Page 30 - ITAtube Journal 1 2024

Technical Papers
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repeatability with high statistical process capability. If any of these process param- eters are outside of preset process limits, secondary inspection may be
HAZControl Technology software screen with Process Limits necessary to qualify the quality of the product. The goal is to ship only qualified performance, high-quality products to the customer.
Another primary benefit of collecting data during HF welding is material tracking and traceability. Product traceability has been a requirement in various industries for many years. However, the tube and pipe industry at large has been slow to adopt this prac- tice. Although product traceability is not mandatory for all tube and pipe products, other companies, particularly in automotive and pressure-bearing applications, have been following this procedure for quite some time now. This can be achieved easily by implementing individual barcodes tied to a full data processing package, made possible by IIoT-enabled equipment and smart machinery.
Data collection can be also beneficial for predictive maintenance. Unlike the pre- vious benefits that were mostly linked to HF welding process data, this advantage
is associated with equipment data and condition-based monitoring (CBM). Ther- matool welders are equipped with a variety of digital sensors, gauges, and transducers to display the equipment’s status, making troubleshooting easier and faster. The data can be utilized for predictive maintenance, which will help prevent unplanned shut- downs and material loss.
Lastly, the advantage of data collection is using the data along with process optimi- zation for HF weld process energy effi- ciency. By identifying areas of inefficiencies, processes can be optimized, which will lead to improved energy efficiency in the long run. Thermatool has integrated a process efficiency value into the latest Human-Ma- chine Interface (HMI) software. This feature provides a readout of the energy measure for every ton of material produced on the mill and is displayed in kWh/ton. This value
can be related to financial metrics and product quality. This enables customers to quantify the efficiency of their process with the help of Thermatool’s calibrated calori- metric measurement of output power.
Challenges and Considerations
While data collection offers many bene-
fits to the tube and pipe industry, it also presents some challenges. Manufacturers need to prioritize data security, system inte- gration, and the expertise that is required to operate and maintain these technolo- gies. Handling large amounts of data can be overwhelming without effective analytical tools available. Thermatool is continuously engaged in fundamental scientific research targeting process parameters that must
be controlled to deliver the best HF weld possible [3].
Data storage is another important consid- eration that needs to be addressed. There are various cloud-based storage solutions available to manage large data packages, however, a system should be in place to manage the vast amount of data gener- ated by sensors, gauges, and transducers with high sampling rates. These devices can produce thousands of data entries per 8-hour shift, making it important to have an efficient and robust system in place.
One way to address this challenge is by using Thermatool+ IIoT, which provides secure cloud-based storage, among other features such as condition-based monitor- ing (CBM), and a data retrieval dashboard. User accounts are secured with two-factor authentication, and the cloud platform uses industry-standard encryption and multi-tenant architecture. The platform is purpose-built for the tube and pipe indus- try, addressing many of the concerns of both large and small tube producers.
When implementing an IIoT-enabled HF welder, it is crucial to assess the current state of equipment and IT systems. An evaluation of the type of equipment and machines on the plant floor should be made, as well as an assessment of the age of the devices and systems currently in use. For example, if we talk about HF welding equipment, depending on the model of the
ITAtube Journal April 2024