应对几何偏差的大口径厚壁海底管道CRC全自动焊接工艺创新与实践

Innovation and Practice in CRC Automatic Welding Process for Large-Diameter Thick-Wall Subsea Pipelines with Geometric Deviations

  • 摘要:   
      针对印度尼西亚拉维拉维单点系泊及陆上设施项目所包含13.9 km海底管道工程中52inch直径、25.4mm壁厚API 5L X65MO钢管焊接存在"管材几何偏差"重大难题,本研究开展了CRC全自动焊接技术的创新应用。项目所用钢管因JCO成型后未进行冷扩径工序,导致管口椭圆度与垂直度严重超标,传统焊接工艺面临组对错边与根焊质量风险。研究通过优化设计"U"型复合坡口、制定根焊参数动态微调策略、精细化控制热输入与摆动参数等措施,形成了一套包容管材偏差的适应性焊接工艺体系。工艺评定(PQR)结果表明,焊接接头力学性能优异,0°C各位置夏比冲击功均值大于169J。现场应用实现了一次合格率99.2%的高标准,焊接效率大约为传统手工电弧焊的15倍1。本研究为应对类似制管工艺缺陷的海洋管道工程提供了可靠的工艺解决方案与实践范例。

     

    Abstract:   
      In the Engineering, Procurement and Construction (EPC) of Lawe-Lawe Facilities RDMP RU-V Balikpapan project, the offshore section involving 13.9km of 52-inch diameter, 25.4mm wall thickness API 5L X65MO steel line pipes, a major challenge of "pipe geometric deviations" was encountered in the welding process. This study explores the innovative application of CRC automatic welding technology to address this issue. The steel line pipes, which did not undergo cold expansion after JCO forming, exhibited severe deviations in ovality and squareness, posing risks of misalignment and root weld quality issues with traditional welding methods. Through the optimized design of a "U"-type compound bevel, the formulation of a dynamic micro-adjustment strategy for root welding parameters, and precise control of heat input and oscillation parameters, an adaptive welding process system tolerant of pipe geometric deviations was developed. Procedure Qualification Record (PQR) results demonstrated excellent mechanical properties of the welded joints, with the average Charpy impact energy at 0°C in all positions exceeding 169J. Field application achieved a high first-pass qualification rate of 99.2%, with welding efficiency approximately 15 times that of traditional shielded metal arc welding 1. This study provides a reliable process solution and a practical reference for similar subsea pipeline projects affected by pipe manufacturing imperfections.

     

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