CN109477598A - 用于连接受疲劳的水下流体输送管的两个独立元件的方法 - Google Patents
用于连接受疲劳的水下流体输送管的两个独立元件的方法 Download PDFInfo
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- B23K9/00—Arc welding or cutting
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- B23K9/00—Arc welding or cutting
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- B23K9/00—Arc welding or cutting
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Abstract
本发明涉及一种用于连接受疲劳的水下流体输送管的两个独立元件(2、4)的方法,该方法包括将两个独立金属或双金属单元管元件焊接在一起,所述单元管元件在其相应的自由端部(2a、4a)处抵接接合,通过形成三个不同的焊缝(6、8、10)进行焊接,其中最后的焊缝(8)位于两个第一侧部焊缝(6、10)之间,之后直接是焊缝的受控喷砂,以便对它们施加压缩应力。
Description
技术领域
本发明涉及在操作中经受疲劳的海下流体输送管的一般领域。本发明更具体地涉及用于输送碳氢化合物(例如,油或气)的管,这些管提供底部到表面的连接或两个浮动支撑件之间的连接。
背景技术
在用于输送碳氢化合物的两个浮动支撑件之间提供连接的底部到表面的连接管或管(在此称为“立管”)通常如下被制造:即,拾取先前已经铺设在海底(sea bottom,海床)上的管,然后例如通过赋予它们悬链构造而使它们连续地直接朝向浮动支撑件升起。
因此,当水深小于数百米时,从底部升起以形成立管的管需要使用具有柔性的管来制造。然而,一旦水深达到或超过800米(m)至1000m,就要用刚性管取代柔性管,刚性管由单位长度的管元件组成,所述管元件由坚固材料(诸如厚钢板)制成并焊接在一起。采用悬链构造并由坚固材料制成的刚性立管通常被称为“钢制悬链立管”(SCR)。
随后,用作刚性立管的管的单元元件在铺设船上彼此连接,并且随着它们被连接在一起而将它们逐渐降低到海底。可以通过使用定位于铺设船上的J-铺设塔或S-铺设塔来执行该铺设。通过J-铺设,海下管通常在它实际上为竖直(以相对于竖直方向在+30°至-10°范围内的角度)的同时,从铺设船下降。J-铺设是单悬链铺设,其中随着管向下移动,管的几乎竖直的倾斜角度逐渐减小,直到它具有海底的斜度。通过S-铺设,海下管通常在它实际上为水平的同时,从铺设船下降,并且随后其弯曲以到达海底。
J-铺设和S-铺设技术要求每个新的单元管元件在下降到海中之前在铺设船上连接到海下管,同时铺设船向前移动与单元管元件的长度相对应的量。通过将新的钢制单元管元件的自由端部对接焊接至已经组装并下降到海中的钢制海下管的自由端部来执行该连接步骤。
此外,单元管元件通常在工厂中除其自由端部之外均涂覆有基于环氧树脂制造的保护涂层,而自由端部没有任何这样的涂层,以使得涂层不会由于在焊接过程中散发的热量而燃烧。当在铺设船上连接在一起时,海下管的自由端部和用于与之组装的新单元管元件的自由端部焊接在一起。在这些端部被焊接在一起后,通常通过磨削操作消除焊缝(weldbead),然后通过熔化将基于环氧树脂的涂层涂覆在以这种方式被磨平的焊缝上以及涂覆在单元管元件和海下管的相应连接端部上,以便在管的整个长度上重构保护涂层。在通过熔化涂覆涂层之前,必须对管的表面执行喷砂(sanding)操作以获得钢的粗糙表面状态,从而提高保护涂层在管上的粘附性。
当将新的单元管元件连接到海下管时,磨削焊缝是特别重要的步骤,因为这使得能消除焊缝附近的有可能引起开裂的任何几何中断部。具体而言,刚性立管是经受高水平动态应力和大量变形的管,因此必须保证它们具有良好的疲劳强度。然而,疲劳强度通常需要很大的强度以抵抗在管的各个单元元件之间形成的焊缝处出现开裂。此外,在焊缝被磨削后,通常的实践是执行人工操作以检查已经获得的结果(通过使用超声探头),以验证所有几何中断部已被消除并且检查该位置处的焊缝,以确保它确实满足焊接标准的质量标准。
这种连接方法存在某些缺点。具体地,会消耗相当长的时间执行其磨削和检查(每次焊接需要接近20分钟执行其磨削和检查)。此外,磨削后获得的结果并不总是可接受的。具体地,检查可能会发现在磨削过程中焊缝受损或者其不符合焊接标准的质量标准,这意味着必须再造焊缝。
从文件WO2008/139116中还已知用于将管的两个钢制单元元件连接在一起的方法,在该方法中,在管内部执行局部喷丸操作,以增加钢在焊缝附近的压缩。尽管在焊缝处的疲劳强度方面是可靠的,但是这种喷丸操作相对难以执行,并且需要用在管内的合适的喷丸工具。
发明内容
本发明的主要目的是提出不存在上述缺点的连接方法。
根据本发明,该目的通过一种连接方法实现,所述连接方法将经受疲劳的海下流体输送管的两个单元元件连接在一起,该方法包括将两个金属或双金属单元管元件(它们已经通过各自的自由端部放置成抵接状态)焊接在一起,通过形成三个不同的焊缝来完成焊接,其中最后一个焊缝位于两个侧向第一焊缝之间,之后直接是通过对焊缝进行受控的喷砂而在焊缝上施加压缩应力。
令人惊讶的是,本发明人已经发现,借助于三个焊缝,然后直接对焊缝进行受控的喷砂使得能在焊缝中提供压缩应力,该压缩应力阻滞了由于管所经受的疲劳而导致的开裂的产生和蔓延。借助于两个焊缝(每个焊缝位于用于连接在一起的单元元件的旁边),然后是位于前两个焊缝之间的第三个焊缝,之后直接进行喷砂,也可以获得压缩应力,从而避免求助于任何磨削(grinding)操作(本发明的方法不包括任何磨削焊缝的操作)并且显著提高至少300%的组件的疲劳寿命。
可以在单元管元件处于竖直位置的情况下执行焊接,最后的焊缝位于前两个侧向焊缝之间。
优选地,喷砂还包括对单元管元件的连接在一起的端部进行喷砂。这使得不论构成管的材料是钢、铝或是钛,都能够获得该材料的粗糙表面状态,从而提高随后保护涂层在管上的粘附。
在喷砂之后,该方法还可以包括通过熔化而在焊缝上以及还在单元管元件的连接在一起的端部上涂覆基于环氧树脂的涂层。
附图说明
本发明的其他特征和优点从以下参考附图的描述中显而易见,附图示出了不具有限制性质的实施方式。在附图中:
图1是通过根据本发明的方法连接在一起的两个单元管元件的剖面图;以及
图2是图1的部分视图,其示出了焊缝。
具体实施方式
本发明适用于将海下管的两个单元元件连接在一起,该海下管经受疲劳且用于输送来自海下开采井的流体(诸如碳氢化合物,例如油或气)。
本发明的应用领域是铺设在海床上且升高到表面的管,以便用作刚性立管,即,用作底部到表面的连接或用作两个浮动支撑件之间的连接。举例来说,术语“浮动支撑件”用于涵盖浮动、生产、存储和卸载(FPSO)单元。
用作刚性立管的管通常由金属单元管元件制成,所述金属单元管元件通过焊接连接在一起(并且由不限于钢的材料制成)。更确切地说,随后用作刚性立管的管的单元元件在铺设船上彼此连接,并且随着它们连接在一起而逐渐下降到海底。这种铺设可以通过使用定位于铺设船上的J-铺设塔或S-铺设塔来执行。
在图1中示意性地示出了在铺设船上所述管的两个单元元件2、4之间的本发明的连接。
在J-铺设或S-铺设期间,两个钢合金单元管元件2和4处于竖直位置。它们被放置成抵接,它们各自的自由端部2a、4a沿着共同的竖直轴线X-X对准。然后在这两个自由端部之间形成三个不同的焊缝6、8和10。
通过用于将由钢合金制成的两个管状元件焊接在一起的任何已知技术从管的外部形成焊缝6、8和10。举例来说,可以使用电弧焊接技术。用于形成焊缝的材料通常可与任何等级的钢兼容。
这三个焊缝6至10按以下顺序形成:执行前两次移动(pass,经过)以形成侧向焊缝(图1和图2中的焊缝6和10),即,位于单元管元件的相应自由端部2a和4a旁边的焊缝,然后执行后一移动,以在侧向的前两个焊缝6和10之间形成最后的焊缝(图中的焊缝8)。
在前两次移动之间形成的最后一个焊缝8,因此用于升高将趋于冷却的前两个侧向焊缝6和10的温度。结果,通过以对称方式加热侧向焊缝6和10,可以减小在两个单元管元件的自由端部2a和4a处的第一焊缝的硬度。
一旦焊缝6至10已经形成并且已经冷却,本发明的连接方法就可以在这些焊缝上以及在单元管元件的连接在一起的端部上直接执行受控的喷砂操作。特别是,在焊缝上不执行磨削步骤或任何其他类型的机械切割。
通过任何已知技术执行喷砂。例如,可以使用一个或多个投射喷嘴12,该投射喷嘴适于沿竖直轴线X-X平移(图1中标记为F1的移动)以及适于围绕该轴线转动(图1中标记为F2的移动)。
喷砂的目的特别是为了制备单元管元件的连接在一起的端部的表面,以便获得钢的粗糙表面状态,这提高了随后保护涂层在管上的粘附(具体是通过熔化而涂覆环氧树脂基涂层)。令人惊讶的是,通过以受控的方式在焊缝6至10上执行喷砂还使得可以在这些焊缝上提供压缩应力,该压缩应力阻滞了由于管所经受的疲劳而导致的开裂的产生和蔓延。
在实践中,除投射持续时间外,对焊缝以及对单元管元件的连接在一起的端部两者使用相同的投射参数(研磨和投射喷嘴)执行喷砂,其中对焊缝执行喷砂的投射持续时间比对单元管元件的连接在一起的端部执行喷砂的投射持续时间更长。
下面描述了本发明的连接方法的实施方式。
在该实施方式中,单元管元件由外部包含API 5L-X65钢且内部包含625钢(添加有钼和铌的镍铬合金)的双金属管制成,用于形成三个焊缝的材料也是625。
举例来说,在形成焊缝之后立即使用58作为磨料执行喷砂处理。58是由供应商“W Abrasives”销售的喷丸磨料。该磨料具有以下化学成分:C≥0.85%;Si≥0.4%;0.6%≤Mn≤1.2%;S≤0.05%;和P≤0.05%。它按照洛氏硬度C标准(HRc)具有大于64的硬度,且具有7.4的最小比重。
通过这种喷砂处理,(与涉及磨削操作的组件相比)在两个单元管元件组件的疲劳寿命上已经观察到相当大的改进(至少300%)。
一旦执行了喷砂操作,则在单元管元件的连接在一起的端部上和焊缝上有利地提供涂覆保护涂层(特别是用于抗腐蚀),例如,基于环氧树脂形成的涂层。
通常,通过熔化而在焊缝上以及在单元管元件的连接在一起的端部上沉积这种涂层,以便在管的整个长度上重构保护涂层。
Claims (6)
1.一种用于将经受疲劳的海下流体输送管的两个单元元件(2、4)连接在一起的方法,所述方法包括将两个金属或双金属单元管元件焊接在一起,所述两个金属或双金属单元管元件已通过它们各自的自由端部(2a,4a)放置成抵接,通过形成三个不同的焊缝(6、8、10)进行焊接,其中最后一个焊缝(8)位于两个侧向第一焊缝(6、10)之间,之后直接进行所述焊缝的受控喷砂,以对它们施加压缩应力。
2.根据权利要求1所述的方法,其中,所述方法不包括对焊缝进行磨削。
3.根据权利要求1或2所述的方法,其中,在所述单元管元件处于竖直位置时执行所述焊接。
4.根据权利要求1至3中任一项所述的方法,其中,所述喷砂还包括对所述单元管元件的连接在一起的端部进行喷砂。
5.根据权利要求4所述的方法,其中,使用从公共喷嘴投射的相同磨料在所述单元管元件的连接在一起的端部上以及在所述焊缝上执行喷砂,所述磨料投射到所述焊缝上的持续时间比所述磨料投射到所述单元管元件的连接在一起的端部上的持续时间更长。
6.根据权利要求1至5中任一项所述的方法,还包括,在所述喷砂之后,通过熔化而在所述焊缝上以及还在所述单元管元件的连接在一起的端部上涂覆基于环氧树脂的涂层。
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FR1656458 | 2016-07-06 | ||
FR1656458A FR3053755B1 (fr) | 2016-07-06 | 2016-07-06 | Procede de raccordement de deux elements unitaires d'une conduite sous-marine de transport de fluides soumise a la fatigue |
PCT/FR2017/051627 WO2018007709A1 (fr) | 2016-07-06 | 2017-06-20 | Procede de raccordement de deux elements unitaires d'une conduite sous-marine de transport de fluides soumise a la fatigue |
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BR112018077498A2 (pt) | 2019-04-09 |
WO2018007709A1 (fr) | 2018-01-11 |
FR3053755B1 (fr) | 2018-08-17 |
US11407052B2 (en) | 2022-08-09 |
CA3029694A1 (fr) | 2018-01-11 |
BR112018077498B1 (pt) | 2022-06-14 |
AU2017294125B2 (en) | 2019-08-08 |
US20190247945A1 (en) | 2019-08-15 |
CN109477598B (zh) | 2020-08-07 |
ZA201808096B (en) | 2019-08-28 |
FR3053755A1 (fr) | 2018-01-12 |
PH12018502726A1 (en) | 2019-04-15 |
MX2018016068A (es) | 2019-03-28 |
EP3482113B1 (fr) | 2020-07-08 |
AU2017294125A1 (en) | 2018-12-20 |
EP3482113A1 (fr) | 2019-05-15 |
MA44034B1 (fr) | 2019-08-30 |
MA44034A1 (fr) | 2018-12-31 |
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