Waf Calgary 2008


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Waf Calgary 2008

  1. 1. High Productivity Welding Processes and Automation A Look Ahead Matthew Yarmuch, MSc, PEng, IWE Program Leader – Welding Engineering Advanced Materials Business Unit June 24, 2008
  2. 2. The Alberta Research Council <ul><li>Canada’s 1 st provincial research organization </li></ul><ul><ul><li>Established 1921; 500 employees; Not-for-profit corporation </li></ul></ul><ul><li>Technical services, R&D and technology commercialization </li></ul><ul><li>Key market sectors: Energy, Life Sciences </li></ul><ul><li>Advanced Materials Business Unit </li></ul><ul><ul><li>29 employees (12 Ph.D’s & 7 P.Eng.) </li></ul></ul><ul><ul><li>Areas of Expertise: </li></ul></ul><ul><ul><ul><li>Coatings and wear engineering </li></ul></ul></ul><ul><ul><ul><li>Corrosion engineering </li></ul></ul></ul><ul><ul><ul><li>Welding engineering </li></ul></ul></ul><ul><ul><ul><li>Polymer/composite materials </li></ul></ul></ul><ul><ul><ul><li>Materials testing and evaluation </li></ul></ul></ul><ul><ul><li>Over 100 customers </li></ul></ul><ul><ul><li>15 US Patents </li></ul></ul><ul><ul><li>6 technologies commercialized </li></ul></ul>
  3. 3. Welding Engineering Group <ul><li>Development & implementation of high-productivity technologies </li></ul><ul><ul><li>Wire-feed Processes </li></ul></ul><ul><ul><li>Automation </li></ul></ul><ul><li>Productivity studies for Fabricators </li></ul><ul><ul><li>On-site productivity monitoring </li></ul></ul><ul><ul><li>Consumable trials </li></ul></ul><ul><ul><li>Welding procedure trials </li></ul></ul><ul><ul><li>Training and consulting </li></ul></ul><ul><li>Third-part assessments </li></ul><ul><li>Technical training programs </li></ul><ul><li>Mechanical & Metallurgical Testing </li></ul><ul><li>Consulting Services </li></ul>
  4. 4. Overview of the Advanced Welding Processes Study and Industry Survey High Productivity Welding Processes and Automation A Look Ahead
  5. 5. Welding Study Background <ul><li>Project Genesis – January 2007 </li></ul><ul><ul><li>Welding Automation Forum - NAIT </li></ul></ul><ul><ul><li>Discussions with industry regarding productivity and automation </li></ul></ul><ul><ul><li>Funding contributions from ARC, AFE, and EEDC </li></ul></ul><ul><li>Study Objectives: </li></ul><ul><ul><li>Identify state-of-the-art in welding technology </li></ul></ul><ul><ul><li>Provide economic justification for modern processes </li></ul></ul><ul><ul><li>Identify road blocks and broad industry-wide issues </li></ul></ul><ul><li>Study Outcomes: </li></ul><ul><ul><li>Technologies and roadblock identified </li></ul></ul><ul><ul><li>In-shop comparisons of traditional vs modern processes </li></ul></ul><ul><ul><li>Economic case for implementation presented </li></ul></ul><ul><ul><li>Comparison of End User welding specifications </li></ul></ul><ul><ul><li>Identified “industry-wide” path forward initiatives </li></ul></ul>
  6. 6. Welding Survey Participants Fronius Nardei Fabricators IPSCO Anonymous Fabricator Aecon Industrial CWB Group Anonymous Engineering Firm Melloy Industrial Services Lockerbie & Hole Euroweld Jacobs ATCO Pipelines Paintearth Energy Services KBR Dietech Automation Acuren Husky Energy GLM Industries Plasma Tech Industries ESAB Qualimet Imperial Oil Cessco Fabrication & Engineering Alco Miller Electric & Hobart Brothers Ludwig and Associates Fort Hills/Petro-Canada Dacro Industries Ledcor Air Liquide AMEC Americas TransCanada Pipelines Tornado Technologies Flint Energy Services Lincoln Electric Colt Worley Parsons Suncor Energy Plains Fabrication Willbros ARC Innovations SNC Lavalin Syncrude Canada Collicutt Energy Services PCL Industrial Constructors Roboweld Fluor Canada Ltd Shell Canada Fabricators – Pressure Vessels Fabricators – Pressure Piping Suppliers and Integrators Engineering Firms & Consultants End Users & Project Developers
  7. 7. Alberta’s Fabrication Industry <ul><li>Demand exceeds supply of skilled labour in Alberta </li></ul><ul><ul><li>Deficit of 400,000 skilled workers by 2010 </li></ul></ul><ul><ul><li>42% of companies facing production difficulties due to labour shortages (predicted to rise) </li></ul></ul><ul><li>Higher Productivity Initiatives Required </li></ul><ul><ul><li>Improved manufacturing (lean) </li></ul></ul><ul><ul><li>Wire-feed processes </li></ul></ul><ul><ul><li>Mechanization and Automation </li></ul></ul><ul><ul><li>Improved materials handling, </li></ul></ul><ul><ul><li>machining, prep, etc. </li></ul></ul>Unique opportunity for Province and Country to become a World Leader
  8. 8. Investigation of Welding Applications <ul><li>Survey of End Users to determine current and future pressure applications </li></ul>
  9. 9. Investigation of Future Applications <ul><li>Survey of End Users to determine current and future material requirements </li></ul>
  10. 10. Current Utilization of Wire Processes <ul><li>Current process use for pressure piping, vessels, structural, pipeline and field applications </li></ul><ul><ul><li>Based on responses from all industry sectors </li></ul></ul>Pressure Piping
  11. 11. Utilization of Wire Processes <ul><li>Differences found in industry perceptions </li></ul><ul><li>( process piping ) </li></ul>Entire Industry End Users Fabricators
  12. 12. Investigation of Modern Technologies <ul><li>Literature search and survey responses </li></ul><ul><li>Key technologies identified: </li></ul><ul><ul><li>Modern Power Sources – solid-state inverters </li></ul></ul><ul><ul><li>Software-based waveform control – STT, RMD, CMT, pulse </li></ul></ul><ul><ul><li>Tubular (FCAW/MCAW) consumable manufacturing advancements </li></ul></ul><ul><ul><li>Overlay technologies – hot-wire GTAW, PTAW, electro-slag </li></ul></ul><ul><ul><li>Advanced inspection techniques – phased array </li></ul></ul><ul><ul><li>Utilization of mechanized welding and automation </li></ul></ul>Very few respondents “attacked” the technology Most concerned with the “proper implementation” of technology
  13. 13. In-Shop Productivity Studies <ul><li>Comparisons of manual vs semi-automated processes </li></ul><ul><ul><li>On-site studies, utilizing existing equipment, consumables, welders </li></ul></ul><ul><ul><li>Collaboration with Aecon Industrial, Plains Fabrication, Altex Industries and GLM Industries </li></ul></ul><ul><li>Shop 1G (Roll) Scenarios: </li></ul><ul><ul><li>6NPS XS (0.432” wall) P1 SMAW vs. GMAW-MSC/FCAW & MCAW </li></ul></ul><ul><ul><li>12NPS XS (0.500” wall) P1 SMAW vs. GMAW-MSC/FCAW & MCAW </li></ul></ul><ul><ul><li>24NPS S40 (0.688” wall) P1 SMAW/SAW-DC vs GMAW-MSC/SAW-AC </li></ul></ul><ul><li>Shop/Field 5G (Position) Scenarios: </li></ul><ul><ul><li>6NPS STD (0.280” wall) P1 SMAW vs. GMAW-MSC/FCAW </li></ul></ul><ul><ul><li>12NPS XS (0.375” wall) P1 SMAW vs. GMAW-MSC/FCAW </li></ul></ul>
  14. 14. <ul><li>Case Study – 6NPS XS Shop Weld </li></ul><ul><li>Shop 12NPS & 24NPS improvements ranged from 35% to 54% </li></ul><ul><li>5G Position welds (6NPS & 12NPS) ranged from 36% to 46% </li></ul>Productivity Studies GMAW-MSC & FCAW SMAW 31% 41%
  15. 15. <ul><li>Extrapolate data to “typical” piping module </li></ul><ul><ul><li>Economic analysis by QGI Consulting, with ARC and Aecon Industrial </li></ul></ul><ul><ul><li>Welding cost reductions = 29% </li></ul></ul><ul><ul><li>Increased welding labour productivity = 36% </li></ul></ul><ul><ul><li>Net productivity improvement = 14.4% </li></ul></ul>Topic 2 – Productivity Study Improvements are expected to rise with further optimization of fabrication procedures
  16. 16. Barriers to Acceptance and Use <ul><li>End User welding specification requirements </li></ul><ul><ul><li>Requirements based on service experience </li></ul></ul><ul><ul><li>Identified conservative requirements that require new investigations </li></ul></ul><ul><li>Insufficient welding-related training (all sectors) </li></ul><ul><ul><li>Average welder not “fabrication ready” for modern processes </li></ul></ul><ul><ul><li>Technical workforce (inspectors, technologists and engineers) require more welding-related education </li></ul></ul><ul><li>Industry Culture - bias against wire-feed & automation </li></ul><ul><ul><li>Past “repeated rejection” of GMAW, FCAW and automation </li></ul></ul><ul><ul><li>Preconceived notion wire-processes “unacceptable” for pressure welding </li></ul></ul>
  17. 17. Barriers to Acceptance and Use <ul><li>Poor industry communication </li></ul><ul><ul><li>Poor communication between end users, engineering firms, and fabricators  key stumbling block </li></ul></ul><ul><ul><li>An industry-based Program required to promote collaboration </li></ul></ul><ul><li>Lack of investment in modern technology </li></ul><ul><ul><li>Fabricators are willing to invest, but are reluctant due to past rejection </li></ul></ul><ul><ul><li>End Users require proof of competency, training, equipment, etc </li></ul></ul><ul><ul><li>Due to the impasse, a collaborative industry-wide approach is required to spur investments and innovations. </li></ul></ul>
  18. 18. Path Forward Strategies <ul><li>Welding Productivity Program (WPP) </li></ul><ul><ul><li>A collaboration of stake-holders from all sectors </li></ul></ul><ul><ul><li>Continuously indentify and discuss industry issues </li></ul></ul><ul><ul><li>Collaborate and fund ARC joint industry projects (JIPs) </li></ul></ul><ul><li>Development of Recommended Practices </li></ul><ul><ul><li>Based on WPP projects  “best practices” for modern technology </li></ul></ul><ul><ul><li>Streamline requirements amongst major projects </li></ul></ul><ul><ul><ul><li>User Input  quality and service requirements </li></ul></ul></ul><ul><ul><ul><li>Supplier Input  technology, practicality, and feasibility </li></ul></ul></ul><ul><ul><ul><li>Examples of Topics: </li></ul></ul></ul><ul><ul><ul><ul><li>“ Modified Waveform Welding Techniques” </li></ul></ul></ul></ul><ul><ul><ul><ul><li>“ GMAW & FCAW welding for Sour Service” </li></ul></ul></ul></ul><ul><ul><ul><ul><li>“ Impact and Hardness Testing of Weldments” </li></ul></ul></ul></ul><ul><ul><ul><ul><li>“ Fusion Issues when Welding Thick-wall Pipe” </li></ul></ul></ul></ul><ul><ul><ul><ul><li>“ Operator Qualification Requirements for Phased Array” </li></ul></ul></ul></ul>
  19. 19. Welding Productivity Program (WPP) <ul><li>WPP Mission Statement and Objectives: </li></ul><ul><ul><li>Collaborative industry “vehicle” through which modern welding technologies are evaluated, and </li></ul></ul><ul><ul><li>Industry barriers are addressed, </li></ul></ul><ul><ul><li>To produce industry-leading technical and practical solutions for Alberta’s Energy Industries. </li></ul></ul>
  20. 20. Path Forward Strategies <ul><li>Pressure Welder Training/Certification </li></ul><ul><ul><li>Development of process specific standards, e.g. B-Pressure (FCAW) </li></ul></ul><ul><ul><li>Preliminary discussions with regulatory authorities, Alberta apprenticeship board, training institutes and industry </li></ul></ul><ul><li>Welding-related Education </li></ul><ul><ul><li>Professional development for all levels of industry </li></ul></ul><ul><ul><li>Strong Institutional support: </li></ul></ul><ul><ul><ul><li>U of A Canadian Centre for Welding & Joining </li></ul></ul></ul><ul><ul><ul><li>NAIT Shell Manufacturing Centre & Souch Campus </li></ul></ul></ul><ul><ul><ul><li>SAIT School of Manufacturing and Automation </li></ul></ul></ul><ul><ul><ul><li>ARC Industrial Materials Laboratory (Devon, Ab) </li></ul></ul></ul>“ If your company is doing well, double you training budget; if you company is not doing well, quadruple it .” Thomas J. Peters
  21. 21. Path Forward Strategies <ul><li>Continued Development of High-Productivity Technology </li></ul><ul><ul><li>Seminars and Workshops  Promote technology uptake </li></ul></ul><ul><ul><li>Automation  Critical productivity-enabling technology </li></ul></ul><ul><ul><li>The hybrid automated welding system (HAWS) </li></ul></ul><ul><ul><ul><li>First automation-related project for the WPP </li></ul></ul></ul><ul><li>Non-Destructive Examination & Quality Control </li></ul><ul><ul><li>“ Proper” implementation strategies required for modern technology </li></ul></ul><ul><ul><li>Greater use of UT phased array, TOFD, digital RT, etc. </li></ul></ul><ul><ul><li>WPP projects  develop testing and quality plans </li></ul></ul>
  22. 22. Path Forward Strategies <ul><li>Alternative Bid Packages </li></ul><ul><ul><li>Fabricators proactively promote wire-processes at RFQ stage </li></ul></ul><ul><ul><li>Emphasize previous experience, schedule improvements, etc </li></ul></ul><ul><li>Investment Tax Incentives </li></ul><ul><ul><li>Provincial/federal governments  establish capital tax-credit programs </li></ul></ul><ul><ul><li>Reduce the financial burden of modernizing fabrication facilities. </li></ul></ul>
  23. 23. Closing Thoughts <ul><li>To realize the full prosperity for the province and country, a collaborative effort from all industry sectors is required. </li></ul><ul><li>The Alberta and Federal government can continue to promote the uptake of modern technology, but industry support and participation is necessary. </li></ul><ul><li>The potential economic gains for the province are significant, and will help to secure the province’s economic future. </li></ul>“ We can't solve problems by using the same kind of thinking we used when we created them.” Albert Einstein