CN109909585B - Surfacing repair method and system for maintaining welding seam of stainless steel branch pipe - Google Patents
Surfacing repair method and system for maintaining welding seam of stainless steel branch pipe Download PDFInfo
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- CN109909585B CN109909585B CN201910184075.2A CN201910184075A CN109909585B CN 109909585 B CN109909585 B CN 109909585B CN 201910184075 A CN201910184075 A CN 201910184075A CN 109909585 B CN109909585 B CN 109909585B
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Abstract
The invention provides a surfacing repair method and a surfacing repair system for maintaining a welding seam of a stainless steel branch pipe, which comprise the following steps: acquiring defect information, original data and field operation environment data of a branch pipe welding line to be repaired; preparing a general surfacing repair scheme according to the acquired defect information of the branch pipe welding seam, the acquired original data and the acquired field operation environment data; processing and surfacing the weld joint of the branch pipe to be repaired according to the prepared surfacing repair overall scheme; and (5) inspecting, testing and evaluating the surfacing welding seam. According to the invention, corrosion-resistant metal is directly surfacing-welded on the surface of the to-be-repaired area of the branch pipe welding line, and the surfacing layer forms a new pressure boundary, so that the structural reinforcement of the branch pipe welding line is realized, the state and distribution of residual stress in the branch pipe welding line are improved, the area near the defect area after surfacing is in a pressure stress state, the initiation and expansion of cracks are inhibited, and the repaired branch pipe welding line is ensured to meet the requirement of full-period safe operation.
Description
Technical Field
The invention relates to the field of welding repair, in particular to a surfacing repair method and a surfacing repair system for maintaining a welding seam of a stainless steel branch pipe.
Background
In piping design, branch welds are a common connection between a main pipe and a branch pipe. The welding seam structure (example: BOSS head welding seam) of the branch pipe of the placing type pipe seat is widely applied, and the structure and the manufacturing process of the welding seam structure belong to mature designs, as shown in figure 1. For the welding seam of the branch pipe with small pipe diameter, the welding accessibility and the interlayer cleaning convenience are poor (particularly when the angle of a groove is small), when the technical level of a welder is poor, the welding process is not properly controlled, and an effective detection means is lacked, the defects of slag inclusion, incomplete fusion, air holes and the like are easily generated, and the defects become failure sources. When the quality of a pipeline system of a nuclear power plant is inspected, the defect that welding seams of part of BOSS heads exceed the standard is found, and the safe and efficient operation of the power plant is influenced. BOSS head and similar branch pipe weld joint structure are widely applied to pressure-bearing equipment and pipelines in industries such as electric power, petroleum, chemical industry and the like, and all have the risks of the quality problems. Therefore, there is a need to develop efficient repair methods for BOSS heads and similar branch welds.
According to the defect type and the field condition, for the welding seam of the tube socket and the branch tube of the mounting type such as the BOSS head welding seam structure, the conventional maintenance method mainly comprises the following steps: (1) repairing and repairing; (2) replacing the pipe fittings; (3) the evaluation was left untreated. The repair is to polish and remove the found defects and then perform repair welding repair, and the method needs to remove part of original weld metal and has requirements on the residual wall thickness. The method needs to isolate related pipeline systems, empties medium in the pipeline, has high irradiation (if any) contact dose, and needs to evaluate the states before and after replacement. The evaluation and non-processing are based on the defect detection information, mechanical integrity analysis is carried out, the safety of the operation of the pipeline with the defects under the non-processing condition is evaluated, the scheme needs to accurately obtain the information of the defects, otherwise, only qualitative evaluation can be carried out, the defects of the method exist all the time, and further failure risks exist under the action of external conditions. Through investigation, the periphery of a failed part is subjected to surfacing repair in foreign countries, and the surfacing repair technology in the ASME specification has some implementation cases, but currently, the U.S. WSI & SI company is mainly used for mastering the surfacing repair technology and realizing engineering application. However, for the welding seam of the branch pipe, the saddle-shaped transition region is complex in shape, and the surfacing repair of the welding seam of the branch pipe by adopting an automatic welding method is not realized at present.
In summary, the existing maintenance methods have some technical limitations, and in some cases (for example, the defect is penetrated, the medium in the pipe cannot be evacuated, the pipeline system cannot be isolated, etc.), the above maintenance methods cannot be implemented effectively. In addition, the contact between the medium in the pipeline and the metal polluted by the medium (especially when irradiation exists) in the repair process is avoided as much as possible, the stay time of personnel in an operation area is reduced, the workload of cutting and polishing is reduced, and the irradiation dose is controlled. Therefore, it is necessary to find an automatic surfacing repair method to solve the problems in the prior art.
Disclosure of Invention
The invention provides a surfacing repair method and a surfacing repair system for introducing automatic pulse tungsten inert Gas (GTAW) into a stainless steel branch pipe weld for maintenance, aiming at the problems in the prior art.
The technical scheme provided by the invention for the technical problem is as follows: the invention provides a surfacing repair method for maintaining a welding seam of a stainless steel branch pipe, which comprises the following steps: s100, acquiring defect information and original data of a branch pipe welding seam to be repaired; s200, working out a general surfacing repair scheme according to the acquired defect information and the acquired original data of the branch pipe welding seam; s300, processing and surfacing the welding seam of the branch pipe to be repaired according to the prepared surfacing repair overall scheme; and S400, inspecting, testing and evaluating the surfacing welding seam.
Wherein, step S100 further comprises: s110, performing nondestructive testing on the welding line of the branch pipe to be repaired to obtain defect information; s120, carrying out surface pattern expansion and size measurement on the weld joint of the branch pipe to be repaired to obtain original data of the weld joint of the branch pipe; s130, measuring the environment of the branch pipe welding line to be repaired to obtain field operation environment data.
Further, step S200 further includes: s210, designing a surfacing structure according to the obtained original data of the branch pipe welding seam; s220, designing a surfacing repair path of the welding gun according to the obtained original data of the branch pipe welding seam and the field operation environment data; judging whether local filling welding is needed or not according to the designed repair path, and designing an implementation step of the local filling welding; s230, designing a surfacing process according to the obtained original data of the branch pipe welding seam and the designed surfacing structure; s240, judging whether surface polishing is needed or not according to the obtained original data of the branch pipe welding line, and if so, formulating a surface polishing mode, a position and a size; s250, judging whether a leakage point exists or not according to the welding seam defect information of the branch pipe, and establishing a sealing step if the leakage point exists; and S260, making dehumidification, foreign matter prevention and protection measures according to the field operation environment data of the branch pipe welding line.
Further, step S300 includes: s310, processing the branch pipe welding seam to be repaired according to the made general surfacing repair scheme, so that the branch pipe welding seam to be repaired meets the surfacing implementation requirement; and S320, performing surfacing on the to-be-repaired branch pipe welding seam which meets the surfacing implementation requirement after treatment according to the surfacing repair overall scheme.
Further, step S310 specifically includes: s311, sealing the leakage point according to the general surfacing repair scheme; s312, according to the general scheme of surfacing repair, dehumidifying, polishing and cleaning the surface of the weld joint of the branch pipe to be repaired, removing dirt on the surface and ensuring smooth transition of the surface to be repaired; and S313, performing local filling welding on the branch pipe welding seam to be repaired according to the local filling welding step formulated by the general surfacing repair scheme.
Further, step S320 specifically includes: s321, performing two-side surfacing on a saddle-shaped part of a weld joint of the branch pipe to be repaired according to a surfacing repair overall scheme, and performing full-circle surfacing around the branch pipe when the surfacing layer of the saddle-shaped part is flush with the axially highest position of the main pipe;
s322, carrying out channel-by-channel visual inspection, layer-by-layer liquid permeation inspection and layer-by-layer size inspection on the surfacing welding seam, checking the temperature between channels, judging whether the surfacing welding implementation requirement is met, and if the surfacing welding implementation requirement is not met, processing the defect and adjusting the process parameters; and if the requirement is met, returning to the step S321, and performing surfacing again according to the sequence until the surfacing size meets the general surfacing repair scheme.
Further, step S400 specifically includes: s410, carrying out visual inspection and liquid permeation inspection on the branch pipe welding seam subjected to surfacing; s420, carrying out surface model expansion and size measurement on the branch pipe welding seam after surfacing, obtaining data of the branch pipe welding seam after surfacing, comparing the data with the original data in the step S120, calculating surfacing size and deformation information, and evaluating whether the surfacing size and deformation meet acceptance requirements according to a calculation result; s430, inspecting the surfacing quality through the simulation piece and/or the process evaluation piece, performing chemical composition, metallographic structure, stretching, impacting and bending tests, and evaluating whether the test result meets the acceptance requirements; s440, carrying out stress analysis on the surfacing member through the simulation piece, and evaluating whether the stress state and distribution meet the acceptance requirements; s450, carrying out mechanical integrity evaluation, and evaluating whether the surfacing structure meets the requirement of safe operation in the whole period.
In another aspect, the present invention provides a weld repair system for repairing a weld of a stainless steel branch pipe, the system comprising: the information acquisition module is used for acquiring the defect information and the original data of the welding seam of the branch pipe to be repaired; the repair scheme making module is connected with the information acquisition module and used for making a total surfacing repair scheme according to the acquired defect information of the branch pipe weld joint and the original data; the surfacing overall implementation module is connected with the repair scheme formulation module and is used for processing and surfacing the weld joint of the branch pipe to be repaired according to the formulated surfacing repair overall scheme; and the detection and evaluation module is connected with the surfacing overall implementation module and is used for inspecting, testing and evaluating surfacing welding seams.
Wherein, the information acquisition module further comprises: the defect information detection module is used for carrying out nondestructive detection on the welding line of the branch pipe to be repaired to obtain defect information; the original state testing module is used for carrying out surface pattern expansion and size measurement on a welding area of the branch pipe to be repaired to obtain original data of a welding seam of the branch pipe; and the environment testing module is used for measuring the environment of the branch pipe welding line to be repaired to obtain field operation environment data.
Wherein, the repair scheme making module further comprises: the surfacing structure design module is connected with the information acquisition module and used for designing a surfacing structure according to the original data of the branch pipe welding seam to be repaired; the repair path design module is connected with the information acquisition module and used for designing a surfacing repair path of the welding gun according to the acquired original data of the branch pipe welding seam and the acquired field operation environment data; judging whether local filling welding is needed or not according to the designed repair path, and designing an implementation step of the local filling welding; the surfacing process designing module is connected with the information acquiring module and is used for designing a surfacing process according to the acquired original data of the branch pipe welding seam and the designed surfacing structure; the polishing scheme design module is connected with the information acquisition module and used for judging whether surface polishing is needed or not according to the acquired original data of the branch pipe welding seam, and if so, the surface polishing mode, position and size are formulated; the leakage prevention scheme design module is connected with the information acquisition module and used for judging whether leakage points exist or not according to the acquired defect information of the branch pipe welding line, and if so, a sealing step is designed; and the protection scheme design module is connected with the information acquisition module and used for formulating dehumidification, foreign body prevention and protection measures according to the acquired field operation environment data of the branch pipe welding line.
Further, the surfacing welding general implementation module comprises: the pre-processing module is connected with the repairing scheme making module and used for processing the branch pipe welding seam to be repaired according to the made surfacing repairing overall scheme so that the branch pipe welding seam to be repaired meets the surfacing implementation requirement; and the surfacing implementation module is connected with the repair scheme formulation module and used for implementing surfacing on the to-be-repaired branch pipe welding seam meeting surfacing implementation requirements after treatment according to a surfacing repair overall scheme.
Further, the preprocessing module specifically includes: the sealing module is connected with the repair scheme making module and used for sealing the leakage point according to the general surfacing repair scheme; the polishing module is connected with the repairing scheme formulating module and is used for polishing and cleaning the surface of the welding line of the branch pipe to be repaired according to the general surfacing repairing scheme, removing dirt on the surface and ensuring smooth transition of the surface to be repaired; and the local filling and welding module is connected with the repairing scheme formulating module and is used for carrying out local filling and welding on the branch pipe welding seam to be repaired according to the local filling and welding step formulated by the surfacing repairing overall scheme.
Further, the build-up welding implementation module specifically comprises: the surfacing module is connected with the repairing scheme establishing module and used for performing two-side surfacing on a saddle-shaped part of a welding seam of the branch pipe to be repaired according to a surfacing repairing overall scheme, and performing full-circle surfacing around the branch pipe when the surfacing layer on the saddle-shaped part is flush with the axial highest position of the main pipe; the process control module is connected with the surfacing module and is used for carrying out channel-by-channel visual inspection, layer-by-layer liquid permeation inspection and layer-by-layer size inspection on a surfacing welding seam, checking the temperature between channels, judging whether the surfacing welding implementation requirement is met or not, and if the surfacing welding implementation requirement is not met, processing the defects and adjusting process parameters; and if the requirements are met, returning to the surfacing module, and surfacing again according to the sequence until the surfacing size meets the surfacing repair overall scheme.
Further, the detection and evaluation module specifically comprises: the nondestructive testing module is connected with the overlaying implementation module and is used for carrying out visual inspection and liquid permeation inspection on the branch pipe welding seam after overlaying is finished; the size inspection module is connected with the surfacing implementation module and used for carrying out surface model development and size measurement on the branch pipe welding seam which is subjected to surfacing, obtaining data after the branch pipe welding seam is subjected to surfacing, comparing the data with the original data in the original state testing module, calculating surfacing size and deformation information, and evaluating whether the surfacing size and deformation meet the acceptance requirements or not according to the calculation result; the structure performance testing module is connected with the surfacing implementation module and is used for inspecting the surfacing quality through the simulation piece and/or the process evaluation piece, performing chemical composition, metallographic structure, tensile, impact and bending tests and evaluating whether the test result meets the acceptance requirements or not; the stress testing module is connected with the surfacing implementation module and used for carrying out stress analysis on a surfacing component through a simulation piece and evaluating whether the stress state and distribution meet the acceptance requirements or not; and the mechanical integrity evaluation module is connected with the surfacing implementation module and used for developing mechanical integrity evaluation and evaluating whether the surfacing structure meets the requirement of full-period safe operation.
The technical scheme provided by the invention has the beneficial effects that: aiming at the problems in the prior art, the invention provides a surfacing repair method for introducing automatic pulse tungsten inert Gas (GTAW) into a stainless steel branch pipe weld for maintenance. According to the invention, the surface of the to-be-repaired area of the welding seam of the branch pipe is directly subjected to surfacing without removing defective metal, so that the workload of grinding and cutting is greatly reduced. The invention does not need to isolate related pipeline systems and empty the medium in the pipeline, thereby avoiding the direct contact between the medium in the pipeline and the metal polluted by the medium in the pipeline in the repair process. The invention can realize the automatic welding implementation of the branch pipe welding seam including the saddle-shaped area, solves the problems of high labor intensity, low efficiency, difficult guarantee of the welding quality and the like of manual welding, reduces the retention time of personnel in an operation area (particularly a high-dose area under the irradiation condition), and controls the irradiation dose. The invention realizes the structural reinforcement of the branch pipe welding line, improves the state and distribution of residual stress in the branch pipe welding line, promotes the area near the defect area to be in a pressure stress state after overlaying, inhibits the initiation and the expansion of cracks, and ensures that the repaired branch pipe welding line meets the requirement of full-period safe operation. The invention masters the automatic surfacing process of the corrosion-resistant metal of the stainless steel branch pipe weld joint, and the quality of the weld joint meets the acceptance requirements. The invention and the improved method thereof can be widely applied to the maintenance of the welding seams or components such as branch pipe welding seams, pipeline welding seams, tubular sealing structures and the like.
Drawings
FIG. 1 is a schematic view of a weld structure of a branch pipe of a seated pipe socket in the prior art;
FIG. 2 is a flow chart of a weld repair method for repairing a weld of a stainless steel branch pipe according to an embodiment of the present invention;
FIG. 3 is a flowchart of step S100 according to an embodiment of the present invention;
FIG. 4 is a flowchart of step S200 according to an embodiment of the present invention;
FIG. 5 is a flowchart of step S300 according to an embodiment of the present invention;
FIG. 6 is a flowchart of step S310 according to an embodiment of the present invention;
FIG. 7 is a flowchart of step S320 according to an embodiment of the present invention;
FIG. 8 is a schematic view of a manifold weld overlay apparatus according to an embodiment of the present invention;
FIG. 9 is a schematic diagram of an internal structure of a weld bead weld overlay implementation of a branch pipe according to an embodiment of the present invention;
FIG. 10 is a schematic diagram of an external structure of a weld bead weld overlay implementation of a branch pipe according to an embodiment of the present invention;
FIG. 11 is a schematic diagram illustrating parameters of a welding process performed by bead welding of a branch pipe according to an embodiment of the present invention;
FIG. 12 is a flowchart of step S400 according to an embodiment of the present invention;
FIG. 13 is a schematic structural diagram of a weld repair system for repairing a weld of a stainless steel branch pipe according to a second embodiment of the present invention;
FIG. 14 is a schematic structural diagram of an information acquisition module of a weld repair system for repairing a weld of a stainless steel branch pipe according to a second embodiment of the present invention;
fig. 15 is a schematic structural diagram of a building block made according to a repair scheme of a weld repair system for repairing a weld of a stainless steel branch pipe according to a second embodiment of the present invention;
FIG. 16 is a schematic structural diagram of a general bead welding implementation module of a bead welding repair system for repairing a weld of a stainless steel branch pipe according to a second embodiment of the present invention;
FIG. 17 is a schematic structural diagram of a pre-processing module of a weld repair system for repairing a weld of a stainless steel branch pipe according to a second embodiment of the present invention;
fig. 18 is a schematic structural diagram of a build-up welding implementation module of a build-up welding repair system for maintaining a weld of a stainless steel branch pipe according to a second embodiment of the present invention;
fig. 19 is a schematic structural diagram of a detection and evaluation module of a weld repair welding system for repairing a weld of a stainless steel branch pipe according to a second embodiment of the present invention.
Detailed Description
In order to solve the problems in the prior art, the invention aims to provide a surfacing repair method and a surfacing repair system for maintaining a stainless steel branch pipe weld joint, which realize the automatic welding implementation of the branch pipe weld joint, reduce the maintenance cost and improve the maintenance efficiency, and the core idea is as follows: the method is characterized in that automatic pulse tungsten inert Gas (GTAW) welding is introduced into the bead welding repair of the stainless steel branch pipe welding line, corrosion-resistant metal with a certain size is directly bead-welded on the surface of a to-be-repaired area of the branch pipe welding line, a new pressure boundary is formed by the bead welding layer, the structural reinforcement of the branch pipe welding line is realized, the state and distribution of residual stress in the branch pipe welding line are improved, the area near a defect after bead welding is in a pressure stress state, the initiation and the expansion of cracks are inhibited, and the repaired branch pipe welding line is guaranteed to meet the requirement of full-period safe operation.
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.
Example one
Automatic pulse tungsten inert Gas (GTAW) welding is one of the international methods with better welding quality in gas-shielded arc welding, during welding, a welding wire is fed by a wire feeding mechanism, a welding gun automatically performs welding according to a set track and arc pressure feedback, inert shielding gas is continuously sprayed out from a nozzle of the welding gun, and a gas protection layer is formed around a molten pool to isolate air. Compared with manual Shielded Metal Arc Welding (SMAW) generally adopted in nuclear power engineering at present, automatic pulse tungsten inert Gas (GTAW) can more accurately control welding heat input, improve weld seam forming and improve weld seam quality, and is widely applied to the field of surfacing welding, particularly welding of thin-walled parts. Therefore, the invention introduces automatic pulse tungsten inert Gas (GTAW) welding into the bead welding repair of the stainless steel branch pipe welding line, and provides a bead welding repair method for the maintenance of the stainless steel branch pipe welding line.
Referring to fig. 2, the method includes:
s100, acquiring defect information, original data and field operation environment data of a branch pipe welding seam to be repaired;
s200, working out a general surfacing repair scheme according to the acquired defect information of the branch pipe welding seam, the acquired original data and the acquired field operation environment data;
s300, processing and surfacing the welding seam of the branch pipe to be repaired according to the prepared surfacing repair overall scheme;
and S400, inspecting, testing and evaluating the surfacing welding seam.
Wherein, referring to fig. 3, step S100 further includes:
s110, performing nondestructive testing on the welding line of the branch pipe to be repaired to obtain defect information;
and S120, carrying out surface model expansion and size measurement on the branch pipe welding line to be repaired to obtain the original data of the branch pipe welding line. The branch pipe weld joint original data comprises relevant data such as the surface roughness, the size, the deformation and the like of the branch pipe weld joint. It should be noted that the relevant data such as the surface roughness, the size, the deformation and the like of the branch pipe weld joint can also be measured by other measuring methods;
s130, measuring the environment of the branch pipe welding line to be repaired to obtain field operation environment data. The field operation environment data comprises data such as construction space, temperature, humidity, irradiation dose and the like.
Referring to fig. 4, step S200 further includes:
s210, designing a surfacing structure according to the obtained original data of the branch pipe welding seam; specifically, the design of the overlaying structure mainly comprises the design of parameters such as welding bead size (overlaying thickness, length, edge gradient and the like), welding bead arrangement, welding sequence and the like, and mainly meets the relevant requirements of ASME specification, volume III, volume XI, ASME Code Case and the like,
s220, designing a surfacing repair path of the welding gun according to the obtained original data of the branch pipe welding seam and the field operation environment data; judging whether local filling welding is needed or not according to the designed repair path, and designing an implementation step of the local filling welding; the specific judging steps are as follows: determining whether each region including the saddle-shaped region exceeds a walking range fed back by arc pressure of the welding gun or not, and if so, carrying out local filling welding on the saddle-shaped region exceeding the walking range;
s230, designing a surfacing process according to the obtained original data of the branch pipe welding seam and the designed surfacing structure; specifically, the design of the surfacing process mainly comprises the design of parameters such as welding current, welding voltage, wire feeding speed, welding speed, inter-channel temperature, welding heat input and the like, and the important points of the surfacing process are the weld joint forming quality and the stress deformation condition.
S240, judging whether surface polishing is needed or not according to the obtained original data of the branch pipe welding line, and if so, formulating a surface polishing mode, a position and a size;
s250, judging whether a leakage point exists or not according to the welding seam defect information of the branch pipe, and establishing a sealing step if the leakage point exists;
and S260, making dehumidification, foreign matter prevention and protection measures according to the field operation environment data of the branch pipe welding line. Effectively improving the safety of the welding line in the implementation process.
Further, with reference to fig. 5, step S300 includes:
s310, processing the branch pipe welding seam to be repaired according to the made general surfacing repair scheme, so that the branch pipe welding seam to be repaired meets the surfacing implementation requirement;
and S320, performing surfacing on the to-be-repaired branch pipe welding seam which meets the surfacing implementation requirement after treatment according to the surfacing repair overall scheme.
With reference to fig. 6, step S310 specifically includes:
s311, sealing the leakage point according to the general surfacing repair scheme; in one embodiment of the invention, a leakage point is sealed in a hammering mode;
s312, according to the general scheme of surfacing repair, dehumidifying, polishing and cleaning the surface of the weld joint of the branch pipe to be repaired, removing dirt on the surface and ensuring smooth transition of the surface to be repaired;
and S313, performing local filling welding on the branch pipe welding seam to be repaired according to the local filling welding step formulated by the general surfacing repair scheme.
Further, with reference to fig. 7, step S320 specifically includes: s321, performing two-side surfacing on a saddle-shaped part of a weld joint of the branch pipe to be repaired according to a surfacing repair overall scheme, and performing full-circle surfacing around the branch pipe when the surfacing layer of the saddle-shaped part is flush with the axially highest position of the main pipe;
s322, performing per-pass visual inspection, layer-by-layer liquid permeation inspection and layer-by-layer size inspection on the surfacing welding seam, checking the inter-pass temperature, judging whether the surfacing implementation requirements are met, and if the requirements are not met, processing the defects and adjusting process parameters; and if the requirement is met, returning to the step S321, and performing surfacing again according to the sequence until the surfacing size meets the general surfacing repair scheme.
It should be noted that the present invention deposits at least two layers.
Specifically, when surfacing welding is carried out, firstly, a welding method is selected, preferably, automatic pulse tungsten inert Gas (GTAW) is adopted in the invention, and high-frequency arc striking can be adopted in an arc striking mode; the high-frequency arc striking is one non-contact arc striking method, and can effectively reduce the abrasion of a tungsten electrode and the pollution to a component to be repaired. Selecting welding materials, preferably, in one embodiment of the invention, the surfacing materials adopt 52/52M nickel-based alloy series solid welding wires, so that the requirement of ASME SFA-5.14 is met, and the surfacing layers are ensured to have good corrosion resistance; by selecting the implementation mode, the invention adopts an automatic mode to implement surfacing, solves the problems of high labor intensity, low efficiency, difficult guarantee of surfacing quality and the like of manual surfacing, reduces the retention time of personnel in an operation area, particularly a high-dose area under the irradiation condition, controls the irradiation dose, and effectively reduces the irradiated dose of maintenance personnel.
Specifically, the weld joint to be repaired can be subjected to surfacing by adopting a rail-type automatic welding trolley or a welding robot, in one embodiment of the invention, the surfacing is performed by adopting the rail-type automatic welding trolley, specifically, the guide rail can be installed on the branch pipe or can be built by taking the main pipe as a supporting surface in combination with the attached figure 8. The welding gun does circular motion along the track along with the walking trolley, namely: the walking trolley does circular motion along the outer circular surface of the guide rail, the turning radius of the guide rail can be adjusted according to actual conditions, the welding gun does up-and-down reciprocating motion through the lifting mechanism so as to realize saddle-shaped area drop compensation, the welding gun realizes swing welding through the swing mechanism, and the welding gun is clamped at the tail end of the swing mechanism and moves along with the movement of the swing mechanism. In the surfacing process, the controller is used for controlling the surfacing process, specifically, arc pressure adjustment and angle adjustment in the surfacing process are realized through the controller, so that welding standard parameters are kept stable, and the welding quality is ensured.
Further, with reference to fig. 9, in the process of performing overlay welding, the saddle-shaped portions are first overlaid, and when the overlay welding layers on the saddle-shaped portions on the two sides reach the highest position in the axial direction of the main pipe, the whole circle of overlay welding is performed around the branch pipe. Further, with reference to fig. 10, at least two layers of weld joints of the branch pipe to be repaired are built up, and the build-up thickness and the total build-up thickness of each layer should meet the build-up design size requirement. During each layer of overlaying, overlaying is performed alternately on the saddle-shaped parts on both sides (ensuring that each weld bead on the saddle-shaped parts on both sides is symmetrically welded), but it is worth noting that, if the number of welding tracks of the saddle-shaped parts at two sides is less, the welding tracks can be firstly and sequentially welded on the saddle-shaped part at one side, as shown in fig. 10, weld pass 1-1 first, then weld pass 1-3, 1-5 in sequence, then surfacing is carried out on the saddle-shaped part at the other side, welding passes 1-2, 1-4 and 1-6 are welded in sequence, but the deformation and the overlaying quality of the structure should be controlled well on the whole, when the overlaying layers at the saddle-shaped parts on the two sides reach the highest position in the axial direction of the main pipe, the whole circle of overlaying is started to be carried out around the branch pipe, welding beads 1-7 and 1-8 are welded to 1-N positions in sequence, and whole-circle overlaying welding is performed from the main pipe side to the branch pipe side in sequence. And after the first layer is welded, judging whether parameters such as surface roughness of the welding line of the first layer meet the standard or not through visual inspection, and inspecting whether liquid leakage exists or not, and if the parameters meet the requirements, welding the second layer according to the same sequence. With reference to fig. 8, the specific surfacing process is as follows: when the saddle-shaped part is subjected to surfacing welding, a welding gun is moved to the 1-1 part of the welding bead, the 1-1 part of the welding bead is welded through a swing mechanism and a lifting mechanism, after the welding is finished, the welding is carried out to the 1-2 parts of the welding bead through a walking trolley moving along a guide rail, the welding of the saddle-shaped part is finished in sequence, when the surfacing layers of the saddle-shaped parts on two sides reach the level with the axial highest position of a main pipe, the whole-circle surfacing welding is carried out around a branch pipe, and the specific process of the whole-circle surfacing welding is as: and the welding gun circularly moves along with the guide rail to complete the welding of the welding bead 1-7, then the welding gun is lifted to the welding bead 1-8 through the lifting mechanism, the welding gun runs along with the guide rail to complete the welding of the welding bead 1-8, and the welding of the welding bead 1-N is sequentially completed.
Referring to the attached figure 11, when the surfacing part is the part on both sides of the saddle shape, the adopted process parameters are the process parameters corresponding to the number 1 in the figure 11, the peak current is 140-250A, the base value current is 80-180A, the frequency is 2Hz, the base value current duty ratio is 50-60%, the voltage is 5-18V, the welding speed is 50-180mm/min, the wire feeding speed is 500-1800mm/min, and the protective gas flow is 5-18L/min. The process parameters adopted during the whole-circle surfacing are the process parameters corresponding to the number 2 in the attached figure 11, the peak current is 100-200A, the base value current is 60-140A, the frequency is 2Hz, the base value current duty ratio is 50-60%, the voltage is 5-18V, the welding speed is 50-180mm/min, the wire feeding speed is 500-1800mm/min, and the protective gas flow is 5-18L/min. Generally, the first pass of each layer is welded by adopting large parameters in the welding process, and the rest passes are welded by adopting smaller parameters.
In the process of implementing surfacing, the heat input should not exceed 1.8kJ/mm, and the temperature between roads should not exceed 175 ℃. The lapping amount of the adjacent welding beads is 40 to 70 percent. And during welding, the welding seam forming and quality are controlled by controlling the pulse of welding current and the arc oscillation. The welding quality is ensured by feeding air in advance, delaying air cut-off, current attenuation and the like. The arc starting and arc stopping positions of each welding line are reasonably selected, so that the welding defects are avoided; polishing layer by layer, and enabling the surfacing layer and the peripheral base material to be in smooth transition.
Further, referring to fig. 12, step S400 specifically includes:
s410, carrying out visual inspection and liquid permeation inspection on the branch pipe welding seam subjected to surfacing; and under the condition of having implementation conditions, performing ultrasonic or ray inspection on the finished welding seam after surfacing; and the nondestructive inspection result can meet the acceptance requirement.
S420, carrying out surface model expansion and size measurement on the welded branch pipe weld joint after overlaying to obtain data of the welded branch pipe weld joint after overlaying, comparing the data with the original data in the step S120, calculating the overlaying size and deformation information, and evaluating whether the overlaying size and deformation meet the acceptance requirements according to the calculation result; specifically, the obtained data comprises information such as the surface state, the size, the deformation and the like of the welded seam of the branch pipe after overlaying;
s430, inspecting the surfacing quality through the simulation piece and/or the process evaluation piece, performing chemical composition, metallographic structure, stretching, impacting and bending tests, and evaluating whether the test result meets the acceptance requirements;
s440, carrying out stress analysis on the surfacing member through the simulation piece, and evaluating whether the stress state and distribution meet the acceptance requirements; specifically, the stress state of a surfacing member is checked on a surfacing simulation piece, the residual stress is tested and analyzed, whether the stress distribution is reasonable or not is analyzed, the surfacing structure is ensured not to have stress concentration, and the inner side of a branch pipe welding seam and the area near a defect are ensured to be mainly based on the compressive stress; the pressure stress is favorable for inhibiting the initiation and the propagation of cracks, so that the surfacing quality is further improved;
s450, carrying out mechanical integrity evaluation, and evaluating whether the surfacing structure meets the requirement of safe operation in the whole period.
Example two
The embodiment of the invention provides a build-up welding repair system for maintaining a weld joint of a stainless steel branch pipe, which is a system structure diagram of a second embodiment of the invention with reference to fig. 13, and comprises:
the information acquisition module 100 is used for acquiring defect information, original data and field operation environment data of a branch pipe welding seam to be repaired;
the repair scheme making module 200 is connected with the information acquisition module 100 and is used for making a general surfacing repair scheme according to the acquired defect information of the branch pipe welding seam, the acquired original data and the acquired field operation environment data;
the surfacing overall implementation module 300 is connected with the repair scheme formulation module 200 and is used for processing and surfacing a branch pipe weld to be repaired according to the formulated surfacing repair overall scheme;
and the detection and evaluation module 400 is connected with the surfacing overall implementation module 300 and is used for detecting, testing and evaluating the repaired branch pipe welding seam.
Referring to fig. 14, the information obtaining module 100 further includes:
the defect information detection module 110 is used for performing nondestructive detection on the welding seam of the branch pipe to be repaired to obtain defect information;
the original state testing module 120 is used for performing surface model expansion and size measurement on the branch pipe welding seam to be repaired, and measuring to obtain original data of the branch pipe welding seam; the branch pipe weld joint original data comprises relevant data such as the surface roughness, the size, the deformation and the like of the branch pipe weld joint.
It should be noted that the relevant data such as the surface roughness, the size, the deformation and the like of the branch pipe weld joint can also be measured by other measuring methods;
and the environment testing module 130 is used for measuring the environment of the branch pipe welding seam to be repaired to obtain field operation environment data. Specifically, the field operation environment data includes data of construction space, temperature, humidity, irradiation dose and the like.
Referring to fig. 15, the repair scenario formulation module 200 further includes:
the overlaying structure design module 210 is connected with the information acquisition module 100 and used for designing an overlaying structure according to the original data of the branch pipe welding seam to be repaired; specifically, the weld overlay structure design mainly includes bead size (weld overlay thickness, length, edge slope, etc.), bead arrangement, welding sequence, etc., mainly according to the requirements associated with ASME Code volume III, volume XI, and ASME Code Case.
A repair path designing module 220, connected to the information obtaining module 100, for designing a build-up welding repair path of the welding gun according to the obtained original data of the branch pipe weld and the field operation environment data; judging whether local filling welding is needed or not according to the designed repair path, and designing an implementation step of the local filling welding; the specific judging steps are as follows: determining whether each region including the saddle-shaped region exceeds a walking range fed back by arc pressure of the welding gun or not, and if so, carrying out local filling welding on the saddle-shaped region exceeding the walking range;
a build-up welding process designing module 230, connected to the information obtaining module 100, for designing a build-up welding process according to the obtained raw data of the branch pipe weld and the designed build-up welding structure; specifically, the design of the surfacing process mainly comprises the design of parameters such as welding current, welding voltage, wire feeding speed, welding speed, inter-channel temperature, welding heat input and the like, and the important points of the surfacing process are the weld joint forming quality and the stress deformation condition.
The polishing scheme design module 240 is connected to the information acquisition module 100, and is configured to determine whether surface polishing is required according to the acquired raw data of the branch pipe weld, and if so, formulate a surface polishing mode, position and size;
the leakage prevention scheme design 250 is connected with the information acquisition module 100 and used for judging whether leakage points exist according to the acquired defect information of the branch pipe welding seam, and if so, designing a sealing step;
and the protection scheme design module 260 is connected with the information acquisition module 100 and used for making dehumidification, foreign matter prevention and protection measures according to the acquired field operation environment data of the branch pipe welding line.
Further, with reference to fig. 16, the weld overlay overall implementation module 300 includes:
the preprocessing module 310 is connected with the repair scheme making module 200 and is used for processing the branch pipe welding seam to be repaired according to the made surfacing repair overall scheme so that the branch pipe welding seam to be repaired meets the surfacing implementation requirement;
and the surfacing implementation module 320 is connected with the repair scheme formulation module 200 and is used for implementing surfacing on the to-be-repaired branch pipe welding seam which meets the surfacing implementation requirements after treatment according to a surfacing repair overall scheme.
With reference to fig. 17, the preprocessing module 310 specifically includes:
the sealing module 311 is connected with the repair scheme making module 200 and used for sealing the leakage point according to the general overlaying repair scheme; in one embodiment of the invention, a leakage point is sealed in a hammering mode;
the polishing module 312 is connected with the repairing scheme formulating module 200 and is used for dehumidifying, polishing and cleaning the surface of the welding line of the branch pipe to be repaired according to the general surfacing repairing scheme, removing dirt on the surface and ensuring smooth transition of the surface to be repaired;
and the local filling and welding module 313 is connected with the repairing scheme formulating module 200 and is used for carrying out local filling and welding on the branch pipe welding seam to be repaired according to the local filling and welding step formulated by the general surfacing repairing scheme.
With reference to fig. 18, the overlay welding implementation module 320 specifically includes:
the surfacing module 321 is connected with the repairing scheme making module 200 and is used for performing two-side surfacing on a saddle-shaped part of a welding line of the branch pipe to be repaired according to a surfacing repairing overall scheme, and performing full-circle surfacing around the branch pipe when the surfacing layer on the saddle-shaped part is flush with the axial highest position of the main pipe;
the process control module 322 is connected with the surfacing module 321 and is used for performing channel-by-channel visual inspection, layer-by-layer liquid permeation inspection and layer-by-layer size inspection on a surfacing welding seam, checking inter-channel temperature, judging whether surfacing implementation requirements are met, and if the requirements are not met, processing defects and adjusting process parameters; and if the requirement is met, returning to the overlaying module 321, and overlaying again according to the sequence until the overlaying size meets the overlaying repair overall scheme.
Specifically, when the surfacing welding is implemented, firstly, a welding method is selected, preferably, automatic pulse tungsten inert Gas (GTAW) is adopted in the invention, and the arc striking mode can adopt high-frequency arc striking; the high-frequency arc striking is one non-contact arc striking method, and can effectively reduce the abrasion in arc striking. Selecting welding materials, preferably, the surfacing materials adopt 52/52M series solid welding wires, and meet the requirements of ASME SFA-5.14; the invention adopts an automatic mode to implement surfacing by selecting a welding mode. The problems of high labor intensity, low efficiency, difficult bead welding quality guarantee and the like of manual bead welding are solved, the retention time of personnel in an operation area, particularly a high-dose area under an irradiation condition is reduced, the irradiation dose is controlled, and the radiation dose of maintenance personnel is effectively reduced. The invention can adopt a rail-type automatic welding trolley or a welding robot to carry out surfacing on the area to be repaired.
Further, referring to fig. 19, the detection and evaluation module 400 specifically includes:
the nondestructive inspection module 410 is connected with the overlaying overall implementation module 300 and is used for carrying out visual inspection and liquid permeation inspection on the branch pipe welding seam after overlaying is finished; and under the condition of having implementation conditions, performing ultrasonic inspection on the finished welding seam after surfacing; and the nondestructive test results all meet the acceptance requirements;
the size inspection module 420 is connected with the general overlaying implementation module 300 and used for performing surface model development and size measurement on the branch pipe welding seam after overlaying, obtaining data of the branch pipe welding seam after overlaying, comparing the data with the original data in the original state testing module 120, calculating overlaying size and deformation information, and evaluating whether the overlaying size and deformation meet acceptance requirements according to the calculation result; specifically, the obtained data comprises information such as the surface state, the size, the deformation and the like of the welded seam of the branch pipe after overlaying;
the structure performance testing module 430 is connected with the surfacing overall implementation module 300 and is used for inspecting the surfacing quality through a simulation piece and/or a process evaluation piece, performing chemical composition, metallographic structure, tensile, impact and bending tests and evaluating whether the test result meets the acceptance requirements;
the stress testing module 440 is connected with the surfacing overall implementation module 300 and used for carrying out stress analysis on a surfacing component through a simulation piece and evaluating whether the stress state and distribution meet the acceptance requirements or not; specifically, the stress state of a surfacing member is detected on a surfacing simulation piece, the residual stress after surfacing is tested and analyzed, and the pressure stress is mainly applied to the inner side of a branch pipe welding seam and the area near a defect; the pressure stress can inhibit the initiation and the propagation of cracks, so that the surfacing quality is further improved;
and the mechanical integrity evaluation module 450 is connected with the surfacing overall implementation module 300 and used for carrying out mechanical integrity evaluation and evaluating whether the surfacing structure meets the full-period safe operation requirement. And analyzing whether the stress distribution is reasonable or not, and ensuring that no stress concentration exists in the surfacing structure.
It should be noted that: in the above embodiment, when the data processing method is implemented in a data processing system, only the division of the functional modules is described as an example, and in practical application, the functions may be distributed by different functional modules according to needs, that is, the internal structure of the device is divided into different functional modules, so as to complete all or part of the functions described above. In addition, the system and method embodiments provided by the above embodiments belong to the same concept, and specific implementation processes thereof are described in detail in the method embodiments and are not described herein again.
In summary, the invention provides a surfacing repair method and a system for maintaining a weld joint of a stainless steel branch pipe, and the technical key points mainly comprise: the surfacing repair method for introducing automatic pulse tungsten inert Gas (GTAW) welding into the stainless steel branch pipe welding line for maintenance is provided, defective metal does not need to be removed, surfacing is directly carried out on the surface of the to-be-repaired area of the branch pipe welding line, and polishing and cutting workloads are greatly reduced; meanwhile, related pipeline systems do not need to be isolated, the medium in the pipeline does not need to be emptied, and the contact between the medium in the pipeline and metal polluted by the medium in the pipeline in the repair process is avoided. The invention sets a whole set of technical scheme for realizing the automatic surfacing repair implementation of the branch pipe weld joint, can realize the automatic welding implementation of the branch pipe weld joint including the saddle-shaped area, solves the problems of high labor intensity, low efficiency, difficult surfacing quality guarantee and the like of manual surfacing, reduces the retention time of personnel in an operation area (particularly a high-dose area under the irradiation condition), and controls the irradiation dose. The structure of the branch pipe welding line is strengthened, the state and distribution of residual stress in the branch pipe welding line are improved, the area near a defect area after overlaying is made to be in a pressure stress state, the initiation and the expansion of cracks are restrained, and the repaired branch pipe welding line is guaranteed to meet the requirement of safe operation in the whole period. Meanwhile, the invention masters the automatic surfacing process of the corrosion-resistant metal of the stainless steel branch pipe weld joint, and the quality of the weld joint meets the acceptance requirements. The invention and the improved method thereof can be widely applied to the maintenance of the welding seams or components of branch pipes, pipeline welding seams, tubular sealing structures and the like.
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 (10)
1. A surfacing repair method for maintaining a welding seam of a stainless steel branch pipe is characterized by comprising the following steps:
s100, acquiring defect information, original data and field operation environment data of a branch pipe welding seam to be repaired;
s200, working out a general surfacing repair scheme according to the acquired defect information of the branch pipe welding seam, the acquired original data and the acquired field operation environment data;
s300, processing and surfacing the welding seam of the branch pipe to be repaired according to the prepared surfacing repair overall scheme;
s400, inspecting, testing and evaluating the surfacing welding seam;
in S300, surfacing is carried out by adopting a rail type automatic welding trolley, wherein the rail type automatic welding trolley comprises a guide rail, a walking trolley, a lifting mechanism, a swinging mechanism, a welding gun and a controller; the guide rail is arranged on the branch pipe or the main pipe is used as a support surface to be built, the welding gun moves circularly along the guide rail along with the walking trolley, the welding gun reciprocates up and down through the lifting mechanism to realize saddle-shaped area drop compensation, the welding gun is clamped at the tail end of the swinging mechanism and moves along with the movement of the swinging mechanism, and the welding gun realizes swinging welding through the swinging mechanism; in the surfacing process, arc pressure adjustment and angle adjustment in the surfacing process are realized through the controller so as to keep welding standard parameters stable and ensure welding quality;
step S300 includes:
s310, processing the branch pipe welding seam to be repaired according to the made general surfacing repair scheme, so that the branch pipe welding seam to be repaired meets the surfacing implementation requirement;
s320, performing surfacing on the to-be-repaired branch pipe weld joint which meets the surfacing implementation requirement after treatment according to the surfacing repair overall scheme;
step S320 includes:
s321, performing two-side surfacing on a saddle-shaped part of a weld joint of the branch pipe to be repaired according to a surfacing repair overall scheme, and performing full-circle surfacing around the branch pipe when the surfacing layer of the saddle-shaped part is flush with the axially highest position of the main pipe;
s322, performing per-pass visual inspection, layer-by-layer liquid permeation inspection and layer-by-layer size inspection on the surfacing welding seam, checking the inter-pass temperature, judging whether the surfacing implementation requirements are met, and if the requirements are not met, processing the defects and adjusting process parameters; and if the requirement is met, returning to the step S321, and performing surfacing again according to the sequence until the surfacing size meets the general surfacing repair scheme.
2. The weld overlay repair method according to claim 1, wherein step S100 further comprises:
s110, performing nondestructive testing on the welding line of the branch pipe to be repaired to obtain defect information;
s120, carrying out surface pattern expansion and size measurement on the weld joint of the branch pipe to be repaired to obtain original data of the weld joint of the branch pipe;
s130, measuring the environment of the branch pipe welding line to be repaired to obtain field operation environment data.
3. The weld overlay repair method according to claim 2, wherein the step S200 further comprises:
s210, designing a surfacing structure according to the obtained original data of the branch pipe welding seam;
s220, designing a surfacing repair path of the welding gun according to the obtained original data of the branch pipe welding seam and the field operation environment data;
s230, designing a surfacing process according to the obtained original data of the branch pipe welding seam and the designed surfacing structure;
s240, judging whether surface polishing is needed or not according to the obtained original data of the branch pipe welding line, and if so, formulating a surface polishing mode, a position and a size;
s250, judging whether a leakage point exists or not according to the welding seam defect information of the branch pipe, and establishing a sealing step if the leakage point exists;
and S260, making dehumidification, foreign matter prevention and protection measures according to the field operation environment data of the branch pipe welding line.
4. The weld overlay repair method according to claim 1, wherein step S310 includes:
s311, sealing the leakage point according to the general surfacing repair scheme;
s312, polishing and cleaning the surface of the welding line of the branch pipe to be repaired according to the general surfacing repair scheme, removing dirt on the surface and ensuring smooth transition of the surface to be repaired;
and S313, performing local filling welding on the branch pipe welding seam to be repaired according to the local filling welding step formulated by the general surfacing repair scheme.
5. The weld overlay repair method according to claim 1, wherein step S400 comprises:
s410, carrying out visual inspection and liquid permeation inspection on the branch pipe welding seam subjected to surfacing;
s420, carrying out surface model expansion and size measurement on the welded branch pipe weld joint after overlaying to obtain data of the welded branch pipe weld joint after overlaying, comparing the data with the original data in the step S120, calculating the overlaying size and deformation information, and evaluating whether the overlaying size and deformation meet the acceptance requirements according to the calculation result;
s430, inspecting the surfacing quality through the simulation piece and/or the process evaluation piece, performing chemical composition, metallographic structure, stretching, impacting and bending tests, and evaluating whether the test result meets the acceptance requirements;
s440, carrying out stress analysis on the surfacing member through the simulation piece, and evaluating whether the stress state and distribution meet the acceptance requirements;
s450, carrying out mechanical integrity evaluation, and evaluating whether the surfacing structure meets the requirement of safe operation in the whole period.
6. The utility model provides a build-up welding repair system for maintenance of stainless steel branch pipe welding seam which characterized in that includes:
the information acquisition module is used for acquiring the defect information of the welding seam of the branch pipe to be repaired, original data and field operation environment data;
the repair scheme making module is connected with the information acquisition module and used for making a general surfacing repair scheme according to the acquired defect information of the branch pipe welding seam, the original data and the field operation environment data;
the surfacing overall implementation module is connected with the repair scheme formulation module and is used for processing and surfacing the weld joint of the branch pipe to be repaired according to the formulated surfacing repair overall scheme;
the detection evaluation module is connected with the surfacing overall implementation module and is used for detecting, testing and evaluating a surfacing welding seam;
the general surfacing implementation module comprises a rail-type automatic welding trolley, wherein the rail-type automatic welding trolley comprises a guide rail, a walking trolley, a lifting mechanism, a swinging mechanism, a welding gun and a controller; the guide rail is arranged on the branch pipe or the main pipe is used as a support surface to be built, the welding gun moves circularly along the guide rail along with the walking trolley, the welding gun reciprocates up and down through the lifting mechanism to realize saddle-shaped area drop compensation, the welding gun is clamped at the tail end of the swinging mechanism and moves along with the movement of the swinging mechanism, and the welding gun realizes swinging welding through the swinging mechanism; in the surfacing process, arc pressure adjustment and angle adjustment in the surfacing process are realized through the controller so as to keep stable welding standard parameters and ensure welding quality;
the surfacing overall implementation module comprises:
the pre-processing module is connected with the repairing scheme making module and used for processing the branch pipe welding seam to be repaired according to the made surfacing repairing overall scheme so that the branch pipe welding seam to be repaired meets the surfacing implementation requirement;
the surfacing implementation module is connected with the repair scheme formulation module and used for implementing surfacing on the to-be-repaired branch pipe weld joint which meets the surfacing implementation requirements after treatment according to a surfacing repair overall scheme;
the build-up welding implementation module comprises:
the surfacing module is connected with the repairing scheme establishing module and used for performing two-side surfacing on a saddle-shaped part of a welding seam of the branch pipe to be repaired according to a surfacing repairing overall scheme, and performing full-circle surfacing around the branch pipe when the surfacing layer on the saddle-shaped part is flush with the axial highest position of the main pipe;
the process control module is connected with the surfacing module and is used for carrying out channel-by-channel visual inspection, layer-by-layer liquid permeation inspection and layer-by-layer size inspection on a surfacing welding seam, checking the temperature between channels, judging whether the surfacing welding implementation requirement is met or not, and if the surfacing welding implementation requirement is not met, processing the defects and adjusting process parameters; and if the requirements are met, returning to the surfacing module, and surfacing again according to the sequence until the surfacing size meets the surfacing repair overall scheme.
7. The weld overlay repair system according to claim 6, wherein the information acquisition module comprises:
the defect information detection module is used for carrying out nondestructive detection on the welding line of the branch pipe to be repaired to obtain defect information;
the original state testing module is used for carrying out surface pattern expansion and size measurement on a welding area of the branch pipe to be repaired to obtain original data of a welding seam of the branch pipe;
and the environment testing module is used for measuring the environment of the branch pipe welding line to be repaired to obtain field operation environment data.
8. The weld overlay repair system according to claim 7, wherein the repair scenario formulation module comprises:
the surfacing structure design module is connected with the information acquisition module and used for designing a surfacing structure according to the original data of the branch pipe welding seam to be repaired;
the repair path design module is connected with the information acquisition module and used for designing a surfacing repair path of the welding gun according to the acquired original data of the branch pipe welding seam and the acquired field operation environment data; judging whether local filling welding is needed or not according to the designed repair path, and designing an implementation step of the local filling welding;
the surfacing process designing module is connected with the information acquiring module and is used for designing a surfacing process according to the acquired original data of the branch pipe welding seam and the designed surfacing structure;
the polishing scheme design module is connected with the information acquisition module and used for judging whether surface polishing is needed or not according to the acquired original data of the branch pipe welding seam, and if so, the surface polishing mode, position and size are formulated;
the leakage prevention scheme design module is connected with the information acquisition module and used for judging whether leakage points exist or not according to the acquired defect information of the branch pipe welding line, and if so, a sealing step is designed;
and the protection scheme design module is connected with the information acquisition module and used for formulating dehumidification, foreign body prevention and protection measures according to the acquired field operation environment data of the branch pipe welding line.
9. The weld overlay repair system according to claim 6, wherein the pre-processing module comprises:
the sealing module is connected with the repair scheme making module and used for sealing the leakage point according to the general surfacing repair scheme;
the polishing module is connected with the repairing scheme formulating module and is used for polishing and cleaning the surface of the welding line of the branch pipe to be repaired according to the general surfacing repairing scheme, removing dirt on the surface and ensuring smooth transition of the surface to be repaired;
and the local filling and welding module is connected with the repairing scheme formulating module and is used for carrying out local filling and welding on the branch pipe welding seam to be repaired according to the local filling and welding step formulated by the surfacing repairing overall scheme.
10. The weld overlay repair system according to claim 7, wherein the detection and evaluation module comprises:
the nondestructive testing module is connected with the overlaying implementation module and is used for carrying out visual inspection and liquid permeation inspection on the branch pipe welding seam after overlaying is finished;
the size inspection module is connected with the surfacing implementation module and used for carrying out surface model development and size measurement on the branch pipe welding seam which is subjected to surfacing, obtaining data after the branch pipe welding seam is subjected to surfacing, comparing the data with the original data in the original state testing module, calculating surfacing size and deformation information, and evaluating whether the surfacing size and deformation meet the acceptance requirements or not according to the calculation result;
the structure performance testing module is connected with the surfacing implementation module and is used for inspecting the surfacing quality through the simulation piece and/or the process evaluation piece, performing chemical composition, metallographic structure, tensile, impact and bending tests and evaluating whether the test result meets the acceptance requirements or not;
the stress testing module is connected with the surfacing overall implementation module and used for carrying out stress analysis on a surfacing component through a simulation piece and evaluating whether the stress state and distribution meet the acceptance requirements or not;
and the mechanical integrity evaluation module is connected with the surfacing implementation module and used for developing mechanical integrity evaluation and evaluating whether the surfacing structure meets the requirement of full-period safe operation.
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| CN111421296B (en) * | 2020-03-05 | 2021-08-13 | 岭澳核电有限公司 | On-line surfacing repair method for maintaining weld joints of carbon steel branch pipe |
| CN111822855B (en) * | 2020-05-27 | 2022-01-25 | 南京航空航天大学 | Systematic regulation and control method for inhibiting welding defects |
| CN111515565B (en) * | 2020-06-03 | 2021-09-17 | 江西正好不锈钢有限公司 | Stainless steel pipe inner weld joint corrosion-resistant reinforcing welding method |
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| CN114669839A (en) * | 2022-03-29 | 2022-06-28 | 岭澳核电有限公司 | Weld repairing method |
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