Automatic welding system for deepwater steel catenary riser

Abstract

The invention discloses a deepwater steel catenary riser automatic welding system which comprises a support, two to-be-welded risers are placed on the support, one of the to-be-welded risers is sleeved with an annular rail, a welding trolley is arranged on the annular rail in a sliding mode, the welding trolley slides along the annular rail, and the welding trolley is arranged on the support. The welding trolley is used for welding a welding seam between the two vertical pipes to be welded, the control system is connected with the welding trolley, the electric arc tracking system and the welding system, and the control system is used for controlling the welding trolley, the electric arc tracking system and the welding system. According to the automatic welding system for the deepwater steel catenary riser, automatic welding of the two to-be-welded risers is achieved, stress concentration is reduced, the fatigue life of the to-be-welded risers is prolonged and can reach 107 times, and the welding efficiency and quality of ocean engineering are improved.

Description

Technical Field

[0001] The invention belongs to the technical field of welding, and in particular relates to an automatic welding system for a deep-water steel catenary riser. Background Art

[0002] The deepwater steel catenary riser (SCR) is the main component of the offshore platform. During use, it is extremely easy to be damaged due to the influence of various environmental factors such as special ocean waves, tides, typhoons, etc., so its welding requires a high-quality welding system. For offshore platforms, a high-quality welding system should have the ability to achieve high fatigue resistance welding and meet the use conditions of high temperature, humidity and salt spray harsh environments. The mechanical system should be light and stable, and easy to use for construction and operation.

[0003] The current domestic pipeline welding system uses ordinary internal welding, or welding with copper liner, and arc tracking mode, which cannot achieve the welding of steel catenary risers and cannot meet high fatigue performance requirements.

[0004] Therefore, it is urgent to design an automatic welding system for deepwater steel catenary risers to solve the problem that the above-mentioned prior art cannot realize welding of steel catenary risers, resulting in poor fatigue resistance. Summary of the invention

[0005] In order to solve the technical problem mentioned in the background technology that the existing technology cannot realize welding of steel catenary risers, resulting in poor fatigue resistance, a deepwater steel catenary riser automatic welding system is provided to solve the above problem.

[0006] To achieve the above purpose, the specific technical scheme of the deepwater steel catenary riser automatic welding system of the present invention is as follows: A deepwater steel catenary riser automatic welding system is characterized in that it includes a bracket, on which two risers to be welded are placed, one of the risers to be welded is provided with an annular track, a welding trolley is slidably arranged on the annular track, the welding trolley slides along the annular track to weld the weld between the two risers to be welded, and also includes a control system, a welding system and an arc tracking system, the control system is connected with the welding trolley, the arc tracking system and the welding system to control the welding trolley, the arc tracking system and the welding system.

[0007] Furthermore, the annular track includes an annular body, which is sleeved outside the vertical pipe to be welded. The annular body is provided with multiple tooth blocks, and the multiple tooth blocks are arranged in sequence along the circumferential direction of the annular body. The welding trolley is provided with gears, which mesh with the multiple tooth blocks.

[0008] Furthermore, the annular body includes a first semi-annular track and a second semi-annular track, the first semi-annular track and the second semi-annular track are spliced ​​into a ring, and the first semi-annular track and the second semi-annular track are detachably arranged outside the riser to be welded.

[0009] Furthermore, a first pulley and a second pulley are respectively arranged on both sides of the welding trolley, the annular body is clamped between the first pulley and the second pulley, and the first pulley and the second pulley slide along the annular track.

[0010] Furthermore, the welding carriage is also provided with a welding gun, a straight swing structure and an angular swing structure. The welding gun is arranged on the straight swing structure, and the straight swing structure is arranged on the angular swing structure. The straight swing structure is used to control the linear swing of the welding gun, and the angular swing structure is used to control the angular swing of the welding gun.

[0011] Furthermore, it also includes a mounting frame, on which a welding wire reel is rotatably arranged, on which welding wire is wound, and a wire feeder is also arranged on the mounting frame, through which the welding wire is transmitted to the welding gun.

[0012] Furthermore, it also includes a gun cable, which is arranged between the welding gun and the wire feeder, and the welding wire is placed in the gun cable.

[0013] Furthermore, the arc tracking system collects welding current and welding voltage through the electrical signal acquisition module, and adjusts the height and left and right position of the welding wire by analyzing the height and left and right deviations of the welding wire in the weld groove so that the welding wire on the welding gun is placed in the center of the weld.

[0014] Furthermore, the control system includes a control box, and the control box is arranged on the mounting frame.

[0015] Furthermore, it also includes a remote controller, which is placed on the mounting frame and is used to remotely control the movement of the welding trolley on the circular track.

[0016] The deepwater steel catenary riser automatic welding system of the present invention has the following advantages: Two risers to be welded are placed on a bracket, one of the risers to be welded is provided with an annular track on its outer casing, a welding trolley is slidably arranged on the annular track, the welding trolley slides along the annular track to weld the weld between the two risers to be welded, and the system also includes a control system, a welding system and an arc tracking system, the control system is connected with the welding trolley, the arc tracking system and the welding system to control the welding trolley, the arc tracking system and the welding system, so as to realize automatic welding of the two risers to be welded, reduce stress concentration, and increase the fatigue life of the risers to be welded, which can reach 107 times, and improve the welding efficiency and quality of marine engineering. BRIEF DESCRIPTION OF THE DRAWINGS

[0017] Figure 1 It is a system schematic diagram of the automatic welding system for deep-water steel catenary riser of the present invention; Figure 2 It is a structural schematic diagram of the automatic welding system for deep-water steel catenary riser of the present invention; Figure 3 It is a system diagram of the arc tracking system of the present invention.

[0018] Description of the markings in the figure: 1. Welding wire; 2. Wire feeder; 3. Control box; 4. Remote control; 5. Arc tracking system; 6. Welding machine; 7. Welding carriage; 8. Circular track; 9. Gun guide wire; 10. Bracket; 11. Mounting frame. DETAILED DESCRIPTION

[0019] In order to make the purpose, technical solution and advantages of the embodiments of the present invention clearer, the technical solution in the embodiments of the present invention will be clearly and completely described below in conjunction with the drawings in the embodiments of the present invention. Obviously, the described embodiments are part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative work are within the scope of protection of the present invention.

[0020] Those skilled in the art will appreciate that, although some embodiments herein include certain features included in other embodiments but not other features, the combination of features of different embodiments is meant to be within the scope of the present invention and form different embodiments. For example, in the claims, any one of the claimed embodiments may be used in any combination.

[0021] Please refer to the attached Figure 1 To Attachment Figure 3 The invention describes an automatic welding system for deepwater steel catenary risers.

[0022] like Figure 1 and Figure 2 As shown, the automatic welding system for deep-water steel catenary riser in the present invention includes a bracket 10, on which two risers to be welded are placed, one of which is provided with an annular track 8, on which a welding trolley 7 is slidably arranged, and the welding trolley 7 slides along the annular track 8 to weld the weld between the two risers to be welded, and also includes a control system, a welding system and an arc tracking system 5, and the control system is connected with the welding trolley 7, the arc tracking system 5 and the welding system to control the welding trolley 7, the arc tracking system 5 and the welding system. In this embodiment, the arc tracking system 5 mainly includes a current and voltage acquisition and feedback unit, and the welding system mainly includes a welding power supply, a wire feeding unit and a gas supply unit. The mechanical clutch part of the welding trolley 7 adopts a compact design, which is small and stable, light in weight, convenient for welder operation, and ensures the long-term stable operation of the welding trolley 7. In this embodiment, the riser to be welded is a deep-water steel catenary riser.

[0023] Two risers to be welded are placed on a bracket 10, wherein an annular track 8 is provided on the outer casing of one of the risers to be welded, a welding trolley 7 is slidably provided on the annular track 8, and the welding trolley 7 slides along the annular track 8 to weld the weld between the two risers to be welded. The bracket also includes a control system, a welding system and an arc tracking system 5. The control system is connected with the welding trolley 7, the arc tracking system 5 and the welding system to control the welding trolley 7, the arc tracking system 5 and the welding system to realize automatic welding of the two risers to be welded, reduce stress concentration, and improve the fatigue life of the risers to be welded, which can reach 107 times, and improve the welding efficiency and quality of marine engineering.

[0024] Further, if Figure 2 As shown, the annular track 8 includes an annular body, which is sleeved outside the riser to be welded. The annular body is provided with a plurality of tooth blocks, which are arranged in sequence along the circumferential direction of the annular body. The welding trolley 7 is provided with gears, which mesh with the plurality of tooth blocks. The welding trolley 7 is also provided with a driving motor, which drives the gears to rotate so that the welding trolley 7 slides on the annular body to achieve welding of the weld. The annular body includes a first semi-annular track and a second semi-annular track, which are spliced ​​into an annular shape, and the first semi-annular track and the second semi-annular track are detachably arranged outside the riser to be welded. The annular body is arranged as the first semi-annular track and the second semi-annular track, which is convenient for installation outside the riser to be welded.

[0025] The welding environment in the offshore platform is harsh, and long-term use can easily lead to damage to the gear blocks. Compared with the traditional integrated track, multiple gear blocks are arranged in sequence. When one or several gear blocks are damaged, only the damaged gear blocks need to be replaced, which greatly reduces resource waste, and is quick to install and improves installation efficiency.

[0026] Furthermore, a first pulley and a second pulley are respectively provided on both sides of the welding trolley 7, and the annular body is clamped between the first pulley and the second pulley. The first pulley and the second pulley slide along the annular track 8. The first pulley and the second pulley cooperate with the annular body, and the gear and the gear block cooperate to achieve the sliding setting of the welding trolley 7 on the annular body.

[0027] Further, if Figure 2 As shown, the welding carriage 7 is also provided with a welding gun, a straight swing structure and an angular swing structure, the welding gun is arranged on the straight swing structure, the straight swing structure is arranged on the angular swing structure, the straight swing structure is used to control the straight swing of the welding gun, and the angular swing structure is used to control the angular swing of the welding gun. In this embodiment, the welding gun is a CMT welding gun, which is mounted on the straight swing structure and the angular swing structure, and establishes communication with the Fronius CMT welding power source.

[0028] The vertical swing structure and the angular swing structure are controlled by servo motors, and the current and voltage collected in real time are used to feedback and adjust the vertical swing structure and the angular swing structure. During the welding process of the vertical pipe to be welded, the welding current and voltage are collected, and a large amount of data is collected by computer during the welding process with different welding layers, different parameters and different angles to form a set of its own database, which can be used for up and down tracking and left and right tracking of the weld during actual use.

[0029] Further, if Figure 2 As shown, the automatic welding system for deep-water steel catenary riser in the present invention also includes a mounting frame 11, on which a welding wire 1 reel is rotatably arranged, and the welding wire 1 is wound on the welding wire 1 reel. A wire feeder 2 is also arranged on the mounting frame 11, and the welding wire 1 is transmitted to the welding gun through the wire feeder 2. The automatic welding system for deep-water steel catenary riser in the present invention also includes a gun cable, which is arranged between the welding gun and the wire feeder 2, and the welding wire 1 is placed in the gun cable. The welding power supply is based on the unified expert library of Fronius welding machine 6, and the welding voltage adjustment is achieved through voltage correction, and the voltage is reduced to increase the arc stiffness. The wire feeding unit is mainly composed of welding wire 1 and wire feeder 2, and the wire feeder 2 and the welding power supply are connected to the welding gun through the gun cable 9.

[0030] Further, if Figure 1 and Figure 2 As shown, the arc tracking system 5 collects welding current and welding voltage through the electrical signal acquisition module, and adjusts the height and left and right position of the welding wire 1 by analyzing the height and left and right deviations of the welding wire 1 in the weld groove so that the welding wire 1 on the welding gun is placed in the center of the weld.

[0031] The welding current and welding voltage are to improve the welding quality of the riser to be welded and solve the problem of unfused side walls, ensuring the full-automatic welding and stability of the riser to be welded. In order to avoid the current and voltage value filter coefficients of the communication return being too large, and the communication data response lag when the arc occurs, the system is additionally equipped with an external current acquisition unit and a tracking unit. The response time of the mutual inductor and the tracking unit can reach 0.1ms, which increases the real-time and accuracy of the data and greatly reduces the adjustment frequency of the operator.

[0032] The excess height at the root of the riser joint to be welded is a key factor that causes stress concentration and fatigue failure. In this embodiment, during the welding process of the deepwater steel catenary riser automatic welding system, the base welding process adopts the cold metal transfer (CMT) welding process, and the filling adopts the pulse welding process, which can achieve a root excess height of ≤0.5mm and achieve a significant improvement in fatigue performance.

[0033] The welding process is directly called through the database. In order to adapt to different welding angles, the 180° on one side is divided into 12 blocks. Different welding parameters are set every 15°, including wire feeding speed, welding speed, swing amplitude, side stop time, welding current, and welding voltage. The database is called and combined to form different welding processes to ensure welding quality.

[0034] Further, if Figure 2 As shown, the control system includes a control box 3, which is arranged on a mounting frame 11. According to the diameter of the pipe to be welded, the control system sends the welding speed at different angles to the welding carriage 7, sends the swing amplitude, frequency and left / right dwell time to the straight swing / angle swing motor, and sends the wire feeding speed, such as welding current and welding voltage, to the welding power supply. During the welding process, the arc tracking system 5 collects current and voltage data from the welding power supply through the electrical signal acquisition module, which is used to analyze the height and left and right deviations of the welding wire 1 in the weld groove, and drives the servo motor to adjust the height and left and right position of the welding wire 1.

[0035] Further, if Figure 2 As shown, the deepwater steel catenary riser automatic welding system of the present invention further includes a remote controller 4, which is placed on the mounting frame 11 and is used to remotely control the movement of the welding trolley 7 on the circular track 8. The deepwater steel catenary riser automatic welding system of the present invention further includes a touch screen as an operating interface of the control system.

[0036] Further, if Figure 3 As shown in the figure, the arc tracking system determines whether the arc is offset by detecting the change of welding current and makes corresponding adjustments. The basic principle of the arc tracking system: the change of arc length between the welding gun and the workpiece during welding and the change of welding current and welding voltage are used to detect the height and left and right deviation of the welding gun. The detection signal is transmitted to the acquisition module through the controller, and the acquisition module transmits the real-time arc voltage to the controller after receiving the boundary arc voltage signal transmitted by the control system. The controller extracts the left and right and upper and lower deviation values ​​through the internal deviation extraction algorithm, and then calculates the difference through the deviation correction algorithm, and then transmits it to the control system through the register reading and writing method, so as to realize automatic adjustment of the tracking step length and tracking direction.

[0037] The deepwater steel catenary riser automatic welding system of the present invention is a fully automatic welding equipment with high fatigue performance welding capability, which can realize high-quality automatic welding of the riser to be welded, with the root excess height ≤0.5mm, thereby reducing stress concentration and improving the high-cycle fatigue life of the riser, with the life span reaching 107 times, realizing high-quality welding of the circumferential weld of the riser to be welded, with a low welding defect rate and good structural fatigue performance, and can cope with complex marine environments.

[0038] The high-precision arc tracking technology of the welding carriage 7 automatic welding has improved the current and voltage collection method, which can achieve high-precision tracking of the height and left and right of the welding process, and improve the welding efficiency and quality of marine engineering.

[0039] The operating interface of the control system is simple and easy to operate, and can realize the calling, modification, storage and transmission of welding parameters, and can realize arc tracking and angular and vertical swing control of the welding carriage 7, ensuring the safe and orderly operation of the welding operation.

[0040] Obviously, the above embodiments of the present invention are merely examples for clearly illustrating the present invention, and are not intended to limit the embodiments of the present invention. For those skilled in the art, other different forms of changes or modifications can be made based on the above description. It is not necessary and impossible to list all the embodiments here. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the claims of the present invention.

Claims

1. A deepwater steel catenary riser automatic welding system, characterized in that: The invention comprises a bracket, on which two risers to be welded are placed, wherein an outer shell of one of the risers to be welded is provided with an annular track, on which a welding trolley is slidably arranged, and the welding trolley slides along the annular track to weld the weld between the two risers to be welded. The invention also comprises a control system, a welding system and an arc tracking system, wherein the control system is connected with the welding trolley, the arc tracking system and the welding system to control the welding trolley, the arc tracking system and the welding system.

2. The deepwater steel catenary riser automatic welding system according to claim 1 is characterized in that: The annular track includes an annular body, which is sleeved outside the vertical pipe to be welded. The annular body is provided with multiple tooth blocks, and the multiple tooth blocks are arranged in sequence along the circumferential direction of the annular body. The welding trolley is provided with gears, which mesh with the multiple tooth blocks.

3. The deepwater steel catenary riser automatic welding system according to claim 2 is characterized in that: The annular body comprises a first semi-annular track and a second semi-annular track, the first semi-annular track and the second semi-annular track are spliced ​​into an annular shape, and the first semi-annular track and the second semi-annular track are detachably arranged outside the riser to be welded.

4. The deepwater steel catenary riser automatic welding system according to claim 2 is characterized in that: A first pulley and a second pulley are respectively arranged on both sides of the welding trolley, the annular body is clamped between the first pulley and the second pulley, and the first pulley and the second pulley slide along the annular track.

5. The deepwater steel catenary riser automatic welding system according to claim 1 is characterized in that: The welding carriage is also provided with a welding gun, a straight swing structure and an angular swing structure. The welding gun is arranged on the straight swing structure, and the straight swing structure is arranged on the angular swing structure. The straight swing structure is used to control the linear swing of the welding gun, and the angular swing structure is used to control the angular swing of the welding gun.

6. The deepwater steel catenary riser automatic welding system according to claim 1 is characterized in that: The utility model also comprises a mounting frame, on which a welding wire reel is rotatably arranged, welding wire is wound on the welding wire reel, and a wire feeder is also arranged on the mounting frame, through which the welding wire is transmitted to the welding gun.

7. The deepwater steel catenary riser automatic welding system according to claim 6 is characterized in that: The utility model also comprises a gun cable, which is arranged between the welding gun and the wire feeder, and the welding wire is arranged in the gun cable.

8. The deepwater steel catenary riser automatic welding system according to claim 6 is characterized in that: The arc tracking system collects welding current and welding voltage through the electrical signal acquisition module, and adjusts the height and left and right position of the welding wire by analyzing the height and left and right deviations of the welding wire in the weld groove so that the welding wire on the welding gun is placed in the center of the weld.

9. The deepwater steel catenary riser automatic welding system according to claim 6, characterized in that: The control system comprises a control box which is arranged on a mounting frame.

10. The deepwater steel catenary riser automatic welding system according to claim 6, characterized in that: The utility model also comprises a remote controller, which is placed on the mounting frame and is used for remotely controlling the movement of the welding trolley on the circular track.

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