CN107782592B - Method and system for manufacturing circumferential weld crack defects - Google Patents
Method and system for manufacturing circumferential weld crack defects Download PDFInfo
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- CN107782592B CN107782592B CN201610764964.2A CN201610764964A CN107782592B CN 107782592 B CN107782592 B CN 107782592B CN 201610764964 A CN201610764964 A CN 201610764964A CN 107782592 B CN107782592 B CN 107782592B
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N1/00—Sampling; Preparing specimens for investigation
- G01N1/28—Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q
- G01N1/286—Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q involving mechanical work, e.g. chopping, disintegrating, compacting, homogenising
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N1/00—Sampling; Preparing specimens for investigation
- G01N1/28—Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q
- G01N1/286—Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q involving mechanical work, e.g. chopping, disintegrating, compacting, homogenising
- G01N2001/2873—Cutting or cleaving
Abstract
The invention discloses a method and a system for manufacturing a circumferential weld crack defect, and belongs to the technical field of oil and gas pipelines. The method comprises the following steps: clamping a metal plate containing a circumferential weld, wherein the metal plate is from a pipeline to be detected; controlling the metal plate to vibrate according to preset machining parameters to crack the metal plate, wherein the shape of a circumferential weld crack defect formed by the cracked metal plate is the same as the shape of a preset crack; welding the cracked metal plate to the pipeline. The invention solves the problem of poor reliability of the verification of the internal detection technology and the pipeline pressure evaluation, improves the reliability of the verification of the internal detection technology and the pipeline pressure evaluation, and is used for the detection and evaluation of the pipeline.
Description
Technical Field
The invention relates to the technical field of oil and gas pipelines, in particular to a method and a system for manufacturing circumferential weld crack defects.
Background
In the technical field of oil and gas pipelines, the defects of the pipelines can be detected through an internal detection technology, and the safety of the pipelines, namely the pressure of the pipelines, is evaluated. The pulling test of the girth weld crack defect pipeline is a basis for researching various internal detection technologies and verifying the internal detection technologies, and is also a basic means for completing calibration and verifying performance indexes of an internal detector in the internal detection technologies, and the processing and manufacturing of the girth weld crack defect meeting requirements on a pipe with a specific pipe diameter and a specific wall thickness is a key for successfully developing the pulling test, so that the girth weld crack defect needs to be manufactured.
In the prior art, a method for manufacturing a circumferential weld crack defect is provided, and the method is based on the processing of an electric spark mode to manufacture the circumferential weld crack defect. The method comprises the steps of firstly cutting a metal plate containing a circumferential weld from a pipeline, then processing and manufacturing the metal plate in an electric spark mode according to a preset target shape to obtain a circumferential weld crack defect with a more regular shape, and finally welding the metal plate back to the pipeline.
However, the shape of the crack actually generated in the pipeline is often irregular, so that the shape of the girth joint crack defect obtained by adopting the method is greatly different from the shape of the actual crack, and therefore, the reliability of the internal detection technology verification and the pipeline pressure evaluation is poor.
Disclosure of Invention
The invention provides a method and a system for manufacturing a circumferential weld crack defect, which aim to solve the problem of poor reliability of internal detection technology verification and pipeline pressure evaluation in the prior art. The technical scheme is as follows:
in a first aspect, a method for producing a circumferential weld crack defect is provided, the method comprising:
clamping a metal plate containing a circumferential weld, wherein the metal plate is from a pipeline to be detected;
controlling the metal plate to vibrate according to preset machining parameters to crack the metal plate, wherein the shape of a circumferential weld crack defect formed by the cracked metal plate is the same as the shape of a preset crack;
welding the cracked metal plate to the pipeline;
wherein the processing parameters comprise vibration frequency, vibration times, average load and alternating load,
the method for controlling the metal plate to vibrate according to the preset processing parameters to crack the metal plate comprises the following steps:
and applying a first acting force and a second acting force to the metal plate according to the processing parameters, so that the metal plate vibrates and cracks at the vibration frequency and the vibration times, wherein the load of the first acting force is the average load, and the load of the second acting force is an alternating load.
Optionally, after the metal plate is controlled to vibrate according to preset processing parameters to crack the metal plate, the method further includes:
and adjusting the processing parameters according to the cracking state of the metal plate.
Optionally, the adjusting the processing parameter according to the cracking state of the metal plate includes:
determining the cracking position and the cracking depth of the metal plate;
and adjusting the processing parameters according to the cracking position and the cracking depth of the metal plate.
Optionally, before the clamping the metal plate including the girth weld, the method further comprises:
marking a metal plate containing the girth weld to be cut off on the surface of the pipeline;
the marked metal plate is cut from the pipe.
Optionally, after the welding the cracked metal plate to the pipe, the method further comprises:
and polishing the pipeline welded with the cracked metal plate.
In a second aspect, a system for producing a circumferential weld crack defect is provided, the system comprising: a testing machine provided with a clamp, a control device and a welding device, wherein the testing machine is connected with the control device,
the clamp is used for clamping a metal plate containing a circumferential weld, and the metal plate is from a pipeline to be detected;
the control device is used for controlling the metal plate to vibrate according to preset processing parameters, so that the metal plate is cracked, and the shape of a circumferential weld crack defect formed by the cracked metal plate is the same as the shape of a preset crack;
the welding device is used for welding the cracked metal plate to the pipeline;
wherein the processing parameters comprise vibration frequency, vibration times, average load and alternating load,
the control device is specifically configured to:
and applying a first acting force and a second acting force to the metal plate according to the processing parameters, so that the metal plate vibrates and cracks at the vibration frequency and the vibration times, wherein the load of the first acting force is the average load, and the load of the second acting force is an alternating load.
Optionally, the system for manufacturing a crack defect of a circumferential weld further includes: the monitoring device is respectively connected with the testing machine and the control device,
the monitoring device is used for monitoring the cracking state of the metal plate;
the control device is also used for adjusting the processing parameters according to the cracking state monitored by the monitoring device.
Optionally, the control device is specifically configured to:
determining the cracking position and the cracking depth of the metal plate;
and adjusting the processing parameters according to the cracking position and the cracking depth of the metal plate.
Optionally, the system for manufacturing a crack defect of a circumferential weld further includes: a marking device and a cutting device, wherein,
the marking device is used for marking a metal plate which is required to be cut and contains the girth weld on the surface of the pipeline;
the cutting device is used for cutting the marked metal plate from the pipeline.
Optionally, the system for manufacturing a crack defect of a circumferential weld further includes: a polishing device is arranged on the base plate,
the grinding device is used for grinding the pipeline welded with the cracked metal plate.
The invention provides a method and a system for manufacturing a circumferential weld crack defect, wherein the method can control the vibration of a metal plate according to preset processing parameters to crack the metal plate, and the shape of the circumferential weld crack defect formed by the cracked metal plate is the same as that of a preset crack.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings needed to be used in the description of the embodiments will be briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts.
FIG. 1 is a flowchart of a method for producing a circumferential weld crack defect according to an embodiment of the present invention;
FIG. 2-1 is a flow chart of another method for producing a crack defect in a circumferential weld according to an embodiment of the present invention;
fig. 2-2 is a schematic view of a marking metal plate according to an embodiment of the present invention;
2-3 are schematic diagrams of a four-point bending fixture for clamping a metal plate according to an embodiment of the present invention;
FIGS. 2-4 are top views of a metal sheet having a girth weld toe crack defect formed therein according to embodiments of the present invention;
FIGS. 2-5 are cross-sectional views of a metal sheet having a girth weld toe crack defect formed therein according to an embodiment of the present invention;
FIG. 3-1 is a schematic structural diagram of a system for producing a circumferential weld crack defect according to an embodiment of the present invention;
3-2 is a schematic structural diagram of another circumferential weld crack defect production system provided by an embodiment of the invention.
The foregoing drawings, while indicating specific embodiments of the invention, are described in detail below. The drawings and the description are not intended to limit the scope of the inventive concept in any way, but rather to illustrate it by those skilled in the art with reference to specific embodiments.
Detailed Description
In order to make the objects, technical solutions and advantages of the present invention more apparent, embodiments of the present invention will be described in detail with reference to the accompanying drawings.
The embodiment of the invention provides a method for manufacturing a circumferential weld crack defect, which comprises the following steps of:
And 102, controlling the metal plate to vibrate according to preset processing parameters to crack the metal plate, wherein the shape of a circumferential weld crack defect formed on the cracked metal plate is the same as the shape of a preset crack.
And 103, welding the cracked metal plate to the pipeline.
Wherein, the processing parameters include vibration frequency, vibration times, average load and alternating load, and step 102 includes: and applying a first acting force and a second acting force to the metal plate according to the processing parameters, so that the metal plate vibrates and cracks at the vibration frequency and the vibration frequency, wherein the load of the first acting force is an average load, and the load of the second acting force is an alternating load.
In summary, according to the method for manufacturing the circumferential weld crack defect provided by the embodiment of the invention, the metal plate can be controlled to vibrate according to the preset processing parameters, so that the metal plate cracks, and the shape of the circumferential weld crack defect formed by the cracked metal plate is the same as that of the preset crack.
The embodiment of the invention provides another method for manufacturing the crack defect of the circumferential weld, as shown in fig. 2-1, the method comprises the following steps:
Specifically, a marking pen can be used to mark the metal plate containing the girth weld to be cut on the surface of the pipeline.
In the prior art, the main means for improving the safe operation level of the pipeline is to discover and repair the defects of the pipeline through various detection technologies. Due to the limitation of the technical level, high requirements on the on-site welding construction quality and the like, the circumferential weld of the pipeline is always the weakest link of the whole pipeline, and cracking accidents of the circumferential weld (especially cracking accidents of the inner wall) occur sometimes. The weld toe is located at the junction of the weld seam (namely the molten liquid solidified and crystallized metal of the welding rod) and the base metal (namely the weldment material), and is the weakest area in the circumferential weld seam. The method for manufacturing the circumferential weld crack defect provided by the embodiment of the invention can be used for manufacturing the circumferential weld crack defect, and the circumferential weld crack defect can be a circumferential weld toe crack defect.
Specifically, the marked metal plate may be cut off from the pipeline by using an oxyacetylene cutting machine, or may be cut off from the pipeline by using other devices, which is not limited in the embodiment of the present invention.
The metal plate is an arc-shaped metal plate. Based on the material fatigue failure principle, the method adopts a fixture on a testing machine to symmetrically fix the metal plate containing the circumferential weld on the fixture along the circumferential weld so as to facilitate the coincidence of the center of the metal plate and the center of the fixture. And then processing the circumferential weld crack defect through an externally added high-frequency alternating load. Wherein, the testing machine is a high-frequency fatigue testing machine, and the clamp is a four-point bending clamp. For the material fatigue failure principle, reference may be made to the prior art, and the embodiments of the present invention are not described herein again.
And 204, controlling the metal plate to vibrate according to preset processing parameters to crack the metal plate, wherein the shape of a circumferential weld crack defect formed on the cracked metal plate is the same as the shape of a preset crack.
The shape of the predetermined crack is similar to the shape of a crack actually generated in the pipe.
The machining parameters include vibration frequency, average load and alternating load, and accordingly, step 204 includes:
and applying a first acting force and a second acting force to the metal plate according to the processing parameters, so that the metal plate vibrates at the vibration frequency and cracks, wherein the load of the first acting force is an average load, and the load of the second acting force is an alternating load.
The method can preset processing parameters, and after the processing parameters are confirmed to be set to be correct, the metal plate is controlled to vibrate and crack, so that the shape of the circumferential weld crack defect formed by the cracked metal plate is the same as the shape of a preset crack.
In addition, the machining parameters may include an amplitude representing a displacement in a vertical direction generated when the metal plate vibrates, and a waveform representing a vibration trajectory of the metal plate. The amplitude in the processing parameters is adjusted, the metal plate can be subjected to displacement limit protection, the average load and the alternating load in the processing parameters are adjusted, and the metal plate can be subjected to force limit protection. In general, the amplitude and waveform may be defaults and no settings are required.
And step 205, adjusting the processing parameters according to the cracking state of the metal plate.
Specifically, step 205 may include: determining the cracking position and the cracking depth of the metal plate; and adjusting the processing parameters according to the cracking position and the cracking depth of the metal plate.
The method can monitor whether the metal plate cracks in real time, and adjust the processing parameters according to the cracking state of the metal plate, such as amplitude, average load and alternating load, so that the metal plate can be prevented from being completely broken, a large opening can be formed, and dispersed cracks can be formed. And finally, processing to manufacture a circumferential weld crack defect (such as a circumferential weld toe crack defect) with a certain depth, wherein the shape of the circumferential weld crack defect is close to that of a crack actually generated by the pipeline.
And step 206, welding the cracked metal plate to the pipeline.
After the metal plate meeting the requirements is obtained, the metal plate is welded on the pipeline by adopting a welding device so as to facilitate the verification of the internal detection technology and the pressure evaluation of the pipeline.
And step 207, polishing the pipeline welded with the cracked metal plate.
Specifically, an angle grinder can be used for grinding the weld reinforcement on the pipeline, so that the surface of the pipeline is smoother. The weld reinforcement refers to the height of the metal on the connecting line of the two weld toes on the surface of the weld.
Assuming that the circumferential weld crack defect manufacturing method provided by the embodiment of the present invention is used to manufacture a circumferential weld toe crack defect on the outer surface of a pipe with a diameter of 813 millimeters (mm) and a wall thickness of 14mm, as shown in fig. 2-2, a metal plate 03 including a circumferential weld 02 to be cut off may be marked on the surface of a pipe 01 by using a marking pen, and the metal plate has a length of 400mm and a width of 100 mm. The marked metal plate is then cut from the pipe using an oxyacetylene cutting machine, 04 in fig. 2-2 being a helical weld on the pipe. Then, as shown in fig. 2 to 3, the metal plate 03 is clamped by a four-point bending jig 05 on a high frequency fatigue testing machine, and the metal plate 03 is symmetrically fixed on the four-point bending jig 05 along a girth weld, wherein the span d1 of the upper fulcrum roll 051 of the four-point bending jig 05 can be 100mm, the span d2 of the lower fulcrum roll 052 can be 160mm, and 02 in fig. 2 to 3 is the girth weld. The control device for controlling the high-frequency fatigue testing machine is then turned on again, and the machining parameters are set, and for example, the vibration frequency may be set to 150 hz, the number of vibrations may be set to 2.2 ten thousand, the average load may be set to 60 kilo-newtons (KN), the alternating load may be set to 30KN, and both the amplitude and the waveform may be set to default values. And then starting the high-frequency fatigue testing machine to enable the metal plate to vibrate and crack. Meanwhile, a monitoring device is adopted to monitor the cracking state of the metal plate, and a control device is adopted to adjust the processing parameters, so that the metal plate is prevented from being completely broken, or a large opening is formed, and scattered cracks are formed. And finally, forming a girth weld toe crack defect with a certain depth at the weld toe position of the metal plate. And then welding the metal plate with the crack defect of the welding toe of the ring welding seam on the pipeline, and grinding the weld reinforcement on the pipeline by using an angle grinder. Fig. 2 to 4 show a plan view of a metal plate formed with a girth weld toe crack defect, 02 in fig. 2 to 4 being a girth weld, 03 being a metal plate, 06 being a girth weld toe crack defect, and u being an operation direction of a pull test. Fig. 2 to 5 are sectional views showing a metal plate formed with a girth weld toe crack defect, where h in fig. 2 to 5 is the thickness of the metal plate 03 and 06 is the girth weld toe crack defect.
Compared with the circular weld toe crack defect in the prior art, the circular weld toe crack defect manufactured by the circular weld toe crack defect manufacturing method provided by the embodiment of the invention has more accurate position, and meets the technical requirement of simulating the circular weld toe crack defect at a preset position.
The method for manufacturing the circumferential weld crack defect provided by the embodiment of the invention simulates the real environment of generating cracks on the pipeline to manufacture the circumferential weld crack defect, so that the shape of the circumferential weld crack defect manufactured by the method is closer to the shape of the circumferential weld crack defect actually generated by the pipeline. The method can be used for manufacturing the weld toe crack defects of the circumferential weld for pipelines with different pipe diameters and wall thicknesses, and can be used for manufacturing the weld toe crack defects of the circumferential weld with different sizes. The method provides data support for completing calibration of different internal detectors and verifying performance indexes of the internal detectors, can be used for verifying the probability and the recognition precision of detecting the girth weld toe crack defects by different internal detection technologies, and is suitable for processing and manufacturing the girth weld toe crack defects of pipelines with different sizes in a traction test.
It should be noted that, the sequence of the steps of the method for manufacturing a circumferential weld crack defect provided in the embodiment of the present invention may be appropriately adjusted, and the steps may be increased or decreased according to the circumstances, and any method that can be easily changed by a person skilled in the art within the technical scope disclosed in the present invention should be included in the protection scope of the present invention, and therefore, the details are not described again.
In summary, according to the method for manufacturing the circumferential weld crack defect provided by the embodiment of the invention, the metal plate can be controlled to vibrate according to the preset processing parameters, so that the metal plate cracks, and the shape of the circumferential weld crack defect formed by the cracked metal plate is the same as that of the preset crack.
An embodiment of the present invention provides a system 300 for manufacturing a circumferential weld crack defect, as shown in fig. 3-1, the system 300 for manufacturing a circumferential weld crack defect includes: the testing machine 310 is provided with a clamp, a control device 320 and a welding device 330, wherein the testing machine 310 is connected with the control device 320.
The clamp is used to clamp a metal plate containing a circumferential weld, the metal plate being from a pipe to be tested.
The control device 320 is used for controlling the metal plate to vibrate according to preset processing parameters, so that the metal plate cracks, and the shape of the circumferential weld crack defect formed by the cracked metal plate is the same as the shape of the preset crack.
The welding device 330 is used to weld the cracked metal plate to the pipe.
Wherein the processing parameters comprise vibration frequency, vibration times, average load and alternating load,
the control device 320 is specifically configured to: and applying a first acting force and a second acting force to the metal plate according to the processing parameters, so that the metal plate vibrates and cracks at the vibration frequency and the vibration frequency, wherein the load of the first acting force is an average load, and the load of the second acting force is an alternating load.
In summary, according to the circumferential weld crack defect manufacturing system provided by the embodiment of the invention, the vibration of the metal plate can be controlled according to the preset processing parameters, so that the metal plate cracks, and the shape of the circumferential weld crack defect formed by the cracked metal plate is the same as that of the preset crack.
Wherein, the circumferential weld crack defect can be a circumferential weld toe crack defect, the testing machine is a high-frequency fatigue testing machine, and the clamp is a four-point bending clamp.
Further, as shown in fig. 3-2, the system 300 for producing a crack defect of a circumferential weld further comprises: the monitoring device 340, the monitoring device 340 is connected with the testing machine 310 and the control device 320 respectively.
The monitoring device 340 is used for monitoring the cracking state of the metal plate.
The control device 320 is further configured to adjust the machining parameters according to the cracking status monitored by the monitoring device 340.
Optionally, the control device 320 is specifically configured to:
determining the cracking position and the cracking depth of the metal plate;
and adjusting the processing parameters according to the cracking position and the cracking depth of the metal plate.
Further, as shown in fig. 3-2, the system 300 for producing a crack defect of a circumferential weld further comprises: a marking device 350 and a cutting device 360.
The marking device 350 is used to mark the surface of the pipe with the metal plate containing the girth weld that needs to be cut. By way of example, the marking device may be a marker pen.
The cutting device 360 is used to cut the marked metal plate from the pipe.
As shown in fig. 3-2, the system 300 for producing a crack defect in a circumferential weld further comprises: a grinding device 370.
The grinding device 370 is used to grind the pipe welded with the metal plates satisfying the preset requirements. By way of example, the grinding device may be an angle grinder.
In summary, according to the system for manufacturing the circumferential weld crack defect provided by the embodiment of the invention, the vibration of the metal plate can be controlled according to the preset processing parameters, so that the metal plate cracks, and the shape of the circumferential weld crack defect formed by the cracked metal plate is the same as that of the preset crack.
It is clear to those skilled in the art that, for convenience and brevity of description, the specific working processes of the system and the apparatus described above may refer to the corresponding processes in the foregoing method embodiments, and are not described herein again.
The above description is only for the purpose of illustrating the preferred embodiments of the present invention and is not to be construed as limiting the invention, and any modifications, equivalents, improvements and the like that fall within the spirit and principle of the present invention are intended to be included therein.
Claims (2)
1. A method for manufacturing a circumferential weld crack defect is characterized by comprising the following steps:
marking a metal plate containing a circumferential weld to be cut on the surface of the pipeline to be detected;
cutting the marked metal plate from the pipe;
clamping the metal plate containing the circumferential weld by a four-point bending fixture on a high-frequency fatigue testing machine;
applying a first acting force and a second acting force to the metal plate according to preset machining parameters including vibration frequency, average load and alternating load, so that the metal plate vibrates and cracks at the vibration frequency and the vibration frequency, wherein the load of the first acting force is the average load, and the load of the second acting force is the alternating load;
determining the cracking position and the cracking depth of the metal plate in real time, adjusting the processing parameters according to the cracking position and the cracking depth of the metal plate, wherein the shape of a girth weld crack defect formed by the cracked metal plate is the same as that of a preset crack;
welding the cracked metal plate to the pipeline;
and polishing the pipeline welded with the cracked metal plate.
2. A circumferential weld crack defect production system, comprising: a high-frequency fatigue testing machine provided with a four-point bending clamp, a control device, a welding device, a marking device, a cutting device and a polishing device, wherein the high-frequency fatigue testing machine is connected with the control device,
the marking device is used for marking a metal plate which is required to be cut and contains a circumferential weld on the surface of the pipeline to be detected;
the cutting device is used for cutting off the marked metal plate from the pipeline;
the four-point bending fixture is used for clamping the metal plate containing the circumferential weld;
the control device is used for applying a first acting force and a second acting force to the metal plate according to preset processing parameters including vibration frequency, average load and alternating load, so that the metal plate vibrates and cracks at the vibration frequency and the vibration frequency, the load of the first acting force is the average load, and the load of the second acting force is the alternating load; determining the cracking position and the cracking depth of the metal plate in real time, adjusting the processing parameters according to the cracking position and the cracking depth of the metal plate, wherein the shape of a girth weld crack defect formed by the cracked metal plate is the same as that of a preset crack;
the welding device is used for welding the cracked metal plate to the pipeline;
the grinding device is used for grinding the pipeline welded with the cracked metal plate.
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| CN111665342B (en) * | 2019-03-07 | 2023-07-04 | 中国石油化工股份有限公司 | Pipeline internal detection data analysis system |
| CN111537619B (en) * | 2020-05-07 | 2023-05-30 | 内蒙古电力(集团)有限责任公司内蒙古电力科学研究院分公司 | TOFD detection simulation test block for circumferential weld of steam drum seal head |
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