CN1671502A - 改良锻焊工艺及由此工艺获得的产品 - Google Patents

改良锻焊工艺及由此工艺获得的产品 Download PDF

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CN1671502A
CN1671502A CNA03818107XA CN03818107A CN1671502A CN 1671502 A CN1671502 A CN 1671502A CN A03818107X A CNA03818107X A CN A03818107XA CN 03818107 A CN03818107 A CN 03818107A CN 1671502 A CN1671502 A CN 1671502A
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R·A·奥尔福德
J·J·登布尔
A·T·科尔
A·J·考克斯
K·季米特里亚季斯
M·埃夫蒂米乌
R·K·S·贡图里
R·N·沃拉尔
D·H·泽斯林格
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K1/00—Soldering, e.g. brazing, or unsoldering
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/0006—Resistance welding; Severing by resistance heating the welding zone being shielded against the influence of the surrounding atmosphere
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K11/00—Resistance welding; Severing by resistance heating
    • B23K11/02—Pressure butt welding
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    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
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    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K13/00—Welding by high-frequency current heating
    • B23K13/01—Welding by high-frequency current heating by induction heating
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    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/02—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating by means of a press ; Diffusion bonding
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    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
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    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
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    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
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Abstract

一种自动锻焊管子的方法，包括在一焊室中加热待接管端，与此同时使受热管端以一小间隔(S)相对彼此保持对正、平行，随后将受热管端压到一起，与此同时将一还原性保护气体注入焊室。管端位置由连至一高温测量与位置监控系统的摄像机监控，该系统在加热工序中自动调节管端彼此相对位置和加到管端的热量，直到管端达到一预定温度为止，随后使管端彼此相对移动距离(S+D)，该距离超过加热工序中管端间受监控的间隔(S)，差值为一选定的外加距离(D)，以使管端彼此对着牢固受压，将焊区管端外部和/或内部的加厚限制在可接受的水平上。

Description

改良锻焊工艺及由此工艺获得的产品
技术领域
本发明涉及一种改良锻焊工艺。
背景技术
锻焊涉及到将待接管端环周加热然后将管端压在一起形成冶金结合。
可采用多种加热技术使管端热得足以形成冶金接头。此类加热技术可包括电加热、电磁加热、感应加热、红外加热、燃弧加热和/或摩擦加热，也可综合运用这些及其他加热方法。
在本说明书中使用的锻焊这一术语拟包括所有牵涉到管端的环周加热及随后受热管端的冶金结合的技术，含通常以熔焊或扩散焊、摩擦焊、火花对焊和/或电阻对焊著称的各种焊接技术。
由授予Per H.Moe的4,566,625、4,736,084、4,669,650和5,721,413号美国专利知，下述做法可能是有益的，即在即将进行锻焊操作前和在此过程中用还原性冲洗气体如氢或一氧化碳冲洗管端，以使表面氧化物从受热管端去除，获得缺陷数量最少的冶金接头。另由2,719,207和4,728,760号美国专利，将含体积百分比约为95％的大体惰性气体如氩、氮和/或氦以及含体积百分比约为5％的还原性气体如氢和/或一氧化碳的不爆炸气体混合物用于火花对焊和感应对焊，也为人们所知。
实验表明，锻焊技术可在管端间形成高质冶金接合，如管端在焊接操作过程中用还原性气体混合物加以冲洗则尤为如此，但是，常会致使赤热的管端变形，在焊区形成加厚(upset)。
为了获得高质锻焊接头，需在加热阶段中以确定好的仅几毫米的间隔将管端与彼此平行的端面完全对正，管端一达到预定温度即终止加热，将管端锻冶一确定好的长度，并以确定好的冷速使管端迅速冷却；但在许多将管端焊在一起的场所如石油钻塔、铺管驳船(barge)和许多地面场所-地下或地上管道要在那里安装，上述工序都难以完成。
本发明的目的是为锻焊管子特别是油井和/或油田用管提供一种改良方法，以便获得高质冶金接合，且只需几分钟即可完成焊接过程。
发明内容
按照本发明，锻焊管子的改良方法包括在一焊室中将待接管端加热到一预定温度，与此同时使受热管端以一间隔(S)保持彼此相互大体对正、平行，随后受热管端彼此对着受压，与此同时将还原性保护气体注入焊室，其中在至少是部分加热、锻焊和/或冷却工序中，管端的位置由一定数量的环周隔开配置的摄像机监控，摄像机则被连接到一个高温测量与位置监控系统上，该系统在加热工序中自动调节管端彼此相对位置和加到管端上的热量，直到高温测量监控系统表明管端已达预定温度为止，随后使管端沿一距离(S+D)彼此相对移动，此距离(S+D)超过加热工序中监控的管端间的间隔(S)，差值为一选定的外加距离(D)。
优选地，这样来选择所述距离(D)，以使管端彼此对着牢固受压并这样变形，以使焊区中管端的外部和/或内部的加厚被限制在可以接受的水平上，并将所述还原性保护气体注入焊室，将氧化物从受热管端去除，以便形成具有最少氧化物夹杂和其他缺陷的锻焊接头。
优选地，将至少三台的一组摄像机环绕焊区以规则环周间隔加以配置，位置监控系统控制一夹持组件，该组件夹持至少其中一管，以使在加热阶段中，在受热管端间保持仅几毫米的间隔(S)，管端在锻焊工序中彼此相对移动一距离(S+D)，此距离(S+D)超过所述间隔(S)，差值小于几毫米。
另优选下法，即至少在部分锻焊操作过程中，将由大体惰性气体和还原性气体的不爆炸冲洗气体混合物注入焊室。一种优选不爆炸冲洗气体含体积百分比大于90％的氮、氩和/或氦以及体积百分比大于2％的氢。
附图说明
拟参照附图通过例子对本发明详加描述，诸图中：
图1绘示出用来实施本发明自动锻焊法的一组件的简图；
图2绘示出本发明一自动锻焊组件的纵剖图，该组件装备有隔件，用来使管端在加热阶段中保持预定的间隔；
图3为图2锻焊组件的横剖图；
图4为一管端的侧视图，该端设置有一系列锁紧和定向槽；
图5为图4管端的纵剖图；
图6为图4、5所示管端的横剖图，它是沿图4剖面线A-A剖开、朝箭头方向的剖视图。
具体实施方式
如图1所示，要被锻焊在一起的管端3、4的位置由摄像机1、2监控，摄像机被连接到一摄像机信号处理器5上，该摄像机信号处理器自动控制一夹持组件6，以使受热管端3A、4A间的间隔S在加热阶段中得到很好的确定，当高温测量控制装置表明管端沿其环周的至少相当大一部分达预定最小和/或最大温度时，使管端彼此相对移动，此后，启动夹持组件以使管端3A和4A朝向彼此移动一预定距离(S+D)，该距离(S+D)超过所述间隔(S)，差值为一小于几毫米的外加距离(D)，以使在锻焊端的整个环周上获得一大体均一的高质锻焊接头，并使在锻焊端3A、4A仅有最小的外部和/或内部加厚产生，所述加厚无须以后通过磨、铣或机加工加以去除。
参看图2、3，图中示出一锻焊组件，其中一组两对电极11A-D传输高频电流通过二管12之壁，此对管之端12a、12b由一组四个隔件13A-D保持一预定间隔S。位于二管12每侧的成对电极11A-B和11C-D由一电绝缘层15绝缘。隔件13A-D由隔电枢轴14固定在电极11上，每个隔件13A-D包括一耐热隔电头部，该头部宜于用陶质材料制造。
隔件13A-D可装有高温测量和/或压敏传感器，这些传感器可在加热阶段中检测每个管端12A-B的温度，还可检测管端12A-B相对隔件3的位置以及由管端12A-B加在隔件13上的压力。压敏传感器可包括位置贴近管端12A、12B或与它们的距离为一选定值的压电元件，以便将所传输与反射的振动之间的时差用来估计隔件13A-D和管端12A、12B之间的接触点和压力。
可将传感器连接到如图1所示的焊接控制组件上，如果管端12A、B达到一选定温度-该温度可低于或大体等于锻焊所需温度，组件就将隔件13从间隔中拉出去。隔件13A-D可另备有通道，将还原性不爆炸保护气体经通道朝受热管端注入。非爆炸性保护气体宜于含体积百分比大于90％的氮和体积百分比大于2％的氢。
管端12A、B在加热和锻焊操作中相对彼此准确定位对在焊区获得高的焊接质量和最小加厚是很重要的。
可能有益的是，给管端设置适应自动锻焊工具的成型夹持臂的锁紧和定向槽。
图4、5、6示出设置有三对半圆槽21-23A-B的管端20。自动焊接工具可备有半圆夹持臂，这些夹持臂具有适应半圆槽21-23A-B的型廓和/或球珠，这样即使将几千米长的管串(tubular string)从管端20悬垂到井中，也能将管端20从夹持臂滑脱的危险减至最小。
可采用本发明的方法通过锻焊将管段连接到任何长度的管串上。此管串可以是油田用管之串，如油和/或气井套管、悬在油和/或气井中的生产管道、在离岸平台甲板和海床间延伸的垂直或悬链状钢制提升器管、离岸结构的管腿、浮动张力腿平台(floating tension legplatform)以链束(tendon)著称的管式张力腿，也可以是输送流体用的海底或离岸的地下或地上管道。
在加热和锻焊操作中，可通过将心轴或矛状体(spear)插入焊区管内将待焊管端内部密封与管串内其他部分隔离，此心轴或矛状体可设置有可扩张密封圈、保护气体注入装置和/或焊接检验装置如以EMAT焊接检验设备著称的电磁声学换能器。换个办法，可在锻焊操作中通过将扩张硬泡状物如聚氨酯泡状物注入管中将邻接焊区的管子的内部封离，在锻焊操作之后将泡状物从管内去除。
可在或靠近自动锻焊工具处用加工工具或在管子制造厂将待锻焊管端加工成互补的凹凸形。
在从制造厂到锻焊场所的运输过程中，可用金属或塑料盖将管端保护起来，此盖可备有可扩张夹持型廓或球珠，型廓或球珠可适应图4、5、6中所示的锁紧槽。
可将本发明自动锻焊装置与以铁质油井修建工(roughneck)著称的油和/或气打井或生产机具上管子操纵装置结合起来。管子操纵装置可备有内部和/或外部抓取管子的抓取臂和/或低痕模(low-scarringdie)和/或球珠。

Claims (17)

1.一种锻焊管子的方法，其中待接管端在焊室内加热至预定温度，与此同时使受热管端以一间隔(S)相对彼此大体保持对正、平行，随后使管端受压而彼此抵靠，与此同时将还原性保护气体注入焊室，在加热、锻焊和/或冷却工序的至少一部分过程中，管端位置由一定数量的环周隔开配置并被连接到一高温测量与位置监控系统上的摄像机监控，所述高温测量与位置监控系统在加热工序中自动调节管端的彼此相对位置和加到管端的热量直到高温测量监控系统表明管子端面达到预定温度为止，随后使管端朝向彼此移动一距离(S+D)，此距离(S+D)超过加热工序中管端间的被监控的间隔(S)，差值为一选定的外加距离(D)。
2.如权利要求1所述的方法，其特征在于，所述外加距离(D)这样加以选择，以使管端彼此靠着牢固受压并这样变形，以使焊区内的管端外部和/或内部加厚量被限制在一可接受的水平上，而且，将还原性保护气体注入焊室，以便将氧化物从受热管端去除，以形成一具有最少量氧化物夹杂和其他缺陷的锻焊接头。
3.如权利要求1所述的方法，其特征在于，将至少三台的一组的摄像机环绕焊区以规则的环周间隔加以配置，位置监控系统则对夹持至少一管的夹持组件这样进行控制，以使在加热阶段中受热管子端面之间保持仅几毫米的间隔，并使管端在锻焊工序中朝向彼此移动一距离(S+D)，此距离(S+D)超过所述间隔(S)，差值小于几毫米。
4.如权利要求1所述的方法，其特征在于，在锻焊操作的至少部分过程中，将一大体惰性气体和一还原性气体的不爆炸冲洗气体混合物注入焊室。
5.如权利要求4所述的方法，其特征在于，不爆炸冲洗气体混合物含体积百分比大于90％的氮、氩和/或氦以及体积百分比大于2％的氢。
6.如任何前述权利要求所述的方法，其特征在于，所述连接的管子为油井和/或油田用管，它们在或靠近钻井机、离岸平台、铺管装置或油和/或气生产设备处通过锻焊连接在一起。
7.如权利要求1所述的方法，其特征在于，在锻焊操作前加热阶段中通过下述方式将待接管端之间保持一预定间隔(S)：在管端之间插入大体等厚度的多个耐热隔件、在加热阶段中将管子的管端压靠在隔件上、在将管端压在一起以便通过锻焊将它们连接之前将隔件从间隔中去除。
8.如权利要求7所述的方法，其特征在于，管端由电极加热，所述电极传输一高频电流通过管壁以便加热管端，每个隔件厚度均小于5毫米。
9.如权利要求8所述的方法，其特征在于，将三个或三个以上隔件的组件插在管端之间，每个隔件厚度均小于2毫米。
10.如权利要求7、8或9所述的方法，其特征在于，隔件装备有检测隔件与相邻管端间的温度、压力和/或接触点的传感器，这些传感器被连接到一焊接控制组件，焊接控制组件这样控制管子夹持设备，以使管端在加热和后续锻焊阶段相对彼此大体对正且不倾斜，焊接控制组件在管端达到一预定温度时将隔件拉离间隔。
11.如权利要求7所述的方法，其特征在于，隔件装备有冲洗气体注入通道，通道在加热阶段中注射一冲洗气体使冲洗气体环绕待接管子的管端并/或注入待接管子的内部。
12.如任何前述权利要求所述的方法，其特征在于，在加热阶段前将一硬泡沫状物注入待接管子内部，泡沫状物在锻焊操作中在邻接待接管端的管子的内部提供一临时密封物，在锻焊操作后将密封物从管内去除。
13.一种管串包括已用按权利要求1-12中的任何一个所述的锻焊方法加以连接的管子。
14.如权利要求13所述的管串，其特征在于，所接管子为油田用管。
15.如权利要求13或14所述的管串，其特征在于，管串形成油和/或气生产井中套管或生产管道的一部分。
16.如权利要求13所示的管串，其特征在于，管串形成离岸油和/或气生产平台与海底油和/或气生产井之间的钢制垂直或悬链状提升器管的一部分。
17.如权利要求13所述的管串，其特征在于，管串形成钢制离岸结构的管腿或张力腿平台的钢制管子张力腿的一部分。
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US7282663B2 (en) 2007-10-16
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CN100346920C (zh) 2007-11-07
ATE415233T1 (de) 2008-12-15
CA2494347A1 (en) 2004-02-12
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