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    • 专利摘要:
    pipeline welding method and apparatus. The present invention relates to a method for laying an oil pipeline in which the outer and inner weld passages are made to weld together the pipe sections (2a, 2b). The method includes arranging a section of pipe (2b) adjacent to the end (2a) of an oil pipeline thus defining a circumferential joint (8) to be welded, performing a passage of the outer weld, with, for example, gmaw - mig torches ( 10), at the root of the joint (8) to be welded in which welding material is deposited at the root of the joint to be welded, thus forming a root welding (4r), and then performing an internal welding passage, with, for For example, a gtwa - tig torch (12) in the root welding (4r) in which the root welding (4r) is melted and reformed. The method has particular application with regard to the corrosion resistant alloy (lrc) pipe capping (6).
    公开号:BR112012013161B1
    申请号:R112012013161-3
    申请日:2010-11-30
    公开日:2018-05-15
    发明作者:Bowers Jonathan
    申请人:Saipem S.P.A.；
    IPC主号:
    专利说明:

    Report of the Invention Patent for "METHOD FOR LAUNCHING A TRANSPORT DUCT, WELDING STATION AND TRANSPORT DUMPING VESSEL".
    Background of the Invention The present invention relates to an apparatus and method for joining pipes by welding. In particular, but not exclusively, the invention relates to welding of coated pipe sections, or other multilayer pipe sections, when casting submerged transport ducts into the ocean.
    [002] When launching a shipping duct into the ocean from a pipeline launcher, one end of the shipping duct (sometimes referred to as a "pipe column") is attached to the vessel and a pipe section is welded to the end of the transport duct. The transport duct and newest welded pipe section are then fed from the ship so that the process can be repeated. The welding joint must be of high quality taking into account the high voltage loads to which the transport duct is subjected during the laying process. The quality of the weld joint is critical when the pipeline, once installed, will be in a position where it is exposed to regular shifting motion in the ocean (eg when the transport pipeline is in the form of a catenary column). In this case, the welding joint must be able to withstand the fatigue loads to which it will be subjected.
    [003] Transport ducts designed to carry liquid (pipeline) or gases (pipeline) that are corrosive or otherwise damaging normal steel pipes are typically lined internally or otherwise coated with an LRC (alloy). corrosion resistant). In addition, such LRC-lined in-house transport pipelines are increasingly perceived to offer an economical solution for remote well exploration. LRC-lined tubes are made by metallurgically or by pressing a LRC cylinder into a carbon steel (AC) tube.
    [004] The process for welding LRC-lined pipes together is more complex than welding normal AC transport ducts. It should be noted that the production rate for an LRC transport duct is typically a factor of 4 or 5 times lower than a AC transport duct of the same size. A typical LRC-coated AC pipe and the welding joint formed therebetween is shown in Figures 1a, 1b and 2.
    [005] A well-known technique for welding LRC-coated pipe sections together is to use a single externally mounted semi-automated GMAW welding head to deposit the first critical pass indicated as a root pass, followed by an internal inspection to ensure weld quality. root is of a sufficiently high standard. The welding area is purged with shielding gas (usually an inert gas such as argon) to reduce the risk of oxidation of the welding material. Internal inspection includes an ultrasonic testing regime and a visual inspection performed with the aid of cameras. Visual inspection is required as ultrasonic testing may be prone to false results due to residual magnetization of LRC material.
    [006] As a result of the nature of the root welding process, it is difficult to ensure correct welding penetration. The entire welding process is very sensitive to variations in many parameters such as joint adjustment, magnetism levels and even small changes in gas composition. Despite the great degree of automation that a welding process provides, the acceptance of welding still largely depends on the skill of the welder. The entire time cycle to complete the first of two root passes and perform the internal inspection is relatively extended. In addition, if the root weld fails to meet strict acceptance criteria, it is generally the case that root repairs are not performed and the entire welding joint is trimmed, leading to further delays. The joint is welded to the hot pass stage and internally inspected before being moved out of the welding station. When production reaches steady state, a welding time cycle of approximately 30 minutes at the first welding station can be achieved, but achieving a welding cycle of this duration can be challenging when placing the shipping duct in the ocean. It will be appreciated that after the root welding is completed, the pipe is moved to subsequent stations to receive further welding passes and / or to be processed / tested in other ways. Operations at the station where the root pass is placed tend, however, to be the step that limits the rate of production.
    The present invention seeks to mitigate the problems mentioned above. Alternatively or additionally, the present invention seeks to provide an improved method for launching a pipeline, an improved welding method, and / or an improved tube welding apparatus.
    SUMMARY OF THE INVENTION The present invention provides a method for launching a transport duct, in which the pipe sections are welded together to form the duct. It will be appreciated that the pipe sections and the transport duct may be referred to as simply pipes. The method includes the steps of providing a pipe section to be welded to the end of a transport duct, arranging the pipe section adjacent to the end of the transport duct, thereby defining a circumferential joint to be welded, performing a pass. Outer weld at the root of the joint to be welded during which welding material is deposited at the root of the joint to be welded, thus forming a root weld, and perform an internal weld pass on the root weld. Advantageously, the step of performing the inner weld pass on the root weld fuses the newly welded root weld. Fusion of the already formed root weld can be performed to cause reflow of the inner surface to a depth of more than 0.5mm and more preferably more than 1mm. Such refluxing of the root weld can improve the chance of achieving full fusion at the weld joint root, which can in turn be difficult to reliably achieve. Redefining the root weld from the inside of the pipe can improve overall weld quality and reduce the chance of weld being rejected for not meeting acceptance criteria.
    The method includes a step of performing an external weld pass on the root of the joint to be welded and a step of performing an internal weld pass on the root weld. The apparatus for performing the external welding pass will be referred to as the external welding apparatus and the apparatus for performing the internal welding pass will be referred to as the internal welding apparatus.
    [0010] The step of performing the outer weld pass to form the root weld may be performed in such a way as to cause the inner tube surface to fuse or deform in the root weld region. Penetration of the root weld, formed by the outer weld pass, through the inner surface of the pipe can leave uneven and undesirable welding. Acquiring a new form of root weld from inside the tubes can be of significant benefit, as explained in more detail below.
    [0011] Acquisition of the new shape of the root weld from inside the tubes can be performed in such a way as to reduce the risk of welding being rejected as a result of tube misalignment. If the pipe section is not exactly aligned with the adjacent end of the transport duct, there may be a so-called "hi-lo" (a gap between a pipe section and the adjacent section) at certain circumferential positions around the pipe circumference. . If the hi is too large, welding will be rejected. In embodiments of the present invention, hi-lo gaps of the order of 1.5mm may be accommodated, resulting in less time being required in joining (aligning) the pipes. Acceptable tolerances in the shape and dimensions of pipe sections also become less critical, allowing for potential savings.
    The use of an internal welding step, following an external welding step in the same welding, can be performed in such a way that certain defects in a root weld can be repaired in a manner not previously contemplated. For example, in prior art welding methods for launching transport pipelines into the ocean, there is no option to repair the event that the root cord is rejected: in such an event, all welding is typically trimmed.
    The remelting of the root weld can improve the fusion fullness between the weld and the pipes. The narrow bevels have already led to the lack of fusion of the sidewall, especially near the welding root. However, the method of the invention can improve the fusion fullness of the weld, thus allowing a narrow bevel to be more readily used. The narrow chamfer may have a maximum width of less than 10 mm, and preferably less than 7 mm. The pipe thickness index (which may, for example, be between 10mm and 30mm) and the maximum bevel width is preferably between 10: 1 and 3: 1, and more preferably between 6: 1 and 20: 7.
    The internal weld pass in the root weld is preferably carried out by means of arc welding. The internal soldering pass can be performed using a non-consumable electrode. The internal solder pass in the root weld can be performed without adding weld filler material The internal solder pass in the root weld can, for example, be performed by means of an autogenous welding process. Internal welding may be performed by means of a plasma welding apparatus. Internal welding can be performed by means of a laser welding apparatus. Internal welding can be performed by a welding apparatus using a tungsten electrode. For example, the apparatus for forming the internal weld may include a GTAW (gas tungsten arc welding) welding torch, for example, a TIG (tungsten inert gas) welding torch. The internal weld pass on the root weld can be performed with the assistance of one or more cameras used to guide the internal weld. One or more of these cameras may, for example, be used to produce a live image on a video monitor device. The internal welding apparatus can be partially controlled manually. For example, a welding operator may use an input device, for example a control, which allows the internal welding apparatus to be steered, or controlled. The internal welding apparatus can be at least partially controlled automatically. The internal welding apparatus may, for example, weld at a substantially constant velocity along the joint to be welded. The internal welding apparatus may include an automatic welding voltage control (AVC) unit. The internal welding apparatus may include an internal alignment clamp arranged to allow the pipes to be aligned and stapled in the ready-to-weld position. One or more welding heads may be mounted on the internal alignment clamp (ILUC).
    [0015] The step of performing the external weld pass on the root weld is preferably performed by arc welding. The external welding step preferably includes adding weld filler material to the welding. The external welding step can be performed using a consumable electrode. The external welding step may include performing a gas metal arc welding (GMAW) process. For example, the GMAW process may be a MIG (metal inert gas) process. The external welding apparatus can be at least partially controlled automatically. The external welding apparatus may, for example, weld at a substantially constant speed throughout the weld. The external welding apparatus may include an automatic welding voltage control unit. The external welding apparatus may include one or more welding torches which are arranged to automatically track (i.e. follow) the center of the joint path to be welded. The welding head may be arranged to oscillate the width of the welding joint. The external welding apparatus may include an external clamping mechanism, for example, a band, on which one or more welding heads are mounted. The external welding apparatus may include one or more welding defects arranged to travel around the pipes.
    In the case where the outer weld pass at the root requires the use of an inert gas, the inner weld pass, in which the root weld is refluxed, preferably results in a final surface with low oxidation properties, as well. reducing the need to purge the welding area with inert gas before external passes. For example, an internal GTAW welding process can result in a low oxidation end surface and potentially improved corrosion properties, and may not adversely affect the mechanical properties of the root weld, although it is in remelting.
    The external weld pass in the root weld may simultaneously include the use of a plurality of separate welding heads. For example, a plurality of heads may deposit the weld material in the root at different circumferential positions around the tubes. The first external pass can be deposited faster with two or more heads used simultaneously. Consistently achieving full penetration with the outer weld pass may not be absolutely necessary as complete fusion can be achieved later through the inner weld pass. Two of the separate welding heads can be positioned more than 60 degrees apart around the circumference of the pipes. For example, only two external welding heads could be provided opposite each other (ie approximately 180 degrees between each other).
    The step of performing an internal weld pass on the root weld may include refluxing the inner surface of the pipes to a depth of more than 1 mm. The reflow depth of the inner surface of the pipes may be less than 4 mm. A typical reflow depth can be between 1.5 and 2.5 mm.
    [0019] The step of performing the outer weld pass on the joint root can produce a root weld that has a rough shape on the inner surface of the pipes. In this case, the inner weld pass advantageously reflows the newly formed root weld so that on the inner surface of the pipes the root weld takes on a smoother shape. By smoothing the shape of the root weld on the inner surface of the pipes, the root weld is less likely to corrode. A weld having a rough shape exposes more surface area by volume and is more likely to corrode. A weld having a rough shape may, for example, have a bulge when viewed at the cross section. The weld having a rough shape may, for example, have a cross section, where the shape changes in height (the dimension along a radius of the pipe) by more than 1 mm over a distance (e.g. along the direction longitudinal) of 1mm. A weld having a smooth shape may be substantially flat and have no protuberance. A weld having a smooth shape may, for example, have no part where the shape changes in height by more than 0.5 mm over a distance of 0.5 mm. The step of performing the inner weld pass on the root weld is preferably performed such that the root weld on the inner surface of the pipes is flatter than the root weld shape formed immediately after performing the pass weld step. external solder at the root of the joint.
    [0020] The step of performing the outer weld pass on the joint root can produce a lack of melting of the material in the chamfer; The root weld is not completely fused to the pipes. In this case, the inner weld pass advantageously reflows the root weld so that it becomes completely fused to the pipes.
    For a given root weld, the method may comprise performing only one internal weld pass per weld joint. The method may include performing only two internal weld passes per weld joint. In some embodiments, the method may include performing a plurality of, for example, at least three internal weld passes per weld joint. Three or fewer internal weld passes per weld joint are preferred. Root welding can be taken to a new shape during each internal welding pass.
    The internal welding step may include adding the solder filler material to the weld. Adding the filler metal during the internal weld pass could, for example, allow defects to be repaired and still fill in the weld cavities.
    The method may include a step of performing the outer cap weld pass on the top of the joint to be welded. For example, the method may include depositing the weld material on top of the joint to be welded, thus forming a cap weld. In this case, the step of performing the inner weld pass on the root weld can be performed prior to completing the step of performing an outer cap weld pass. The internal weld pass at the joint root can be performed at the same time as an internal weld pass is performed. The method can be performed such that the inner weld pass is initiated only after the outer weld pass at the root has been completed. The root weld may have solidified until the inner weld pass is conducted on the root weld.
    The method may include a step in which non-destructive testing (NDT) is performed. For example, such an NDT may be performed after performing the internal weld pass on the root weld. During the non-destructive testing (NDT) step, the quality of the root weld can be inspected through one or more cameras inside the tubes. During the non-destructive testing (NDT) step, the quality of the root weld can be tested by ultrasonic testing. The non-destructive test (NDT) step can be performed prior to completing the step of performing an outer cover welding pass. The non-destructive test (NDT) step can use one or more cameras.
    In its broad sense the present invention encompasses welding together two pipe sections which are subsequently welded to other pipe sections, or a conveying duct, when launching or laying a duct. Thus, one of the two pipe sections can be considered as defining the end of a transport duct. More commonly, however, is the case where the pipe section is added to a transport duct that is significantly longer (more than 10 times longer, for example) than the pipe section. The pipeline may extend into water, for example when the pipeline being placed is an underwater pipeline. One end of the duct can certainly be held above water, for example, attached to a transport duct launch vessel, to allow a new pipe section to be welded to the duct end.
    The method of the present invention has particular application when the transport duct is a multilayer duct having a metal layer which is made of a metal other than that of an adjacent layer. For example, the pipe section may be an LRC-lined conveying pipe. The step of performing the outer weld pass on the joint root may include adding a welding material of a first type to the joint. The step of performing the inner weld pass on the joint root may include adding a second type welding material to the joint. The welding material of the second type may be of a different composition than the first type. For example, it might be possible to weld a pipe coated externally with an AC filler metal, and internally by GTAW with LRC compliant filler material. The welding material of the second type may be of the same composition as the welding material of the first type. For example, it might be possible to weld an externally and internally lined pipe with LRC-compatible filler material such as "Inconel". Together, the steps for (i) conducting the outer weld pass and (ii) performing the inner weld pass may include adding the same weld material to the carbon steel material and the LRC material. For example, "Inconel" material can be used in an external weld pass, where Inconel material welds carbon steel material and LRC material in the duct.
    The method of the present invention has particular application when the transport duct is subjected to high loads, and / or fatigue load. For example, at least part of the duct may form at least part of a catenary column. The method can be performed as part of a method for launching a duct into the ocean. The duct can be a submerged or submarine duct.
    The tubes can be welded together with the tube axes being approximately horizontal. For example, the placement of the method may be an S-launch method. The pipes may be welded together with the pipe axes being more vertical than horizontal. For example, the placement method may be a J-throwing method. The orientation of the pipes need not materially affect the extent to which the inner weld may be refluxed or redefined.
    The present invention also provides according to a second aspect of the invention a welding station for use in a method for launching a transport duct. The welding station may include an outer welding apparatus and an inner guide apparatus. The inner guide apparatus and the outer welding apparatus are preferably arranged for simultaneous operation. The outer welding apparatus may include a plurality of welding heads and an external guide apparatus, each head having at least one welding torch, the welding heads being arranged to simultaneously weld the pipe sections together from the outside of the welding sections. pipe to form a welding joint and be guided along the joint to be welded at least partially by the outer guide apparatus. The inner guiding apparatus may include an inner alignment clamp holding an inner guiding apparatus and at least one welding head, the welding head being arranged to reflow a welding joint formed by the outer welding apparatus and being guided along the joint by the internal guiding apparatus. The internal alignment clamp can also hold non-destructive test equipment (NDT), including, for example, one or more electronic cameras, to perform NDT on the root weld inside the tube sections. The internal alignment clamp may include integrated plasma welding equipment to perform the internal welding. The welding station may include an inner alignment clamp and inner guide apparatus disposed separately from the inner alignment clamp. For example, the inner guide apparatus may be provided in a cart that moves independently of the inner alignment clamp. The inner guiding apparatus may be arranged to define a central open region to accommodate an umbilical or work axis. In this case, an existing installation of a welding station having an internal alignment clamp and umbilical assembly and an external welding apparatus may be readily modified to carry out the method of the present invention by mounting an internal welding apparatus on the internal alignment clamp. of the existing installation, for example, in front of the internal alignment clamp.
    The welding heads of the outer welding apparatus may be consumable electrode welding heads (such as GMAW welding heads). The welding head of the inner guide apparatus may be a non-consumable electrode welding head. The inner guide apparatus may comprise a GTAW welding equipment. The inner guide apparatus may comprise plasma welding equipment. The inner guide apparatus may comprise one or more GTAW and / or plasma welding heads.
    The present invention also provides according to a third aspect of the invention, a transport duct launch container including a plurality of welding stations arranged in series in the duct placement direction, wherein at least one of the Welding stations is a welding station according to the present invention.
    Of course, it will be appreciated that the features described with respect to one aspect of the present invention may be incorporated into other aspects of the present invention. For example, the method of the invention may incorporate any of the features described with reference to the apparatus of the invention and vice versa. DESCRIPTION OF THE DRAWINGS An embodiment of the present invention will now be described by way of example only with reference to the accompanying schematic drawings which: Figure 1a is a longitudinal cross-sectional view of two LRC casing tubes which have been welded. together according to conventional techniques;
    Fig. 1b is a cross-sectional view of the pipes shown in Fig. 1a along the lines B-B in Fig. 1a;
    Fig. 2 is a longitudinal cross-sectional view of a welding joint between two pipes which have been welded together according to conventional techniques;
    Figures 3a to 3c are longitudinal cross-sectional views of the ends of the LRC-coated chamfered pipe sections to be welded by a method according to the embodiment of the invention;
    Figures 4a and 4b show two tubes being welded together according to the embodiment of the invention;
    Figures 5a to 5c are photographs showing the sections of a first pipe joint including sections showing the welding during and after the execution of the welding method of the embodiment;
    Figures 6a to 6c are photographs, similar to those of Figures 5a to 5c, but showing the sections of a second pipe joint; and Figures 7a to 7c are photographs, similar to those of Figures 5a to 5c, but showing the sections of a third pipe joint.
    Detailed Description The presently described embodiment of the invention relates to the butt-weld joining of corrosion resistant alloy (LRC) coated pipe sections during a method of launching an undersea transport duct. from a floating ferry or ship. The pipe is discharged into the sea from the ship by welding successive pipe sections at the pipe end. When throwing a duct, the stress on the duct being thrown is significant and is typical of several hundred kilo-Newtons. During launch and subsequent use of the duct, joints may be subject to fatigue loading.
    Thus, it is of particular importance to ensure that the joints between the pipe sections constituting the duct are of high quality. Failure of any joint in the pipeline after the joint has been lowered from the ship into the water can be both dangerous and extremely expensive.
    [0044] Figure 1a shows two sections of tube 2, in longitudinal cross section. There is a first pipe section 2a connected to a second pipe section 2b by means of a solder 4. The pipe sections are carbon steel pipes internally lined with corrosion resistant alloy (LRC) 6 (Figure 1b), which in this case in the form of a nickel alloy, but could also be austenitic stainless steel or other LRC materials. Solder 4 is in the form of a girth weld and is illustrated in more detail by the section shown in Figure 2. Solder 4 is formed by one or more welding torches depositing the separate layers of material. welding in the region between the two pipes 2a, 2b. In Figure 2, the various layers of the welding joint after welding are shown. The weld joint comprises a root zone 4r, two hot pass zones 4h1, 4h2, five filler zones 4f1 to 4f5, and a weld cap zone 4c. Figure 2 is a schematic representation of the various zones, which may not be readily discernible in the final weld, but as a gross indication of scale, each filler zone 4f has a depth that is typically on the order of 0.5 to 3. mm
    An embodiment of the present invention regarding a method for forming an oil pipeline in the form of an LRC liner pipeline will now be described with reference to Figures 3a to 7c.
    [0046] The transport duct is launched by welding new pipe sections at the end of the duct, which is attached to a transport duct launch vessel (raft or ship). The pipes are chamfered before joining to create a gap between the pipes 2a, 2b. A tube section 2a is defined by the end of the duct being launched. The other pipe section 2b is a new pipe section being added to the end of the duct to increase its length. Different forms of chamfering are well known in the art. The chamfer shape used in the present embodiment is one where the sides of the weld joint are formed, defined by the opposite ends of the pipes, which are very parallel to most of the depth of the weld joint. A schematic illustration of a typical chamfering shape (before welding) is shown in figure 3a. An alternative geometry is shown in figure 3b, which will be described later. The exact choice of parameters for chamfer dimensions depends on many factors. In this particular embodiment (based on the geometry of Figure 3a), the notch in the inner surface of the pipes (the notch in the LRC material 6) is absent, or too small, so that there is no gap that needs to be filled in the inner surface of the pipes. tubes. The parameters defining the shape of the chamfer for the first embodiment (using a pipe 2 having a wall thickness of approximately 20mm including a 3mm layer of LRC 6 material) are then as follows: A = 4mm; B = 3.5 mm; C = 3.5mm; D <0.1mm; G = 3 °; R 1 = 3.5 mm.
    Pipe sections 2a, 2b, once chamfered, are arranged end to end thus defining a circumferential joint 8 to be welded. For example, the chamfer geometry shown in figure 3a defines a joint 8 to be welded as shown schematically in figure 3c.
    The formation of high quality 4r root weld is of critical importance. A first welding station is provided to form the root weld between the pipe sections 2a, 2b. The tubes are aligned and secured in place by an internal alignment clamp (not shown). The welding station includes an outer welding apparatus including two GMAW (MIG) external welding heads arranged 180 degrees apart around the pipe sections (ie on opposite sides of the pipes 2). Only one external welding head 10 is shown in figures 4a, 4b. The welding heads 10 are mounted on an external guide apparatus clamped to the outside of the pipes in a manner well known in the art (such as a bug-on-band system). In use, the heads 10 are guided partly along the joint 8 to be welded by the outer guide apparatus, which includes a chamfer tracking system (although in other embodiments, a welding operator may assist in tracing and tracing). beveling). Each outer welding head 10 has a welding torch (but in other embodiments, each head may have two or more torches), in the form of a consumable electrode torch using filler wire. The outer welding heads 10 are arranged to simultaneously weld the pipe sections together from the outside of the pipe sections to form a welding joint 4. Since the weld is formed around the circumference of the pipes, the welding process is typically known as girth welding.
    In the first welding station, an interior guide apparatus is also provided. The inner guiding apparatus includes the above-mentioned ILUC (inner alignment clip - not shown in figures 4a, 4b) which holds the tubes in place. The ILUC also holds an inner guide apparatus (not shown in figure 4) and a single inner welding head 12. Inner welding head 12 carries a single GTAW Gas Tungsten Arc Welding (TIG) welding torch, using a non-consumable tungsten electrode. The GTAW internal welding head is designed to operate under inert gas protection, typically a mixture including argon. In use, the inner welding head 12 is partially guided along the joint to be welded by the inner guide apparatus and partly by a welding operator. The welding operator can control the movement of the welding torch by the width of the chamfer (in the direction parallel to the pipe axis) by means of a control, while monitoring the welding position through an ILUC mounted camera system which which provides video feedback on a video monitor viewed by the operator.
    [0050] The method of the embodiment includes using the outer weld heads 10 to perform an outer weld pass on the root of the joint 8 to be welded, in which the weld material is deposited on the joint root, thus forming a root weld. 4r. Two separate external welding heads 10 are simultaneously used to deposit the welding material to the root at different circumferential positions around the pipes 2. Root welding 4r then cools and begins to solidify. While the outer heads 10 are used to fill the top layers (the hot pass zones 4h1, 4h2), the inner welding head 12 is used to perform an internal solder pass on the 4r root weld. . The internal welding torch on the welding head travels at 25 cm / min and operates at 150A. This inner weld pass fuses the root weld deposited by the outer welder without using any additional filler material. Root weld 4r will typically be refluxed as weld 4r will be solidified, or at least partially solidified. The inner weld pass fuses the root weld and surrounding material to a depth of approximately 1.5-2 mm. The resulting cord has a width of approximately 8-10 mm. This makes it relatively tolerant to variations in its lateral position, and makes it relatively easy for the welding operator to guide the internal welding apparatus with sufficient precision.
    [0051] Figure 4a represents the performance of the external soldering pass, where Figure 4b represents the performance of an internal soldering pass.
    Changing the shape of the 4r root weld has several potential benefits and can improve the quality of the root weld. The quality of the root weld formed by an external welding process may be adversely affected by factors such as: [0053] · Hi-welding being very high (misalignment between pipe walls resulting from different shapes than pipe sections and / or pipe shaft misalignment), affecting structural integrity;
    · Lack of penetration of the root weld, affecting structural integrity;
    · Excessive penetration of root weld, making the weld more susceptible to corrosion; and [0056] · Root weld concavity, rough weld shape and / or minor weld defects, making the weld more susceptible to corrosion and / or affecting structural integrity.
    A hi-lo mismatch can produce a step between adjacent pipe sections, which may lead to stress concentration during fatigue loading and thus potentially affect the mechanics and structural integrity of the weld joint. . An internal weld pass that melts and smooths the weld in the one-step region can then affect improved weld quality and structural strength.
    If the outer weld pass produces a root weld that is not completely fused to the pipes, the lack of melting is likely to be close to the inner surface of the pipes. The inner weld pass can then reflow the root weld so that it is better fused to the pipes. It should be noted that the reflux of the 4r root weld does not adversely affect the mechanical properties of the root weld.
    If an outer weld pass produces a roughly shaped root weld, for example having bulges or concavities, or a large protrusion inside the tube, the step of performing the inner weld pass on the root weld smooths out. and smooths the shape of the root weld, making it less susceptible to corrosion. Minor weld defects such as small cracks or near the inner surface of the pipes can be removed by refluxing the weld.
    [0060] Some of the factors described above that affect weld quality and acceptability and the solutions provided by the present embodiment will now be described with reference to Figures 5a to 7c. Figure 5a is a photograph of the inner surface showing the progression of an inner weld (left to right). Figure 5b shows a cross section (by the surface BB indicated in figure 5a) of the pipes 2a, 2b in the root weld region 4r that has not yet been subjected to the inner weld pass and Figure 5c shows a cross section (by the indicated surface DC Figure 5a) of pipes 2a, 2b in the region of root weld 4r which has not yet been subjected to the internal weld pass. The cross section of figure 5b shows that there is a hi-lo of approximately 3mm. After the internal GTAW pass the weld bead 4i on the inner surface changes the shape of the weld 4 so that the hi-pitch is changed in a gradual incline.
    [0061] Figure 6a is a photograph of the inner surface showing the progression of an inner weld (left to right) on a different pair of pipe sections 2a, 2b. Figure 6b shows a cross section (through the surface BB indicated in figure 6a) of the pipes 2a, 2b in the root weld region 4r which is not yet subjected to the internal welding pass and Figure 6c shows a cross section (through the indicated surface DC 6a) of pipes 2a, 2b in the region of root weld 4r which has not yet been subjected to the internal weld pass. The cross-section of figure 6b shows that there is a lack of penetration of the LRC layer 6 by the outer weld 4e formed by the outer pass, such absence of penetration, for example, being due to a high root surface. After the GTAW inner pass, the weld 4i on the inner surface fuses the LRC layer 6 and the outer weld 4e so that the weld 4 penetrates completely.
    Figures 7a to 7c are photographs showing the inner surface and root weld 4r before and after the internal TIG pass in the presence of a 3 mm loop and irregular and excessive penetration of the welding material. The cross-section of figure 7b (taken from surface B-B shown in figure 7a) shows that there is a loop of approximately 3 mm and a bump of welding material with a very rough profile and sharp edges. Especially as the right pipe section 2b is related, there is an excessive amount of welding material penetration. As shown in Fig. 7c (showing a cross section through the CC surface indicated in Fig. 7a), after the GTAW inner pass, the weld bead 4i on the inner surface changes the shape of the weld 4 so that the step of it. be changed at a gradual slope and the bulge and rough shape of the weld be smoothed.
    Thus, the shape of the root weld can be significantly improved to result in improved fatigue performance, increase the chance of complete root weld fusion, and reduce the presence of pipe joint defects.
    After the internal weld pass is completed, the root weld solidifies again. The internal welding step may include making one, two or even three passes with the internal welding apparatus. After the internal weld passes in the root weld are completed, the non-destructive test (NDT) is performed at the first welding station. NDT tests include inspecting the root weld with ultrasonic sensors and performing a visual inspection of the interior of the tubes using the ILUC mounted camera system. If a weld defect is detected, the defect can be one that can be repaired by simply performing one or more internal weld passes, and using GTAW to reflow the root weld. In contrast to normal weld passes made during the method of this embodiment of the invention, one or more internal weld passes used to repair the root weld may include adding weld filler material.
    Following NDT operations, and repair processes if deemed necessary, in the first station, the pipe sections are then moved to subsequent welding stations where even more external welding passes are performed including the end butt welding.
    The method and apparatus of the embodiment described above have many advantageous features: The first external pass can be deposited much faster with two heads being used simultaneously and high travel speeds. This is possible because consistently the full penetration range with this outer cord is not required as complete fusion can be achieved internally by the GTAW passage.
    [0068] · Significantly reduced welding cycle time periods and increased productivity.
    · High assurance of full bead fusion and full penetration is achieved by reflowing the inner 1.5 to 2 mm of the inner surface by GTAW torches.
    · The inner bead profile is extremely flat and great for corrosion and / or fatigue resistant properties.
    [0071] · Redefinition of the inner bead shape can be achieved in all welding positions, regardless of pipe orientation.
    · The technique has a high tolerance for variations in pipe fit. Less time is required to fit the pipes in the first station. Pipe tolerances also become less critical in the process of purchasing coated pipes, as the pipes can be joined with sufficient weld quality with up to 3 mm hi-values, which could allow for cost savings on these items.
    · The GTAW process used in an internal soldering pass is relatively simple, requires no filler wire, and has high reliability.
    · Prior art techniques for welding coated pipe required the chamfer to be relatively wide to achieve full penetration of the first outer pass. Because the range of full penetration externally is not critical when an internal GTAW pass is subsequently applied, the entire width of the chamfer may be reduced. This has the benefit of reducing the number of filling passes. It also has the potential to reduce the defect rate in the fill passes, as there is a greater tendency for lack of fusion defects to be produced at higher passes with the increased wobble widths required for wider chamfers.
    The use of GTAW internally allows a degree of root cord repair in the rejection event as the cord may be refluxed by another pass. In the prior art, there was no option to repair the root bead rejection event and consequently the entire weld is typically trimmed.
    · Since a root pass is reflowing, there is no need to purge the weld area before the outer weld pass. GTAW's internal process results in a final weld bead surface with low oxidation and improved corrosion properties.
    The apparatus can certainly also be used with different chamfering geometries. The chamfer geometry can be adapted as appropriate. Factors that should be generated in mind include: 1) the root surface may need to be thick enough to support the first outer weld if copper supports are not used; 2) Dimension C should be thicker than the coating layer to reduce the LRC material wrapped during welding of the first outer pass; 3) it may be necessary to provide an inner groove for the inner welder and use filler material in the inner pass, where the dimension D and angle E will need to be sized to allow the TIG arc to fully reach the groove, but Not too large to avoid depositing excessive amount of filler metal.
    The apparatus of the embodiment described above may be used in a chamfer geometry as shown in Figure 3b. The chamfer shown in figure 3b can be defined by a set of parameters as follows: A = 3.2 mm; B = 2.3 mm; C = 3.8 mm; D = 4.0 mm; E = 15 ° G = 3 ° R 1 = 3.2 mm; and R2 = 2.4 mm. It will be appreciated that such parameters require the use of filler material in an internal weld pass to connect the groove formed between the pipe sections 3a, 3b on the inner surface of the pipes. The choice of chamfer dimensions and the manner in which internal and external welding is performed needs careful consideration when performing heterogeneous welding between AC and LRC materials, especially in view of the possible negative consequences on metallurgy of the resulting weld joint. For example, high Ni alloys are generally subject to hot cracking due to: 1) wide range of solidification gap, aggravation by dilution with different materials (such as carbon steel); 2) presence of impurities (S, P, low melt metalloid) in the welding area; and 3) dilution, decrease in Ni percentage in the 30% -50% range results in high probability of hot cracking. It is believed that in practice it will be permissible (in terms of structural integrity risk) to weld an AC-based material with LRC filler, but not vice versa. In either case, there are benefits in reducing the amount of dilution of LRC material to not impair the anti-corrosion properties of LRC material. In the present embodiments, the chamfer geometry allows external welding to be performed on the AC-based material using the AC filler wire, and allows the internal welding to be subsequently performed on the LRC-based material using a filler wire suitable (for example, "Inconel" yarn, an austenitic nickel-chrome based super alloy made by Special Metals Corporation of New York, USA).
    It should be noted that the choice of chamfer may also affect the interaction between the inner and outer arcs (GTAW and GMAW) and such arcs are used simultaneously and cross the same position at the same time. The arcs can interact by means of the magnetic field related to one torch, disturbing and causing deviation in the other (magnetic blowing effect). Simultaneous use of the inner and outer arcs in the same position would overheat the material being soldered potentially leading to burning, which could damage one or both torches and / or produce an unacceptable defect. However, a weld deposition layer provided sufficient protection against unwanted effects as a result of the simultaneous use of the inner and outer arches.
    While the present invention has been described and illustrated with reference to particular embodiments, it will be appreciated by the person skilled in the art that the invention provides for many different variations not specifically illustrated herein. By way of example only, certain possible variations will now be described.
    The apparatus of the embodiment described above may be used to weld standard (uncoated) steel pipes. The embodiments are, for example, applicable to carbon steel catenary conductors which are highly sensitive to fatigue.
    The internal weld pass for controlling the shape of the root weld can be performed anywhere between depositing the external root pass for complete completion of all external weld passes. There is no need for an internal soldering pass to be performed at the first welding station.
    The internal welding means may, instead of comprising a GTAW gas tungsten arc welding (TIG) welding torch, comprise a plasma welding torch.
    There may be many developments that could be made to improve efficiency and reliability, which are outlined below: · Evaluation of PAW (or plasma MIG hybrid) technology for improved travel speed, penetration and durability of the electrode for an internal solder pass.
    [0086] · TIG hot wire process evaluation to improve filler deposit, if required for an internal weld pass.
    [0087] · Evaluation and study of special commercially available flows, which allow for increased penetration with the TIG process. This could help solve any problems due to the wettability of different materials during heterogeneous welding.
    · Evaluation of different gas mixture compositions with the addition of small amounts of H2, which should improve penetration and limit bead surface oxidation.
    Where in the foregoing description, integers or elements are mentioned which knew obvious and predicted equivalents, then such equivalents are incorporated herein as individually represented. Reference should be made to the claims to determine the true scope of the present invention which should be created to encompass such equivalents. It will also be appreciated by the reader that the integers or features of the invention which are described as preferred, advantageous, convenient or the like are optional and do not limit the scope of the independent claims. Furthermore, it should be understood that such integers or optional features, while the possible benefit in some embodiments of the invention, may not be desirable, and may therefore be absent in other embodiments.
    权利要求:
    Claims (18)
    [1]
    1. A method for launching an underwater transport duct, in which pipe sections (2a, 2b) are welded together to form a multilayer transport duct having a metal layer that is made of a different metal than the adjacent layer; wherein the method includes the steps of: providing a pipe section (2b) to be welded to the end (2a) of a transport duct; arranging the pipe section (2b) adjacent to the end (2a) of the pipeline, thereby defining a circumferential joint (8) to be welded; and performing an external weld pass on the root of the joint (8) to be welded, during which welding material is deposited on the root of the joint (8) to be welded, thereby forming a root weld (4r); characterized by the step of: performing an internal weld pass on the root weld (4r) by means of a plasma welding equipment during which the root weld (4r) is fused and takes on new shape.
    [2]
    2. Method for launching an undersea transport duct, in which pipe sections (2a, 2b) are welded together to form the duct, where the method includes the steps of: providing a pipe section (2b) to be welded to the pipe. end (2a) of a transport duct; and arranging the pipe section (2b) adjacent to the end (2a) of the pipeline, thereby defining a circumferential joint (8) to be welded; and performing an external weld pass on the root of the joint (8) to be welded, during which welding material is deposited on the root of the joint (8) to be welded, thereby forming a root weld (4r), whereby the Said outer weld pass is realized using a plurality of separate weld heads (10) which simultaneously deposit weld material at the root in different circumferential positions around the pipe sections (2a, 2b), characterized in that it performs a Internal weld pass into the root weld (4r) by means of plasma welding equipment during which the root weld (4r) is fused and takes on a new shape.
    [3]
    Method according to claim 2, characterized in that the transport duct is a multilayer duct having a metal layer which is made of a metal other than that of an adjacent layer.
    [4]
    Method according to claim 1 or 3, characterized in that: the transport duct is a carbon steel duct (6) having a corrosion resistant alloy interior; and taken together, the steps of (i) performing the outer weld pass at the joint root (8) and (ii) performing the inner weld pass at the joint root (8) include adding weld material of the same type carbon steel material in the duct and corrosion resistant alloy material (6) in the duct.
    [5]
    Method according to any one of claims 1 to 4, characterized in that the step of performing the external weld pass on the root weld (4r) is performed using a consumable electrode.
    [6]
    Method according to any one of the preceding claims, characterized in that: the step of performing the outer weld pass on the joint root produces a root weld (4r) which on the inner surface of the pipes is roughly shaped ; and the step of performing the inner weld pass on the root weld (4r) fuses the root weld back into a new shape so that on the inner surface of the pipes the root weld (4r) has a smoother shape .
    [7]
    Method according to any one of the preceding claims, characterized in that: the step of performing the outer weld pass on the joint root (8) produces a root weld (4r) that is not completely fused to the pipes. ; and the step of performing the inner weld pass on the root weld (4r) fuses the root weld (4r) again so that it becomes completely fused to the tubes.
    [8]
    Method according to any one of the preceding claims, characterized in that: the method includes a step of performing an external butt weld pass on the joint cover (8) to be welded, in which the welding material is deposited on the joint cover (8) to be welded, thus forming a butt weld (4c); and the step of performing the inner weld pass on the root weld (4r) is performed prior to the completion of the step of performing an outer butt weld pass.
    [9]
    Method according to any one of the preceding claims, characterized in that after the step of performing the internal weld pass on the root weld (4r), a non-destructive test (NDT) step is performed during which the quality of the root weld (4r) is inspected by means of one or more cameras within the pipe sections.
    [10]
    Method according to any one of the preceding claims, characterized in that the method includes performing a plurality of internal solder passes per solder joint.
    [11]
    Method according to any one of the preceding claims, characterized in that at least part of the duct forms at least part of an underwater catenary column.
    [12]
    Welding station for use in a method for launching an undersea transport duct, in which pipe sections (2a, 2b) are welded together to form the transport duct, comprising: outer welding apparatus including a plurality of spindle heads. welding (10) and external guide apparatus, each head (10) having at least one welding torch, the welding heads (10) being arranged to simultaneously weld the pipe sections (2a, 2b) together from the outside of the pipe sections (2a, 2b) to form a welding joint (8) and to be guided along the joint (8) to be welded at least partially by the outer guide apparatus; and an internal alignment clamp for holding the pipe sections (2a, 2b) aligned in place; characterized in that it further comprises: interior welding apparatus having at least one welding head (12) having a plasma welding torch, wherein the welding head is arranged to melt a welding joint formed by the welding apparatus. outer welding and be guided along the joint (8) by means of an inner guiding apparatus; wherein the outer welding apparatus is arranged to be able to operate simultaneously with the inner guiding apparatus.
    [13]
    Welding station according to claim 12, characterized in that the welding heads (10) of the outer welding apparatus are consumable electrode welding heads and the welding head (12) of the inner guide apparatus. It is a non-consumable electrode welding head.
    [14]
    Welding station according to any one of claims 12 to 13, characterized in that the inner alignment clamp includes an umbilical assembly, and the inner welding apparatus defines an open central region accommodating the umbilical assembly.
    [15]
    Welding station according to any one of claims 12 to 14, characterized in that the internal alignment clamp holds the inner guide apparatus.
    [16]
    Welding station according to any one of claims 12 to 15, characterized in that the inner welding apparatus is arranged on a moving carriage independently of the internal alignment clamp.
    [17]
    Welding station according to any one of claims 12 to 16, characterized in that the internal alignment clamp also holds the non-destructive test equipment (NDT) for performing the NDT on the root weld (4r) to from the inside of the pipe sections.
    [18]
    18. Transport pipeline launch vessel, characterized in that it includes a plurality of welding stations arranged in series in the direction of pipeline placement, wherein at least one of the welding stations is a welding station as defined in any one. claims 12 to 17.
    类似技术:
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    同族专利:
    公开号 | 公开日
    RU2588930C2|2016-07-10|
    CA2782165A1|2011-06-09|
    EP3213851A1|2017-09-06|
    MY158738A|2016-11-15|
    GB0921078D0|2010-01-13|
    US9339886B2|2016-05-17|
    EP2507006B1|2018-04-11|
    IN2012DN04994A|2015-10-02|
    US20120298628A1|2012-11-29|
    CA2782165C|2018-03-27|
    EP2507006A1|2012-10-10|
    CN102639274A|2012-08-15|
    CN102639274B|2015-11-25|
    BR112012013161A2|2016-03-01|
    AU2010326379A1|2012-06-28|
    WO2011067589A1|2011-06-09|
    RU2012127437A|2014-01-10|
    AU2010326379B2|2015-05-14|
    EP3213851B1|2021-04-14|
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    法律状态:
    2017-10-17| B07A| Technical examination (opinion): publication of technical examination (opinion)|
    2018-04-17| B09A| Decision: intention to grant|
    2018-05-15| B16A| Patent or certificate of addition of invention granted|
    优先权:
    申请号 | 申请日 | 专利标题
    GB0921078.2|2009-12-01|
    GBGB0921078.2A|GB0921078D0|2009-12-01|2009-12-01|Pipeline welding method and apparatus|
    PCT/GB2010/051995|WO2011067589A1|2009-12-01|2010-11-30|A method of and a welding station for laying a pipeline, with pipe section welded together by internal and external welding|
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