CN109354738A - 一种深海油管的制备工艺及材料 - Google Patents
一种深海油管的制备工艺及材料 Download PDFInfo
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- CN109354738A CN109354738A CN201811211276.9A CN201811211276A CN109354738A CN 109354738 A CN109354738 A CN 109354738A CN 201811211276 A CN201811211276 A CN 201811211276A CN 109354738 A CN109354738 A CN 109354738A
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Abstract
本发明公开了一种深海油管的制备工艺及材料，涉及高性能材料领域。本发明深海油管的制备工艺，包括在线内衬管挤出、在线纤维浸渍、在线熔融缠绕、在线外衬管复合四个步骤。本发明的有益效果在于：本发明通过工艺简化、功能性材料的组合，辅以自动化、数字化的实施，大幅降低生产成本，同时实现复合油管工业化、规模化、连续化生产，本发明深海油管材料，可承受3000m深海内压、外压操作压力，具有寿命长、可卷绕、轻量化、高机械强度的优点，可满足深海石油勘探、油气输送的要求。
Description
技术领域
本发明主要涉及高性能材料领域，具体是一种深海油管的制备工艺及材料。
背景技术
近年来我国在深海石油钻井平台船开发成功，中国深海钻井技术日渐成熟，我国已由深海钻井平台装备进口大国，转变为深海钻井平台制造大国，我国大陆油气资源经过50多年的开采已进入后发展阶段。加之家庭用小轿车普及，我国已成为石油第一进口大国，每年68％石油进口。能源安全问题特别突出，石油战备储量不到2个月，严重威胁国家安全，向深海要油气显得比以往任何时候更加紧迫。
海洋经济已上升到中国经济战略选择层面，是二十一世纪最具发展潜力的经济，目前浅海使用塑料钢丝管结构已远远不能满足深海钻探的需求，金属合金管自载重、易腐蚀、不易安装、勘探综合费用高，由于自载重连接难，需租赁特殊海上作业船，费用高安装时间长，安装效率低；海洋天气风雨突变更无法掌控，给安装作业带来极大困难，这些因素严重制约了深海石油天然气勘探和发展，市场迫切需要水深超过3000m深海复合管，超高压、轻质、高强度、耐盐雾、耐石油化学品、腐蚀液、高抗紫外、高拉伸、耐磨、同质化、实壁结构、长距离新型柔性超高压压力管的工业化、规模化、连续化生产，对于打破国外企业在该领域的封锁，保障我国能源安全，大幅降低勘探成本具有特别重大的意义。
发明内容
为解决现有技术的不足，本发明提供了一种深海油管的制备工艺及材料，可大幅降低生产成本，实现复合油管工业化、规模化、连续化生产，并且油管轻质、高强、寿命长，能满足长距离深海石油勘探、油气输送的要求。
本发明为实现上述目的，通过以下技术方案实现：
一种深海油管的制备工艺，包括以下步骤：
(1)在线内衬管挤出：镜面模具和功能性内衬改性料在挤出机的作用下挤出，得到内腔壁超高光洁的内衬管，然后内衬管经真空定型、喷淋水冷却、吹风干燥机烘干、红外线加热器加热后，备用；
(2)在线纤维浸渍：增强层碳纤维或玻璃纤维在表面干燥处理后放在玻纤架上，经预浸槽进行预浸润预保护，然后经过热风管道干燥进入碳纤张力控制器进行分纱，随后依次进入高压浸渍模头内浸渍，钢带热压辊热压牵引和冷却，得到带材、丝束备用；
(3)在线熔融缠绕：将步骤(2)中带材、丝束保持一定的温度进入全自动带材缠绕或丝束缠绕输送系统，经激光瞬时加热器熔融后与步骤(1)的内衬管进行熔融缠绕，所述缠绕层数为2-16层，所述缠绕模式为带材、丝束混搭缠绕模式，在熔融缠绕过程中，界面玻纤融接检测仪实施在线融接检测和监视，导向装置对角度进行精密导向，铺带头进行自动送带，形成零张力缠绕；
(4)在线外衬管复合：步骤(3)得到的管道经过外衬管管道进行外衬复合后，经真空定型、喷淋水冷却、干燥箱吹干后，将管道截断，得到本发明深海油管。
步骤(1)中所述挤出机的作用条件为：一区温度110-120℃、二区温度125-130℃、三区温度135-140℃、四区温度160-170℃，模具温度165-175℃，喂料转速30r/min，挤出转速270r/min。
步骤(3)中所述带材、丝束保持70-90℃进入全自动带材缠绕或丝束缠绕输送系统。
步骤(4)中所述管道的截断长度为3000m或4000m。
上述制备工艺制备的深海油管的材料，包括内衬管材料、增强层材料、外衬管材料；
所述内衬管材料由以下材料组成：聚乙烯84-93.5％、主抗氧剂0.5-1％、辅助抗氧剂1-2％、热稳定剂0-1％、超细煅烧高岭土或合成云母1-3％、相容剂Ⅰ1-3％、光亮剂1-2％、颜料1-2％、成核剂0.5-1％、润滑剂0.5-1％；
所述增强层材料由以下材料组成：碳纤维或玻璃纤维40-70％、聚乙烯16.5-53.5％、主抗氧剂0-1％、辅助抗氧剂1-2％、分散剂1-2％、相容剂Ⅱ3-5％、偶联剂0.5-1％、抗浮纤剂1-3％；
所述外衬管材料由以下材料组成：聚乙烯79-90％、主抗氧剂0.5-1％、辅助抗氧剂1-2％、热稳定剂0-1％、抗老化剂0-1％、耐磨剂3-5％、高效抗紫外剂1％、耐候剂0-1％、抗盐雾剂0-1％、柔性改质剂3-5％、颜料0.5-1％、阻隔剂1-2％。
所述相容剂Ⅰ为含有苯氧基官能团结构相容剂或含有氧化聚乙烯结构相容剂。
所述相容剂Ⅱ为马来酸酐接枝PE或环氧基团接枝PE。
所述光亮剂采用有机硅表面改质剂，
所述耐磨剂为聚四氟乙烯、硅酮粉、二硫化钼或超高分子聚乙烯微粉。
所述偶联剂为KH550、KH570或有机硅。
所述高效抗紫外剂为二苯甲酮。
所述热稳定剂为硬脂酸钙。
所述润滑剂为聚乙烯蜡。
对比现有技术，本发明的有益效果是：
1、本发明通过工艺简化、功能性材料的组合，辅以自动化、数字化的实施，使复杂油管的制造工艺更简单、更方便，从而实现深海油管的高效、低成本、高性能、规模化生产、长距离环保生产的新模式，与传统方式相比重量减轻80％，能耗下降50％，工作效率是传统的5-10倍；并且本发明深海油管材料，可承受3000m深海操作，具有拉伸负载高、抗化学性、抗石油钻井液腐蚀、抗老化、抗紫外线、抗海水渗透、阻隔性好、可卷绕、轻量化、高机械强度的优点，大大延长了管道的使用寿命。
2、本发明油管制备工艺由传统涂覆、包覆技术改变成高压浸渍和低压浸渍，反复交替浸渍技术，可以使每跟丝束、带材都得到充分浸润，提高带材拉伸和丝束拉伸强度，从而提高油管的拉伸负载。
3、本发明油管制备工艺采用熔融连接方式，从而整个管材形成整体的实壁结构，其明显作用是管壁没有滑动位移、无间隙、无气泡，提升了整体抗爆破能力。
4、发明油管内衬管材料采用聚乙烯和超细煅烧高岭土或合成云母片层结构可以阻隔石油、天然气、H2S等腐蚀性物质对管道的侵蚀，加之光亮剂为有机硅形成了一层薄薄的保护膜，可提高输送流速，减少蜡沉积，提高管道抗爆破压力；增强层材料由碳纤维或玻璃纤维与聚乙烯组成，碳纤维经有机化表面处理，并辅以高效相溶剂，解决了极性的碳纤维与无极性的聚乙烯结合难题；外衬管材料采用聚乙烯与高效耐磨剂和高效抗紫外剂、耐候剂以及抗盐雾剂等形成功能材料，避免在收放等操作作业下容易形成刮擦易损伤，即使在阳光、强烈的紫外线、海水腐蚀中也能轻松面对，并能保证管道使用寿命。
具体实施方式
结合具体实施例，对本发明作进一步说明。应理解，这些实施例仅用于说明本发明而不用于限制本发明的范围。此外应理解，在阅读了本发明讲述的内容之后，本领域技术人员可以对本发明作各种改动或修改，这些等价形式同样落于本申请所限定的范围。
实施例：
一种深海油管的制备工艺，包括以下步骤：
(1)在线内衬管挤出：镜面模具和功能性内衬改性料在挤出机一区温度110℃、二区温度125℃、三区温度135℃、四区温度160℃，模具温度165℃，喂料转速30r/min，挤出转速270r/min的作用下挤出，得到内腔壁超高光洁的内衬管，然后内衬管经真空定型、喷淋水冷却、吹风干燥机烘干、红外线加热器加热后，备用；
(2)在线纤维浸渍：增强层碳纤维或玻璃纤维在表面干燥处理后放在玻纤架上，经预浸槽进行预浸润预保护，然后经过热风管道干燥进入碳纤张力控制器进行分纱，随后依次进入高压浸渍模头内浸渍，钢带热压辊热压牵引和冷却，得到带材、丝束备用；
(3)在线熔融缠绕：将步骤(2)中带材、丝束保持一定的温度进入全自动带材缠绕或丝束缠绕输送系统，经激光瞬时加热器熔融后与步骤(1)的内衬管进行熔融缠绕，所述缠绕层数为2-16层，所述缠绕模式为带材、丝束混搭缠绕模式，在熔融缠绕过程中，界面玻纤融接检测仪实施在线融接检测和监视，导向装置对角度进行精密导向，铺带头进行自动送带，形成零张力缠绕；
(4)在线外衬管复合：步骤(3)得到的管道经过外衬管管道进行外衬复合后，经真空定型、喷淋水冷却、干燥箱吹干后，将管道截成300m，得到本发明深海油管。
上述制备工艺制备的深海油管的材料，包括内衬管材料、增强层材料、外衬管材料；
所述内衬管材料由以下材料组成：聚乙烯89％、主抗氧剂1％、辅助抗氧剂1％、热稳定剂1％、超细煅烧高岭土或合成云母2％、相容剂Ⅰ2％、光亮剂1.5％、颜料1.5％、成核剂0.5％、润滑剂0.5％；
所述增强层材料由以下材料组成：碳纤维或玻璃纤维65％、聚乙烯25％、主抗氧剂1％、辅助抗氧剂1％、分散剂1％、相容剂Ⅱ4％、偶联剂1％、抗浮纤剂2％；
所述外衬管材料由以下材料组成：聚乙烯85％、主抗氧剂0.5％、辅助抗氧剂1％、热稳定剂1％、抗老化剂1％、耐磨剂4％、高效抗紫外剂1％、耐候剂1％、抗盐雾剂1％、柔性改质剂3％、颜料0.5％、阻隔剂1％。
实验例：为了验证本发明具有高强度的轻质柔性深海油管材料的性能，本发明依据API RP17B和API RP17J、APIRP17K，美国石油协会、API标准对实施例1中的深海油管材料进行生产、制造测试和评估，得到检测结果如表1所示。
表1检测结果
| 检测指标 | 管道内压 | 管道外压 | 管道工作压力 | 管道抗爆破压力 |
| 实施例1 | 2×10<sup>8</sup>Pa | 3×10<sup>7</sup>Pa | 110-125MPa | 245-260MPa |
实验结果表明：本发明具有高强度的轻质柔性深海油管材料，可承受较高的工作压力和抗爆破压力，可在深海操作。
Claims (10)
1.一种深海油管的制备工艺，其特征在于：包括以下步骤：
(1)在线内衬管挤出：镜面模具和功能性内衬改性料在挤出机的作用下挤出，得到内腔壁超高光洁的内衬管，然后内衬管经真空定型、喷淋水冷却、吹风干燥机烘干、红外线加热器加热后，备用；
(2)在线纤维浸渍：增强层碳纤维或玻璃纤维在表面干燥处理后放在玻纤架上，经预浸槽进行预浸润预保护，然后经过热风管道干燥进入碳纤张力控制器进行分纱，随后依次进入高压浸渍模头内浸渍，钢带热压辊热压牵引和冷却，得到带材、丝束备用；
(3)在线熔融缠绕：将步骤(2)中带材、丝束保持一定的温度进入全自动带材缠绕或丝束缠绕输送系统，经激光瞬时加热器熔融后与步骤(1)的内衬管进行熔融缠绕，所述缠绕层数为2-16层，所述缠绕模式为带材、丝束混搭缠绕模式，在熔融缠绕过程中，界面玻纤融接检测仪实施在线融接检测和监视，导向装置对角度进行精密导向，铺带头进行自动送带，形成零张力缠绕；
(4)在线外衬管复合：步骤(3)得到的管道经过外衬管管道进行外衬复合后，经真空定型、喷淋水冷却、干燥箱吹干后，将管道截断，得到本发明深海油管。
2.根据权利要求1所述的一种深海油管的制备工艺，其特征在于：步骤(1)中所述挤出机的作用条件为：一区温度110-120℃、二区温度125-130℃、三区温度135-140℃、四区温度160-170℃，模具温度165-175℃，喂料转速30r/min，挤出转速270r/min。
3.根据权利要求1所述的一种深海油管的制备工艺，其特征在于：步骤(3)中所述带材、丝束保持70-90℃进入全自动带材缠绕或丝束缠绕输送系统。
4.根据权利要求1所述的一种深海油管的制备工艺，其特征在于：步骤(4)中所述管道的截断长度为3000m或4000m。
5.根据权利要求1所述制备工艺制备的深海油管的材料，其特征在于：包括内衬管材料、增强层材料、外衬管材料；
所述内衬管材料由以下材料组成：聚乙烯84-93.5％、主抗氧剂0.5-1％、辅助抗氧剂1-2％、热稳定剂0-1％、超细煅烧高岭土或合成云母1-3％、相容剂Ⅰ1-3％、光亮剂1-2％、颜料1-2％、成核剂0.5-1％、润滑剂0.5-1％；
所述增强层材料由以下材料组成：碳纤维或玻璃纤维40-70％、聚乙烯16.5-53.5％、主抗氧剂0-1％、辅助抗氧剂1-2％、分散剂1-2％、相容剂Ⅱ3-5％、偶联剂0.5-1％、抗浮纤剂1-3％；
所述外衬管材料由以下材料组成：聚乙烯79-90％、主抗氧剂0.5-1％、辅助抗氧剂1-2％、热稳定剂0-1％、抗老化剂0-1％、耐磨剂3-5％、高效抗紫外剂1％、耐候剂0-1％、抗盐雾剂0-1％、柔性改质剂3-5％、颜料0.5-1％、阻隔剂1-2％。
6.根据权利要求5所述的深海油管的材料，其特征在于：所述相容剂Ⅰ为含有苯氧基官能团结构相容剂或含有氧化聚乙烯结构相容剂。
7.根据权利要求5所述的深海油管的材料，其特征在于：所述相容剂Ⅱ为马来酸酐接枝PE或环氧基团接枝PE。
8.根据权利要求5所述的深海油管的材料，其特征在于：所述光亮剂采用有机硅表面改质剂。
9.根据权利要求5所述的深海油管的材料，其特征在于：所述耐磨剂为聚四氟乙烯、硅酮粉、二硫化钼或超高分子聚乙烯微粉。
10.根据权利要求5所述的深海油管的材料，其特征在于：所述偶联剂为KH550、KH570或有机硅。
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| CN114272852B (zh) * | 2021-12-30 | 2024-06-04 | 郑立 | 一种碳纤维增强高温高压反应容器及其加工方法 |
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Application publication date: 20190219 |