Commercial Homopolar Welding Systems

SYSTEM COMPONENTS

  • Homopolar Generator with control system
  • Hydraulic Welding system
  • Commercial pipe facing machine for joint preparation
Drawing of 15 MJ HPG
SIZING HPGS
  • Estimate 1 MJ of HPG capacity per square inch of cross-section for low carbon steel pipe
  • Multiple HPGs may be paralleled to achieve required capacity
Graph for HPG capacity
FEATURES OF 15 MJ HPG
  • Size: 1.4 m x 1.53m dia.
  • Weight: 133kN
  • Self motoring for lower cost, simpler design
  • Maintenance Schedule: requires single 8 hour shift to perform brush maintenance after 10,000 full energy discharges
Layout of proposed spooling HPG system
PROPOSED LAND-BASED SPOOLING YARD OPERATION
  • First commercial Homopolar Welding System
  • For spooling yard to join 4 in., 6 in., and 8 in. scheduled pips
  • 15 MJ HPG with control system for PKD, Austin
  • Hydraulic Welding Fixture from CRC-Evans, Houston
 

NDE OF HPW

NATURE OF POSSIBLE HPW FLAWS

Planar, no volume flaw, oriented along weld plane, similar to other forge welding processes.

"Kissing" bonds and arrays of microinclusions possible of HPW flaws.

AUTOMATIC ULTRASONIC TESTING AND REQUIREMENTS OF NDE METHOD

Automatic ultrasonic testing selected based on meeting the requirements for NDE method:

  • Detect HPW flaws

  • Provide permanent record

  • Rapid inspection and analysis

  • Automated

CURRENT WORK

Characterize HPW flaws using Homopolar welds containing intentionally placed flaws

Identify optimum probe configurations of detection of HPW flaws

Additional Pages on Homopolar Welding:

Program Description

The Program

Basics of Homopolar Welding

Homopolar Generators

Homopolar Welding Parameters

Weld Parameters and Results Using Modified HPW Method

Joining 12 Inch Pipe in 3 Seconds

X-65 Impact Toughness

Real World Welding Conditions

Commercial Hompolar Welding Systems

 

For further information please Contact:

Dr. Robert Hebner

(512) 232-1628