– Comparison of End User welding specifications – Identified “industry-wide” path forward initiatives

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Welding Survey ParticipantsEnd Users & Project

DevelopersEngineering Firms &

ConsultantsSuppliers and

IntegratorsFabricators –

Pressure PipingFabricators – Pressure

Vessels

Shell Canada Fluor Canada Ltd RoboweldPCL Industrial Constructors

Collicutt Energy Services

Syncrude Canada SNC Lavalin ARC Innovations Willbros Plains Fabrication

Suncor EnergyColt Worley

ParsonsLincoln Electric

Flint Energy Services

Tornado Technologies

TransCanada Pipelines

AMEC Americas Air Liquide Ledcor Dacro Industries

Fort Hills/Petro-Canada

Ludwig and Associates

Miller Electric & Hobart Brothers

AlcoCessco Fabrication

& Engineering

Imperial Oil Qualimet ESABPlasma Tech

IndustriesGLM Industries

Husky Energy AcurenDietech

AutomationKBR

Paintearth Energy Services

ATCO Pipelines Jacobs Euroweld Lockerbie & HoleMelloy Industrial

Services

Anonymous Engineering Firm

CWB Group Aecon IndustrialAnonymous Fabricator

IPSCO Nardei Fabricators

Fronius

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Alberta’s Fabrication Industry• Demand exceeds Demand exceeds

supply of skilled supply of skilled labour in Albertalabour in Alberta– Deficit of 400,000 skilled

workers by 2010 – 42% of companies facing

production difficulties due to labour shortages (predicted to rise)

• Higher Productivity Initiatives RequiredHigher Productivity Initiatives Required– Improved manufacturing (lean)– Wire-feed processes– Mechanization and Automation– Improved materials handling,

machining, prep, etc.

Unique opportunity Unique opportunity for Province and for Province and Country to become a Country to become a World LeaderWorld Leader

Sector# Total

Projects

Value of Projects ($ millions)

Chemicals & Petrochemicals 4 $ 372.00 Manufacturing 3 $ 46.00 Mining 7 $ 1,985.40 Oil & Gas 15 $ 4,195.40 Oil Sands 52 $ 155,596.00 Pipelines 35 $ 11,713.10 Power 40 $ 10,245.00 Total 156 $ 184,152.90

Inventory of Major Alberta ProjectsSummary, December 2007

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Investigation of Welding Applications• Survey of End Users to determine current and future Survey of End Users to determine current and future

pressure applicationspressure applications

44

2.5

58

17

7

2025

90

460

870.5

9

1 0 20

10

20

30

40

50

60

70

80

90

100

All Users Pipeline Oilsands/Refinery

Per

cen

t (%

)

Pressure Piping (ASME B31) Pressure Vessel (ASME Section VIII)Pipeline (CSA Z662) Overlays and CladdingStructural Attachments Other

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Investigation of Future Applications• Survey of End Users to determine current and future Survey of End Users to determine current and future

material requirementsmaterial requirements

71

92.5

64

11

0

159

2.5

113 2.5 42 2.5 14

05

0

10

20

30

40

50

60

70

80

90

100

All Users Pipeline Oilsands/Refinery

Per

cen

t (%

)

Carbon and Microalloyed SteelsLow- and High-alloy SteelsStainless SteelsNickel AlloysNon-ferrous Alloys (aluminium, Titanium, copper)Welded and sprayed overlays (Chromium Carbide, MMCs,etc)

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Current Utilization of Wire Processes

37%

5%

60%

49%

9%

44%

86%

26%

2%7%

12%

2%0%

35%

53%

23%

30%

7%

21% 21%

5%5%

19%

40%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

GTAW SMAW GMAW FCAW MCAW SAW

Per

cen

t F

req

uen

cy o

f P

roce

ss U

tili

zati

on

Not Used Rarely Used Commonly Used Frequently Used

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

Pressure PipingPressure Piping

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Utilization of Wire Processes• Differences found in Differences found in

industry perceptions industry perceptions

((process pipingprocess piping))

5%

35%

44%

30%

19%

0%

26%

12%

2%

53%

60%

7%9%

5%5%

86%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

SMAW GMAW FCAW MCAW

Per

cen

t F

req

uen

cy o

f P

roce

ss U

tili

zati

on

Not Used Rarely Used Commonly Used Frequently Used

Entire IndustryEntire Industry

End UsersEnd Users

FabricatorsFabricators

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Investigation of Modern Technologies• Literature search and survey responses Literature search and survey responses • Key technologies identified:Key technologies identified:

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

Very few respondents Very few respondents “attacked” the technology“attacked” the technology

Most concerned with the Most concerned with the “proper implementation” of “proper implementation” of technologytechnology

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In-Shop Productivity Studies

• Comparisons of manual vs semi-automated processesComparisons of manual vs semi-automated processes– On-site studies, utilizing existing equipment, consumables, welders– Collaboration with Aecon Industrial, Plains Fabrication, Altex

Industries and GLM Industries

• Shop 1G (Roll) Scenarios:Shop 1G (Roll) Scenarios:6NPS XS (0.432” wall) P1 SMAW vs. GMAW-MSC/FCAW & MCAW

12NPS XS (0.500” wall) P1 SMAW vs. GMAW-MSC/FCAW & MCAW

24NPS S40 (0.688” wall) P1 SMAW/SAW-DC vs GMAW-MSC/SAW-AC

• Shop/Field 5G (Position) Scenarios:Shop/Field 5G (Position) Scenarios:6NPS STD (0.280” wall) P1 SMAW vs. GMAW-MSC/FCAW

12NPS XS (0.375” wall) P1 SMAW vs. GMAW-MSC/FCAW

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• Case Study – 6NPS XS Shop Weld Case Study – 6NPS XS Shop Weld

• Shop 12NPS & 24NPS improvements ranged from Shop 12NPS & 24NPS improvements ranged from 35% to 54%35% to 54%• 5G Position welds (6NPS & 12NPS) ranged from 5G Position welds (6NPS & 12NPS) ranged from 36% to 46%36% to 46%

Productivity Studies

GMAW-MSC & FCAWGMAW-MSC & FCAW

SMAWSMAW

31%31%41%41%

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

Topic 2 – Productivity Study

Improvements Improvements are expected to are expected to rise with further rise with further optimization of optimization of fabrication fabrication proceduresprocedures

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Barriers to Acceptance and Use• End User welding specification requirementsEnd User welding specification requirements

– Requirements based on service experience– Identified conservative requirements that require new investigations

• Insufficient welding-related training (all sectors)Insufficient welding-related training (all sectors)– Average welder not “fabrication ready” for modern processes– Technical workforce (inspectors, technologists and engineers) require

more welding-related education

• Industry Culture - bias against wire-feed & automation Industry Culture - bias against wire-feed & automation – Past “repeated rejection” of GMAW, FCAW and automation– Preconceived notion wire-processes “unacceptable” for pressure welding

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Barriers to Acceptance and Use• Poor industry communicationPoor industry communication

– Poor communication between end users, engineering firms, and fabricators key stumbling block

– An industry-based Program required to promote collaboration

• Lack of investment in modern technologyLack of investment in modern technology– Fabricators are willing to invest, but are reluctant due to past rejection– End Users require proof of competency, training, equipment, etc

– Due to the impasse, a collaborative industry-wide approach is required

to spur investments and innovations.

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Path Forward Strategies• Welding Productivity Program (WPP) Welding Productivity Program (WPP)

– A collaboration of stake-holders from all sectors– Continuously indentify and discuss industry issues – Collaborate and fund ARC joint industry projects (JIPs)

• Development of Recommended PracticesDevelopment of Recommended Practices– Based on WPP projects “best practices” for modern technology– Streamline requirements amongst major projects

• User Input quality and service requirements• Supplier Input technology, practicality, and feasibility • Examples of Topics:

– “Modified Waveform Welding Techniques”– “GMAW & FCAW welding for Sour Service”– “Impact and Hardness Testing of Weldments”– “Fusion Issues when Welding Thick-wall Pipe”– “Operator Qualification Requirements for Phased Array”

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Welding Productivity Program (WPP)

• WPP Mission Statement and Objectives:WPP Mission Statement and Objectives:– Collaborative industry “vehicle” through which modern welding

technologies are evaluated, and – Industry barriers are addressed, – To produce industry-leading technical and practical solutions for

Alberta’s Energy Industries.

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Path Forward Strategies• Pressure Welder Training/CertificationPressure Welder Training/Certification

– Development of process specific standards, e.g. B-Pressure (FCAW)– Preliminary discussions with regulatory authorities, Alberta

apprenticeship board, training institutes and industry

• Welding-related EducationWelding-related Education– Professional development for all levels of industry– Strong Institutional support:

• U of A Canadian Centre for Welding & Joining• NAIT Shell Manufacturing Centre & Souch Campus• SAIT School of Manufacturing and Automation• ARC Industrial Materials Laboratory (Devon, Ab)

Thomas J. Peters “If your company is doing well, double you training budget;if you company is not doing well, quadruple it.”

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Path Forward Strategies• Continued Development of High-Productivity TechnologyContinued Development of High-Productivity Technology

– Seminars and Workshops Promote technology uptake– Automation Critical productivity-enabling technology– The hybrid automated welding system (HAWS)

• First automation-related project for the WPP

• Non-Destructive Examination & Quality ControlNon-Destructive Examination & Quality Control– “Proper” implementation strategies required for modern technology– Greater use of UT phased array, TOFD, digital RT, etc.– WPP projects develop testing and quality plans

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Path Forward Strategies• Alternative Bid Packages Alternative Bid Packages

– Fabricators proactively promote wire-processes at RFQ stage – Emphasize previous experience, schedule improvements, etc

• Investment Tax Incentives Investment Tax Incentives – Provincial/federal governments establish capital tax-credit programs– Reduce the financial burden of modernizing fabrication facilities.

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Closing Thoughts

• To realize the full prosperity for the province and To realize the full prosperity for the province and country, a collaborative effort from all industry sectors country, a collaborative effort from all industry sectors is required. is required.

• The Alberta and Federal government can continue to The Alberta and Federal government can continue to promote the uptake of modern technology, but promote the uptake of modern technology, but industry support and participation is necessary. industry support and participation is necessary.

• The potential economic gains for the province are The potential economic gains for the province are significant, and will help to secure the province’s significant, and will help to secure the province’s economic future.economic future.

“We can't solve problems by using the same kind of thinking we used when we created them.” Albert Einstein