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Copyright © Nelson <strong>Stud</strong> <strong>Welding</strong>, Inc.<br />
<strong>Green</strong> <strong>Stud</strong> <strong>Welding</strong> <strong>Technologies</strong><br />
<strong>NSRP</strong> 2011-420<br />
Ingalls, Bath Iron Works, Newport News<br />
Shipbuilding<br />
Chris Hsu<br />
Nelson <strong>Stud</strong> <strong>Welding</strong>, Inc.<br />
May 8, 2012<br />
<strong>NSRP</strong> <strong>Welding</strong> Panel Meeting Fort Collins 2012<br />
1
Copyright © Nelson <strong>Stud</strong> <strong>Welding</strong>, Inc.<br />
Thank our yard sponsors!<br />
Lee Kvidahl<br />
Kevin Roossinck<br />
Albert Williams<br />
Nick Evans<br />
Dean Brown<br />
Paul Hebert<br />
Jim Thomas<br />
Moody Harp<br />
2
Copyright © Nelson <strong>Stud</strong> <strong>Welding</strong>, Inc.<br />
Cost savings opportunities<br />
Electricity Costs<br />
<br />
<br />
<br />
<strong>Welding</strong> power<br />
Idle power<br />
Heat strip power<br />
Cost of Poor Quality<br />
<br />
Philip Crosby: Quality is free<br />
Labor costs<br />
<br />
<br />
<br />
<br />
<br />
Gun setup<br />
Surface preparation and preheat<br />
Electrician power hook-up<br />
Maintenance, training, rework<br />
Logistics of relocating equipment<br />
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Copyright © Nelson <strong>Stud</strong> <strong>Welding</strong>, Inc.<br />
Deliverables<br />
Hardware<br />
Drawn arc inverter (Ingalls)<br />
Prototype switch-mode CD welder (NNS)<br />
Prototype motorized gun system (Ingalls)<br />
Energy monitoring devices (Ingalls, BIW)<br />
Knowledge<br />
Lab and yard data on energy savings (Ingalls, BIW)<br />
Yard feedback on prototype experience (Ingalls, BIW, NNS)<br />
Weld parameters for pinning on primer paint (BIW)<br />
May 8, 2012<br />
<strong>NSRP</strong> <strong>Welding</strong> Panel Meeting Fort Collins 2012<br />
4
Copyright © Nelson <strong>Stud</strong> <strong>Welding</strong>, Inc.<br />
Energy measurement devices<br />
Weld Data Storage<br />
480V CTs and Meter<br />
Improved Meter<br />
Reed Switch Counter<br />
May 8, 2012<br />
Power Analyzer<br />
<strong>NSRP</strong> <strong>Welding</strong> Panel Meeting Fort Collins 2012<br />
5
Copyright © Nelson <strong>Stud</strong> <strong>Welding</strong>, Inc.<br />
Controlled Test – drawn arc<br />
<strong>Welding</strong> at 550A,<br />
330ms and 100ms<br />
plunge time. 12<br />
studs/min<br />
Idle power of<br />
N6000 is 70X<br />
higher due to<br />
magnetizing<br />
current<br />
During welding<br />
N1500i saves 46%<br />
energy than N6000<br />
KWh<br />
<strong>Welding</strong><br />
1335 studs<br />
in 112<br />
minutes<br />
While Idle<br />
18.5 hours<br />
N1500i<br />
Inverter<br />
Nelweld 6000<br />
Transformer<br />
Rectifier<br />
Energy<br />
Savings<br />
2.45 kWh 13.06 kWh 81%<br />
1.16 kWh 81.2 kWh 99%<br />
May 8, 2012<br />
<strong>NSRP</strong> <strong>Welding</strong> Panel Meeting Fort Collins 2012<br />
6
Copyright © Nelson <strong>Stud</strong> <strong>Welding</strong>, Inc.<br />
Power Factor & efficiency – Drawn<br />
Arc<br />
In idle: transrec<br />
consumes<br />
70X more kVA<br />
(1.145KW savings)<br />
In welding:<br />
N1500i<br />
consumes half<br />
the kVA<br />
(2.25KW savings)<br />
N800i<br />
Inverter<br />
N1500i<br />
Inverter<br />
N6000<br />
Trans-<br />
Rec<br />
S5000<br />
Trans-<br />
Rec<br />
KW idle 0.05 0.06 1.2 1.2<br />
KVA idle 0.06 0.08 5.9 2.2<br />
PF idle 0.4 0.3 0.2 0.5<br />
Load<br />
800A<br />
27V<br />
800A<br />
42V<br />
800A<br />
27V<br />
800A<br />
27V<br />
KW load 29.2 28.4 31 35.6<br />
kVA load 40 39 81 59.8<br />
PF load 0.72 0.71 0.35 0.57<br />
Efficiency 0.74 0.76 0.70 0.61<br />
May 8, 2012<br />
<strong>NSRP</strong> <strong>Welding</strong> Panel Meeting Fort Collins 2012<br />
7
Copyright © Nelson <strong>Stud</strong> <strong>Welding</strong>, Inc.<br />
Power Factor & efficiency – CD<br />
200V,<br />
115Vac<br />
input, 8<br />
studs/min<br />
NCD+<br />
saves 43%<br />
energy of<br />
CD Lite<br />
NCD+<br />
1600<br />
(new)<br />
NCD+<br />
1000<br />
(new)<br />
CD<br />
Lite<br />
CD 212<br />
NCD60<br />
mF 81 54 66 66 54<br />
VA 278 210 559 528 560<br />
PF 0.86 0.86 0.60 0.60 0.60<br />
Output<br />
Power (W)<br />
Input<br />
Power (W)<br />
216 144 176 176 144<br />
239 181 335 317 336<br />
Efficiency 0.90 0.80 0.52 0.56 0.43<br />
May 8, 2012<br />
<strong>NSRP</strong> <strong>Welding</strong> Panel Meeting Fort Collins 2012<br />
8
Copyright © Nelson <strong>Stud</strong> <strong>Welding</strong>, Inc.<br />
Ingalls inverter vs. Trans-<br />
Rec<br />
N800i<br />
Inverter<br />
Series 4000<br />
Transformer<br />
Rectifier<br />
# studs shot 11,178 6,000 est<br />
Total<br />
Energy<br />
Energy per<br />
Weld<br />
193 kWh 144 kWh<br />
17 Wh 24 Wh<br />
Energy savings: 29%<br />
May 8, 2012<br />
<strong>NSRP</strong> <strong>Welding</strong> Panel Meeting Fort Collins 2012<br />
9
Copyright © Nelson <strong>Stud</strong> <strong>Welding</strong>, Inc.<br />
Ingalls motorized gun test<br />
3/8” stainless steel<br />
welding<br />
New front end to<br />
extend stroke from<br />
½” to 5/8”<br />
“High quality welds”<br />
Motor shaft<br />
improvement<br />
identified and in<br />
progress<br />
May 8, 2012<br />
<strong>NSRP</strong> <strong>Welding</strong> Panel Meeting Fort Collins 2012<br />
10
Copyright © Nelson <strong>Stud</strong> <strong>Welding</strong>, Inc.<br />
BIW Inverter vs. Grid DC<br />
power<br />
N800i inverter vs.<br />
DC1000 and timer<br />
boxes for pinning<br />
Energy Savings:<br />
75%<br />
N800i<br />
Inverter<br />
DC1000 &<br />
Timer Boxes<br />
# studs shot 635 899<br />
Total<br />
Energy<br />
1.53 kWh 9 kWh<br />
Energy per<br />
Weld<br />
2.4 Wh 10 Wh<br />
May 8, 2012<br />
<strong>NSRP</strong> <strong>Welding</strong> Panel Meeting Fort Collins 2012<br />
11
Copyright © Nelson <strong>Stud</strong> <strong>Welding</strong>, Inc.<br />
BIW inverter pinning<br />
findings<br />
Older equipment has no safety check – operator can<br />
be exposed to 80V shock hazard<br />
RECOMMENDATION: Require “safety check” in new<br />
stud welder purchases<br />
Thick paint has marginal conductivity (1 in 20)<br />
Pecker Mode was improved to penetrate paint<br />
Peck as needed: fast shooting w/o compromise<br />
safety<br />
Prefer grid power without calling electrician for<br />
480V hook up<br />
May 8, 2012<br />
<strong>NSRP</strong> <strong>Welding</strong> Panel Meeting Fort Collins 2012<br />
12
Copyright © Nelson <strong>Stud</strong> <strong>Welding</strong>, Inc.<br />
Pecker mode for paint<br />
Poor contact<br />
Peck Twice<br />
May 8, 2012<br />
<strong>NSRP</strong> <strong>Welding</strong> Panel Meeting Fort Collins 2012<br />
13
Copyright © Nelson <strong>Stud</strong> <strong>Welding</strong>, Inc.<br />
Newport News switch-mode CD<br />
Test<br />
<strong>Welding</strong> 3/16” pins on Dry<br />
Dock 12 Gerald Ford CVN-78<br />
Likes the low weight (17 lb)<br />
Need pressure dial on the gun<br />
Need plug in CD Lite guns<br />
Need longer power cord<br />
Need GFCI extension cord<br />
May 8, 2012<br />
<strong>NSRP</strong> <strong>Welding</strong> Panel Meeting Fort Collins 2012<br />
14
Copyright © Nelson <strong>Stud</strong> <strong>Welding</strong>, Inc.<br />
Pinning on primer paint @<br />
BIW<br />
TFNC 3/16”<br />
insulation pins<br />
MIL-S-24149, Type<br />
3, Class 6<br />
SigmaKalon USA,<br />
MC7177, 1 mil or less<br />
Low zinc silicate<br />
PPG coating<br />
May 8, 2012<br />
<strong>NSRP</strong> <strong>Welding</strong> Panel Meeting Fort Collins 2012<br />
15
Copyright © Nelson <strong>Stud</strong> <strong>Welding</strong>, Inc.<br />
Primer paint pinning DOE<br />
Weld Lobe Development<br />
Current [100-500A]<br />
Time [25-150ms]<br />
Lift [0-1 ½ click]<br />
Polarity<br />
Coating thickness<br />
May 8, 2012<br />
<strong>NSRP</strong> <strong>Welding</strong> Panel Meeting Fort Collins 2012<br />
16
Copyright © Nelson <strong>Stud</strong> <strong>Welding</strong>, Inc.<br />
Energy savings estimate<br />
Assumptions (BIW data)<br />
$0.0765 per kWh<br />
284,148 pins and 339,206 electrical (623K total)<br />
40 PowCons, 9 Nelson inverters, 45 “energy guzzlers”<br />
Annual Energy Savings per drawn arc welder<br />
100% Idle: 8766 hours x 1.145 kW x $0.0765 = $768<br />
100% <strong>Welding</strong>: 8766 hours x 2.25 kW x $0.0765 = $1509<br />
Assume 10% duty cycle: $842 per welder<br />
Annual Energy Savings per stud<br />
$842 / 6558 studs per welder = $0.128 per stud<br />
Potential annual savings examples<br />
BIW $842 x 45 welders = $37,899 based on welder<br />
<strong>NSRP</strong> group $842 x 700 welders = $589,400 based on welder<br />
$0.128 x 5 million studs = $640,000 based on studs<br />
May 8, 2012<br />
<strong>NSRP</strong> <strong>Welding</strong> Panel Meeting Fort Collins 2012<br />
17
Copyright © Nelson <strong>Stud</strong> <strong>Welding</strong>, Inc.<br />
$ummary<br />
Energy Savings<br />
In idle 70X less energy<br />
In welding 40-50% savings<br />
$842 per welder per year<br />
$0.128 per stud<br />
$589K per year for all <strong>NSRP</strong> member yards<br />
Safety vs. Speed<br />
New equipment has better safety<br />
Labor and quality savings<br />
18
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