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Paul, Arun Kumar
- Air-Cooled Induction Heating Solution for Heat Treatment of P91 Grade Steel in Welding Applications
Authors
1 Electronics Devices (World Wide) Private Limited 22 Mistry Industrial Estate, Cross Road A MIDC, Andheri (E), Mumbai - 400093, IN
Source
Indian Welding Journal, Vol 51, No 3 (2018), Pagination: 81-88Abstract
To have long operating life and to withstand high temperature and pressure of steam, now a days, the standard material used in power industry is the P91 Grade steel. It has high creep resistance. In a fabrication process when arc welding is used for joining this material the high energy density of arc heat makes strong influence on its microstructure. Moreover, the prospect of hydrogen cracking increases if pre-heating is not properly done. Therefore, for long term quality of P91 Grade steel, detailed heat treatment operation must be performed before and after the welding. For heat treatment operations, the induction heating method is ideally suitable. This article proposes to use air-cooled system to improve the efficiency of power delivery to the requisite area of pipe in high power applications.Keywords
Post Weld Heat Treatment (PWHT), Programmable Logic Controller (PLC), Self-tuning Controller, Wide Range Induction Heating, Zero Voltage And Near Zero Current Switching (ZVS-N-ZCS).
References
- Coleman KK and Newell Jr. WF (2007); P91 and Beyond, Welding Journal, 86(8), pp. 29-33.
- Taniguchi G and Yamashita K (2013); Effects of post weld heat treatment (PHWT) temperature on mechanical properties of weld metals for high-Cr Ferritic heat-resistant steel, Kobelco Technology Review, 32, pp. 33-39.
- Post weld heat treatment of welded structures, Guidance note 6, WTIA-Panel 1, pp. 1-10.
- Ahmed K and Krishnan J (2003); Post weld heat treatment – A case studies, BARC Newsletter, pp. 111-114.
- Messler Jr. RW (2004); Principles of Welding, WileyVCH, Verlog, ISBN 9780471253761.
- Chaboudez C et al (1994); Numerical modelling of induction heating of long work pieces, IEEE Trans.
- Mag., 39(6), pp.5028-5037.
- Skoczkowski TP and Kalus MF (2003); The mathematical model of induction heating of ferromagnetic pipes, IEEE Trans. Mag., 25(3), pp. 2745-2750.
- Paul AK (2018); Active-controlled passive distribution of power offers efficient heat treating solution for quality arc welding joints of steel pipes, IEEE Trans. Ind. Appln., Early Access.
- Fujita, H et al (2011); A new zone-control induction heating system using multiple inverter units applicable under mutual magnetic coupling conditions, IEEE Trans. Power Electron., 26(7), pp. 2009 – 2017.
- Paul AK and Chinoy SB (2016); Air cooled induction heater for efficient sealing of containers using wide range foils, IEEE Trans. Ind. Appln., 52(2), pp. 3398-3407.
- Paul AK (2017); Robust control by SOSM facilitates optimizing under actuated induction cap sealing process, IEEE Trans. Ind. Electron., 64(6), pp. 45114519.
- Mishima T, Takami C and Nakaoka M (2014); A new current phasor-controlled ZVS twin half-bridge highfrequency resonant inverter for induction heating, IEEE Trans. Ind. Electron., 61(5), pp. 2531 – 2545.
- Koertzen HW, van Wyk JD and Ferreira, JA (1992); An investigation of the analytical computation of inductance and ac resistance of the heat-coil for induction cookers, Conf. Proc IEEE IAS, pp. 1113 – 1119.
- Paul AK (2018); Robust features of SOSMC guides in quality characterization of tank circuit in air-cooled induction cap sealing, IEEE Trans. Ind. Appln., 54(1), pp. 755-763.
- Meziane B and Zeroug H (2015); Improved efficiency determination for a PLL-controlled series resonant inverter for induction metal surface hardening, Conf. Proc. IEEE Ind. Appl. Ann. Meeting, pp. 1 – 8.
- Paul AK (2010); Comparative study of functional integrity on major topologies for induction heating equipment, Conf. Proc. IEEE PEDES, New Delhi, India, pp. 1-6.
- Practical Reliability, Availability and Acceptability Aspects of Modem Arc Welding Equipment
Authors
1 1602 Fiona, Hiranandani Estate, Thane (W) - 400 607, IN
Source
Indian Welding Journal, Vol 44, No 1 (2011), Pagination: 19-27Abstract
The role of smart engineering process is to optimize its resources such as energy, material, labor, time to yield desired quality engineering goal etc. Arc welding equipment is engaged to feed its process to produce mechanical joints having diverse characteristics. Inverter technology provides multitude of benefits virtually to each entity associated with arc welding process. Still its acceptance among users, though gradual, is s\ow. India is in real upsurge in creating its infrastructure. The demand on welding equipment will be great. Hence, efficient system of welding should be in operation. This paper intends to clear wrong notions that inverter technology has inherent problem of reliability and availability that acts as hindrance for its acceptance in arc welding process.
- Qualitative Study of Status of Indigenous Arc Welding Equipments in India
Authors
1 1502 Fiona, Hiranandani Estate, G. B. Road, Patlipada, Thane 400 607, IN
Source
Indian Welding Journal, Vol 44, No 3 (2011), Pagination: 58-66Abstract
Energy contributes to less than 2% of arc welding process cost. However, the way energy is controlled dynamically in the weld gap, its role becomes catalytic in nature to the whole process, beyond weld gap. In open or close loop, manual, semi-automatic or automatic mode of operation, power source is lone actuating element in the whole arc welding process influencing not only output characteristics, but also on other input elements. Welding equipment together with efficient method converts arc welding process load as efficient in electrical energy domain. Matching of power source and equipment is essential. However, in many developing countries in the world the matching is yet to take place causing a lot of all round concerns, wastage and productivity are a few of them. Concern is, India being a large size large growing country, also falls in that category. Indian process is heavily inclined to SMAW process using old fashioned equipments. Among population of arc welding equipments, CC power sources are dominant. This makes, ironically enough, data generation and its analysis easy. As it is difficult to have direct and correct statistical data, this article takes the route of qualitative analysis on the status of arc welding equipments in India.
- Energy Efficiency Prospect of Power Electronics: Example: Welding Inverter
Authors
1 B503, Caviana, Hiranandani Estate, G. B. Road, Patlipada Thane (W) - 400607, IN
Source
Indian Welding Journal, Vol 42, No 2 (2009), Pagination: 24-36Abstract
Energy resources are available in various forms and it is being used by people in various ways. Its efficient conversion to usable form reduces global warming and creates less environmental hazards. Electrical energy (EE) domain makes an attractive means to make energy available to the end users at any location. More and more applications use it. It is cleanest form of energy to use. Like all other means of energy usage, it has also grown by improving the efficiency and reliability of constituent components such as generator, transformer, motor, lighting equipments etc. Achieving E2 of different components does not, necessarily, optimize the utility of EE. Process efficiency, process innovations are major goals to be achieved.
Better understanding of applications and processes has resulted changing pattern in load behavior to achieve E2 and most importantly, the performance. As a natural course, more and more non-linear loads have been connected to the passive electrical grid. The grid looses control to support large non-linear loads as the compatibility between source and load is reduced. The changing relation between source and load needs a system that creates compatibility between them. Power electronics equipments (PEEs) exactly meet that requirement. Performance, E2 reliability, compactness, ease of usage, better economics etc. are key inherent features modern PEEs offer This article details the multi-dimensional role played by PEEs in the EE domain and create certain definite hope in terms of energy balance and better environment to live in. As a case study the importance of welding inverter is detailed here.
- Rooting for Environment Friendly Arc Welding Process in India
Authors
1 1602 Fiona, Hiranandani Estate, Thane (W) 400607, IN
Source
Indian Welding Journal, Vol 43, No 2 (2010), Pagination: 14-24Abstract
India needs large energy along with large increase in demand for its present arc welding load. Energy coupling between resource and joint in arc welding is loose. One reason is that fuel to joint preparation involves dual conversion. Each energy conversion phase incurs large losses. Poor conversion at load end is critical for cascading process as loss makes large impact on passive grid. Loosely coupled energy network depletes resources and pollute environment faster. Its optimization in arc welding is complex as it has multiple and diverse loss centers at load end. Concrete understanding of loss centers always looks for efficient method and energy delivery mechanism to achieve simultaneously energy efficiency, process efficiency, productivity with weld quality, and maintain local and global environment - for our working and living. High frequency power electronics equipments, as if, re-discover ‘the subject of arc welding process’ to generate total solution. Performance, energy efficiency, reliability, compactness, better economics and reduction of life cycle cost etc are inherent features modern equipments offer. Evolution in arc welding equipments has successfully met the characteristics of optimum weld gap dynamics to reduce process diversity and simplified process learning. The concept ‘Green’ makes such process perfectly optimized to create a balance between energy use and environment we live in. This article details the procedure for finding efficient equipment controlling arc welding process using compatible and efficient method to achieve quality, energy and process efficiency and also minimize its impact on environment.
- Search for Establishing Nationally Integrated Optimum Arc Welding Process
Authors
1 Fiona 1602, Hiranandani Estate, Ghodbunder Road, Thane (West) - 400607, IN
Source
Indian Welding Journal, Vol 43, No 4 (2010), Pagination: 22-33Abstract
Arc welding process is an integral part towards building basic infrastructure of India. India consumes alarmingly large quantum of energy in arc welding process. Moreover, the quantum of energy need is steadily growing - making it virtually insensitive to both - growth in technology and process innovations. Globally, energy efficiency parameters, for example, of evolving arc welding process are not uniform as there is phase lag for modern technology and innovative processes to reach places. Welding professionals play a key role here. Optimization in arc welding process intends to reduce stress in facility by drawing minimum energy, maximizes productivity with requisite quality, simplifies process learning, reduces local and global impact on environmental parameters etc. It will be detailed in this article that understanding of different loss centers in energy flow helps evolve right technology to embrace right method or technique to simultaneously achieve energy and process efficiency, weld quality, and maintain balance in environment. Modern high-frequency power electronics equipments, as if, re-discover the process to generate better productivity with energy efficiency, reliability, compactness, better economics etc. They meet all the characteristic requirements of optimum weld gap dynamics. This article discusses a futuristic, yet very much real, scenario for India by interlinking all constituent elements of arc welding process. The aim Is to define compatibility among them. Compatibility issue intends to inherently reduce diversity of the process.
- Solving Critical Issues at Low Current in TIG Welding by Controlling Levels of Saturation at the Input of the Inverter
Authors
Source
Indian Welding Journal, Vol 41, No 1 (2008), Pagination: 27-33Abstract
The operating current range for TIG welding is wide. Welding at very low current in TIG mode is common. However, managing low current operation in dynamic situation is critical. High frequency inverter has the extra ability to take care some of these problems to a great extent. To meet such requirement(s), the amplifier for the inverter is normally a ‘P+I’ controller with large DC gain. The bandwidth of this type of inverters is limited by the presence of lag compensating elements of the controller. However, lag compensator with ‘controlled peak current mode control’ can develop, to our advantage, ‘wind-up’ in the controller to bring benefits on the dynamical aspects for TIG welding inverters at lower current setting. This paper would discuss the issues of TIG welding at low operating current and also demonstrate how wind-up is created to eliminate the problematic issues. It is absolutely critical for non-contact TIG welding inverter.
Keywords
Full Bridge Inverter, Low Current TIG Welding, Integral Windup, Transition Process.- Arc Controllers for TIG Welding Applications:A Review
Authors
1 Electronics Devices World Wide Private Limited, MIDC, Mumbai 400093, IN
Source
Indian Welding Journal, Vol 52, No 2 (2019), Pagination: 56-64Abstract
An arc welding joint could utilize the features of discretely different arc welding methods to obtain the desired joint characteristics. The continuous improvement in arc welding controllers has helped redefine the need of proper parametric control of the process. For efficiency and productivity improvement, modern arc controllers come handy to re-define various aspects of the process (e.g. metal transfer, arc stiffness, etc.). One fascinating outcome is the virtual convergence of complete multi-functional arc welding process to GMAW. Still, there are applications where SMAW and TIG welding processes are regularly being used. Like other welding methods, TIG welding, as well, consists of several derivative approaches. For example, for creating joints of reactive metals (aluminum or magnesium), the AC-TIG welding is commonly employed. Here, the role of arc controller is to generate consistent pattern of desirable rectangular shape AC current waveform through the arc gap. It could cause severe stress (during polarity transition) in all secondary side components of the controller. This review, using indigenously designed peripheral interface controller (PIC) based arc welding inverter, explains the role of arc controllers to handle issues of majority of TIG welding applications.Keywords
Gas Metal Arc Welding, Shielded Metal Arc Welding, Alternating Current Tungsten Inert Gas Welding, HF TIG, Arc Shape Control, Joining Reactive Metals.References
- Parslow MA (2012); Reducing the ecological impact of arc welding, Welding Journal, vol. 91, no. 12, pp. 24 - 27.
- Paul AK (2010); Power electronics help reduce diversity of arc welding process for optimal performance", Proc. IEEE PEDES, pp. 1-7.
- Schupp J, Fischer W and Mecke H (2000); Welding arc control with power electronics, IEE conf. publ. no. 475, pp. 443 - 450.
- Paul AK and Bandyopadhyay B (2018); Multi-Functional Arc Welding Controller using SOSMC Technique, Early access article at IEEE Trans. Control Syst. Technol.
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- Qi BJ, Yang MX, Cong BQ and Liu FJ (2013); The effect of arc behavior on weld geometry by high-frequency pulse GTAW process with 0Cr18Ni9Ti stainless steel, Int J Adv Manuf Technol, vol. 66, pp. 1545-1553.
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- Paul AK (2006); Optimizing the transition process from sparking for non-contact TIG welding inverters, Proc. IEEE ICIT, pp. 1413-1418.
- Navarro-Crespin A, Lopez VM, Casanueva R and Akcondo FJ (2013); Digital control for an arc welding machine based on resonant converters and synchronous rectification, IEEE Trans. Ind. Informatics, vol. 9, pp. 839-847.
- Dudrik J, Pastor JM, Lacko M and Zatkovic R (2017); High-freuency soft-switched PWM DC-Dc converter with active output rectifier operating as a current source for arc welding applications, Electric Power Components and Systems, vol. 45 (6), pp. 681-691.
- Efficient SMAW Arc Controller for Wide Range Applications and also for Emerging Economies
Authors
1 Research and Development, Electronics Devices World Wide Private Limited 22 Mistry Industrial Estate, Cross Road A, MIDC, Mumbai 400093. Maharastra, IN
Source
Indian Welding Journal, Vol 52, No 4 (2019), Pagination: 73-80Abstract
Due to simplicity of arrangement, initial-cost implication and ease of process learning the shielded metal arc welding process (SMAW) is more popular in developing and underdeveloped countries. Apparently, this manual process needs simple constant current power source. Large number of welding consumables have made the arc characteristics of the process quite diverse; the current range for this non-linear process is wide. The input energy source to feed the arc controller could have diverse output characteristics, it could be from infinite bus i.e. the national grid or moderate size diesel generators in isolated locations (e.g. for pipeline welding) or from mini and micro grids in emerging economies. To make the power controller ideally compatible to the process behavior, that includes the wide range non-linear arc characteristics, as well as to the varied input source, it should be able to create requisite joint characteristics drawing minimum input current from the input source. This article details the features of arc controller meeting the wide range applications in the presence of source constraints and details one such equipment with experimental details. It also details the design of mini grid compatible arc controller.Keywords
Arc Characteristics, Mini Grid, Micro Grid, Power Electronics Topology, Robust Control Technique, Second Order Sliding Mode (SOSM) Control, Soft-switching Converter.References
- Parslow MA (2012); Reducing the ecological impact of arc welding, Welding Journal, 91(12), pp. 24 – 27.
- Paul AK (2010); Power electronics help reduce diversity of arc welding process for optimal performance”, Proc. IEEE PEDES, pp. 1-7.
- Cale J, Lute C, Simon J and DelCore A (2019); Modeling minimally-processed shielded metal arc weld transformers for rural minigrid applications, IEEE Trans Power and Energy Syst. Technol., 6(2), pp. 95-103.
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- Paul AK (2016); Robust product design using SOSM for control of shielded metal arc welding (SMAW) process, IEEE Trans. Ind. Electron., 63(6), pp. 3717-3724.
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- Dudrik J, Pastor JM, Lacko M and Zatkovic R (2017); High-freuency soft-switched PWM DC-Dc converter with active output rectifier operating as a current source for arc welding applications, Electric Power Components and Systems, 45 (6), pp. 681–691.
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