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

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

Jan 31, 2023 310 likes •703 views

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 Kaldors

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CII WELDING CONFERENCE 2016 16TH 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

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Kaldor’s growth laws (1970);

1st Law

“The growth of the GDP is positively related to the growth of the manufacturing sector”

2nd Law

“The productivity of the manufacturing sector is positively related to the growth of the manufacturing sector”

3rd Law “The productivity of the non-manufacturing sector is

positively related to the growth of the manufacturing sector”

World class Cambridge economist

Industrial Growth

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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 Manufacturing in India

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Not ONLY the Integral part ALSO the most Critical part of manufacturing

Welding

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Domestic LPG Cylinder Hydrocracker Reactor

Pressure : 6.4 bar Temp : 25°C Size : 0.6m L X 0.3m  Weight : 16 Kg One Cylinder Burst !!! : 150 bar : 450°C : 45m L X 5.5m  : > 1000 MT : 5 Lakh cylinders ????

Mounting Risks with Technology Growth

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The Refinery Before Fire The Refinery After Fire

A defective, high pressure, steam boiler ruptured. Skikda, Algiers - Jan. 20, 2004

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

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Radiation from Fukushima Disaster Still Affects 32 Million Japanese, HUMINIA Affairs: Energy, Asia, Health, Human Security, Risk, Carol Smith, 2015

>30 Km Radius area evacuated >1700 people died 32 Million people affected from Radiation

Fukushima Atomic Power Station, Mar. 11, 2011

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

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  • Union of Discipline's - The “Science”

– Material Science & Steel making – Physics & Physical Metallurgy – Mechanics – Electronics & Controls – Non Destructive Testing – Virtual & Physical Simulations

Science Art

Last 30 yrs moving closer to Science

  • Human Element –

The “Art”

Welding : Art or Science ?

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Key sectors:

  • Process Plant (Refineries, Petrochemicals, Fertilizers..)
  • Nuclear Power Plant
  • Defence
  • Aerospace

Welding Technology has Vital role in Nation’s Growth Welding in Manufacturing

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E.O. Reactor - 1500 MT World’s Largest

Present Competencies … Process plant equipments

FCC Regenerator – 1200 MT World’s Largest Cryogenic Column - 121 m World’s Longest

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Macro section of 400 mm thick weld

Welding Technology in Process Plant

~25 mm

Reduction in deposition by 64%

1° Included angle

Narrow Gap SAW

Thickness – 400 mm Diameter – 10 m

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Narrow Gap SAW - Parallel Circ. Seams (5 No)

Station 1 Station 2 Station 3 Station 4 Station 5

Welding Technology in Process Plant

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120 x 0.5 mm - 2400 Amp - 42 kg/hr 90 x 0.5 mm - 1800 Amp - 33 kg/hr 60 x 0.5 mm - 1200 Amp - 22 kg/hr

India World

Double layer - 120x0.5mm 60-90x0.5mm Single layer - 150x0.4mm 60-90x0.5mm

Weld Overlay with ESSC Welding Technology in Process Plant

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FCAW/ GMAW buttering by robot

Clad restoration in horizontal position Buttering on Dish end cutout 3D profile Plant

Welding Technology in Process Plant

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700 MWe PHWR Steam Generator

Present Competencies… Nuclear Power

FBR Steam Generator

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

Present Competencies… Nuclear Power

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MOC - SS 304/304L Thickness - 50 mm to 200 mm Stringent dimensional tolerance at module level –

  • Distortion Control during welding
  • Profile measurement with laser

instrument

ITER Cryostat

Present Competencies… Nuclear Power

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In-situ Ultra narrow groove Hot wire TIG

P91 – 90 mm thk (FBR-SG) SS – 200 mm thk ITER- Cryostat

13-14 mm

  • pening

45% reduction in weld deposition from NG-SAW

Welding Technology in Nuclear

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Internal Bore Welding – PHWR End shield

Highlights :

  • Process - Auto GTAW
  • Joint thickness 13 mm

Automatic Ultrasonic Examination

Welding Technology in Nuclear

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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

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Nuclear Submarine - Ti Sonar Dome

  • Large scale Ti fabrication, Dust free environment required
  • Maintaining Shape – Extremely Critical & Skilled Manpower

Welding Technology in Defence

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Nuclear Submarine

  • Automatic Twin-pulsed GMAW for T-Frame

Welding

  • Laser based automatic bead sequencing and

control

MOC - AB2 Steel

Welding Technology in Defence

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GSLV Launch - Indigenous cryogenic upper stage (CUS) engine

Present Competencies …Aerospace

GSLV-F05 lobs advanced weather satellite INSAT-3DR into orbit- 8 Sep 2016, The Hindu

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MOC – Maraging Steel

Proof Pressure Testing of segments

  • Massive fixturing to achieve fabrication

tolerances

  • Mechanized GTAW welding with stringent

x-ray quality weld

PSLV/ GSLV Motor Casings Welding Technology in Aerospace

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Welding Market

India China USA World 2014 1.4 6.1 2.42 18.25 2020 1.94 8.17 3 23.78

5 10 15 20 25

In Bn USD

India Share ~8% of the Global market

  • Data from Local Market &Transparency Market Research Report
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Indian Welding Market

Arc welding consumables 83% Welding Machines 11% Other processes + Accessories 6%

Total Market Size of India is 1400 Mn USD

20 40 60 80 100 120 140 Mkt Val Mln USD Imp-Others Imp-Eqpt Imp-Cons

Import is more than 10%

  • From Keith Hartley Memorial Lecture 2014
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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

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Equipment & Control

BRABO - First Made in India Robot, Launched in 2016 Inverter

 Limited indigenization/ technology tie-ups  Robots – Very few OEMs (system integrators - available)

Diesel Generator

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Global vs India

5 8 6 7 4 4 6 9 8 8 6 5

2 4 6 8 10 Welding consumable Technology Arc welding Processes and Technique Advance Technique & Processes Automation Equipment & control R&D on new materials

2014 2020

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

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Laser hybrid welding Automobile

FSW-Aerospace & Shipbuilding

 Limited applications of Non arc welding processes  Additive manufacturing in nascent stage

Advanced Processes

Laser Engineering Net Shaping (LENS)

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Increase in plant efficiency by AUSC Technology

  • P92, Alloy 617 - Superior creep & oxidation resistance

Enhancement of nuclear plant life

  • Improve resistance to degradation due to irradiation
  • Reduced Activation Ferritic Martensitic Steel (RAFM)

Increase in Aerospace Launch Vehicles Payload

  • Al-Li alloy - 1% Li density by 3% and stiffness by 5%

Advancements in Materials Need for technology up-gradation for emerging materials

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Investment in R&D

  • Sr. No

Country GDP PPP (Bn int$) GERD* PPP (Bn int$) R&D as % 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 %

Significantly lower than World average

*GERD = Gross Expenditure on R&D

Source: R&D Magazine; 2014

Focus & Incentivize R&D

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– Poor conversion from graduation to specialized education – Lack of quality Industry projects – Acute shortage of skilled workmen – Inadequate training facilities

Human Resource & Skill Development

India USA Undergraduate Engineering Students 16,34,596 99,173 Postgraduate Engineering Students 63,430 Full Time – 51,690 Part Time – 71,009

More Industry-Academy Collaboration Standardized training & Up-gradation of ITIs

*Source: AICTE Report 2014

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