МурманшельфИнфо. 2009, N 1 (6).

Система автоматической двухдуговой сварки Ñèñòåìà ñâàðêè «Ñàòóðíàêñ», âêëþ÷àþùàÿ íà- ïðàâëÿþùèé ïîÿñ è ñâàðî÷íûé àïïàðàò ñ äâóìÿ ýëåêòðîäàìè, èñïîëüçóåòñÿ íà òðóáîóêëàäî÷íûõ áàðæàõ ñ 1988 ã., à ïðè ðåàëèçàöèè íàçåìíûõ ïðî- åêòîâ – ñ 1994 ãîäà. Ñèñòåìà íàõîäèò ïðèìåíå- íèå ïðè ðàáîòå ñ òðóáàìè äèàìåòðîì îò 4,5 äî 64 äþéìîâ (114 - 1626 ìì.) è òîëùèíîé ñòåíêè 6 - 45 ìì. Åå èñïîëüçóþò ïðè ñâàðêå ñòàëåé âñåõ òèïîâ, â òîì ÷èñëå ñâåðõïðî÷íûõ (ìàðêè Õ80 è âûøå), íåðæàâåþùèõ, àðìèðîâàííûõ, äóïëåêñà, ñóïåð- äóïëåêñà è äð. Ïðè äâóõýëåêòðîäíîì ìåòîäå ñâàðêè çà êàæ- äûé ïðîõîä ïðîèñõîäèò íàëîæåíèå âäâîå áîëüøå- ãî êîëè÷åñòâà ïðèñàäî÷íîãî ìàòåðèàëà, ÷åì ïðè îäíîýëåêòðîäíîì, ÷òî ïîçâîëÿåò óäâîèòü ïðîèç- âîäèòåëüíîñòü ñâàðî÷íûõ ðàáîò. Ïîìèìî ýòîãî òåõíîëîãèÿ ïîçâîëÿåò äîáèòüñÿ ïîâûøåíèÿ êà÷å- ñòâà ñâàðêè, óìåíüøåíèÿ æåñòêîñòè ñâàðíîãî øâà è óëó÷øåíèÿ åãî ìåõàíè÷åñêèõ õàðàêòåðèñòèê. Ñâàðî÷íûå êàáèíû «Ñàòóðíàêñ» ñîäåðæàò äâà ñâàðî÷íûõ àïïàðàòà è åùå äâà çàïàñíûõ, ãîòîâûõ â ëþáîé ìîìåíò âêëþ÷èòüñÿ â ðàáîòó.  êàæäîé êà- áèíå ïðåäóñìîòðåíû èñòî÷íèêè ñâàðî÷íîãî òîêà, èíòåðôåéñû ðàñïðåäåëåíèÿ çàùèòíîãî ãàçà, îáî- ðóäîâàíèå äëÿ ïîäà÷è ïðîâîëîêè è ýëåêòðîííîå óñòðîéñòâî äëÿ êîíòðîëÿ ïàðàìåòðîâ ïðîöåññà. Äëÿ ðàáîòû êàáèíû òðåáóåòñÿ òîëüêî ïðîâåñòè ýëåêòðè÷åñòâî è çàùèòíûé ãàç. Ñâàðî÷íóþ ñòàí- öèþ ìîæíî íàñòðîèòü íà âûïîëíåíèå îäèíî÷íîãî ïðîõîäà èëè ïîëíóþ ñâàðêó ñòûêà îò êîðíåâîãî øâà äî îáëèöîâêè. Îáîðóäîâàíèå ïðîøëî èñïûòàíèÿ â êëè- ìàòè÷åñêîé êàìåðå ïðè íèçêèõ òåìïåðàòóðàõ äî – 47 ãðàäóñîâ. Îñíîâíàÿ ñôåðà èñïîëüçîâàíèÿ - ìîðñêèå ïðîåêòû è ñòðîèòåëüñòâî ñóõîïóòíûõ òðóáîïðîâî- äîâ.  2008 ãîäó ïðè èñïîëüçîâàíèè äàííîé òåõíî- ëîãèè âûïîëíåíà ñâàðêà â çîíàõ ñåéñìè÷åñêîé àê- òèâíîñòè íà î. Ñàõàëèí íà òðóáàõ âûñîêîãî êëàññà áåçîïàñíîñòè. Íà ó÷àñòêè ãåîëîãè÷åñêèõ ðàçëîìîâ çåìíîé êîðû ïðèøëîñü 1065 ñòûêîâ. «Ñàòóðíàêñ»- òåõíîëîãèþ ïëàíèðóåòñÿ èñïîëüçîâàòü ïðè ðàçðà- áîòêå Áîâàíåíêîâñêîãî íåôòåãàçîêîíäåíñàòíîãî ìåñòîðîæäåíèÿ äëÿ ñâàðêè 200-êèëîìåòðîâîãî ó÷àñòêà òðóá äèàìåòðîì 56 äþéìîâ (1420 ìì) ñ òîëùèíîé ñòåíîê 23 - 33,4 ìì. Интеллектуальный тепловизионный контроль Òåïëîâèçîð – ýòî èçìåðèòåëüíûé ïðèáîð, ïî- çâîëÿþùèé âèäåòü òåïëîâîå èçëó÷åíèå è ïîëó÷àòü òåðìîãðàììó îáúåêòà íà äèñïëåå. Èñïîëüçóåòñÿ â íåôòåãàçîâîé îòðàñëè äëÿ èçìåðåíèÿ óðîâíÿ æèäêîñòè â ðåçåðâóàðàõ.  2008 ãîäó íà ðîññèé- ñêîì ðûíêå òåïëîâèçèîííîé òåõíèêè áûëà ïðåä- ñòàâëåíà íîâèíêà îò âåäóùåãî ïðîèçâîäèòåëÿ ïîðòàòèâíîãî èçìåðèòåëüíîãî îáîðóäîâàíèÿ íå- ìåöêîãî êîíöåðíà Testo AG. Òåïëîâèçîð Testo 880 äåòàëüíî âèçóàëèçèðóåò ïîâðåæäåíèÿ ñîåäèíå- íèé ýëåêòðè÷åñêèõ ñèñòåì è êîìïîíåíòîâ, îáëà- äàåò âûñîêîé òåìïåðàòóðíîé ÷óâñòâèòåëüíîñòüþ (ìåíåå 0,1 ãðàäóñîâ). Ïðåèìóùåñòâà - îïöèîííûé ñìåííûé òåëåîáúåêòèâ, çàïàòåíòîâàííûé ôèëüòð äëÿ çàùèòû îáúåêòèâà, äåòåêòîð 160õ120 ñ èíòåð- ïîëÿöèåé èçîáðàæåíèÿ äî 320õ240 ïèêñåëåé. Ïðîãðàììíîå îáåñïå÷åíèå, âõîäÿùåå â ñî- ñòàâ ïîñòàâêè, ïðåäëàãàåò øèðîêèå âîçìîæíîñòè System of automatic two-arc welding Saturnax welding system including a pilot and a welder with two electrodes has been used on pipe- laying barges since 1998; since 1994 it has been used in onshore projects. The system can be applied for pipes from 4,5 to 64 inches (114-1626 mm) in diameter and from 6 to 45 mm thick. It is used for welding steel of all types, including ultrastrong (type X80 and higher), stainless, reinforced, duplex, superduplex and others. The two-electrode method of welding compared to the one-electrode one, allows to lay a double amount of adding material in one operation which doubles the productivity. Besides this technology makes it possible to improve the quality of welding, to decrease the rigidity of weld and to improve its mechanical characteristics. Saturnax welding chambers contain two basic welders and two spare ones, which can be put into operation at any moment. Each chamber is provided with welding current supply, an interface for distributing shielding gas, equipment for wire supply and electronic equipment to control the parameters of the process. It is necessary just to supply electricity and shielding gas in order to put the chamber into operation. The welding station may be programmed to perform a simple single welding operation or to perform a complex operation from root welding to coating. The sphere of application of the equipment is mostly offshore projects and onshore construction of pipelines. In 2008 the technology was applied for pipes of the highest safety class while welding in the zones of seismic activity on the island of Sakhalin. 1065 joints were made in areas of the Earth’s crust fractures. The Saturnax technology is planned to be used in developing the Bovanenkovo oil and gas deposit to weld a 200-kilometer stretch of pipes, 56 inches (1420 mm) in diameter and 23-33,4 mm thick. Intellectual thermal-imaging control A thermal imager is a measuring device providing the opportunity to see heat emission and to obtain a thermogramme of an object on the display. It is used in oil and gas industry for measuring the level of liquid in tanks. The new product of the German concern TestoAG, the leading producer of portable measuring equipment, was presented at the Russian market of thermal-imaging equipment in 2008. The thermal imager Testo-880 visualizes in detail damages in joints of electric systems and their components, possesses high temperature sensitivity (less than 0,1 degree). Its new advanced features are an optional replaceable telescopic lens, patent filter protecting the lens, a detector 160x120 with the picture interpolation up to 320x240 pixels. The software included in the package offers great opportunities for picture processing and the built-in digital camera makes ordinary pictures of objects under control in addition to their thermal images. Since January 2009 the production of the modernized TESTO-880-1 version was started. At present the thermal imager TESTO-880-1 is equipped with a built-in digital camera and possesses new features: automatic detection of hot/cold spots; rapid tuning of emission factor which enables to observe the changes of thermal image in real-time mode; manual start of self-calibrating thermal imager. Íîâûå òåõíîëîãèè New technologies ìàðò 2009 ¹ 1 (6) ÌóðìàíøåëüôÈíôî 71