Key data analysis and digital transfer of mechanized anti-corrosion joint repair

With the rapid development of technology, networking, digitization, and intelligence have become the major trends in social development, and the construction of oil and gas pipelines has also entered the era of "smart pipelines". In order to comply with the development trend of pipeline construction, China Petroleum Corporation has timely proposed the "Five Modernizations" of standardized design, factory prefabrication, modular construction, mechanized operation, and information management, as well as the "Three Comprehensive" construction goals of full digital transfer, full intelligent operation, and full lifecycle management. It is determined to build the China Russia East Gas Pipeline Project into the first "smart pipeline" in China. The mechanized anti-corrosion and patching technology and equipment have promoted the mechanized assembly line operation of on-site anti-corrosion and patching in the China Russia East Pipeline Project, effectively improving the quality and construction efficiency of anti-corrosion and patching. In order to achieve strict control over the quality of anti-corrosion joint repair during pipeline construction and fully digital data transfer, avoid human tampering, and ensure the authenticity, integrity, and traceability of key construction data, China Petroleum Pipeline Science Research Institute Co., Ltd. has analyzed and determined the key factors and construction data that affect the quality of on-site anti-corrosion joint repair of pipelines. Through the development of data collection and wireless transmission systems, It can automatically collect, store, and transmit real-time wireless remote data to the data receiving terminal for key construction data that affects the quality of anti-corrosion joint repair.

1 Analysis of key factors affecting the quality of mechanized anti-corrosion joint repair

The premise and basis for achieving the full digital transfer of key construction data for mechanized anti-corrosion joint repair is the analysis of key factors affecting the quality of anti-corrosion joint repair and the determination of construction data that needs to be collected and transmitted. Surface treatment of pipe mouth, preheating of pipe mouth, shrinkage of heat shrink tape and melting glue are key processes for heat shrink tape or 3LPE Heat Shrink Sleeves anti-corrosion joint repair, while automatic rust removal equipment Intermediate frequency heating equipment and infrared heating equipment are the main equipment for achieving mechanized operations in the key process of anti-corrosion joint repair.
 

1.1 Surface treatment of pipe openings

The indicators directly related to the quality of pipe surface treatment are surface roughness, rust removal level, and surface dust level.

1.2 Preheating of pipe openings

The direct factors affecting the preheating quality of the nozzle are preheating temperature, depth, and temperature uniformity. The intermediate frequency heating equipment at the nozzle is shown in Figure 2.

1.3 Heat shrink sleeves shrinkage and melt adhesive

The direct factors affecting the shrinkage of heat shrink tape and the melting of adhesive are temperature and time. The infrared heating equipment at the pipe mouth is shown in Figure 3. The heat source of the infrared heating equipment comes from the infrared radiator. When the heat shrink sleeves shrinks, an axial segmented stepped programmable heating technology is used, which gradually shrinks from the middle to both sides, forming a beautiful shape and facilitating the discharge of bubbles. The shrinkage temperature and time of each section, as well as the time interval between the start of each section, are the key factors affecting the quality of the heat shrink band contraction. When using heat shrinkable adhesive tape, the infrared heating equipment adopts overall heating, and the key factors affecting the quality of the adhesive are the adhesive temperature and time.

2 Data Collection and Wireless Transmission SchemeKey

2.1  construction data to be collected

After analyzing the key factors affecting the quality of joint repair, it is believed that the key construction data that needs to be collected for mechanized anti-corrosion joint repair mainly include: total pressure of compressed gas and partial pressure of the storage tank, flow rate of metal abrasive, lateral speed and rotation amplitude of the spray gun, preheating temperature of the bare pipe at the pipe mouth, preheating temperature of the PE layer overlap area, shrinkage temperature and shrinkage time of each infrared heating segment, and melting temperature and melting time. In addition, in order to facilitate management and accurately trace the construction data of mechanized anti-corrosion joint repair, it is necessary to collect the specific construction date and start and end time of each joint.

2.2 Data Collection and Wireless Transmission Scheme

The key construction data collected can be divided into two types: one is the data that can be fed back to the PLC and displayed through the display screen or PID controller, such as the lateral movement speed and rotation amplitude of the spray gun, the preheating temperature of the bare pipe at the nozzle, the preheating temperature of the PE layer overlap area, the shrinkage temperature and shrinkage time of each section of infrared heating, and the melting temperature and melting time. This type of data can be obtained by writing a new communication program based on the original program of the equipment control system,

2.3 Association between construction data and QR codes

In order to accurately grasp the detailed construction information of each intersection, during the construction of the China Russia East Pipeline Project, the number of each intersection is independently generated into a QR code, which becomes the "ID card" of each intersection and has uniqueness. By writing programs, it is possible to achieve the collection of mechanized anti-corrosion joint data and the association between wireless transmission systems and QR codes. Before collecting key construction data, a QR code scanner is used to scan the QR code. By association, the collected construction data can be named after the pipe number in the QR code, achieving accurate matching between the pipe and construction data

3.On site application

The data acquisition and wireless transmission system has been installed and used in multiple sets of mechanized joint repair equipment on the China Russia East Line. It can accurately collect and store key construction data that affects the quality of mechanized anti-corrosion joint repair, and achieve wireless remote real-time transmission with the receiving terminal. The application has proven that the system is stable and reliable, with accurate and complete data collection, timely remote transmission, convenient installation, and small space occupation. Effectively ensuring the full digital transfer of key construction data for mechanized anti-corrosion joint repair of the China Russia East Pipeline Project.