Flexible internal welding technology for large-diameter long-distance pipelines

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On March 1, reporters learned from the Research Institute of the Pipeline Bureau that, after comprehensive evaluation, the second welding test of the CPP900-FIW48-001 flexible internal welder demonstrated ideal performance in terms of tube-end alignment via one-button automatic centering and rapid positioning, welding, ramping, and safety braking – thus providing an important tool for pipeline construction in mountainous areas by the Pipeline Bureau. 　　Recently, there have been continuous good news regarding the automatic pipeline welding technology used in mountainous areas by the Pipeline Bureau. On February 9, the automatic internal welding machine for pipelines in steep mountainous areas, developed independently by Pipeline Company No. 1, successfully carried out the industry’s first 6G-bit automatic welding process. On February 11, the CPP900-FIW48-001 flexible internal welding machine developed by the Pipeline Bureau’s Research Institute successfully completed its first welding test. Both devices can meet the welding requirements for pipe diameters of 1219 millimeters and 1442 millimeters. 　　Data shows that by the end of the 14th Five-Year Plan period, the total length of oil and gas pipelines in China will reach 250,000 kilometers, with substantial demand for pipeline construction in mountainous and hilly areas such as East China, South China, and Southwest China. Breaking through the bottlenecks in automatic welding in steep mountainous areas, and possessing related equipment and technologies with independent intellectual property rights, plays a crucial role in enhancing core competitiveness and gaining an advantage in the market. 　　Based on its forecasts regarding market prospects, Pipeline Company No. 1, leveraging its own technology center, submitted a project proposal to CNPC Engineering in 2019 titled “Research on Automatic Welding Equipment and Technologies for Pipelines in High-Slope Mountainous Areas.” This project involved the development and application of three types of equipment: groove cutters, internal welders, and construction vehicles. With the successful development of the internal welder, the development of the other two types of equipment has also entered its final stage. 　　As a professional R&D institution, the Pipeline Bureau Research Institute, focusing on the development of the industry, has carried out a series of research and development efforts to address the challenges associated with automatic welding in mountainous terrain. To date, the research institute has successively carried out research and development on a range of automated welding equipment for mountainous areas, including the CPP900-FIW flexible internal welding machine, the CPP900-FPC flexible internal alignment tool, the CPP900-TWR large-diameter TIG external root welding equipment, the CPP900-W1N large-diameter 6G-position automatic welding equipment, and the CPP900-FM pipe bending groove maker. 　　The R&D efforts of these two organizations have achieved the goal of improving the intelligence level of automatic welding in mountainous areas while reducing the need for manual intervention. Once implemented on a wider scale, the construction efficiency and quality of pipeline projects in mountainous regions will be significantly enhanced. 　　It is worth noting that these two “technological giants” pursue the same goal while also having their own strengths. The CPP900-FIW48-001 flexible internal welder features significant technological innovations in areas such as high-torque drive, one-button automatic centering and precise positioning, flexible-rigid mode conversion, one-button remote control for automatic welding, and lifting without a crane beam. It ensures safe and stable climbing, descending, and parking; it enables more accurate and efficient alignment of pipe ends; the welding process is completed automatically without any manual intervention; and it offers convenient operation with a simple procedure. The traveling system of the automatic internal welding machine for pipelines in steep mountainous areas adopts a dual-power mode of \"electric drive + pneumatic drive\", enabling automatic control for efficient operation with electric power on slopes and pneumatic power on flat sections. To address the issue of increased speed when going downhill, a single-cylinder multi-point brake disc brake is used to control the downhill speed, while the positioning arm makes use of a pneumatic mechanical lock cylinder to ensure accurate positioning of the internal welder on steep slopes. 　　Following this test, these two technological marvels will undergo further tests in various construction scenarios, including those involving upward and downward work. After completing the necessary technical evaluations and process assessments, they will be deployed at the construction site of the middle section of the West-East Gas Pipeline Project, thereby providing another valuable technological tool for the project’s development and helping to usher in a new era of automatic welding in steep mountainous areas.