Kemppi launched the first generation of welding monitoring systems in 2008 with the introduction of the Kemppi Arc System 1.0. By introducing the new 2.0 release of the system, Kemppi takes the philosophy of welding parameter monitoring to new heights. In fact, we can stop talking about welding monitoring and instead start truly discussing the importance of welding management, including quality, productivity, fleet management and integration of welding into other phases of metal fabrication.

Kemppi Arc System 2.0 is the solution for all welding management needs. Latest welding equipment technology serves as a platform for collecting and analyzing all relevant welding related data in your production and enables you to know exactly where you are. Decision making becomes easier based on true facts and the overall performance of your welding operation improves dramatically. The system can be tailored specifically to suit every situation, thanks to its modular structure.

Kemppi ArcQuality - the Most Advanced Welding Quality Management System Available

Welding procedure specifications (WPS) include all necessary information that a welder needs for managing the welding task. It is the foundation of all quality welding. The technical content of the WPS is determined to the detail in standards, such as ISO 15609-1 and ASME IX.

It's also likewise with the qualification of the WPS. How do the workshops observe the compliance to the WPS today, especially in manual welding work? The procedures vary according to the companies and projects. Even in most demanding offshore and nuclear power plant projects, often only random checks are made. Comprehensive control is not used, because there hasn't been a suitable commercial solution available.

To correct this fault, Kemppi with some of its key customers, has developed a smart solution, the ArcQuality (see Figure 1). The ArcQuality, or 'ArcQ', is an easy and comprehensive way of controlling that the welders are qualified and that all welding procedure specifications are followed. The system reports non-conformances automatically in real time. The system can also anticipate service needs and collect welding information for quality documentation, offering traceability up to individual welds. The productivity benefits come from increased quality and effectiveness of the welding work, automated monitoring and faster and easier collection of project documentation.

ArcQuality Monitors Compliance to WPS, and Ensures that Welders are Appropriately Qualified

The non-destructive testing (NDT) of welded joints is a very important phase but it does not produce sufficiently reliable information about the quality of the welding. That is why it is important to apply control measures also to ensure that correct work methods are used and that the welders have the necessary qualifications. The ArcQuality solution has been developed to respond to this need. It is suited to all companies that use welding. It is based on the basic requirements set forth in welding quality management standards, which comprise the cornerstone of high quality manufacturing:

• The welder shall have valid professional qualifications that cover all the requirements of welding work.
• Qualified welding procedure specifications must be adhered to in welding work.
• Regular maintenance of welding machines must be planned in a systematic way.
• Non-conformances must be reported and addressed.
• Welded joint details must be traceable.

ArcQuality is the first quality control service that can automatically monitor compliance to welding procedure specifications, as well as the validity and coverage of welding qualifications in manual welding. The monitoring function in the system is activated when the welder's barcoded identity code, the WPS number, filler material make and, if necessary, the shielding gas designation are entered via the reader device into the system before the welding work is started, Figure 2. The smart reader device compares the WPS data to the filler material make and warns the welder if a wrong filler material was accidentally selected. Thus the system ensures that the welder is always using the correct filler material.

During welding work the system compares the values used by the welder and measured from the machine to the values in the WPS. A reporting server reports a non-conformance if the welding current or voltage does not stay within allowed limits, Figure 3.

The system also checks the database to ensure that the welder has valid qualifications that cover the requirements set forth by the WPS. At the initial stage, the ArcQuality system is designed for monitoring MIG/MAG welding, and monitoring TIG welding will be available during 2013. TIG welding is extensively used particularly in nuclear power plant projects for manufacturing pressure devices and pipework under strict supervision and obligation to produce appropriate documentation.

To ensure reliable operation of the system, it must have access to correct and up-to-date information. If a company is not using separate software for maintaining welder qualifications and WPS's, the reference data are entered and maintained in the ArcQuality database. Optionally, the ArcQ solution can be integrated in the existing maintenance software used by the company. In such a case an interface will be built between the two software systems which is used for welder qualification and WPS data queries.

The Smart Reader, the Core of the ArcQuality System, also Collects Quality Documentation

The ArcQuality solution can be tailored to meet many needs. Barcoded identification information, such as personal identity codes, WPS numbers, and filler material batch numbers can also be retrieved for use in a detailed quality documentation of welding work as necessary. Weld-specific traceability will be attained when, in addition to the above-mentioned information, a unique barcode of each welded joint is read into the system. All barcode reads will be time-stamped, so the exact time of the different actions can be traced. Collection, transfer and storing of quality documentation in the customer's system is always designed and implemented according to each customer's needs as part of the ArcQuality project delivery.

The system provides clear cost savings by automating a considerable part of arduous manual work involved in the collection, interpreting and storing information for welding quality documentation. Also production control becomes easier, when you have precise records of who has done what and when. For instance, in extensive and demanding offshore projects, the collection of data for quality documentation can often form a bottleneck that causes delays in NDT inspections. It is not allowed to start inspections before weld-specific documentation has been collected, checked and stored as part of the project documentation.

ArcQuality Anticipates Service Needs and Records History of Repair and Service Operations

Reliable operation of tools is one of the cornerstones for high quality and productivity in industrial production, ensuring disturbance-free completion of all production stages. The ArcQuality solution includes a welding fleet management tool that allows saving detailed information about the welding machines, including records of all service and repair operations performed. The system alarms in advance about upcoming annual service, approaching maximum usage hours, or if it detects problems in the wire feeding. Problems in the wire feeding may cause welding defects, so it is important to prevent such problems in advance. The follow-up of service and repair costs will be included in the ArcQuality solution during 2013.

ArcQuality also Monitors the Efficiency of Welding Production

The report clearly visualises the arc time ratio and deviations from the target values. The arc time ratio refers to the relationship between arc time and the time used for welding work. The arc time ratio is an important measure of productivity, but it alone does not offer means for assessing the effect of other factors, such as set-up time, idle time or downtime to the efficiency of welding work. That is why there will be developed a new feature in ArcQuality system that enables the welder to easily report time spent to other than actual welding work. Detailed information about welding work is valuable for instance when trying to find ways of reducing production lead time.

Structure and Components of the ArcQuality Service

The ArcQuality system is very simple by structure. It consists of reader devices equipped with a user interface and attached to welding machines, a wireless network, and a Web based reporting software, Figure 5. Non-Kemppi welding devices can be connected to the system by means of a smart arc detector device.

Summary

ArcQuality is the first welding quality management system in the world that offers an easy and comprehensive way of ensuring that the WPS is adhered to during welding and that the welders' qualifications meet the requirements throughout the project. The system also enables you to anticipate the service needs for your machinery. In addition, the smart scanning device can collect quality-related documentation that allows traceability of each individual weld.

Now, you can easily manage all the factors that affect the quality and productivity of welding - with a single system. Productivity benefits are attained via improved quality and efficiency of work, automated monitoring, and easier creation of project documentation.