DESC:FORM 2
THE PATENTS ACT 1970
39 of 1970
&
The Patent Rules 2003
COMPLETE SPECIFICATION
(See sections 10 & rule 13)

SYSTEM AND METHOD FOR WELDING AUTOMATION IN FGD (FLUE-GAS DESULFURIZATION) ABSORBERS

1. APPLICANTS (S)
(a) NAME (b) NATIONALITY (c) ADDRESS(d)
MITSUBISHI POWER INDIA PRIVATE LIMITED INDIAN GROUND & 5TH FLOOR, PRIDE HULKUL, 116, LALBAGH ROAD, BANGALORE, KARNATAKA, 560027, INDIA.

2. PREAMBLE TO THE DESCRIPTION
COMPLETE SPECIFICATION
The following specification particularly describes the invention and the manner in which it is to be performed.

SYSTEM AND METHOD FOR WELDING AUTOMATION IN FGD (FLUE-GAS DESULFURIZATION) ABSORBERS

FIELD OF INVENTION:

The present invention generally relates to the field of automated welding. More particularly, this invention relates to automated welding systems and methods in FGD (Flue-Gas Desulfurization) absorbers with faster,better, cheaper & safer approach in welding/execution.

BACKGROUND OF THE INVENTION

[0001] Welding systems isa core part of Manufacturing Technology and modern industrial age. From massive assembly operations to automated manufacturing environments, these systems facilitate joining in ever more complicated manufacturing operations. Conventional welding system includes an electric arc welding system. This may involve movement of a consumable electrode, toward a work piece while current is passed through the electrode and across an arc developed between the electrode and the work piece. The electrode may be a non-consumable or consumable type, wherein portions of the electrode may be melted and deposited on the work piece. Often, hundreds or perhaps thousands of welders are employed to drive multiple aspects of an assembly process, wherein sophisticated controllers enable individual welders to operate within relevant portions of the process.
[0002] Many conventional welding systems operate in individually controlled and somewhat isolated manufacturing locations in regard to the overall joining, fabrication and/or other production process. Controlling, maintaining, servicing and supplying multiple isolated locations in large centres, and/or across the globe, has become more challenging, time consuming and expensive. Another issue is conventional welding system requires larger man power such as multiple welders and/operators. All these ancillaries incur lot of manpower and maintenance cost.
[0003] From the aforementioned standpoint there has been a need for awelding device and/or a method, which may be executed with accuracy, aesthetics & quality and may be much better than conventional method. Therefore, there is a genuine need to overcome all the above problems by developing an improved system and method, which is accurate, efficient, dynamic and simple.

OBJECTS OF THE INVENTION

[0004] It is an object of the present invention to provide automatic welding in FGD (Flue-Gas Desulfurization) Absorbers on alloy side (C-276) welding Submerged Arc Welding (Submerged Arc Welding (SAW) or Welding Gas Metal Arc Welding (Gas Metal Arc Welding (GMAW)& on Carbon steel side Welding Submerged Arc Welding or Welding Gas Metal Arc welding& also Automatic double end bevel operation for Carbon Steel + N10276 (C276) cladded plate.
[0005] It is an object of the present invention to provide faster welding speed than conventional welding method.
[0006] It is an object of the present invention to provide accuracy of beveling angle which improves welding quality.
[0007] It is an object of the present invention to provide application of Automatic Double Bevel End at construction sites and specifically for FGD (Flue-Gas Desulfurization) Applications and Alloy C 276 is unique and 5-7 times faster than the conventional Edge Preparation methods.
[0008] It is an object of the present invention to provide a system and method which is accurate, efficient, dynamic and simple.
[0009] It is an object of the present invention to provide a system and method which is faster, better, cheaper & safer approach in welding/execution.
[00010] It is object of the present invention to provide a system & method which improve quality, productivity, repeatability, efficiency& aesthetics in welding/execution.
[00011] It is object of the present invention to reduce man power and reduce dependence on welders or skillset with respect to manual or conventional method.

SUMMARY OF THE INVENTION
[00012] The present invention generally relates to the field of automated welding. More particularly, this invention relates to automated welding systems and methods in FGD (Flue-Gas Desulfurization) absorbers with an increase welding/execution speed and efficiency.
[00013] Although the present disclosure is explained with respect to systems and methods for pulse diagnosis, it would be appreciated that this application is used for illustration purposes, but it is not a limitation.
[00014] The various embodiments of the invention illustrate automatic welding systemwhich may be applied in FGD (Flue-Gas Desulfurization) Absorbers on alloy side (C-276) welding Submerged Arc Welding (Submerged Arc Welding (SAW)) and same may be applied to Gas Metal Arc Welding (GMAW) process. In an embodiment welding speed of the automated systemmay be3 -5 times faster than the conventional welding method, as routine, around 35 meters of welding have been achieved in 1 shift (8 Man-hours) forGas Metal Arc Welding (GMAW) process & 120 meter of welding may be achieved in 1 shift (8 Man-Hours) for Submerged Arc Welding (SAW) process. Automated Gas Metal Arc Welding (GMAW) welding speed may beachieved up to 300mm/min & Automated Submerged Arc Welding (SAW) welding speed up to 550 mm/min as compare to convention method which is around 50-100 mm/min.
[00015] The various embodiments of the invention provide an automated welding system which may create heat input less than <1.1kJ/mm which may be half of manual welding which improves welding distortion especially in bottom plate & also in Shell plate welding. In an embodiment accuracy of beveling angle improves which may improve welding quality, productivity & repeatability. Beveling machine may create a double-sided bevel eliminating the need to turn a plate over which may reduce handling & improve shop safety.
[00016] Additional aspects of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The aspects of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims. It is to be understood that the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

[00017] The other objects, features and advantages will occur to those skilled in the art from the following description of the preferred embodiment and the accompanying drawings in which.
[00018] Fig. 1 is a block diagram illustrating an Automated Double Sided Bevel Welding Automation in FGD (Flue-Gas Desulfurization) Absorber with various embodiments of the invention.
[00019] Fig. 2 is a block diagram illustrating a Gas Metal Arc Welding (Gas Metal Arc Welding (GMAW)) with Magnetic track for Carbon Steel Welding and/or Vacuum Cup track / magnetic track arranged for Cladded side welding with various embodiments of the invention.
[00020] Fig. 3 is a block diagram illustrating anAutomated Submerged Arc Welding (Submerged Arc Welding (SAW) for cladded C-276 side welding of absorber with cage type trolley mounted & rolled on shell plate, and for Carbon Steel side Welding with magnetic track mounted on shell with various embodiments of the invention.
[00021] Although specific features of the present invention are shown in some drawings and not in others, this is done for convenience only as each feature may be combined with any or all of the other features in accordance with the present invention.

DETAILED DESCRIPTION

[00022] Embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying figures and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[00023] In the following description, numerous specific details are set forth in order to provide a thorough understanding of embodiments of the present invention. It will be apparent to one skilled in the art that embodiments of the present invention may be practiced without some of these specific details.
[00024] Embodiments of the present invention may include various steps, which will be described below. Steps may be performed by hardware components or may be embodied in machine-executable instructions, which may be used to cause a general-purpose or special-purpose with the instructions to perform the steps. Alternatively, steps may be performed by a combination of hardware, software, and/or by human operators.
[00025] If the specification states a component or feature “may”, “can”, “could”, or “might” be included or have a characteristic, that component or feature is not required to be included or have the characteristic.
[00026] Some of Abbreviations used in this disclosure:
FGD: Flue-Gas Desulfurization
GMAW: Gas Metal Arc Welding
SAW: Submerged Arc Welding
CS: Carbon Steel
C276/N10276: UNS No. N10276
Fe: Symbol of element Iron
WPS: Welding Procedure Specifications
PQR: Procedure Qualification Record
[00027] The foregoing illustrated and described embodiments of the invention are susceptible to various modifications and alternative forms, and it should be understood that the invention generally, as well as the specific embodiments described herein, are not limited to the particular forms or embodiments disclosed, but cover all modifications, equivalents and alternatives falling within the scope of the appended claims. By way of non- limiting example, it will be appreciated by those skilled in the art that particular features or characteristics in one embodiment may be combined as suitable with features or characteristics described in another embodiment. Moreover, the device and method for of the present invention can be a system used along with an automated or even with a manual system.
[00028] The present invention generally relates to the field of automated welding. More particularly, this invention relates to automated welding systems and methods in FGD (Flue-Gas Desulfurization) absorbers with an increase an execution/welding speed.
[00029] Although the present disclosure is explained with respect to systems and methods for pulse diagnosis of human being, it would be appreciated that this application is used for illustration purposes, but it is not a limitation.
[00030] The various embodiments of the invention illustrate automatic welding system which may be applied in FGD (Flue-Gas Desulfurization) Absorbers on alloy side (C-276) welding Submerged Arc Welding (Submerged Arc Welding (SAW) and same may be applied to Gas Metal Arc Welding (GMAW) process.
[00031] Figure 1 is a block diagram illustrating a Welding Automation in FGD (Flue-Gas Desulfurization) Absorber 100) with various embodiments of the invention. According to Figure 1, illustrating a welding automation in FGD absorber; Automatic Double End Bevel (100b) comprises Explosion Bonded CS+N10276 absorber Cladded Platefor beveling operation (102); and beveling as per Typical Double Bevel Weld configuration (104); with Automatic Double Bevelmachine first bevel operation on CS Side (106)and then; Automatic 1800 Machine Inversionwhich Avoid Plate Turn/Flip Over which reduce handling time, bring efficiency and Improve Safety (108) and then Automatic Double Bevel machine second bevel operation on C276 Side (110)and both Automatic Bevel operations are operatively coupled.
[00032] Figure 2 is a block diagram illustrating a Welding Automation in FGD (Flue-Gas Desulfurization) Absorber (200)with various embodiments of the invention. According to Figure 2 is a block diagram illustrating a Gas Metal Arc Welding (Gas Metal Arc Welding (GMAW))200bwith Magnetic track for Carbon Steel Welding and/or Vacuum Cup track / magnetic track arranged for Cladded side welding with various embodiments of the invention.
[00033] According to Figure 2, The welding automation in FGD absorber with Automatic GMAW machines (200b) comprises operation as FGD Shell Or Ring Formation (202)withAutomated Gas Metal Arc Welding (GMAW) machineWith Magnetic Flexible / Straight Track mounted on shell for Carbon Steel Side welding (204)and Automated Gas Metal Arc Welding (GMAW)machine with Magnetic (Flexible / Straight)Or Vacuum Cup Track mounted on shell for C-276 Cladded Side welding (206) and both automatic operations are operatively coupled.
[00034] In an embodiment welding speed of the automated system may be3 -5 times faster than the conventional welding method, as routine, around 35 meters of welding have been achieved in 1 shift (8 Man-hours) for Automated Gas Metal Arc Welding (GMAW) process& 120 meter of welding may be achieved in 1 shift(8 Man-hours) for Submerged Arc Welding (SAW)process. Automated Gas Metal Arc Welding (GMAW) welding operational speed may be achieved up to 300mm/min & Automated Submerged Arc Welding (SAW) weldingoperational speed up to 550 mm/min as compare to convention method which is around 50-100 mm/min.
[00035] The various embodiments of the invention provide an automated welding system which may create heat input less than <1.1kJ/mm which may be half of manual welding which improves welding distortion especially in bottom plate & also in FGD Absorber Shell plate welding.
[00036] In an embodiment accuracy of beveling angle improves which may improve welding quality, productivity & repeatability. Beveling machine may create a double-sided bevel eliminating the need to turn a plate over which may reduce handling & improve shop safety.Accuracy, aesthetics & quality in welding may be better than conventional method. Manpower may be saved with respect to manual welding is in range of 5-6 times.
[00037] Figure 3 is a block diagram illustrating a Welding Automation in FGD (Flue-Gas Desulfurization) Absorber (300) with various embodiments of the invention. Figure 3 is a block diagram illustrating an Automated Submerged Arc Welding (Submerged Arc Welding (SAW) 300boperationfor cladded C-276 side welding of absorber with cage type trolley mounted & rolled on shell plate, and for Carbon Steel side Welding with magnetic track mounted on shell with various embodiments of the invention.
[00038] According to Figure 3, The welding automation in FGD absorber with Automatic SAW machines (300b) comprises operation as FGD Absorber ShellFormation (302)with; Automated Submerged Arc Welding machine with Cage Type Trolley Mounted & Rolled on Shell Plate for C-276 Cladded SideWelding (304) and Automated Submerged Arc Welding (SAW) with Magnetic Track Mounted on Shell–Carbon Steel Side (306)and both Automatic Welding Operations are operatively coupled.
[00039] The various embodiments of the invention illustrateone or more automated aspects, such as automated Gas Metal Arc Welding (Gas Metal Arc Welding (GMAW)) with Magnetic track (straight/ flexible) for Carbon Steel Welding & Vacuum Cup track (straight/flexible) arrangement for Cladded side welding.Automated Submerged Arc Welding (Submerged Arc Welding (SAW)) for Carbon Steel Welding for Outside shell of absorber with Magnetic holder & with Automatic Girth Welding Rail. Automated Submerged Arc Welding (Submerged Arc Welding (SAW)) for cladded side welding of absorber with cage type trolley mounted & rolled on shell plate, and Automated Beveling Machine (Double End double V/Bevel Machine), which improves the welding quality.
[00040] The various embodiments of the invention illustrate, specific studies and validations with WPS/PQR qualification & with Chemical, Mechanical, Corrosion, Fe Analysis like specific parameters & meets specification/customer requirements.
[00041] The present invention provides easy usage mechanism. The mechanism provided is easy to work on thereby making the device very user friendly and easy.
[00042] While embodiments of the present invention have been illustrated and described, it will be clear that the invention is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents will be apparent to those skilled in the art, without departing from the spirit and scope of the invention, as described in the claim.
[00043] The present invention successfully deployed at Construction Project and have exhibited the intended results in field of Fabrication, welding leading to overall efficiency in Absorber tank Fabrication and erection. This is also appreciated by the Customer.
[00044] While embodiments of the present invention have been illustrated and described, it will be clear that the invention is not limited to these embodiments only. Numerous modifications, changes, variations, substitutions, and equivalents will be apparent to those skilled in the art, without departing from the spirit and scope of the invention, as described in the claim.

ADVANTAGES OF THE INVENTION:

[00045] The present invention provides provide automatic welding in FGD (Flue-Gas Desulfurization) Absorbers on alloy side welding Submerged Arc Welding (Submerged Arc Welding (SAW)& Welding Gas Metal Arc Welding (Gas Metal Arc Welding (GMAW)) for Carbon Steel +N10276(C276) cladded plates.
[00046] The present invention provides automated welding heat input less than <1.1kJ/mm.
[00047] The present invention provides accuracy, aesthetics & quality in welding, which may be much better than conventional method.
[00048] The present invention reduces man power with respect to manual welding in range of 3-5 times.
[00049] The present invention provides a system and method which is accurate, efficient, dynamic and simple.
[00050] The present invention provides a system and method which is faster, better, cheaper & safer approach in welding/execution.
[00051] The present invention provide a system & method which improve quality, productivity, repeatability, efficiency & aesthetics in welding/execution which is also relatively less prone to repairs.
,CLAIMS:We Claim:
1. A method for welding automation in FGD (Flue-Gas Desulfurization) absorber (100) comprising:
Automation of welding in the FGD (Flue-Gas Desulfurization) absorbers (100) on alloy side C-276 welding Submerged Arc Welding (Submerged Arc Welding (SAW)) and/or welding gas metal arc welding (Gas Metal Arc Welding (GMAW)) and/or on Carbon steel side Welding submerged arc welding or welding gas metal arc welding and/or automatic Double End Bevel operation for Carbon Steel + N10276 (C-276) cladded plate; at construction sites and/or FGD (Flue-Gas Desulfurization) applications.

2. The welding automation in FGD (Flue-Gas Desulfurization) absorber (100) as claimed in claim 1, wherein System & Method-Automatic Double Sided Bevel (100b) for Explosion Bonded CS +N10276 absorber Cladded Plate forDouble Sided beveling operation, wherein Automatic double-sided bevel (106) avoids a plate turn over which reduces handling & improve shop safety

3. The welding automation in FGD (Flue-Gas Desulfurization) absorber (100) as claimed in claim 1, wherein System & Method-Gas Metal Arc Welding (Gas Metal Arc Welding (GMAW)) (200b) with Magnetic track (204) for Carbon Steel Welding and/or Vacuum Cup track / magnetic track (206) arranged for Cladded side welding

4. The welding automation in FGD (Flue-Gas Desulfurization) absorber (100) as claimed in claim 1, wherein System & Method -Automated Submerged Arc Welding (Submerged Arc Welding (SAW)) (300b) for cladded C-276 side welding of absorber with cage type trolley mounted & rolled on shell plate (304), and for Carbon Steel side Welding with magnetic track mounted on shell (306).

5. A system for welding automation in FGD (Flue-Gas Desulfurization) absorber (100) comprising:
Automation of welding in the FGD (Flue-Gas Desulfurization) absorbers (100) on alloy side C-276 welding Submerged Arc Welding (Submerged Arc Welding (SAW) ) and/or welding gas metal arc welding (Gas Metal Arc Welding (GMAW)) and/or on Carbon steel side Welding submerged arc welding or welding gas metal arc welding and/or automatic Double End Bevel operation for Carbon Steel + N10276 (C-276) cladded plate; at Construction Sites and/or FGD (Flue-Gas Desulfurization) applications.
Dated this 17th Day of April 2021

Nalini Kant Pandey
Bizrights IP Partners LLP
(IN/PA 2187)
Agent for applicant(s)