Welding Sector in India : Advancements and Challenges Y S Trivedi - PowerPoint PPT Presentation

CII WELDING CONFERENCE 2016 16 TH NOVEMBER 2016, MUMBAI Welding Sector in India : Advancements and Challenges Y S Trivedi SVP & Member of Boards - HE IC, HE LLC Oman, LTSSHF Larsen & Toubro Limited 1/38

Industrial Growth Kaldor’s growth laws (1970) ; 1 st Law “The growth of the GDP is positively related to the growth of the manufacturing sector” 2 nd Law “ The productivity of the manufacturing sector is positively related to the growth of the manufacturing World class Cambridge economist sector” 3 rd Law “ The productivity of the non-manufacturing sector is positively related to the growth of the manufacturing sector” 2/38

Manufacturing in India Make In India  Growth from 16% to 25% of GDP by 2025  Transform India into a global manufacturing hub  Build best-in-class manufacturing infrastructure  Foster innovation  Employment generation & skill development Welding is an Integral part of Manufacturing 3/38

Welding Not ONLY the Integral part ALSO the most Critical part of manufacturing 4/38

Mounting Risks with Technology Growth Domestic LPG Cylinder Hydrocracker Reactor Pressure : 6.4 bar : 150 bar Temp : 25°C : 450°C : 0.6m L X 0.3m  : 45m L X 5.5m  Size Weight : 16 Kg : > 1000 MT One Cylinder Burst !!! : 5 Lakh cylinders ???? 5/38

Skikda, Algiers - Jan. 20, 2004 The Refinery Before Fire A defective, high pressure, steam boiler ruptured . The Refinery After Fire 6/38

Skikda, Algiers - Jan. 20, 2004 23 Killed, 74 Injured Damage: $800 Mn 7/38

Fukushima Atomic Power Station, Mar. 11, 2011 >30 Km Radius area evacuated >1700 people died 32 Million people affected from Radiation Radiation from Fukushima Disaster Still Affects 32 Million Japanese, HUMINIA Affairs: Energy, Asia, Health, Human Security, Risk, Carol Smith, 2015 8/38

Kakrapar Atomic Power Station, Mar. 11, 2016 A Rupture in the coolant System of one of the nuclear reactors 9/38

Welding : Art or Science ? • Human Element – The “Art” • Union of Discipline's - The “Science” – Material Science & Steel making – Physics & Physical Metallurgy – Mechanics – Electronics & Controls Science – Non Destructive Testing – Virtual & Physical Simulations Art Last 30 yrs moving closer to Science 10/38

Welding in Manufacturing Key sectors:  Process Plant (Refineries, Petrochemicals, Fertilizers..)  Nuclear Power Plant  Defence  Aerospace Welding Technology has Vital role in Nation’s Growth 11/38

Present Competencies … Process plant equipments E.O. Reactor - 1500 MT FCC Regenerator – 1200 MT World’s Largest World’s Largest Cryogenic Column - 121 m World’s Longest 12/38

Welding Technology in Process Plant Narrow Gap SAW Macro section of 400 mm thick weld Reduction in deposition Thickness – 400 mm by 64% Diameter – 10 m ~25 mm 1° Included angle 13/38

Welding Technology in Process Plant Narrow Gap SAW - Parallel Circ. Seams (5 No) Station Station Station Station 1 4 5 Station 3 2 14/38

Welding Technology in Process Plant Weld Overlay with ESSC 120 x 0.5 mm - 2400 Amp - 42 kg/hr India World 90 x 0.5 mm - 1800 Amp - 33 kg/hr Double layer - 120x0.5mm 60-90x0.5mm 60 x 0.5 mm - 1200 Amp - 22 kg/hr Single layer - 150x0.4mm 60-90x0.5mm 15/38

Welding Technology in Process Plant FCAW/ GMAW buttering by robot Buttering on Dish end cutout Clad restoration in horizontal 3D profile Plant position 16/38

Present Competencies… Nuclear Power 700 MWe PHWR Steam Generator FBR Steam Generator 17/38

Present Competencies… Nuclear Power WEC Areva AP1000 EPR NPCIL and AREVA France entered into an agreement on April 10, 2015 for setting up of two EPR. US-India Agree To Construct 6 Nuclear Reactors In India Updated: June 07, 2016 23:03 IST 18/38

Present Competencies… Nuclear Power ITER Cryostat Stringent dimensional tolerance at module level – • Distortion Control during welding • Profile measurement with laser instrument MOC - SS 304/304L Thickness - 50 mm to 200 mm 19/38

Welding Technology in Nuclear In-situ Ultra narrow groove Hot wire TIG 13-14 mm opening 45% reduction in weld deposition SS – 200 mm thk from NG-SAW P91 – 90 mm thk (FBR-SG) 20/38 ITER- Cryostat

Welding Technology in Nuclear Internal Bore Welding – PHWR End shield Automatic Ultrasonic Examination Highlights : • Process - Auto GTAW • Joint thickness 13 mm 21/38

Present Competencies ….. Defence First Indigenous Nuclear Submarine "India set to complete N-triad with Arihant commissioning - Times of India". The Times of India. Retrieved 2016-10-18 22/38

Welding Technology in Defence Nuclear Submarine - Ti Sonar Dome • Large scale Ti fabrication, Dust free environment required • Maintaining Shape – Extremely Critical & Skilled Manpower 23/38

Welding Technology in Defence Nuclear Submarine MOC - AB2 Steel • Automatic Twin-pulsed GMAW for T-Frame Welding • Laser based automatic bead sequencing and control 24/38

Present Competencies … Aerospace GSLV Launch - Indigenous cryogenic upper stage (CUS) engine GSLV-F05 lobs advanced weather satellite INSAT-3DR into orbit- 8 Sep 2016, The Hindu 25/38

Welding Technology in Aerospace PSLV/ GSLV Motor Casings MOC – Maraging Steel • Massive fixturing to achieve fabrication tolerances Proof Pressure • Mechanized GTAW welding with stringent Testing of segments x-ray quality weld 26/38

Welding Market 25 India Share 20 ~8% of the Global market In Bn USD 15 10 5 0 India China USA World 2014 1.4 6.1 2.42 18.25 2020 1.94 8.17 3 23.78 - Data from Local Market &Transparency Market Research Report 27/38

Indian Welding Market Total Market Size of India is 1400 Mn USD Other Import is more than 10% processes + Welding Accessories Machines 11% Mkt Val Mln USD 6% 140 Arc welding 120 consumables Imp-Others 100 83% Imp-Eqpt 80 Imp-Cons 60 40 20 0 - From Keith Hartley Memorial Lecture 2014 28/38

Arc Welding Consumables Major in-house production SMAW Electrodes & Wires for: Structural steels, few grades of alloy steels & SS Import of critical consumables  Ni alloys  Al & Ti alloys  Fluxes for SAW/ ESSC  ESSC strips Limited indigenization & 90% imports of critical consumables 29/38

Equipment & Control Inverter Diesel Generator BRABO - First Made in India Robot, Launched in 2016  Limited indigenization/ technology tie-ups  Robots – Very few OEMs (system integrators - available) 30/38

Global vs India Welding consumable Technology 10 8 6 Arc welding 6 R&D on new 9 5 Processes and materials 4 Technique 8 5 2 4 0 4 6 8 6 Equipment & Advance Technique 7 control & Processes 8 Automation 2014 2020 31/38

Future Challenges & Way Ahead …  Advanced Processes  Advancements in Materials  Education and R&D  Human resources and skill development 32/38

Advanced Processes  Limited applications of Non arc welding processes  Additive manufacturing in nascent stage Laser hybrid welding FSW-Aerospace & Laser Engineering Automobile Shipbuilding Net Shaping (LENS) 33/38

Advancements in Materials Increase in plant efficiency by AUSC Technology • P92, Alloy 617 - Superior creep & oxidation resistance Increase in Aerospace Launch Vehicles Payload • Al-Li alloy - 1% Li density by 3% and stiffness by 5% Enhancement of nuclear plant life • Improve resistance to degradation due to irradiation • Reduced Activation Ferritic Martensitic Steel (RAFM) Need for technology up-gradation for emerging materials 34/38

Investment in R&D Sr. No Country GDP PPP GERD* PPP R&D as % (Bn int$) (Bn int$) GDP PPP 1 United States 17,460 485.39 2.78 % 2 China 17,630 343.78 1.95 % 3 India 7,277 61.85 0.85 % 4 World avg. 105,757 1803.10 1.70 % *GERD = Gross Expenditure on R&D Significantly lower than World average Focus & Incentivize R&D Source: R&D Magazine; 2014 35/38

Human Resource & Skill Development India USA Undergraduate Engineering 16,34,596 99,173 Students Postgraduate Engineering 63,430 Full Time – 51,690 Students Part Time – 71,009 – Poor conversion from graduation to specialized education – Lack of quality Industry projects – Acute shortage of skilled workmen – Inadequate training facilities More Industry-Academy Collaboration Standardized training & Up-gradation of ITIs *Source: AICTE Report 2014 36/38

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