长输管道自动焊接工艺研究
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摘要
本文以国产PAW-2000焊机为对象,分析研究了熔化极混合气体(Ar+CO2)的比例对焊接工艺的影响,其中随着CO2比例的增加,熔深在平焊位、立焊位、仰焊位也在相应增加,并且保护气体比例相同时,熔深H_(立焊)>H_(平焊)>H_(仰焊)。
研究了PAW-2000主要参数的匹配规律,形成一套用于指导焊接工艺参数的调节、提高焊接一次合格率的理论计算公式;送丝速度VS = KVh,K为速度比系数并且速度比系数K与焊丝直径D~2成反比、与每层熔敷金属的横截面积S成正比。并确定了送丝速度与焊接速度参数的调节原则。
通过对管道自动焊产生主要缺陷的分析,提出防止的有效措施。对射线检测(RT)和全自动超声波检测(AUT)结果进行对比分析,提出了针对管道自动焊焊缝的最佳检测方法。
通过对常温和低温环境下管道自动焊三种焊接工艺的接头力学性能、冲击韧性、硬度、金相对比,以及在哈萨克斯坦扎那若耳-K13管道的现场实际焊接情况证实,环境温度-30℃,预热温度120℃,层间温度大于100℃,预热范围300mm条件下的管道自动焊焊接接头的性能完全可以满足规范所要求的指标。
The PAW-2000 welding machine is as research object in this paper, the influence of mix-gas (Ar+CO2) proportion to welding process was studied. With the increase of CO2 proportion, the fusion depth in horizontal position, Vertical position, and position also increases. When the proportion of field gas is similar, the fusion depth H_(Vertical)>H_(horizontal)>H_(overhead).
The parameters matching rule of PAW-2000 was studied, a suit of theory formula of increase eligibility ratio formed, the wire speed VS = KVh, the K is speed ratio . The speed ratio K is inverse ratio to the wire diameter, and direct ratio to each fusion metal cross section S. Wire speed and welding speed parameters adjust principle was confirmed.
The defects of pipeline auto-welding was analyzed, and put forward the prevent method measurement. The result of radial test and auto-ultrasonic test was contrast and analyzed, and put forward the prime test method of pipeline auto-welding joints.
Contrast by the normal temperature and low temperature environment three auto-welding process, analyzed the mechanics properties, impact tenacity, hardness, metallo-graphy. When the environment temperature -30℃, pre-heat temperature 120℃, inter-pass temperature than 100℃, and the pre-heat range 300mm, the pipeline auto-welding joints properties contents the request, the welding process is good.
研究了PAW-2000主要参数的匹配规律,形成一套用于指导焊接工艺参数的调节、提高焊接一次合格率的理论计算公式;送丝速度VS = KVh,K为速度比系数并且速度比系数K与焊丝直径D~2成反比、与每层熔敷金属的横截面积S成正比。并确定了送丝速度与焊接速度参数的调节原则。
通过对管道自动焊产生主要缺陷的分析,提出防止的有效措施。对射线检测(RT)和全自动超声波检测(AUT)结果进行对比分析,提出了针对管道自动焊焊缝的最佳检测方法。
通过对常温和低温环境下管道自动焊三种焊接工艺的接头力学性能、冲击韧性、硬度、金相对比,以及在哈萨克斯坦扎那若耳-K13管道的现场实际焊接情况证实,环境温度-30℃,预热温度120℃,层间温度大于100℃,预热范围300mm条件下的管道自动焊焊接接头的性能完全可以满足规范所要求的指标。
The PAW-2000 welding machine is as research object in this paper, the influence of mix-gas (Ar+CO2) proportion to welding process was studied. With the increase of CO2 proportion, the fusion depth in horizontal position, Vertical position, and position also increases. When the proportion of field gas is similar, the fusion depth H_(Vertical)>H_(horizontal)>H_(overhead).
The parameters matching rule of PAW-2000 was studied, a suit of theory formula of increase eligibility ratio formed, the wire speed VS = KVh, the K is speed ratio . The speed ratio K is inverse ratio to the wire diameter, and direct ratio to each fusion metal cross section S. Wire speed and welding speed parameters adjust principle was confirmed.
The defects of pipeline auto-welding was analyzed, and put forward the prevent method measurement. The result of radial test and auto-ultrasonic test was contrast and analyzed, and put forward the prime test method of pipeline auto-welding joints.
Contrast by the normal temperature and low temperature environment three auto-welding process, analyzed the mechanics properties, impact tenacity, hardness, metallo-graphy. When the environment temperature -30℃, pre-heat temperature 120℃, inter-pass temperature than 100℃, and the pre-heat range 300mm, the pipeline auto-welding joints properties contents the request, the welding process is good.
引文
[1]高惠临等,论管线钢韧性的控制因素,焊管,1995,18(5):6-50
[2]张文钺,焊接物理冶金,天津:天津大学出版社,1991
[3]雷胜利等,螺旋缝埋弧焊钢管焊缝韧性的研究,焊管,1994,17(30):41-47
[4]尹士科等,焊接接头性能调控与应用,北京:兵器工业出版社,1993
[5]石凯等,螺旋管双面埋弧焊焊接热循环的测定,焊管,1995,18(6):13-18
[6]罗志昌,X80与X100级管线钢的焊接性,焊管,1990,13(1):3-9
[7]钱百年等,管线钢的局部脆化研究,焊管,1993,6(6):8-12
[8]李钟麟等,低合金钢焊缝金属韧化研究,焊接学报,1987,8(2):83-86
[9]陈伯,高强钢埋弧焊焊缝的强韧化研究,焊接学报,1987,8(3):153-161
[10]陈茂爱等,冷却时间对微合金钢焊接粗晶区组织及性能的影响,金属学报,1998,34(3):263-270
[11]肖纪美,应力作用下的金属腐蚀,化学工业出版社,1990
[12]高惠临,管线钢,陕西科学技术出版社,1991
[13]对于发展我国天然气储运技术项目建议,四川石油管理局,1999
[14]油气田腐蚀(上)与防护技术手册,四川石油管理局,1999
[15]彭祖铭,中国腐蚀与放扩学报,1982,5(2):34-40
[16]翁永基,油气储运,1986,5(1)
[17]肖纪美,金属材料的腐蚀问题——腐蚀金属学,中国工业出版社,1962.
[18]王燕斌等,氢致解理断裂机理,中国科学,1989,A1065-1073.
[19]肖纪美,断裂化学中的若干重要问题,第六届全国断裂学术会议论文集,1991:738-746
[20]肖纪美等,材料的失效分析,性能预测和结构设计,新材料研究,1998:l-10 [2 1]A.Ikeda et al,Influence of Environmental Condition and Metallurgical Factors on Hydrogen induced Cracking of Line Pipe Steel,Nace Conference corrosion 80,Paper Number 8.
[22]T.tiara etal,Resistance of Line Pipe Steel to Wet Sour Gas.V01.40,No.7,1984
[23]American Petroleum Institution,API 11 04,Welding of Pipelines and Related Facilities,American.1999
[24]NACE TM0177,Laboratory Testing of Metals for Resistance to Sulfide Stress Cracking and Stress Corrosion Cracking in H2S Environments,American.1996
[251ASTM G39,Standard Practice for Preparation and Use of Bent-Beam Stress-Corrosion Test Specimens,American.1996
[26]NACE TM 0284,Evaluation of Pipeline&Pressure Vessel Steels for Resistance to Hydrogen,Induced Cracking,American.1996
[27]British standard Institution,BS 4515,Process of Welding Steel Pipelines on Land and Offshore,British.1995
[28]SY4103,钢质管道及相关设施焊接,石油天然气总公司,1995
[29]Q/BT 004-93,输气管道线路工程环焊现场焊接及其验收规范,北京集输公司,1993
[30]四川石油管理局,Q/CY 428,H2S环境中金属抗硫化物应力破裂弯梁试验方法,四川石油管理局,1997
[31]冯斌等,我国油气管道钢生产技术水平现状与发展方向,中国石油天然气管道局2001优秀论文集,管道局,2001,35-46
[32]管线钢管,宝鸡:石油天然气总公司焊接钢管研究所,1995,6-72
[33]于英姿,输气管道硫化物应力腐蚀分析,焊管,2000,22(5):6-9
[34]高压天然气管线断裂性能评估,天然气管道建设论文集,2000
[35]吕向阳等,非金属夹杂物对焊接氢致裂纹敏感性影响及机理研究,第六界焊接年会论文集,西安,1990
[36]陈楚等,低合金高强度钢模拟中氢致裂纹行为的研究,第五界全国焊接学术会议论文集,哈尔滨,1986
[38]张文钺等,焊接冶金与金属焊接性,北京:机械工业出版社,1988
[39]佐藤邦彦,焊接接头的强度设计,北京:机械工业出版社,1983
[40]郑文龙,钢的环境敏感断裂,化学工业出版社,1988
[41]潘家华,油气管道断裂力学分析,石油工业出版社,1989
[42]李根全,石油天然气输送管线用焊管焊接性试验,石油天然气输送管线用焊管项目技术资料之八,中国石油天然气总公司,1998.375-400
[43]王茂堂,高韧性钢管研制现场低温环焊研究,石油天然气输送管线用焊管项目技术资料之八,中国石油天然气总公司,1998.756-779
[44]张相权等,管线钢冷裂纹和再热裂纹敏感性评定,石油天然气输送管线用焊管项目技术资料之六,中国石油天然气总公司,1998.811-82l
[45]康志新,蒋雪华等,X60、X65管线钢的机械性能评定,石油天然气输送管线用焊管项目技术资料之六,中国石油天然气总公司,1998.837-842
[46]Nobvtaka yufioka,An analysis of effects of micro—structure,strain and stress on the hydrogen accumufation in the weld heat-affected zone,1990
[47]NACE Standard mr0175,Sulfide Stress Cracking Resistant Metallic Materials for oilfield Equipment,American,1995
[48]A.BROWN and C.L.JDNES,Hydrogen Induced Cracking in Pipeline Steels,Corrosion,V01.40(7)
[49]American Welding Society,AWS A5.1,Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding,American,1991
[50]American Welding Society,AWS A5.5,Specification for Low alloy Steel Electrodes for Shielded Metal Arc Welding,American,1991
[2]张文钺,焊接物理冶金,天津:天津大学出版社,1991
[3]雷胜利等,螺旋缝埋弧焊钢管焊缝韧性的研究,焊管,1994,17(30):41-47
[4]尹士科等,焊接接头性能调控与应用,北京:兵器工业出版社,1993
[5]石凯等,螺旋管双面埋弧焊焊接热循环的测定,焊管,1995,18(6):13-18
[6]罗志昌,X80与X100级管线钢的焊接性,焊管,1990,13(1):3-9
[7]钱百年等,管线钢的局部脆化研究,焊管,1993,6(6):8-12
[8]李钟麟等,低合金钢焊缝金属韧化研究,焊接学报,1987,8(2):83-86
[9]陈伯,高强钢埋弧焊焊缝的强韧化研究,焊接学报,1987,8(3):153-161
[10]陈茂爱等,冷却时间对微合金钢焊接粗晶区组织及性能的影响,金属学报,1998,34(3):263-270
[11]肖纪美,应力作用下的金属腐蚀,化学工业出版社,1990
[12]高惠临,管线钢,陕西科学技术出版社,1991
[13]对于发展我国天然气储运技术项目建议,四川石油管理局,1999
[14]油气田腐蚀(上)与防护技术手册,四川石油管理局,1999
[15]彭祖铭,中国腐蚀与放扩学报,1982,5(2):34-40
[16]翁永基,油气储运,1986,5(1)
[17]肖纪美,金属材料的腐蚀问题——腐蚀金属学,中国工业出版社,1962.
[18]王燕斌等,氢致解理断裂机理,中国科学,1989,A1065-1073.
[19]肖纪美,断裂化学中的若干重要问题,第六届全国断裂学术会议论文集,1991:738-746
[20]肖纪美等,材料的失效分析,性能预测和结构设计,新材料研究,1998:l-10 [2 1]A.Ikeda et al,Influence of Environmental Condition and Metallurgical Factors on Hydrogen induced Cracking of Line Pipe Steel,Nace Conference corrosion 80,Paper Number 8.
[22]T.tiara etal,Resistance of Line Pipe Steel to Wet Sour Gas.V01.40,No.7,1984
[23]American Petroleum Institution,API 11 04,Welding of Pipelines and Related Facilities,American.1999
[24]NACE TM0177,Laboratory Testing of Metals for Resistance to Sulfide Stress Cracking and Stress Corrosion Cracking in H2S Environments,American.1996
[251ASTM G39,Standard Practice for Preparation and Use of Bent-Beam Stress-Corrosion Test Specimens,American.1996
[26]NACE TM 0284,Evaluation of Pipeline&Pressure Vessel Steels for Resistance to Hydrogen,Induced Cracking,American.1996
[27]British standard Institution,BS 4515,Process of Welding Steel Pipelines on Land and Offshore,British.1995
[28]SY4103,钢质管道及相关设施焊接,石油天然气总公司,1995
[29]Q/BT 004-93,输气管道线路工程环焊现场焊接及其验收规范,北京集输公司,1993
[30]四川石油管理局,Q/CY 428,H2S环境中金属抗硫化物应力破裂弯梁试验方法,四川石油管理局,1997
[31]冯斌等,我国油气管道钢生产技术水平现状与发展方向,中国石油天然气管道局2001优秀论文集,管道局,2001,35-46
[32]管线钢管,宝鸡:石油天然气总公司焊接钢管研究所,1995,6-72
[33]于英姿,输气管道硫化物应力腐蚀分析,焊管,2000,22(5):6-9
[34]高压天然气管线断裂性能评估,天然气管道建设论文集,2000
[35]吕向阳等,非金属夹杂物对焊接氢致裂纹敏感性影响及机理研究,第六界焊接年会论文集,西安,1990
[36]陈楚等,低合金高强度钢模拟中氢致裂纹行为的研究,第五界全国焊接学术会议论文集,哈尔滨,1986
[38]张文钺等,焊接冶金与金属焊接性,北京:机械工业出版社,1988
[39]佐藤邦彦,焊接接头的强度设计,北京:机械工业出版社,1983
[40]郑文龙,钢的环境敏感断裂,化学工业出版社,1988
[41]潘家华,油气管道断裂力学分析,石油工业出版社,1989
[42]李根全,石油天然气输送管线用焊管焊接性试验,石油天然气输送管线用焊管项目技术资料之八,中国石油天然气总公司,1998.375-400
[43]王茂堂,高韧性钢管研制现场低温环焊研究,石油天然气输送管线用焊管项目技术资料之八,中国石油天然气总公司,1998.756-779
[44]张相权等,管线钢冷裂纹和再热裂纹敏感性评定,石油天然气输送管线用焊管项目技术资料之六,中国石油天然气总公司,1998.811-82l
[45]康志新,蒋雪华等,X60、X65管线钢的机械性能评定,石油天然气输送管线用焊管项目技术资料之六,中国石油天然气总公司,1998.837-842
[46]Nobvtaka yufioka,An analysis of effects of micro—structure,strain and stress on the hydrogen accumufation in the weld heat-affected zone,1990
[47]NACE Standard mr0175,Sulfide Stress Cracking Resistant Metallic Materials for oilfield Equipment,American,1995
[48]A.BROWN and C.L.JDNES,Hydrogen Induced Cracking in Pipeline Steels,Corrosion,V01.40(7)
[49]American Welding Society,AWS A5.1,Specification for Carbon Steel Electrodes for Shielded Metal Arc Welding,American,1991
[50]American Welding Society,AWS A5.5,Specification for Low alloy Steel Electrodes for Shielded Metal Arc Welding,American,1991