CN101967619B - Method for reinforcement repair of pipeline by using metal hot spraying and fibrous composite - Google Patents
Method for reinforcement repair of pipeline by using metal hot spraying and fibrous composite Download PDFInfo
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- CN101967619B CN101967619B CN201010525682XA CN201010525682A CN101967619B CN 101967619 B CN101967619 B CN 101967619B CN 201010525682X A CN201010525682X A CN 201010525682XA CN 201010525682 A CN201010525682 A CN 201010525682A CN 101967619 B CN101967619 B CN 101967619B
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Abstract
The invention relates to a method for the reinforcement repair of a metal pipeline with defects, which is particularly suitable for the on-site operation under the condition of the continuous transmission of the pipeline. The method is characterized in that after the surface treatment of a pipeline, a defect 2 is filled and leveled up by hot spraying metal alloy. The surface of the integral circle of the pipe body 1 is sprayed to form a metal alloy basement layer 3. A fiber resin composite 4 formed by fibers and an epoxy bonder is wound on the basement layer. The cured fiber resin composite has a high tensile strength and an elastic modulus, so that the fiber resin composite limits the radial dilatational strain at the defect through the metal alloy basement layer to realize the reinforcement repair on the defect of the pipeline. Due to the adoption of the method, the metal alloy basement layer and the steel pipeline are high in bonding strength, while the anti-compression strength is excellent and the shrinkage ratio is low. Therefore, the reinforcement material and the pipeline are tightly bonded to each other. Due to the adoption of the corrosion resistant alloy material, the electrochemical corrosion resistant capability at the defect and the cathode protection compatibility are greatly improved.
Description
Technical field
The present invention relates to a kind of outer entanglement fiber reinforced plastics matrix material that utilizes behind the metal thermal spraying and realize the body defective of steel pressure pipeline is carried out the method that reinforcement is repaired, especially can not stop under the defeated condition body defective to be carried out on-the-spot reinforcement reparation at pipeline.
Background technology
Steel pipe is the main carrier in China's fluid medium transmission engineering; But under environment (atmosphere, soil and mikrobe etc.) and interior delivery medium effect, can corrode; The intensity reduction and the pitting corrosion perforation phenomenon that are caused by corrosion are very serious; Leakage accident happens occasionally, and causes tremendous loss to enterprise production.Outer wall corrosion by corrosion causes is cheated, the repairing of groove equal-volume type defective; Mainly adopt site welding to mend scar, oversleeve or section in the past and cut off the method for welding new pipeline section again; But, reduce the security of pipeline operation because (1) welding causes the tough brittle transition temperature of the pipeline section of transfer lime repairing to reduce; (2) high renewal expense; (3) be prone to produce problems such as hydrogen embrittlement, unrelieved stress in the welding process; (4) welding operator state of the art is required height, need carry out necessary scene flaw detection after the welding; (5) transport pipe needs out of servicely during repairing sometimes, and medium needs emptying in the pipe, Sweet natural gas oil pipeline particularly, thereby cause the tremendous economic loss, so to the reparation of outer wall corrosion defective transport pipe must development of new the repairing enhancement techniques.
The matrix material reinforcement recovery technique of steel pipe is a new pipe rehabilitation technology that came into effect in recent years.When in pipeline is imposed, pressing, produce the hoop tensile stress in pipeline generation radial swelling and the tube wall.At tube wall weakened region (like corrosion pit), want serious by radial protrusion and hoop stress, strain ratio normal thickness zone that interior pressure causes.When radial protrusion acquired a certain degree, this fault location lost efficacy breaking and leaked.The matrix material recovery technique utilizes fortifying fibre and matrix resin outside pipeline, to form the matrix material strengthening course; Share the load that pipeline bears; Radial swelling and hoop tensile stress that the restriction conduit fault location is caused by interior pressure; Thereby reach purpose, recover the normal bearing capacity of pipeline the defective reinforcement.Foreign oil company and service provider should technology put in the industrial application widely; Such as several companies such as U.S. TDW, APPW, ClockSpring and StrongBack, its dimension damage repair technology and product can be represented the advanced level in present pipeline rehabilitation field basically.
The matrix material of aforementioned several companies is repaired product all has application in the fld of Sichuan.2004 so far; The unacceptable defective that Southwest Oil branch office of PetroChina Company Limited. finds in to pipeline Intelligent Measurement and conventional sense on nearly 50 gas pipe lines of its administration has been carried out the reinforcement reparation, and above product (the reinforcement reparation external member) installation application of 100,000 covers is arranged.Reinforcing effect and preservative effect these reinforcement being repaired external member detect in the evaluation procedure; We find to have situation such as layering unsticking, pitch immersion have appearred in the part external member, the fiber infiltration is not enough, body rust cleaning cleaning is not thorough, have had a strong impact on body defect repair effect.Trace it to its cause; Such reinforcement recovery technique has three shortcomings: the one, in construction process; Because the body injustice that weld reinforcement, undercut cause and the self-constriction of resin extender cause composite material laminated board and body surface not to fit tightly, and occur hollowing easily; The 2nd, the bonding strength of resin extender and steel body is low, and steel/veneer sheet interface tension slip resistance is low, causes composite material laminated board to be prone to peel off the body surface; The 3rd, construction process control point is many; Receive operating environment, workman's skills involved in the labour, workman's influence of various factors such as sense of responsibility, difficult quality guarantee, especially the resin matrix quality is wayward; Cause its mechanical property not enough, will have a strong impact on the reinforcement repairing effect.This shows that such reinforcement recovery technique has several big CCPs: the one, the body surface treatment; The 2nd, basal plane is filled and led up; The 3rd, the quality of resin extender and resin matrix, the 4th, the associativity at resin and steel interface, the 5th, the associativity of resin and fiber.
Hot-spraying techniques is the important component part of Surface Engineering, and it is the new technology of a kind of material surface strengthening and surface-treated.Hot-spraying techniques is to utilize certain thermal source that coated material is heated to fusion or semi-melting state; By means of flame stream or high-speed gas it is atomized simultaneously; And promote particle spraying after these atomizings to matrix surface, accomplish workpiece size recovery (like sealing of hole) or be deposited as coating with certain function.
Hot-spraying techniques of China and practical applications have just begun the electric-arc thermal spray coating (according to document announcement, just spraying Zn coating antiseptic on the high voltage power transmission steel structure tower of Jiangsu and Zhejiang Provinces one band is still playing etch-proof effect so far) of silk as far back as the beginning of the fifties in last century.Electric arc spraying is the top that utilizes the arc-melting silk that produces between two one metal wires; The composition of two one metal wires can be identical; Also can be inequality, atomizing through a branch of or multi beam gas-jet (being generally pressurized air), the molten metal molten drop is ejected into the process method that on pretreated matrix surface, forms coating.The arc-spraying machine volume is less, and is simple to operate, is easy to field work.
Summary of the invention
The purpose of this invention is to provide a kind of reinforcement restorative procedure that is used to contain the defective metallic conduit, be specially adapted to pipeline and do not stop the site work under the defeated condition.Develop the reinforcement repair system of metal alloy/fibre composite; Solved well in the conventional composite materials reinforcement recovery technique, the bonding strength of matrix material and steel body is low, the resin extender shrinking percentage big, resin extender quality problem of unstable.This reinforcement repair system is made up of thermospray metal alloy basic unit, fibre resin veneer sheet and three parts of high-performance epoxy adhesive, between each component and and the pipeline matrix surface between on mechanics, chemical property, all have good matching.When defect repair; At first use sandblast (recommendation) or electronic angle grinding machine to carry out after the body surface treatment; Through the thermospray metal alloy defective 2 is filled and led up processing, and form layer of metal alloy basic unit 3 in whole circle body 1 surface spraying, metal alloy basic unit has excellent ultimate compression strength; In this basic unit, twine the fibre resin matrix material 4 that fiber and epoxy adhesive are formed then; Have high tensile strength and Young's modulus behind the fibre resin composite material solidification; It will be through the radial swelling distortion of metal alloy basic unit restriction fault location; Reduce the tensile stress and the strain of fault location, realize reinforcement reparation defect of pipeline.
The present invention carries out the reinforcement reparation to steel pipe body defective and may further comprise the steps: 1, the surperficial base treatment of body surface treatment tubing generally should finish in 4 hours before reinforcement, with the generation of avoiding the surface to reoxidize.Use sandblast (recommendation) or electronic angle grinding machine to carry out surperficial base treatment.Basic unit's pretreatment quality should reach Sa2.5 or the St3 level of stipulating among the GB/T8923-1988.If there is more tiny corrosion pit defective in pipe surface, be difficult to use electronic angle grinding machine thoroughly to eliminate rust, can corrosion product in the corrosion pit and dirt be cleaned out with wire brush.After guaranteeing that original corrosion protection coating of steel tube surface and oxide compound are removed, clean steel tube surface with clean-out system, and make its thorough drying.The construction before at need reinforcement position unwrapping wire, location.
2, metal alloy thermospray hot-spraying techniques method commonly used includes flame plating, electric arc spraying, plasma spraying, detonation flame spraying and supersonic spray coating, wherein with electric arc spraying optimum site operation.Hot spray wire should be selected the spray coating alloy silk material that can obtain higher hardness for use, like ferrous alloy, alumel etc.
Through heat spraying method metal alloy wires material fusing injection is filled into body surface imperfection place; And can spray the metal-based layer that formation one deck have higher-strength and good antiseptic property on whole circle body surface; Metal alloy basic unit has excellent ultimate compression strength, plays the radially effect of transfer tube wall pressure power.
Thermospray should be carried out after the workpiece surface sandblast as early as possible, and in spraying process, workpiece surface should keep clean always, dry and do not have a macroscopic oxidation.Time to be sprayed should be short as far as possible according to the region situation, no longer than 4h.When workpiece surface to be sprayed is in condensation state following time, can not spray.The temperature of workpiece surface to be painted should remain on more than the dew point, and just can spray more than 3 ℃ than dew-point temperature is high at least.
3, the fibre resin veneer sheet is coated in fiber reinforcement coiled material and epoxy resin-base parcel in the metal alloy basic unit, generates fibre composite behind the resin solidification, has advantages of higher tensile strength.It can transmit pressure with self and the bonding force of pipeline through metal alloy basic unit, shares in the pipeline and pressing and the restriction conduit dilatational strain, reduces the tensile stress and the strain of fault location, and realization is to the reinforcement reparation of defect of pipeline.
Defect point should be arranged in fibre resin veneer sheet middle part, and the defect point to vertically long should guarantee during installation that the defect point edge is not less than 50mm apart from the distance of laminate edge; If defect point is long, can not satisfy above-mentioned requirements, then two coiled materials of considered are installed side by side.Coiled material twines to be installed and must be accomplished by two people.The starting point that first floor coiled material is installed cover defect point and with defect point at a distance of 45 °～90 ° angles, the coiled material uneven surface should be close to pipe surface.In the installation process, should align all the time and on pipeline, draw good reparation sideline in advance in the coiled material both sides, and maintenance is vertical with conduit axis.When adopting layering to twine, second coiled material head should overlap with article one coiled material tail should be less than 3cm, the 3～5cm that preferably staggers between the joint of layer and layer, by that analogy.
4, edge sealing need tamp laminate edge and smear into groove with remaining hybrid resin after the whole installations of the required fibrous webs number of plies are complete.It is floating that last layer coiled material end is also used filler.It is floating to dip in little water in case of necessity.
5, cured composite material setting up period can not be immersed in the water or drenched with rain.As temperature is lower than 25 ℃ when installing, or hopes to solidify as early as possible, can wrap up a clean plastic cloth outside, encases the fibre resin matrix material with electric blanket then and heats.
6, smear sealing paint or winding external anti-corrosion layer for work-ing life attractive in appearance or prolongation reinforcement repair system, can carry out artificial sealing treatment through the mode of smearing sealing paint or winding external anti-corrosion layer.
This matrix material reinforcement technology can be used to contain the renovation reinforced of burn into crackle, hydrogen-induced damage, physical abuse, weld defect, geometrical defect and material defective pipeline, also can be used for the interim enhancing of internal corrosion pipeline; Can be used for the reinforcement of single-point defective, also can be used for the defective reinforcement of whole pipeline section.
In practical application,, carry out the consumption that thickness, width and the supporting material of strengthening course are confirmed in reinforcement reparation design according to the relevant regulations among ASME PCC-2 and the ISO/TS 24817 according to the particular case of defect of pipeline.
The matrix material recovery technique of comparing traditional adds fibre composite with metal thermal spraying the method for pipeline strength rehabilitation reparation is had the following advantages: 1, is easy to execute-in-place, and do not receive workpiece size and shape limits; 2, the body material temperature rise is little in the spraying process, does not produce stress and distortion, and coating thickness is more easy to control; 3, the bonding strength of metal alloy basic unit and steel body is high; 4, metal alloy basic unit ultimate compression strength is excellent, and moulding is fast, and shrinking percentage is lower; 5, have good antiseptic property, be applicable under various complicated environmental conditions and use that the repair layer life-span was 50 years; 6, do not influence pipeline Intelligent Measurement and cathodic protection system work; 7, production efficiency is high, less energy consumption, and facility investment is low, and total cost is low, has good economic benefit.
Description of drawings
Fig. 1 is pipeline and defect repair synoptic diagram, 1-metallic conduit wherein, 2-body defective, 3-metal alloy electric arc spraying basic unit, 4-fibre resin veneer sheet.
Fig. 2 is the defective manufacturing drawing that short-term is twined pressure test pipe appearance, and wherein the 4-degree of depth is 80% weakened region, 5-transition boundary, 6-steel tube appearance; Dimensional units is a millimeter among the figure.
Fig. 3 is the photo that matrix material reinforcement system short-term is twined pressure test.
Embodiment
In order further to set forth the related construction technology of present technique, provided following embodiment.But, the scope that these embodiment do not limit the present invention in any way.
According to the requirement of twining pressure test among the ASME PCC-2-2006 about short-term; Gas pipe line with φ 219 * 10 is an example; Mechanical workout grooved defective after method enforcement reinforcement reparation of the present invention, adopts the hydraulic bursting test method that this technology is estimated.Process of the test is following: 1, intercepting gas transmission line 1.7m (this pipe is a 20# steel seamless tube, and caliber is 219mm, and wall thickness is 10mm), two ends are with the end socket shutoff that leaves venting hole, prosopyle.
2, the grooved defective of a 150mm * 80mm * 8mm of large-sized gantry milling machine processing, position pipeline middle part (concrete size is seen Fig. 2).
3, according to method mentioned above and construction procedure this defective is carried out reinforcement and repair (see figure 3).
(1) the body surface treatment is cleared up the body position that needs reinforcement, with preservative coat, bituminous primer and the dirt of removal outer tube surface, and makes its surface treatment quality reach the Sa3 level of stipulating among the GB/T8923-1988.The construction before at need reinforcement position unwrapping wire, location.
(2) the alumel electric arc spraying is sprayed ni-al alloyed wire material fusing back through arc spray process and is filled and led up the body surface imperfection; And, play the radially effect of transfer tube wall pressure power putting in order the metal-based layer that spraying formation one deck in circle body surface is even and have advantages of higher compressive strength.
(3) the carbon fibre resin veneer sheet needs to twine 6 layers of thomel and strengthens coiled material according to design calculation result.Construction procedure according to standard is coated in coiled material and epoxy resin-base parcel in the alumel basic unit, waits for resin solidification.
(4) edge sealing tamps and smears into groove with laminate edge with last layer coiled material end with residual resin.
(5) with the hardness of Shore durometer inspection resin, hardness surpasses 40 after 24 hours in curing, and the expression resin solidifies, meets the installation quality technical requirements.
4, calculate limit burstpressures P
fBe 22.3MPa, according to TR, the reinforcement repair system must sustain this pressure.
5, test pipe is carried out the water filling exhaust, under inspection sample fills with water and gastight situation, pressurize step by step, break until sample.Grooved fault location on this test pipe (see figure 3) of when boosting to 26.4MPa, breaking.
The pipeline of reinforcement can sustain P
fBe the pressure of 22.3MPa, we think that the reinforcement system is effective to the reinforcement of attenuate defective.
Claims (6)
1. add the method that fibre composite is repaired pipeline strength rehabilitation with metal thermal spraying; It is characterized in that: use sandblast or electronic angle grinding machine to carry out after the body surface treatment; Through the thermospray metal alloy defective is filled and led up processing, and in whole circle body surface spraying formation layer of metal alloy basic unit; In this basic unit, twine the fibre resin matrix material that fiber and epoxy adhesive are formed then, have high tensile strength and Young's modulus behind the fibre resin composite material solidification; After performance test is qualified, carry out artificial sealing treatment.
2. the method for claim 1, wherein said body surface ought to finish in 4 hours before reinforcement, with the generation of avoiding the surface to reoxidize; Body surface treatment quality should reach Sa2.5 or the St3 level of stipulating among the GB/T8923-1988; The construction before at need reinforcement position unwrapping wire, location.
3. the method for claim 1, wherein said hot-spraying techniques method comprises flame plating, electric arc spraying, plasma spraying, detonation flame spraying and supersonic spray coating; Hot spray wire is selected the spray coating alloy silk material that can obtain higher hardness for use; Through heat spraying method metal alloy wires material fusing injection is filled into body surface imperfection place, and has the metal-based layer of higher-strength and good antiseptic property at whole circle body surface spraying formation one deck; Thermospray should be carried out after the workpiece surface sandblast as early as possible, and in spraying process, workpiece surface should keep clean always, dry and do not have a macroscopic oxidation; Time to be sprayed according to the region situation no longer than 4h; When workpiece surface to be sprayed is in condensation state following time, can not spray; The temperature of workpiece surface to be painted should remain on more than the dew point, and just can spray more than 3 ℃ than dew-point temperature is high at least.
4. the method for claim 1, wherein said fibre resin matrix material comprises aramid fiber reinforced plastics (AFRP), carbon fiber reinforced plastics (CFRP), glass filament reinforced plastics (GRP); Fiber reinforcement coiled material and epoxy resin-base parcel are coated in the metal alloy basic unit, generate the fibre resin matrix material behind the resin solidification; Defect point should be arranged in fibre resin veneer sheet middle part, and the defect point to vertically long should guarantee during installation that the defect point edge is not less than 50mm apart from the distance of laminate edge, if defect point is long, can not satisfy above-mentioned requirements, and then two coiled materials of considered are installed side by side; Coiled material twines and must be accomplished by two people; The starting point that first floor coiled material is installed cover defect point and with defect point at a distance of 45 °～90 ° angles, the coiled material uneven surface should be close to pipe surface; In the installation process, should align all the time and on pipeline, draw good reparation sideline in advance in the coiled material both sides, and maintenance is vertical with conduit axis; When adopting layering to twine, second coiled material head should overlap with article one coiled material tail should be less than 3cm, the 3～5cm that should stagger between the joint of layer and layer, by that analogy; After the whole installations of the required fibrous webs number of plies are complete, need laminate edge be tamped and smeared into groove with hybrid resin; It is floating that last layer coiled material end is also used filler.
5. the method for claim 1, wherein said matrix material during curing can not be immersed in the water or drenched with rain; Temperature is lower than 25 ℃ when installing, or hopes to solidify as early as possible, should wrap up a clean plastic cloth outside, encases the heating of fibre resin matrix material with electric blanket then.
6. the method for claim 1, wherein said artificial sealing treatment are meant in moulding and detect and smear sealing paint outside the qualified fibre resin matrix material or twine external anti-corrosion layer.
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| CN201010525682XA CN101967619B (en) | 2010-11-01 | 2010-11-01 | Method for reinforcement repair of pipeline by using metal hot spraying and fibrous composite |
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| CN103542227A (en) * | 2012-07-16 | 2014-01-29 | 西安格林石油科技有限公司 | Method for reinforcing corroded position of pipeline by using carbon fibers |
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| CN108591673A (en) * | 2018-06-11 | 2018-09-28 | 中海油安全技术服务有限公司 | A kind of pipeline corrosion defect fast repairing method and a kind of safe emergency toolbox |
| CN108895240A (en) * | 2018-07-26 | 2018-11-27 | 郑州新锐石油工程技术有限公司 | Method of the composite material to pipeline rehabilitation reinforcement or enhancing |
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| CN113492295B (en) * | 2020-11-07 | 2023-05-26 | 胜利油田金岛工程安装有限责任公司 | Shaping process for steel pipes with unequal wall thickness |
| CN114214587B (en) * | 2021-12-16 | 2024-02-06 | 国铭铸管股份有限公司 | Method for reducing surface defects of spheroidal graphite cast tube |
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