CN115507247A - Fully automatic welding method and equipment for pressure repair of in-service oil and gas pipelines - Google Patents
Fully automatic welding method and equipment for pressure repair of in-service oil and gas pipelines Download PDFInfo
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- 238000003466 welding Methods 0.000 title claims abstract description 199
- 238000000034 method Methods 0.000 title claims abstract description 57
- 239000011324 bead Substances 0.000 claims abstract description 45
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 10
- 239000010959 steel Substances 0.000 claims abstract description 10
- 238000011144 upstream manufacturing Methods 0.000 claims abstract description 10
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 6
- 230000002950 deficient Effects 0.000 claims description 6
- 238000010438 heat treatment Methods 0.000 claims description 6
- 230000007547 defect Effects 0.000 claims description 5
- 238000007789 sealing Methods 0.000 claims description 4
- 238000004140 cleaning Methods 0.000 claims description 3
- 229910052742 iron Inorganic materials 0.000 claims description 3
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
- F16L55/00—Devices or appurtenances for use in, or in connection with, pipes or pipe systems
- F16L55/16—Devices for covering leaks in pipes or hoses, e.g. hose-menders
- F16L55/168—Devices for covering leaks in pipes or hoses, e.g. hose-menders from outside the pipe
- F16L55/1683—Devices for covering leaks in pipes or hoses, e.g. hose-menders from outside the pipe by means of a patch which is fixed on the wall of the pipe by means of an adhesive, a weld or the like
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Abstract
Description
技术领域technical field
本发明涉及焊接技术领域,尤其是涉及一种在役油气管道带压修复全自动焊接方法及设备。The invention relates to the field of welding technology, in particular to a fully automatic welding method and equipment for pressure repair of in-service oil and gas pipelines.
背景技术Background technique
随着长输油气管道和城市管网的不断建设与发展,管道维修焊接施工的工作量不断增多。With the continuous construction and development of long-distance oil and gas pipelines and urban pipeline networks, the workload of pipeline maintenance and welding construction continues to increase.
目前,钢质油气管道带压修复焊接的方法是采用手工电弧焊。但是现有的手工电弧焊存在以下问题:焊接效率低、焊接质量受焊接操作人员的主观因素影响比较大。尤其是高钢级大口径管道,带压修复焊接工作量大,长时间高强度的焊接作业,手工焊焊接质量难以保障。At present, the method of hot-press repair welding for steel oil and gas pipelines is manual arc welding. However, the existing manual arc welding has the following problems: the welding efficiency is low, and the welding quality is greatly influenced by the subjective factors of the welding operators. Especially for high-grade and large-diameter pipelines, the welding workload under pressure repair is heavy, and the welding quality of manual welding is difficult to guarantee for long-term high-strength welding operations.
同时,钢质油气管道带压修复无法采用现有的主要针对无压管道的自动焊接工艺,一方面,由于带压的油气管道内的介质存在,常规的预热温度达不到预期效果;另一方面,常规的自动焊接工艺是同时从两个横焊道的上游端向下游端焊接,这种方式会导致两个横焊道的下游端受力张开,导致下游端的横焊道焊接难度加大,且非常容易在带压的油气管道上造成裂纹、气孔烧穿等问题。At the same time, the existing automatic welding process mainly for non-pressure pipelines cannot be used for the repair of steel oil and gas pipelines under pressure. On the one hand, due to the presence of the medium in the oil and gas pipelines under pressure, the conventional preheating temperature cannot achieve the expected effect; on the other hand On the one hand, the conventional automatic welding process is to weld from the upstream end of the two horizontal welds to the downstream end at the same time. This method will cause the downstream ends of the two horizontal welds to be stretched by force, making it difficult to weld the horizontal welds at the downstream end. Increase, and it is very easy to cause problems such as cracks and burn-through of pores on the pressurized oil and gas pipeline.
综上,无论是手工电弧焊还是现有的自动焊接工艺均无法完全满足带压钢质管道修复焊接要求。In summary, neither manual arc welding nor the existing automatic welding process can fully meet the welding requirements for the repair and welding of steel pipelines under pressure.
发明内容Contents of the invention
本发明的目的在于提供一种在役油气管道带压修复全自动焊接方法及设备,以解决现有的手工电弧焊以及自动焊接工艺均无法完全满足带压钢质管道修复焊接要求的技术问题。The purpose of the present invention is to provide a fully automatic welding method and equipment for repairing oil and gas pipelines under pressure to solve the technical problem that the existing manual arc welding and automatic welding processes cannot fully meet the welding requirements for repairing steel pipelines under pressure.
为解决上述技术问题,本发明提供的技术方案在于:In order to solve the problems of the technologies described above, the technical solution provided by the invention is:
一种在役油气管道带压修复全自动焊接方法,用于将套袖焊接于带压管道的缺陷位置,所述套袖由上套袖和下套袖对合形成,上套袖和下套袖相邻接的部分分别形成第一横焊道和第二横焊道,该方法包括横焊道焊接步骤:A fully automatic welding method for in-service oil and gas pipeline under pressure repair, which is used to weld the sleeve to the defect position of the pipeline under pressure. The adjacent parts of the sleeve form the first transverse bead and the second transverse bead respectively, and the method comprises the steps of welding the transverse bead:
其中一自动焊机自所述第一横焊道的第一起始点沿第一方向焊接,同时,另一自动焊机自所述第二横焊道的第二起始点沿第二方向焊接;One of the automatic welding machines welds along the first direction from the first starting point of the first horizontal welding run, and at the same time, the other automatic welding machine welds along the second direction from the second starting point of the second horizontal welding run;
其中,所述第一方向和所述第二方向相反,所述第一起始点为所述第一横焊道的上游端点,所述第二起始点为所述第二横焊道的下游端点。Wherein, the first direction is opposite to the second direction, the first starting point is the upstream end point of the first horizontal welding bead, and the second starting point is the downstream end point of the second horizontal welding bead.
更进一步地,go a step further,
还包括清理步骤:在役钢制管道需要维修的地方进行管道防腐层清理剥离,剥离采用火焰或冷去除法,去除防腐层的范围为沿着环焊缝位置向外500mm,向内50mm。It also includes cleaning steps: clean and peel off the anticorrosion layer of the pipeline at the place where the in-service steel pipeline needs to be repaired. Flame or cold removal method is used for the stripping. The scope of removing the anticorrosion layer is 500mm outward and 50mm inward along the girth weld position.
更进一步地,go a step further,
还包括管道壁厚的复测步骤:使用超声波测厚仪确定管道真实壁厚。It also includes a re-measurement step of the pipe wall thickness: use an ultrasonic thickness gauge to determine the true wall thickness of the pipe.
更进一步地,go a step further,
还包括表面垫层焊接步骤,焊接采用全自动焊焊接垫层,垫层范围宽度为不少于5道,厚度在1mm-2.3mm,全自动焊接接头为角摆式。It also includes the surface cushion welding step. The welding adopts automatic welding and welding of the cushion. The width of the cushion is not less than 5, and the thickness is 1mm-2.3mm. The fully automatic welding joint is angle pendulum.
更进一步地,go a step further,
所述横焊道焊接步骤中,还包括套袖安装步骤:In the horizontal bead welding step, the sleeve installation step is also included:
所述套袖包住管道上的缺陷位置,并将缺陷位置至于套袖中心;The sleeve covers the defective position on the pipeline and places the defective position at the center of the sleeve;
用U型卡固定上下套袖,并通过垫楔铁调整套袖与管道的同轴度。Use U-shaped clips to fix the upper and lower sleeves, and adjust the coaxiality between the sleeve and the pipe through the wedge iron.
更进一步地,go a step further,
还包括预热步骤:进行横向组对坡口、套袖位置、管道预热,预热采用中频加热或火焰加热。It also includes a preheating step: perform transverse alignment of the groove, sleeve position, and pipe preheating, and the preheating adopts intermediate frequency heating or flame heating.
更进一步地,go a step further,
还包括角焊缝步骤:Also includes fillet weld steps:
以所述套袖与管道形成的其中一个环形焊缝为第一环形焊缝,以所述套袖与管道形成的另一个环形焊缝为第二环形焊缝;One of the annular welds formed by the sleeve and the pipe is the first annular weld, and the other annular weld formed by the sleeve and the pipe is the second annular weld;
所述第一环形焊缝以时钟点位划分12个定位点,所述第二环形焊缝以时钟点位划分12个定位点;The first annular weld is divided into 12 positioning points by clock points, and the second circular weld is divided into 12 positioning points by clock points;
所述第一环形焊缝自12点位置顺时针焊接至6点位置,所述第二环形焊缝自12点位置逆时针焊接至6点位置,最后在6点位置两个焊道接头搭接。The first annular weld is welded clockwise from the 12 o'clock position to the 6 o'clock position, the second annular weld is welded counterclockwise from the 12 o'clock position to the 6 o'clock position, and finally the two weld bead joints overlap at the 6 o'clock position .
更进一步地,go a step further,
封根、填充和盖面均采用角焊缝步骤。Fillet weld steps are used for root sealing, filling and capping.
更进一步地,go a step further,
角焊缝步骤还包括:The fillet weld step also includes:
当套袖环向坡口为直口,套袖壁厚超过运行管道壁厚的1.4倍时,超出部分倒45度角进行过渡。When the groove of the sleeve ring is straight and the wall thickness of the sleeve exceeds 1.4 times the wall thickness of the running pipe, the excess part is transitioned at an angle of 45 degrees.
一种采用了上述的在役油气管道带压修复全自动焊接方法的设备。A device adopting the above-mentioned fully automatic welding method for pressure repair of in-service oil and gas pipelines.
由于本发明提供了一种在役油气管道带压修复全自动焊接方法,该方法用于将套袖焊接于带压管道的缺陷位置,所述套袖由上套袖和下套袖对合形成,上套袖和下套袖相邻接的部分分别形成第一横焊道和第二横焊道,该方法包括横焊道焊接步骤,具体而言:Since the present invention provides a fully automatic welding method for pressure repair of in-service oil and gas pipelines, the method is used to weld the sleeve to the defect position of the pipeline under pressure, and the sleeve is formed by joining the upper sleeve and the lower sleeve , the adjacent parts of the upper sleeve and the lower sleeve respectively form a first transverse weld bead and a second transverse weld bead, the method includes a transverse bead welding step, specifically:
其中一自动焊机自所述第一横焊道的第一起始点沿第一方向焊接,同时,另一自动焊机自所述第二横焊道的第二起始点沿第二方向焊接;One of the automatic welding machines welds along the first direction from the first starting point of the first horizontal welding run, and at the same time, the other automatic welding machine welds along the second direction from the second starting point of the second horizontal welding run;
其中,所述第一方向和所述第二方向相反,所述第一起始点为所述第一横焊道的上游端点,所述第二起始点为所述第二横焊道的下游端点。Wherein, the first direction is opposite to the second direction, the first starting point is the upstream end point of the first horizontal welding bead, and the second starting point is the downstream end point of the second horizontal welding bead.
本方案的核心方案是采用的全自动对向焊接,如此,一方面可以避免人工焊接导致的各种问题,另一方面,采用了与现有的自动焊接完全不同的工艺方法,两个横焊道相向同步焊接,可以避免现有的同向焊接存在的下游端张开的问题,因此也就很好的解决了管道上造成裂纹、气孔烧穿等问题。The core scheme of this scheme is the fully automatic opposite welding, so that, on the one hand, various problems caused by manual welding can be avoided; on the other hand, a completely different process method from the existing automatic welding is adopted. The simultaneous welding in opposite directions can avoid the problem of opening of the downstream end in the existing welding in the same direction, so it also solves the problems of cracks on the pipeline and burn-through of pores.
附图说明Description of drawings
为了更清楚地说明本发明具体实施方式或现有技术中的技术方案,下面将对具体实施方式或现有技术描述中所需要使用的附图作简单地介绍,显而易见地,下面描述中的附图是本发明的一些实施方式,对于本领域普通技术人员来讲,在不付出创造性劳动的前提下,还可以根据这些附图获得其他的附图。In order to more clearly illustrate the specific implementation of the present invention or the technical solutions in the prior art, the following will briefly introduce the accompanying drawings that need to be used in the specific implementation or description of the prior art. Obviously, the accompanying drawings in the following description The drawings show some implementations of the present invention, and those skilled in the art can obtain other drawings based on these drawings without any creative work.
图1为本发明实施例中套袖修复焊缝布置示意图;Fig. 1 is a schematic diagram of sleeve repair weld arrangement in an embodiment of the present invention;
图2为本发明实施例中管线横焊道位置壁厚测量点分布示意(K和H为横向壁厚测量点);Figure 2 is a schematic diagram of the distribution of wall thickness measurement points at the position of the horizontal weld bead of the pipeline in an embodiment of the present invention (K and H are lateral wall thickness measurement points);
图3为本发明实施例中横焊道的焊接方向示意图;Fig. 3 is the schematic diagram of the welding direction of the transverse weld bead in the embodiment of the present invention;
图4为本发明实施例提供的环形焊道的点位分布图;Fig. 4 is the point distribution diagram of the annular weld bead provided by the embodiment of the present invention;
图5为本发明实施例提供的两个环形焊道的同步焊接的焊接方向的示意图;Fig. 5 is the schematic diagram of the welding direction of the synchronous welding of two annular welds provided by the embodiment of the present invention;
图6为本发明实施例提供的横向焊道的角焊缝焊接示意图;Fig. 6 is a schematic diagram of a fillet weld of a transverse bead provided by an embodiment of the present invention;
图7为现有的手动焊的焊接成型效果图;Fig. 7 is the welding shaping rendering of existing manual welding;
图8为本实施例提供的自动焊接方法成型效果图。Fig. 8 is an effect drawing of the automatic welding method provided in this embodiment.
图标:100-套袖;200-管道;Icons: 100-sleeve; 200-pipe;
310-第一横焊道;320-第二横焊道;310-the first transverse weld bead; 320-the second transverse weld bead;
410-第一环形焊缝;420-第二环形焊缝。410—the first circular weld; 420—the second circular weld.
具体实施方式detailed description
目前,钢质油气管道200带压修复焊接的方法是采用手工电弧焊。但是现有的手工电弧焊存在以下问题:焊接效率低、焊接质量受焊接操作人员的主观因素影响比较大。尤其是高钢级大口径管道200,带压修复焊接工作量大,长时间高强度的焊接作业,手工焊焊接质量难以保障。同时,钢质油气管道200带压修复无法采用现有的主要针对无压管道200的自动焊接工艺,一方面,由于带压的油气管道200内的介质存在,常规的预热温度达不到预期效果;另一方面,常规的自动焊接工艺是同时从两个横焊道的上游端向下游端焊接,这种方式会导致两个横焊道的下游端在应力作用下张开,导致下游端的横焊道焊接难度加大,且非常容易在带压的油气管道200上造成裂纹、气孔烧穿等问题。At present, the method of welding under pressure for the steel oil and
针对上述问题,本发明提供了一种在役油气管道200带压修复焊接方法,请一并参见图1至图8。In view of the above problems, the present invention provides a repair welding method under pressure for an in-service oil and
该方法用于将套袖100焊接于带压管道200的缺陷位置,所述套袖100由上套袖100和下套袖100对合形成,上套袖100和下套袖100相邻接的部分分别形成第一横焊道310和第二横焊道320。This method is used to weld the sleeve 100 to the defect position of the
该方法包括横焊道焊接步骤,具体而言:The method includes the steps of cross-bead welding, specifically:
其中一自动焊机自所述第一横焊道310的第一起始点沿第一方向焊接,同时,另一自动焊机自所述第二横焊道320的第二起始点沿第二方向焊接;One of the automatic welding machines welds along the first direction from the first starting point of the first horizontal welding bead 310, and at the same time, the other automatic welding machine welds along the second direction from the second starting point of the second
其中,所述第一方向和所述第二方向相反,所述第一起始点为所述第一横焊道310的上游端点,所述第二起始点为所述第二横焊道320的下游端点。Wherein, the first direction is opposite to the second direction, the first starting point is the upstream end point of the first horizontal welding bead 310, and the second starting point is the downstream of the second
本方案的核心方案是采用的全自动对向焊接,如此,一方面可以避免人工焊接导致的各种问题,另一方面,采用了与现有的自动焊接完全不同的工艺方法,两个横焊道相向同步焊接,可以避免现有的同向焊接存在的下游端张开的问题,因此也就很好的解决了管道200上造成裂纹、气孔烧穿等问题。The core scheme of this scheme is the fully automatic opposite welding, so that, on the one hand, various problems caused by manual welding can be avoided; on the other hand, a completely different process method from the existing automatic welding is adopted. The synchronous welding in opposite directions can avoid the problem of opening of the downstream end existing in the existing same-direction welding, so it also solves the problems of cracks on the
其中,关于横焊道焊接步骤,具体而言,包括如下步骤:Wherein, with regard to the horizontal bead welding step, specifically, the following steps are included:
S1:清理步骤:在役钢制管道200需要维修的地方进行管道200防腐层清理剥离,剥离采用火焰或冷去除法,去除防腐层的范围为沿着环焊缝位置向外500mm,向内50mm。S1: Cleaning steps: clean and peel off the anticorrosion layer of the
S2:管道200壁厚的复测步骤:使用超声波测厚仪确定管道200真实壁厚。S2: Step of re-testing the wall thickness of the pipeline 200: using an ultrasonic thickness gauge to determine the real wall thickness of the
本实施例中对焊接位置进行管道200壁厚的复测,横焊道为沿着管道2003点和6点位置进行测量,测量点分布为:3点位置K1、K2、K3、K4、K5、K6、K7、K8、K9、K10、K11·····和9点位置H1、H2、H3、H4、H5、H6、H7、H8、H9、H10、H11·····,横焊道测量点数量一般为奇数,并均匀分布,数量以横焊道长度为准,越多测得的实际管道200壁厚越趋于实际值。关于上述的3点位置和9点位置,需要说明的是:如图4,将上游角焊缝位置管壁厚测量点分割为A1、A2、A3、A4、A5、A6、A7、A8、A9、A10、A11、A12下游角焊缝测厚点分割为B1、B2、B3、B4、B5、B6、B7、B8、B9、B10、B11、B12,测点数量和管径成正比,测量点位置按360°均分,最少为12个,上述的3点位置为A3和B3的连线,上述的9点位置为A9和B9的连线。In this embodiment, the re-measurement of the wall thickness of the
S3、表面垫层焊接步骤,焊接采用全自动焊焊接垫层,垫层范围宽度为不少于5道,厚度在1mm-2.3mm,全自动焊接接头为角摆式。垫层宽度以角焊缝焊脚高度为准,垫层为排焊。S3, the surface cushion welding step, the welding adopts automatic welding and welding cushion, the width of the cushion is not less than 5, the thickness is 1mm-2.3mm, and the fully automatic welding joint is angle pendulum. The width of the cushion is based on the height of the fillet weld leg, and the cushion is row welding.
S4、套袖100安装步骤:S4. Installation steps of the sleeve 100:
所述套袖100包住管道200上的缺陷位置,并将缺陷位置至于套袖100中心;The sleeve 100 wraps the defective position on the
用U型卡固定上下套袖100,并通过垫楔铁调整套袖100与管道200的同轴度。Fix the upper and lower sleeves 100 with a U-shaped card, and adjust the coaxiality of the sleeves 100 and the
S5、预热步骤:S5. Preheating steps:
进行横向组对坡口、套袖100位置、管道200预热,预热采用中频加热或火焰加热。Carry out horizontal group alignment of the groove, sleeve 100 position,
S6、焊接步骤:调整自动焊焊接机头,调整焊接送丝机的送丝速度,调整焊接参数,电流、电压、焊接速度、保护气体的压力和流量。S6. Welding steps: adjust the automatic welding head, adjust the wire feeding speed of the welding wire feeder, adjust welding parameters, current, voltage, welding speed, pressure and flow of shielding gas.
本实施例中,横焊道焊接,两个焊接操作人员同时操作自动焊焊机,自动焊焊机机头为角摆方式,角摆宽度26mm,焊前预热温度不小于80℃,根焊、热焊、填充和盖面焊接时,焊接人员分别在管道200轴线方向的两侧,一个从管道200上游向下游方向焊接,一个从管道200下游向上游方向焊接,焊接小车的焊枪运动采用角摆的方式。In this embodiment, for horizontal bead welding, two welding operators operate the automatic welding machine at the same time. , heat welding, filling and capping welding, the welders are on both sides of the
本实施例中,垫层位置为角焊缝焊接位置,采用全自动焊接工艺完成,垫层不少于5道,垫层厚度1mm-2.3mm,自动焊焊机机头为角摆方式,角摆宽度26mm,焊前预热温度不小于40℃,焊接由两个焊接操作人员同时操作两台焊机进行施焊,焊接起始6点钟,按照图5所示,焊工A1和B1分别操控全自动焊接设备从6点向12点位置焊接。搭接时需要将先焊接的收尾点磨掉,并进行圆滑过渡,再进行两个接头的搭接,垫层所选焊丝的直径为直流反接,上向焊,电流200-240A,电压20-27V,焊接速度在10-11in/min,保护气体为80%Ar+20%CO2,保护气体流速为28-33L/min。In this embodiment, the position of the cushion layer is the welding position of the fillet weld, which is completed by a fully automatic welding process. The cushion layer is not less than 5 layers, and the thickness of the cushion layer is 1mm-2.3mm. The pendulum width is 26mm, and the preheating temperature before welding is not less than 40°C. Two welding operators operate two welding machines at the same time for welding. The welding starts at 6 o'clock. As shown in Figure 5, welders A1 and B1 operate respectively Fully automatic welding equipment welds from 6 o'clock to 12 o'clock. When lapping, it is necessary to grind off the ending point of the first welding, and make a smooth transition, and then carry out the lapping of the two joints. The diameter of the welding wire selected for the cushion layer is DC reverse connection, upward welding, current 200-240A, voltage 20-27V, welding speed 10-11in/min, shielding gas 80% Ar+20% CO2, shielding gas flow rate 28-33L/min.
本实施例中,根焊艺,采用手工电弧焊,焊条直径直流反接,焊接方向为横向,焊条摆动方式为直拉或者微摆动,电流90-115A,电压20-27V,焊接速度在3.0-4.0in/min。In this embodiment, the root welding process adopts manual arc welding, and the electrode diameter The DC is reversed, the welding direction is horizontal, the electrode swing mode is straight pull or micro swing, the current is 90-115A, the voltage is 20-27V, and the welding speed is 3.0-4.0in/min.
本实施例中,热焊工艺,采用手工电弧焊,焊条直径直流反接,焊接方向为横向,焊条摆动方式为直拉或者微摆动,电流115-130A,电压20-27V,焊接速度在3.0-4.0in/min。In this embodiment, the heat welding process adopts manual arc welding, and the electrode diameter The DC connection is reversed, the welding direction is horizontal, the electrode swing mode is straight pull or micro swing, the current is 115-130A, the voltage is 20-27V, and the welding speed is 3.0-4.0in/min.
本实施例中,所述填充工艺,采用自动焊工艺,图6中3、4、5、6、7、8、9、10、11、12、13、14、15、16、17、18、19为填充焊道,焊丝直径直流反接,焊接方向为横向,自动焊焊接机头为角摆方式,角摆宽度26mm,电流200-250A,电压20-27V,送丝速度270-350in/min,焊接速度在8-10in/min,保护气体为80%Ar+20%CO2,保护气体流速为28-33L/min,焊道层间温度在80℃-150℃。In this embodiment, the filling process adopts an automatic welding process, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19 is the filler bead, the wire diameter DC reverse connection, welding direction is horizontal, automatic welding welding head is angular swing mode, angular swing width 26mm, current 200-250A, voltage 20-27V, wire feeding speed 270-350in/min, welding speed 8-10in/min min, the shielding gas is 80% Ar+20% CO2, the flow rate of the shielding gas is 28-33L/min, and the interpass temperature is 80°C-150°C.
本实施例中,所述盖面工艺,采用自动焊工艺,图6中20、21、22、23、24为盖面焊道,焊丝直径直流反接,焊接方向为横向,自动焊焊接机头为角摆方式,角摆宽度26mm,电流180-235A,电压20-27V,送丝速度270-350in/min,焊接速度在15-20in/min,保护气体为80%Ar+20%CO2,保护气体流速为28-33L/min,焊道层间温度在80℃-150℃。In the present embodiment, the cover surface process adopts an automatic welding process, and 20, 21, 22, 23, and 24 in Fig. 6 are cover surface weld passes, and the diameter of the welding wire DC reverse connection, welding direction is horizontal, automatic welding welding head is angular swing mode, angular swing width 26mm, current 180-235A, voltage 20-27V, wire feeding speed 270-350in/min, welding speed 15-20in/min min, the shielding gas is 80% Ar+20% CO2, the flow rate of the shielding gas is 28-33L/min, and the interpass temperature is 80°C-150°C.
另一方面,本发明还提供了一种角焊缝的焊接工艺:On the other hand, the present invention also provides a welding process for fillet welds:
以所述套袖100与管道200形成的其中一个环形焊缝为第一环形焊缝410,以所述套袖100与管道200形成的另一个环形焊缝为第二环形焊缝420;One of the annular welds formed by the sleeve 100 and the
所述第一环形焊缝410以时钟点位划分12个定位点,所述第二环形焊缝420以时钟点位划分12个定位点;The first
所述第一环形焊缝410自12点位置顺时针焊接至6点位置,所述第二环形焊缝420自12点位置逆时针焊接至6点位置,最后在6点位置两个焊道接头搭接。The first
与横焊道焊接相类似的,角焊缝也采用了全自动焊接的方式,并且,第一环形焊缝410和第二环形焊缝420的焊接方向相反,具体为:其中一个为顺时针,另一个为逆时针。这种反向同步焊接的方式,一方面可以完全避免人工焊接导致的各种问题,另一方面,如果两个角缝焊,采用的是同向焊接,同样会在末端(远离起始焊点的位置)造成张开的问题,因此会存在裂纹、气孔烧穿等问题。而本方案采用的是逆向同步焊接,不会给焊接末端造成应力,因此不会存在张开变形的问题,因此也就很好的解决了管道200上造成裂纹、气孔烧穿等问题。Similar to the horizontal bead welding, the fillet weld also adopts a fully automatic welding method, and the welding directions of the first
关于角焊缝步骤,进一步的,封根、填充和盖面均采用角焊缝步骤。Regarding the fillet weld step, further, the fillet weld step is used for root sealing, filling and capping.
本实施例中封根工艺,采用上述的角焊缝步骤,焊丝直径直流反接,焊接方向为上向,自动焊焊接机头为角摆方式,角摆宽度26mm,电流200-250A,电压20-27V,送丝速度250-300in/min,焊接速度在8-10in/min,保护气体为80%Ar+20%CO2,保护气体流速为25-30L/min,焊道层间温度在50℃-150℃。In this embodiment, the root sealing process adopts the above-mentioned fillet weld steps, and the diameter of the welding wire DC reverse connection, welding direction is upward, automatic welding welding head is angular swing mode, angular swing width 26mm, current 200-250A, voltage 20-27V, wire feeding speed 250-300in/min, welding speed 8-10in /min, the shielding gas is 80% Ar+20% CO2, the flow rate of the shielding gas is 25-30L/min, and the interpass temperature is 50°C-150°C.
本实施例中填充工艺,采用上述的角焊缝步骤,焊丝直径直流反接,焊接方向为横向,自动焊焊接机头为角摆方式,角摆宽度26mm,电流200-250A,电压20-27V,送丝速度270-350in/min,焊接速度在8-10in/min,保护气体为80%Ar+20%CO2,保护气体流速为28-33L/min,焊道层间温度在50℃-150℃。In this embodiment, the filling process adopts the above-mentioned fillet weld steps, and the diameter of the welding wire DC reverse connection, welding direction is horizontal, automatic welding welding head is angular swing mode, angular swing width 26mm, current 200-250A, voltage 20-27V, wire feeding speed 270-350in/min, welding speed 8-10in/min min, the shielding gas is 80% Ar+20% CO2, the flow rate of the shielding gas is 28-33L/min, and the interpass temperature is 50°C-150°C.
本实施例中盖面工艺,采用上述的角焊缝步骤,焊丝直径直流反接,焊接方向为横向,自动焊焊接机头为角摆方式,角摆宽度26mm,电流180-235A,电压20-27V,送丝速度270-350in/min,焊接速度在15-20in/min,保护气体为80%Ar+20%CO2,保护气体流速为28-33L/min,焊道层间温度在50℃-150℃。In this embodiment, the capping process adopts the above-mentioned fillet weld steps, and the diameter of the welding wire DC reverse connection, welding direction is horizontal, automatic welding welding head is angular swing mode, angular swing width 26mm, current 180-235A, voltage 20-27V, wire feeding speed 270-350in/min, welding speed 15-20in/min min, the shielding gas is 80% Ar+20% CO2, the flow rate of the shielding gas is 28-33L/min, and the interpass temperature is 50°C-150°C.
本实施例中,套袖100环向坡口为直口,套袖100壁厚超过运行管道200壁厚的1.5倍时,超出部分倒45度角进行过渡,当T1<1.4T2+C时,按照图7所示,当T1>1.4T2+C按照图8所示。In this embodiment, the circumferential groove of the sleeve 100 is a straight opening, and when the wall thickness of the sleeve 100 exceeds 1.5 times the wall thickness of the running
本实施例中,套袖100边缘与垫层边缘间距3mm-0mm,调整套袖100与管道200之间的间隙均匀。In this embodiment, the distance between the edge of the sleeve 100 and the edge of the cushion layer is 3mm-0mm, and the gap between the sleeve 100 and the
实施例二Embodiment two
本实施例提供了一种采用了实施例1述及的在役油气管道200带压修复焊接方法的设备。This embodiment provides a device that adopts the hot-press repair welding method for the in-service oil and
综合效果评价,请参见图7和图8,图7为现有的手动焊的焊接成型效果图;图8为本实施例提供的自动焊接方法成型效果图。Comprehensive effect evaluation, please refer to Fig. 7 and Fig. 8, Fig. 7 is the welding forming effect drawing of the existing manual welding; Fig. 8 is the forming effect drawing of the automatic welding method provided in this embodiment.
从效果图中可以看出,现有的手动焊接方法焊接后的表面凹凸不平,存在较多的缺陷,而本实施例提供的自动焊接方法焊接后的表面平整光滑。It can be seen from the effect diagram that the surface after welding by the existing manual welding method is uneven and has many defects, while the surface after welding by the automatic welding method provided by this embodiment is smooth and smooth.
最后应说明的是:以上各实施例仅用以说明本发明的技术方案,而非对其限制;尽管参照前述各实施例对本发明进行了详细的说明,本领域的普通技术人员应当理解:其依然可以对前述各实施例所记载的技术方案进行修改,或者对其中部分或者全部技术特征进行等同替换;而这些修改或者替换,并不使相应技术方案的本质脱离本发明各实施例技术方案的范围。Finally, it should be noted that: the above embodiments are only used to illustrate the technical solutions of the present invention, rather than limiting them; although the present invention has been described in detail with reference to the foregoing embodiments, those of ordinary skill in the art should understand that: It is still possible to modify the technical solutions described in the foregoing embodiments, or perform equivalent replacements for some or all of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the technical solutions of the various embodiments of the present invention. scope.
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