CN100363678C - Method for reinforcing defective pipeline and composite material therefor - Google Patents
Method for reinforcing defective pipeline and composite material therefor Download PDFInfo
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- CN100363678C CN100363678C CNB2004100841643A CN200410084164A CN100363678C CN 100363678 C CN100363678 C CN 100363678C CN B2004100841643 A CNB2004100841643 A CN B2004100841643A CN 200410084164 A CN200410084164 A CN 200410084164A CN 100363678 C CN100363678 C CN 100363678C
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Abstract
The present invention relates to a method for reinforcing a defective pipeline and a composite material thereof. In the method, a composite material is used to repair and reinforce the corrosive defect of the outer wall of an oil gas conveying pipeline. The method is characterized in that a reinforcing composite material sheet, a defect filling material and an interlayer adhesive are used to repair and reinforce a defective position. The reinforcing composite material sheet is formed from high-strength glass fiber unidirectional cloth or carbon fiber unidirectional cloth, an epoxy resin adhesive and an interlayer adhesive, wherein the epoxy resin adhesive contains 593 curing agents or triethanolamine curing agents or acrylate liquid rubber. The reinforcing method comprises the following steps: carrying out proper surface treatment for the defective position; leveling up the defective position with the reinforcing filling material; covering reinforced winding sheets on the pipeline; adopting the interlayer adhesive and the curing agents between interlayers without welding. The pipeline can reach to the bearing ability in the state of no defect after being repaired. For the defect with the depth reaching more than one half of the thickness of the pipeline wall, no leakage and dehiscence occurs at the defective position during the full-size water pressure blasting of the pipeline, and a blasting hole is positioned at the non-defective position of the pipeline.
Description
Technical field
The present invention relates to a kind of composite material that utilizes realizes the outer wall corrosion defective of pipe-line is repaired method with the reinforcing defective pipeline of reinforcement.
Background technique
Contain the outer wall corrosion defective and be pipe-line one of ubiquitous defect type in the process under arms, the existence of these defectives and development thereof can have a strong impact on the Security of pipeline operation, and how to carry out renovation reinforced effectively to this class corrosion default is to guarantee pipeline safety operation and the key technology measure that improves the oil-gas gathering and transportation benefit.To the repairing of this class defective, at present domestic main employing field welding is mended scar, oversleeve or section and is cut off the method for welding new pipeline section again, but because (1) welding causes the tough brittle transition temperature of the pipeline section of delivery pipe repairing to reduce, reduces the Security of pipeline operation; (2) high renewal expense; (3) easily produce problems such as hydrogen embrittlement, residual stress in the welding process; (4) welding operator technical merit is required height, need carry out necessary scene flaw detection after the welding; (5) conveyance conduit needs out of servicely during repairing sometimes, and oil gas needs emptying in the pipe, tracheae line particularly, thereby cause the tremendous economic loss, so to the reparation of outer wall corrosion defective conveyance conduit must development of new the repairing enhancement technique.The method that adopts " firmly special " board glass fibre reinforced plastics reinforcement sheet material pipe-repairing defective that CLOCK SPRING COMPANY L P (US) company produces is abroad arranged, and (this product patent number is: US5683530), but this method cost higher (about 500 dollars of every reparation one place's defective cost), intensity is on the low side, and the product key component easily lost efficacy (storage life is half a year), failed to apply.Domesticly launching some researchs aspect glass fibre reinforced plastics reinforcement technology and the product development, but in general, the glass fibre reinforced plastics reinforcement is repaired research work and is carried out lessly, and the performance of some products and renovation technique instability, intensity are difficult to satisfy the requirement of line transportation pressure.And polymer resin that the technology of fw frp reinforcement is outside adopted and the matching aspect between pipeline material and resin and reinforcing fiber, comprise not further investigation as yet such as expansion coefficient, Young's modulus and intensity, this has also influenced glass fibre reinforced plastics reinforcement technology greatly and has applied.For defective pipeline, the thickness of outer fw frp is by rule of thumb more than 10mm, and then consumption is too much to the pipeline of little defective, causes the unnecessary raising of rehabilitation expense; To the pipeline of big defective, then do not reach the purpose that safety is repaired.
Summary of the invention
The objective of the invention is at containing outer wall corrosion defective pipeline rehabilitation reinforcement problems such as volume type defective, develop the renovation reinforced used composite material of multicomponent defect of pipeline, on mechanics, chemical property, have good matching, the bearing capacity when making defective pipeline meet or exceed zero defect between each component of this composite material and between composite material and steel pipe.
1. be raw material with some other auxiliary material such as epoxy resin and glass fibre, carbon fiber and interlaminated adhesive, curing agent, thixotropic agent, obtain having epoxy resin and the glass fiber compound material sheet material or the carbon fiber composite sheet of higher-strength, the high tensile of glass fiber compound material sheet material can reach 903MPa, and the carbon fiber composite sheet maximum pulling strength can reach 1480Mpa.
Epoxy resin and glass fibre or carbon fiber composite sheet material are to be made of following raw material and proportioning:
(1) epoxy resin adds 593 curing agent or triethanolamine curing agent, with the flexural strength of epoxy resin reinforcing agent 651 more as can be known, the former flexural strength height, and viscosity is little, environmental protection and economy, select 593 to be curing agent for epoxy resin, and its Recipe has been carried out optimizing research by following formula.
A=(molecular weight/active hydrogen number) * epoxide number
Wherein a is the consumption of per 100 parts of epoxy resin 593.Consider that epoxy resin or triethanolamine curing agent and 593 raw materials are industrial goods, actual amount when combination property is best should be about 30phr, curing process is 30 ℃/4h+100 ℃/2h (reprocessing), combination property: tensile strength is that 63.4Mpa, stretch modulus are that 2.53Gpa, fracture rate elongation are 2.92%, flexural strength is that 100Mpa, impact strength are 22.1KJ/m
2, heat distortion temperature is 65 ℃.
(2) since epoxy resin to add toughness indexs such as impact strength that 593 curing agent and epoxy resin adds the triethanolamine curing agent, fracture elongation lower, and the toughness of the body material key factor of decision tree resin-based composite tensile strength just.Therefore acrylic liquid rubber has good toughening effect to epoxy resin by studying as can be known, and addition is that the liquid rubber of 5-15phr carries out toughening modifying in two systems.Both impact strengths have improved respectively about 20% and 120% as a result.
(3) composite material sheet preparation process is: the preparation of reinforcing material cutting and resin adhesive liquid, patrix shop layer (control length, a thickness and a width), gluing (epoxy resin-base), with the mould rolling, according to setting the curing in the heating plant frock of curing process temperature, reprocessing, mould unloading, repairing corner, encapsulation etc.
(4) kind of the kind of resin matrix and curing agent is very big to the performance of composites influence in the material preparation, epoxy resin is than the better effects if of unsaturated polyester resin as matrices of composite material, and flexural strength and tensile strength are corresponding to have improved 22.5% and 25.7%; 593 curing agent are better than 651 curing agents, and the flexural strength of composite material and tensile strength have improved 32.4% and 84.6%; Epoxy resin-593 (30phr)/S-glass fibre unidirectional cloth composite material combination property the best, room temperature tensile intensity is that 903Mpa, flexural strength are 810Mpa, to cut intensity be 51.5Mpa to layer, cryogenic tensile intensity raises to some extent, when temperature is 0～5 ℃, tensile strength reaches 1029Mpa, and stretch modulus reaches 39.3GPa.
(5) matching performance of strengthening course and steel pipe after the reinforcement: the resiliently deformable of the performance test shows pipeline that expands with heat and contract with cold in temperature is 5 ℃～95 ℃ scopes can not have influence on the combination force of strengthening course and matrix.
(6) tensile strength values of carbon fiber one-way cloth reinforced composite effective than glass fibre unidirectional cloth reinforced composite materials is that 1480Mpa, flexural strength are that 930Mpa, interlaminar shearing strength are 51.Mpa for epoxy resin-593/ carbon fiber one-way cloth composite material tensile strength.
2. composite material interlayer adhesive: in the time of 25 ℃, be 30 minutes curing time, and in the time of 18 ℃, be 45 minutes curing time.
(1) the base-material kind of interlaminated adhesive is an epoxy resin, and curing agent is 593; Prepared two component room curing interlaminated adhesives: the A component is 100 parts of epoxy resin, 10 parts of acrylic liquid rubbers, 5 parts of thixotropic agent aerosils; The B component is 100 parts in 593 curing agent, promoter 2,4,40 parts of 6-three [(dimethylamino) methyl] phenol; Press the A component: the B component=weight ratio was mixed in 100: 26.Curing process is 18 ℃/12h.18 ℃ of test tensile shear strengths (aluminium-aluminium) are 26.0Mpa; Tensile shear strength (glass steel-glass reinforced plastic) is 16.0Mpa; Tensile shear strength (steel-steel) is 16.8Mpa.
(2) adhesive solidification temperature: gel time is 30 minutes during 60 ℃ of middle temperature, and gel time is 66 minutes during 30 ℃ of room temperatures, and gel time is 240 minutes in the time of 15 ℃, and gel time is 400 minutes in the time of 10 ℃.By regulating promoter 2,4,6-three [(dimethylamino) methyl] phenol (DMP-30) consumption, the gel solidification time of the cured adhesive that can regulate the room temperature: gel time is between 60～30 minutes in the time of 30 ℃, 15 ℃ between 240～110 minutes, in the time of 10 ℃ between 400～150 minutes.
3. the defective packing material is to adopt 593
#Curing agent, ethanolamines epoxy resin, and silica, quartz flour, titanium dioxide etc. adopt bisphenol A modified as auxiliary packing simultaneously.
(1) the defective packing material is two components system, and the A component is epoxy resin (100 parts), filler quartz flour flicker stone (200 parts), thixotropic agent aerosil (5 parts); The B component is curing agent 593 (100 parts), altax P-30 (40 parts).The flexural strength of transmitting material is that 41.0Mpa, impact strength are 6.KJ/m
2, draw that to cut strength steel-steel be 7.9Mpa.Full-scale hydraulic bursting test result shows that pipeline is after surrender and breaking, and the variation of loading transfer material is very little, shows good toughness and intensity.
4. determined and contained defective steel pipe reinforcement process parameter, on-the-spot reinforcing construction technical specification etc.
(1) preparation of construction
Preparation of construction work mainly comprises to be carried out required all kinds of reinforcing materials of reinforcement repair and construction auxiliary equipment, contains the measurement of the excavation cleaning of defective pipeline section and defective and record etc.Each construction stage material requested, facility are as shown in table 1 below.Except type of material, also should determine the specification and the quantity (record also capable of taking pictures in case of necessity) of material therefor, and confirm the quality of product according to supply of material proof and quality of product certificate.
Table 1 material that each construction stage uses, instrument Schedule
| Operation | Material | Instrument and other supporting facility |
| The steel tube surface cleaning | Gasoline, special-purpose derusting cleaning liquid, acetone etc. | Labour protection apparatus such as jetting tool, rubber gloves, protective spectacles |
| The reinforcement area identification | Autoadhesion adhesive tape | Marking tool such as plummet, marking pen etc. |
| Defective is filled | The special-purpose putty of filling | Rubber spatula, measurement instrument, rubber gloves, protective spectacles |
| The primer brushing | Special-purpose adhesive | Adhesive application roller, plastic container, measurement instrument, Hygrothermograph, hand blender, rubber gloves, protective spectacles etc. |
| Out-of-flatness face is repaired | The special-purpose putty of filling | Rubber spatula, rubber gloves, protective spectacles |
| The glass fibre reinforced plastics roll film | The glass fibre reinforced plastics roll film, | Glass fibre reinforced plastics roll film support, adhesive application roller, Sheng glue hold |
| Volume pastes and coats | Special-purpose adhesive | Device, measurement instrument, Hygrothermograph, hand blender, rubber gloves, protective spectacles, glass fibre reinforced plastics roll film parting tool etc. |
| Fastening before strengthening course solidifies | Autoadhesion adhesive tape | Fastened tools |
| The strengthening course end face is filled and led up coating | Adhesive, pyrocondensation belt | Adhesive application roller, plastic container, measurement instrument, heating tool, rubber gloves, protective spectacles etc. |
The site of storage of material should be avoided the daylight direct irradiation, and water and contamination by dust can not be arranged.Should notice that material deposits the temperature conditions in place because fill materials such as putty, adhesive except meeting is subjected to the influence of construction temperature, deposit the place variation of temperature can the time material great changes will take place working life.In addition, construction equipment and cleaning solvent etc. will keep fire away.
In addition, if necessary, before construction, begin to repair after the pipeline operating pressure need being reduced, so not only help operator's safety, and after the pipeline operating pressure returns to normal condition, can make pipeline and glass fibre reinforced plastics strengthening course in conjunction with tightr, help the transmission of load.
(2) steel tube surface cleaning
Big and humidity is greater than 75% o'clock at dust storm, as do not have the reliable protective measures should not the brushing primer.In order to guarantee best bond effect, the removing surface operation of steel pipe is one step of key that reinforcement is repaired.Be repaired the surface and should guarantee not have oil, anhydrous, remove impurity such as the dirt of rejected region and scale fully, expose the steel pipe body.
(3) reinforcement zone line sign
For guaranteeing that follow-up defective filling, primer brushing and glass fibre reinforced plastics roll film are coated on the tram, need determine the reinforcement repair region according to rejected region, defective effect district size, and adopt line or autoadhesion adhesive tape that the reinforcement zone is marked.Should adopt eye-catching color to indicate.
(4) adopt special-purpose defective packing material filling defect
If the defective of steel tube surface is not filled, after the glass fibre reinforced plastics roll film was coated on the steel pipe, rejected region can not contact with strengthening course, and load can not evenly be delivered on the strengthening course, and then rejected region still can exist stress to concentrate, and does not reach reinforcing effect.
(5) brushing primer
Defective fill putty reach dry tack free and confirm the steel tube surface drying, pollution-free after, can begin the brushing primer.
(6) out-of-flatness face is repaired
At primer with after filling the putty gel, rejected regions such as sagging or other depression, cavity are repaired.
(7) the composite material sheet volume pastes and coats
After the primer surface gel, (harden) with the finger contact, confirming does not have moisture and dust to adhere to, composite material sheet volume is attached to the defect of pipeline position that mark is good, in volume subsides coating process, is coated with between composite material sheet layer and the layer and brushes special-purpose adhesive with roller.When flaw size to be repaired surpasses the limit reparation size of composite material sheet, can carry out continuous winding reinforcing reparation, the spacing between adjacent roll film is exceeded so that overlap joint not to take place, and fill with interlaminated adhesive in the space between roll film.
(8) the strengthening course end face is filled and led up the repaired mouth of coating and overlapping part
The sloping is smeared in the glue spatula, treat that surface of pressure-sensitive adhesive solidifies after, carry out repaired mouth with head position, thermal shrinkage type adhesive tape opposite end.
(9) backfilling of pipe canal
After treating that strengthening course solidifies substantially, can carry out backfill to pipe trench and handle.
(10) carry out construction note
The site operation record comprises on-the-spot preceding repair engineering, method of construction, weather condition, the check of temperature and humidity, enforcement and the some other necessary item etc. of mending.A complete construction note is very important to the manager of pipeline operation, and it helps the progress that the manager holds engineering, determine whether to have or not abnormal conditions and finish as construction after reference etc.Therefore in each mending course and repairing all need to carry out abundant construction note after finishing.Essential record comprises:
1. the main contents of reinforcement repair, method of construction and process thereof;
2. quality inspection record;
3. reprocessing record should comprise and reprocess position, reason, method, quantity;
4. other relevant data data.
(11) safety control notice
Any one link in work progress all needs to observe some necessary security clauses.Adopt the glass fibre reinforced plastics roll film to repair defective pipeline, material therefor comprises multiple materials such as special-purpose surface cleaning agent, defective filling putty, special-purpose adhesive, glass fibre reinforced plastics reinforcement sheet material, therefore for construction safety, need the operator to be familiar with the feature of used various materials, note execution conditions and operating environment.
Adopt the renovation reinforced product of composite material of the present invention the pipeline reparation that contains different defectives to be had following advantage with technology:
(1) adopts the renovation reinforced product of being developed of composite material the pipeline that contains different defectives to be repaired, the pipeline bearing capacity is enhanced, reach the bearing capacity under the trouble-free state with technology; The degree of depth is reached pipe thickness defective over half, after adopting special-purpose packing material filling and composite material reinforcement sheet material to repair, seepage and cracking do not take place in rejected region during the full-scale hydraulic pressure demolition of pipeline, seam broken appears at pipeline zero defect position, the description defect place suffered stress of pipeline is lower than pipeline zero defect place stress value, that is the fault location bearing capacity is greater than zero defect pipeline bearing capacity.
(2) adopt the composite material roll film that defective pipeline is repaired and reinforcement, the main material of its reinforcement can machine indoor.Only need during reinforcement rejected region is carried out suitable surface treatment, again rejected region is filled and led up with the reinforcement packing material, then the reinforcement roll film is wrapped on the pipeline, adopt the sticking and curing agent of special-purpose adhesive between sheet layer, need not welding, need not special-purpose machines and tools, operation gets final product.
(3) the used performance of composites (table 2 and table 3 and Fig. 1) of reinforcement.
Table 2 epoxy resin-593#/carbon fiber composite performance
| Project | Epoxy resin+593# | |
| Carbon fiber (T-300) | Glass fibre (T-700S) unidirectional cloth | |
| Tensile strength (MPa) flexural strength (MPa) layer is cut intensity (MPa) Vf (%) | 623.0 1063.0 39.8 40 | 1480.0 930.0 44.1 51.1 |
Table 3 epoxy resin-593#-ethanolamine/glass fiber compound material performance
| Project | Epoxy resin+25phr593#+5phr ethanolamine | |
| Carbon fiber (T-300) | Glass fibre (T-700S) unidirectional cloth | |
| Tensile strength (MPa) flexural strength (MPa) layer is cut intensity (MPa) Vf (%) cryogenic tensile intensity (MPa) (0 ~ 5 ℃) cryogenic tensile modulus (GPa) (0 ~ 5 ℃) | 623.0 1063.0 39.8 40 | 1331.0 1138.0 70.0 46.9 1484.0 101.3 |
Fig. 1 is the bend tension intensity and the resin matrix system graph of a relation of carbon fiber one-way composite material.As can be seen from Figure 3, the tensile strength values of composite material has improved much than the tensile strength of glass fibre unidirectional cloth reinforced composite materials, and for epoxy resin-593 system, tensile strength has improved 63.9%, reach 1480Mpa, flexural strength is 930Mpa, to cut intensity be 51.Mpa to layer.
(2) performance of loading transfer material
Test and select by experiment suitable kind and consumption (performance index see Table 4) at the important indicators such as impact strength, shear strength, adhesion and workability that improve material.
Table 4 loading transfer material performance index
| Test event | Performance | Test method |
| Solid content (%) | 96.3 | GB/T1725 |
| Preliminary sclerosis (minute) 10 ℃ | 160 | Actual measurement |
| Sclerosis fully (minute) 10 ℃ | 220 | Actual measurement |
| Preliminary sclerosis (minute) 25 ℃ | 100 | Actual measurement |
| Sclerosis fully (minute) 25 ℃ | 150 | Actual measurement |
| Flexural strength (Mpa) | 41.0 | GB/T2570-1995 |
| Impact strength (KJ/m 2) | 6.2 | GB/T2571-1995 |
| Draw and cut intensity (MPa) [steel-steel] | 7.9 | GB/7124-86 |
| 100 ℃ of heat resistances 24 hours | No change | GB/T1725 |
(4) optimize glass fibre reinforced composion sheet material and steel pipe matching performance
When the matching performance of test sheet material and pipeline to be repaired, adopt the sheet material coil diameter greater than outer diameter tube to be wound, twining used roll film specification is that 1mm is thick, the test outer diameter of steel pipes is 105mm, probe temperature is 5 ℃～95 ℃, testing procedure is: the sample that is cured is placed 95 ℃ of hot water, soaked 12 hours, place 5 ℃ cold water after the taking-up immediately, place hot water to take out after 10 minutes afterwards again and immerse cold water, 3 times so repeatedly, observe combining and the situation of change of strengthening course of strengthening course and body.The result shows that the combination force between strengthening course and steel pipe matrix does not have any variation before and after the test.
(5) mechanical property of adhesive
Epoxy resin-diethylenetriamine base glycerol n-butyl ether system solidfied material toughness is relatively poor, in splicing and solidification process, can produce bigger internal stress, cause the tensile shear strength of adhesive lower, three kinds of material test piece tensile and shear property test values see Table 5 after adding acrylic liquid rubber plasticizer, add promoter and thixotropic agent simultaneously for improving workability.
Table 5 adhesive tensile and shear property
(6) adhesive antikathode stripping performance
The Bond of epoxy resin+593+ thixotropic agent as glass fibre reinforced plastics reinforcement sheet material and steel pipe adopted in test, by antikathode stripping ability between Canadian standard CAN/CSA-Z245.21-M92 test adhesive layer and body.Test conditions and the results are shown in Table 6.
The antikathode stripping performance of table 6 adhesive
| Test event | Test conditions | Code requirement | Test result | Reference standard |
| Cathodic disbonding | Test temperature: 65 ℃; Cathodic polarization potential: 3.5V; Testing liquid: 3.5% NaCl solution; Test period: 48 hours | ≤10mm | Average out to 2mm | CAN/CSA- Z245.21-M92 |
(7) hydrostatics testing condition and result
Employing is from the advanced person's of U.S.'s introduction hydrostatics testing system.System's maximum pressure reaches 210MPa, and pumping rate can be controlled automatically, control accuracy≤1%.To the zero defect pipeline section, adopt directly pressurization to explode mode; Pipeline section is repaired in the reinforcement that contains defectiveness, in the hydrostatic test process, all adopted the cascade load mode, i.e. segmentation voltage stabilizing.The test temperature of test body is 12 ℃ in the test.
Fig. 2 be the zero defect pipe and contain in defective pipeline section 2 hydrostatic test processes in press change curve in time, obviously passed through the plastic history that ruptures from surrendering to from the pressure-time curve pipe.Pairs of 3 pipe yield pressures of table 7 and burst pressure tests value and theoretical value have been done contrast, and the result shows that the test value of yield pressure and bursting pressure and calculated value are identical substantially.Table 8 provides test front and back pipe girth test result.
Table 7 pipe yield pressure and burst pressure tests value and theoretical value (unit: MPa)
| The pipe number | Yield pressure | Bursting pressure | ||
| Theoretical value | Measured value | Theoretical value | Measured value | |
| The zero defect pipe | 18.4 | 19.7 | 19.9 | 23.3 |
| Contain the defective pipeline section No. 1 | 18.4 | 20.0 | 19.9 | 23.2 |
| Contain the defective pipeline section No. 2 | 18.4 | 20.6 | 19.9 | 23.7 |
Dimensional changes situation (mm of unit) before and after the full-scale hydrostatic test pipeline section test of table 8
| The pipe number | The D external diameter | The T wall thickness | L length | External diameter of pipe when not suppressing | Suppress the back external diameter of pipe | ||
| Looping place not | Glass fibre (L1, L2) | Carbon fiber (L3) | |||||
| The zero defect pipeline section | 273 | 6 | 3000 | 867 | 910 | ||
| Contain |
273 | 6 | 3000 | 866 | 911 | 871 | |
| Contain defective pipeline section 2 | 273 | 6 | 3000 | 867 | 870 | 868 | |
Description of drawings
The bend tension intensity of Fig. 1 carbon fiber one-way composite material and resin matrix system graph of a relation
Pressure time curve in Fig. 2 hydrostatic test process
Fig. 3 contains defective steel pipe stress interference range size computation model
Fig. 4 contains defective steel pipe stress interference range size computation model
Fig. 5 contains the reinforcement of defective steel pipe glass fibre reinforced plastics and repairs computation model
Fig. 6 glass fibre reinforced plastics sheet material reinforcement defective pipeline stress distribution cloud atlas (interior pressure: 5.5Mpa)
(flaw size: 30 * 30 * 2mm, 4 synusia materials)
Fig. 7 glass fibre reinforced plastics sheet material reinforcement defective pipeline stress distribution cloud atlas (interior pressure: 5.5Mpa)
(flaw size: 30 * 30 * 2mm, 6 synusia materials)
Fig. 8 carbon fiber plate reinforcement defective pipeline stress distribution cloud atlas (interior pressure: 5.5Mpa)
(flaw size: 30 * 30 * 2mm, 4 synusia materials)
Embodiment
1. the preparation of reinforcement composite material sheet
(1) cutting reinforced composite
Composite material sheet sample reinforcing material is the high-strength glass fibre unidirectional cloth, and the Dimensions of composite material sheet will be decided according to used raw material and pipe condition to be repaired.Generally speaking, the coil diameter of composite material sheet is 50～80% of an outer diameter tube to be repaired, and the thickness of individual layer roll film is decided on the rigidity of sheet material between 0.5～1.5mm, is advisable slightly firmly can roll up to be attached on the pipeline; The width of sheet material and length will be decided according to flaw size, and generally between 200～400mm, length is between 400cm～1000cm for width; To adopt metering method (every layer of fibre weight and resin matrix usage ratio are by setting value) with the control gel content in the gluing process, and determine the reinforcement number of plies by FEM (finite element) calculation.
(2) resin glue configuration
Adopt epoxy resin/593=100/30.94 as resin matrix, and add acrylic liquid rubber it is carried out toughening modifying, liquid rubber addition scope is 5-15phr.Curing process is: room temperature was solidified 4 hours for 30 ℃, 100 ℃ of reprocessings,
(3) with mould rolling and curing
With in the process of mould rolling on reinforced composite the brushing resin glue, solidify in the heating plant frock according to the curing process temperature of setting then.Curing process is: room temperature was solidified 100 ℃ of reprocessings 4 hours for 30 ℃.
(3) carry out mould unloading after, repair corner and encapsulation.
2. the preparation of defective packing material and construction
(1) prescription
Prepared loading transfer material is two components system, and the A component is epoxy resin (100 parts), filler quartz flour flicker stone (200 parts), thixotropic agent aerosil (5 parts); The B component is curing agent 593 (100 parts), altax P-30 (40 parts).
(2) construction process
Surface treatment: should eliminate rust to Sa2.5 level or St3 level in processed surface, requires the surface not have oil, rustless, dry cleansing;
Form of construction work: adopt the trowelling mode, press the A component: B component=100: 10 (weight ratio) is mixed A and B component, once is no more than 500 grams, and slaking was constructed with spatula after 30～60 minutes;
Notice: being repaired the material surface temperature should need heat during operation below 5 ℃ more than 5 ℃, and the job site be protected and be handled to the rainy day will, avoids sneaking into of water.
3. the preparation of interlaminated adhesive
(1) prescription
Prepared adhesive is two component room curing interlaminated adhesives: the A component is epoxy resin (100 parts), acrylic liquid rubber (10 parts), thixotropic agent aerosil (5 parts); The B component is curing agent 593 (100 parts), promoter (40); Press the A component: B component=100: 26 (weight ratio) is mixed.Curing process is 18 ℃/12h, 18 ℃.
(2) preparation
The surface treatment of test piece: the aluminum alloy test piece is handled (the treatment fluid proportioning is: 1 part of sodium dichromate, 5 parts of the concentrated sulphuric scids, 20 parts of distilled water) with sulfuric acid-sodium dichromate solution, treatment process: clean-70 ℃ of oven dry of 66～71 ℃/15min-washing; The glass fibre reinforced plastics test piece is cleaned with anhydrous alcohol, 70 ℃ of oven dry.
The preparation of adhesive: the A component is epoxy resin, acrylic liquid rubber, filler, thixotropic agent; The B component is curing agent, promoter
The preparation of glued part: under the room temperature, cold is put behind the gluing, closes up the back and adopts the contact pressure pressurization, and the control bondline thickness is conventional thickness, 1～3 hour gel, test performance after 24 hours.
4. FEM (finite element) model and computational methods
Adopt three-dimensional finite element to calculate.According to symmetry properties, be symmetric points with the central point of rejected region, get 1/4 of pipeline section and analyze; For eliminating the St.Venant effect, length of pipe section is got 4～5 times of tube outer diameter; Element adopts the three-dimensional linear element of four node tetrahedrons, carries out the unit refinement in defective edge, finds the solution by numerical approximation algorithm.
Calculating used steel pipe specification is external diameter 273mm, and wall thickness 6mm, grade of steel are X42.Getting tube length is 500mm.Computation model is divided into two classes: the first kind is to contain defective steel pipe stress interference range size calculation, is intended to obtain the width of reinforcement with the glass fibre reinforced plastics sheet material, and this class model length direction is got 50 unit, each unit 10mm; Circumferentially get 20 unit, the about 10mm in each unit, radially get two-layer, interior bed thickness 5mm, skin is defect layer thickness 1mm, computation model is shown in Fig. 5,6; Another kind of model is the calculating that contains loss of defective steel strength and glass fibre reinforced plastics reinforcement reparation thickness, is used to obtain the thickness size of reinforcement with the glass fibre reinforced plastics sheet material, and the model length direction is got 50 unit, each unit 10mm; Circumferentially get 20 unit, the about 10mm in each unit radially gets three layers, and internal layer 4mm is thick, and middle level 2mm is thick, and skin is the frp layer thickness of being mended.Computation model is seen Fig. 7.
5. reinforcement glass fibre reinforced plastics THICKNESS CALCULATION
Reinforcement adopts second class model to calculate with the thickness of glass fibre reinforced plastics sheet material.With the defective that is of a size of 30mm * 30mm * 2mm is example, calculates equivalent stress that pipeline bore and circumference stress value under different glass steel sheets and the carbon fiber plate reinforcement thickness situation, and result of calculation is as shown in table 8 below.
Wherein, element number is 509,510,511, at the internal layer of computation model, under the defective.Element number is 830,831, and at the internal layer of computation model, glass fibre reinforced plastics is mended the outer 120～140mm place of layer.Fig. 7～8 are pipe stress cloud atlas under the different strengthening course thickness of part.
(interior pressure: P=5.5Mpa) (flaw size is 30 * 30 * 2mm) in table 8 glass fibre reinforced plastics roll film thickness reinforcement calculating
| The sheet material number of plies | Equivalent stress | Circumference stress | Annotate | ||
| Maximum value (MPa) | Element number | Maximum value (MPa) | Element number | ||
| 2 layers of glass fibre reinforced plastics sheet material | 132.66 | 510 | 143.92 | 511 | Can not use |
| 4 layers of glass fibre reinforced plastics sheet material | 117.94 | 510 | 128.01 | 511 | Critical |
| 6 layers of glass fibre reinforced plastics sheet material | 115.54 | 509 | 113.59 | 511 | Available |
| 7 layers of glass fibre reinforced plastics sheet material | 111.34 | 831 | 110.64 | 832 | Available |
| 2 layers of carbon fiber plate | 112.03 | 511 | 121.91 | 511 | Critical |
| 4 layers of carbon fiber plate | 112.30 | 830 | 114.52 | 831 | Available |
Claims (2)
1. the method for a reinforcing defective pipeline is characterized in that:
(1) adopt the reinforcement composite material sheet, the reinforcement composite material sheet is by high-strength glass fibre unidirectional cloth or carbon fiber one-way cloth and contains 593 curing agent or the epoxy resin glue of triethanolamine curing agent, acrylic liquid rubber that interlaminated adhesive constitutes;
(2) adopt the defective packing material, the defective packing material is two components system, and the A component is 100 parts of epoxy resin, 200 parts in stone of filler quartz flour flicker, 5 parts of thixotropic agent aerosils; The B component is 100 parts in 593 curing agent, 40 parts of altax P-30;
(3) adopt interlaminated adhesive, interlaminated adhesive is to be mixed by two component room curing interlaminated adhesives: the A component is 100 parts of epoxy resin, 10 parts of acrylic liquid rubbers, 5 parts of thixotropic agent aerosils; The B component is 100 parts in 593 curing agent, promoter 2,4,40 parts of 6-three [(dimethylamino) methyl] phenol; Press the A component: the B component=weight ratio was mixed in 100: 26, and curing process is 18 ℃/12h;
(4) reparation, reinforcement rejected region,
At first carrying out surface treatment: should eliminate rust to Sa2.5 level or St3 level in processed surface, requires the surface not have oil, rustless, dry cleansing;
Filling defect: the defective packing material is pressed the A component: B component=100: 10 weight ratios, A and B component are mixed, and once be no more than 500 grams, slaking construction in 30～60 minutes;
Out-of-flatness face is repaired: the defective packing material reach dry tack free and confirm the steel tube surface drying, pollution-free after, the brushing primer behind primer and packing material gel, is repaired rejected regions such as sagging or other depression, cavities;
The composite material sheet volume pastes and coats: after the primer surface gel, the composite material sheet volume is attached to the defect of pipeline position that mark is good, paste brushing interlaminated adhesive in the coating process at volume between composite material sheet layer and the layer, fill with interlaminated adhesive in the space between composite material sheet layer and the layer.
2. the method for a kind of reinforcing defective pipeline according to claim 1, it is characterized in that: high-strength glass fibre unidirectional cloth or its coil diameter of carbon fiber one-way cloth are 50～80% of outer diameter tube to be repaired, the thickness of individual layer roll film is between 0.5～1.5mm, the width of sheet material and length will be decided according to flaw size, generally between 200～400mm, length is between 400cm～1000cm for width.
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