Tuyin tap bao cao Hdi nghj KHCN "30 nam D û khi Viet Nam Cff hdi moi, thach thde mdi" 231 AP DUNG CONG NGHE M d i DE TANG TOC DQ RAI Dl/OfNG ONG BIEN TAI XNLD VIETSOVPETRO Dd Minh Hda, Nguyen Hdng Gi[.]
Tuyin tap bao cao Hdi nghj KHCN "30 nam D^u Viet Nam: Cff hdi moi, thach thde mdi" 231 AP DUNG CONG NGHE M d i DE TANG TOC DQ RAI Dl/OfNG ONG BIEN TAI XNLD VIETSOVPETRO Dd Minh Hda, Nguyen Hdng Giang XNLD Vietsovpetro TOM TAT Chi phi cho cdng tdc rdi duang dng tren biin bao gdm cdc chi phi: tdu rdi dng, sd lan chd dng, vdt tu vd nhdn cdng qudn ly diiu hdnh, khdo sdt Trong chi phi tdu sd lan chiim ty trgng ldn vd muc dich bdi viit ndy Id phdn tich cdc buac cdng nghi rdi dng vd cdc biin phdp nhdm gidm thai gian a edng dogn hdn di tdng ndng sudt rdi dng vd dd gidm chi phi tdu thuyen CAC PHUONG PHAP XAY DlTNG DUONG ONG TREN BIEN Cac phuang phap xay dyng dudng dng tren bien hien cd the bao gdm cac phuong phap sau: • Rai dng theo phuong phap chir S (S-lay), ap dyng phd bien cho cac vung nude cd sau nude den 300m • Rai dng theo phuang phap chd J (J-lay), ap dyng cho vung cd sau nude ldn, cd thi len tdi 1000m • Ong dugc che tao tung doan tren bd sau dd cudn vao tang tdi tren tau chuyen dung, chieu dai mdi tang tdi cd the den 5km Dudng kinh tang dugc tinh toan de dam bao ung lyc xuat hien dng cudn vao tang gidi ban dan hdi • Che tao tung doan tren bd sau dd keo bien Cac doan se dugc ket ndi vdi sau dd Ddi vdi vung bien Viet Nam, cho den mdi chi ap dyng phuong phap S-lay Doan dng dau tien dugc ban vao dau keo va dugc ndi vdi neo dinh hudng hoae vao mdt ket eau cd san bang phuong phap day treo Cac dng tiep theo dugc ghep, ban ndi tiep thdng qua cac tram ban, dugc kiem tra khdng pha buy, lam bao ve chdng an mdn va dugc tdi cang dng nha ket hgp vdi cdng viec cudn neo tau de tha dng xudng bien MO TA CAC CONG DOAN RAI ONG CUA XNLD VIETSOVPETRO Tai XNLD Vietsovpetro, viee rai dng ngam dugc thyc hien bang tau Cdn Son Cac cdng doan chinh tren tau rai dng bao gdm: • Bude 1: Chudn bi mep vdt Mep vat da dugc nha san xuat dng vat theo tieu chuin, thudng vat chu V gdc vat 30 Cdng viec chuan bj bao gdm mai sach mep vat, sua ehda nhdng chd bj mdp meo qua trinh van chuyen de dam bao dinh dang mep vat theo yeu ciu cua quy trinh ban Nhugc dilm la viec mai lam sach su dyng may mai, thdi gian keo dai, ddi hdi thg cd tay nghi nlu khdng se lam hdng dinh dang mep vat, gay khuyit tat moi han Ngudi thg 232 Ap dung cdng nghe mdi de tang tde dd rai difdng dng bien tai XNLD phai lam viec vdi cudng cao, khdng tri dugc kha nang lam viec lau dai • Bude 2: Ldp ghep dng vd hdn lap lot (tai tdi sd 1) Thudng dung tdi de ghep khdng su dung djnh tam hoae su dyng dinh tam ngoai Phuang phap han hd quang tay (SMAW) vdi que ban hydro thap (E7016) dugc su dyng Nhugc diem la thdi gian lap phy thudc vao ky nang dieu khien tdi va kinh nghiem cua ngudi lap ghep Neu khe hd, mep cun, lech mep khdng chuan thi thdi gian ban se tang, cd khuyet tat tai ldp Idt nhu khdng ngau, ldm day • Bude 3: Hdn lap giira (tai tdi sd 2) Phuong phap ban hd quang tay (SMAW) vdi que ban hydro thap ( E7016) dugc su dyng Nhugc diem cua phuang phap ban la he sd dien day thap, chat lugng phy thudc vao tay nghe va tinh trang sue khoe cua thg ban • Bude 4: Hdn lap phu (tai tdi sd 3) Phuang phap ban bd quang tay (SMAW) vdi que ban hydro thap ( E7016) nhu d tdi dugc su dyng • Bude 5: Kiim tra mdi hdn (tai tdi sd 4) Phuang phap kiem tra bang chup X-ray ngoai dng qua hai lin dng Phuong phap hoan toan khdng phu hgp cho viec rai dng vi mot mdi ban phai chyp khoang tu den lan, thdi gian kiem tra xong mot mdi ban thudng tu 20 25 phut • Btfdc 6: Bgc chdng dn mdn (tai tdi sd 5) Be mat dugc lam sach, dugc son Idt va cudn bang keo bao ve Vdi cdng nghe nhu da md ta, ddi vdi cac dudng dng cd dudng kinh tu 219mm din 426mm, chieu day dng tu 15,9mm din 31mm thi toe rai chi cd thi dat tu 700 800m/ngay Tdc rai dng chi bing 1/3 tdc dd cua cac cdng ty khae khu vuc (tu 2000 - 4000m/ngay) KHA NANG CAI TIEN Nang cao tdc rai dng da dugc cac cdng ty nude ngoai dac biet chu trgng nhu diu tu tau rai dng ldn ban, trang bi cac thilt bi mdi, bd tri them day chuyin ban ty ddng ndi ddi dng 12m 24m tren tau, trang bi he thdng dn dinh ddng hgc dl nang cao kha nang lam viec, khdng phai keo tha neo Cac cdng doan dugc tinh toan de thdi gian thyc hien phu hgp va dd tit ca cac bude edng viec deu phai dugc xem xet ddng bd tu dat hang nhu dua cac yeu ciu vl chinh xac chieu day dng, d van, thing cua dng Tdc rai dng cdn phu thudc rat nhieu vao cdng tac phye vy khae nhu keo tha neo, cung cap dng, khao sat, dinh vi va dich vy ddi sdng day ehi de cap din vin dl ddi mdi cdng nghe han, kiem tra NDT mdi ban la nhOmg ylu to quylt dinh tde rai ong Cac phuong phap ban dugc su dyng ban dudng dng bao gdm: Tuygn tap bao cao Hgi nghj KHCN "30 nam Dau Viet Nam: Cff hgi mdi, thach thde moi" 233 - Han hd quang tay (SMAW) su dyng que ban hydro thap han tu dudi len hoae tu tren xudng - Han hd quang tay (SMAW) su dung que han cellulose, han tu tren xudng - Han bang day ban cd ldi thudc (FCAW), ed dung hoae khdng dung bao ve - Han hd quang mdi trudng bao ve (GMAW), su dung hdn hgp cua Argon va CO2 Bang 1: So sanh mot so chi tieu giira cac phirong phap han Khe hd moi ghep Goc vat Chong nut ngudi Toe dp ban ldp Idt He sd dien day So sanh FCAW SMA W, que SMA W que hdn EXXIO hdn EXX16 Cd the ldn Nhd va yeu cau Nhd va yeu cau chinh xac chinh xac Chii V, gdc vat Chii V, gdc vat Chii V, gdc vat 25 - 30 30 30 Tot Kem ban so vdi Binh thudng queEXX16 30 - 50cm/phut - Scm/phiit 20- 50cm/phut 8,5 - 9,5gr/Ah 9,5- Ugr/Ab 11,5- 13gr/Ah 1,35 1,12 GMA W> Khong cd Chii J, gdc vat dd Tot 50 - 60cm/phut 12,5 - 14gr/Ah 1,47 Ghi chu: (1): Khi ban tu ddng GMAW cd su dung dinh tam gan vong lot ddng va cac thong sd cua mdt day Ap dyng phuong phap ban ty ddng bao ve GMAW va cac bien phap khae dam bao sy ddng bd giua cac bude la bien phap nang cao tdc rai dng Tdc ban cao bang phuong phap ban GMAW khdng chi vi he sd dien day cao ma cdn vi tiet dien mdi ghep giam cau hinh mdi ban chu J Viec cai tien phai dugc xem xet d tung bude cdng nghe de hgp ly hda va giam thdi gian Cac yeu cau ve chinh xac kich thudc dng, them cdng doan chuan bi mep vat, su dyng djnh tam lap ghep, cac bien phap nang cao tdc da dugc de nhu thiet ke tau rai dng ldn hon, dai hon de bd tri them day chuyen ban ty ddng ndi ddi dng 12m 24m Dat dng cd chieu dai ldn ban (chang ban 16m) de giam sd lugng mdi ndi Bien phap dugc nhieu hang chu trgng nhat la ddi mdi cdng nghe ban de giam thdi gian ban CAC BIEN PHAP CAI TIEN Dl/OC AP DUNG TAI XNLD VIETSOVPETRO Tai XNLD, tu nhiing nam 1990 da ap dung mdt sd bien phap nhu ndi phan dng ddi tren bd 24m, cung tang dugc tdc rai dng nhung khdng dang ke chieu dai dng 24m vugt qua kich thudc tau, khdng the ap dyng dinh tam va cdng nghe han van la ban hd quang tay Ap dyng cdng nghe ban tu tren xudng, dung que Cellulose (E60xx, E80xx), vdi loai que cd he sd dien day cao ban loai hydro thap, nhien, chi cd uu diem rd ret ong cd dudng kinh ldn, chieu day dng nhd (thudng la 12,7mm) Toe rai dng cua cac phuang phap tren cung chi Ikm/ngay Nam 2001, thyc hien dudng dng Rang Ddng - Bach Hd, XNLD Vietsovpetro da ap dyng mdt loat bien phap de thay ddi cdng nghe ban, kilm tra nhim myc tieu tilp can vdi cdng nghe cua khu vyc Nhung ddi mdi cy thi nhu sau: 234 Ap dung cdng nghe mdi de tang tdc rai dirdng dng bien tai XNLD • Bude 1: Chudn bi mep vdt Su dyng may vat mep de vat lai dau dng dam bao chinh xac theo yeu cau, gdc vat chu V, gdc 25 dl giam tiet dien ban • Bu-dc 2: Ldp ghep dng vd hdn lap Idt (tai tdi sd 1) Su dung dinh tam hoae su dyng dinh tam Han ldp Idt bing phuang phap GMAW, mode STT • Bude 3: Hdn lap giira (tai tdi sd 2) Phuang phap han GMAW ban ty ddng bao ve, su dung may han M300, loai mdt day • Bu-dc 4: Hdn lap phii (tai tdi sd 3) Phuong phap han GMAW ban ty ddng frong bao ve, su dyng may han M300, loai mdt day • Birdc 5: Kiim tra mdi hdn (tai tdi sd 4) Phuong phap kilm tra bing chyp X-ray dng qua mdt lin dng Sau su dyng ROTOSCAN ty ddng cho phep kilm tra mdi ban vdng phut Phuong phap kilm tra sieu am ty ddng bing ROTOSCAN la phuong phap tien tiln mdi phd biin cac nam gan day LTu diem cua phuong phap la tdc kilm tra nhanh, kilm tra tu ben ngoai dng nen tranh nguy co bi ket ben dng, khdng bi cac nguy hiim vl buc xa Cac tieu chuan qudc te ve thi cdng dudng dng tren biin nhu API 1104 (phien ban 1999), DNV OS-FlOl (phien ban 2000) diu da dua phuang phap vao ap dung • Bu-dc 6: Bgc chdng dn mdn (tai tdi sd 5) Be mat dugc lam sach, su dyng loai tam co nhiet Khi thyc hien cdng trinh nay, da cd dat dugc tdc 2km/ngay; trung binh la 1,3km/ngay Vdi sd rai la 42 ngay; neu ap dyng phuang phap ban tay thi sd phai la 55,2 Nhu vay, sd tau rut ngan dugc la 13 tau Sau mdt thdi gian dao tao ya su dyng, xi nghiep den da cd mdt ddi ngu cdng nhan van hanh thao Nhugc diem cua he thdng la qua trinh dieu chinh nhu chieu dai hd quang, dieu chinh tam dudng ban, van tdc ban cua may ban d cac vi tri khae tren dng cdn ngudi thg thyc hien, d van tdc ban cao lam cho ngudi thg chiu nhieu ap lyc tam ly va khdng tri kha nang lam viec lau dai va vao thdi gian cudi ca lam viec mdi thudng cd xac suat xuat hien khuyet tat cao Khae phye cac nhugc diem tren, XNLD Vietsovpetro da dau tu mdt he thdng mdi, dd la loai may ban ty ddng cd hai md loai P600 cho phep ban hai day ciing luc C) he thdng nay, tat ca cac thdng sd ban dugc cai dat trudc, chieu dai hd quang, dieu chinh tam dudng ban, thay ddi thdng sd theo vi tri ban dugc lap trinh san Ngoai ra, kim loai ban cua day thu se thyc hien qua trinh luyen kim cho ldp kim loai ban day trudc, lam tang ca tinh cua mdi ban Vdi hai md ban, sd tram ban da tang gap ddi Mep vat mdi ban se la chd J, cd gdc vat giam dang ke khdi lugng kim loai ban phai dien day CGng vdi tram ban, nhung ap dyng he thdng se dat tdc ban dng tu 3km/ngay Tuygn tap bao cao Hdi nghj KHCN "30 nam DSu Viet Nam: Co hdi mdi, thach thde moi" 235 KET LUAN Nhirng cdng ty ldn chuyen rai dng d nude ngoai thudng ty thiet kl liy cac thilt bi han, cd loai ty ddng vdi md ban cung luc Dau tu cho thiet bi rat ldn, nhung bieu qua mang lai thi ldn gap nhieu lan He thdng may ban md cd gia khoang 400.000USD/tram/2 may Vdi tram ban phai dau tu 1,2 trieu USD Neu phai rai 100km dudng dng, gia tau tren the gidi thudng tu 70.000 - 150.000USD/ngay, so sanh hieu qua cua hai phuong phap nhu sau: Bang Phuang phdp hdn Tdc So rai Chi phi thue tau dy kien Hdn hd quang tay SMA W Hdn tu ddng GMA W mdy hdn md Ikm/ngay 2km/ngay 100 50 7.000.000- 15.000.000USD 3.500.000 - 7.500.000USD PHAN Bd CHI PHI THI CdNG Dl/dNG ONG NGAM Nhan c6ng CO/ Thus' cac loai 30% Chi phi khae 4% ^lay thi c6ng 0% Chi phi chung 4% Tau thuyen 56% Hinh 1: Phan bo chi phi thi cong dudng ong ngam Trong thi tren ta chi so sanh cac chi phi phye vy thi cdng dudng dng ngam Chi phi vat tu khdng bao gdm dd thi Trong dieu kien thi cdng ngoai bien phy thudc vao thdi tiet, cham mdt cd the dan tdi khdng hoan cdng trinh nam va phai chd thdi tiet cua mua bien nam sau thi viec giam thdi gian va tinh dn dinh cua thiet bi eho phep kiem soat tdt hon ke hoach rai dng, giam thieu rui ro Nhieu hang nude ngoai van khdng ngung cai tien cdng nghe ban nhu cdng nghe ban laser de ban dudng dng da cd san pham thuang mai nam 2004 Vdi loai thiet bj ban laser, mep dng vat thang, chi can mdt tram ban, giam sd lugng ngudi tren tau Viec ap dyng cac thiet bi cdng nghe mdi da cai thien dang ke tdc rai dng tai XNLD Vietsovpetro Tuy nhien, de phat huy hit hieu qua cua thilt bi ban cin nang cap ddng bd ve thiet bi vat mep, dinh tam, tau rai dng cung nhu kha nang dap ung cua tau keo tha neo TAI LIEU THAM KHAO Hoang Tung Sd tay dinh mirc tieu hao vdt lieu vd ndng lugng diin Kobe Steel Ltd Welding of pipes and pipeline ... ddi mdi cdng nghe ban de giam thdi gian ban CAC BIEN PHAP CAI TIEN Dl/OC AP DUNG TAI XNLD VIETSOVPETRO Tai XNLD, tu nhiing nam 1990 da ap dung mdt sd bien phap nhu ndi phan dng ddi tren bd 24m,... cua cac phuang phap tren cung chi Ikm/ngay Nam 2001, thyc hien dudng dng Rang Ddng - Bach Hd, XNLD Vietsovpetro da ap dyng mdt loat bien phap de thay ddi cdng nghe ban, kilm tra nhim myc tieu... cudi ca lam viec mdi thudng cd xac suat xuat hien khuyet tat cao Khae phye cac nhugc diem tren, XNLD Vietsovpetro da dau tu mdt he thdng mdi, dd la loai may ban ty ddng cd hai md loai P600 cho phep