CN109590180A - 一种钢管3pe全粉末化涂层的喷涂工艺 - Google Patents

一种钢管3pe全粉末化涂层的喷涂工艺 Download PDF

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CN109590180A
CN109590180A CN201811464226.1A CN201811464226A CN109590180A CN 109590180 A CN109590180 A CN 109590180A CN 201811464226 A CN201811464226 A CN 201811464226A CN 109590180 A CN109590180 A CN 109590180A
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steel pipe
powder
electrostatic
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adhesive
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刘云
孙文盛
刘亚明
芦琳
黄晓江
张阿昱
胡卫国
张超
杨继平
张鹏
高霞
李超
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China Petroleum and Natural Gas Co Ltd
Baoji Petroleum Steel Pipe Co Ltd
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Baoji Petroleum Steel Pipe Co Ltd
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Abstract

本发明公开了一种钢管3PE全粉末化涂层的喷涂工艺，该喷涂工艺采用的设备包括钢管传输滚轮、中频加热装置、环氧粉末静电喷涂装置、胶黏剂粉末静电喷涂装置、聚乙烯粉末静电喷涂装置和水冷却装置。三种静电喷涂装置的喷枪紧邻设置，保证胶黏剂粉末在环氧粉末固化前熔融形成胶黏剂层，聚乙烯粉末在胶黏剂层固化前熔融形成聚乙烯层。环氧粉末层、胶黏剂层和聚乙烯层均以粉末静电喷涂的方式涂敷，不需要对管体进行二次加热，只需喷涂前对钢管进行加热，通过钢管余热使环氧粉末层、胶黏剂层和聚乙烯层固化，工艺简单，节约电力资源。

Description

一种钢管3PE全粉末化涂层的喷涂工艺
技术领域：
本发明属于钢管防腐层复合结构成型技术领域，具体涉及一种钢管3PE全粉末化涂层的喷涂工艺。
背景技术：
管道为石油天然气、水等流体介质输送最为安全经济的方法,然而管道的腐蚀问题是影响管道可靠性和使用寿命最关键的因素。管道防腐涂层在50-70年代主要是采用石油沥青防腐涂层，从70年代开始，先后研究和应用了环氧煤沥青涂料、聚乙烯胶粘带和煤焦油瓷漆等防腐材料，80年代初，开发和应用了2PE聚乙烯防腐层、单环氧粉末(FBE)以及新一代的煤焦油瓷漆等防腐材料。
三层结构聚乙烯(3PE)防腐技术在20世纪80年代初由德国曼内斯曼公司与巴斯夫化学工业公司共同研制成功，该防腐层集中了熔结环氧粉末(FBE)和挤压聚烯烃涂层的性能优势，克服了两种涂层单独使用时性能上的不足，成为管道防腐层的主导材料。现阶段的3PE防腐工艺主要是挤出包覆法：首先表面处理完成的钢管直线向前传输，通过加热装置加热至200℃左右，然后进入环氧粉末喷涂区，侧向布置的环氧粉末静电喷涂装置将环氧粉末均匀喷涂至钢管表面并熔融，然后两台挤出机侧向挤出成型的胶黏剂膜片和聚乙烯膜片依次缠绕在环氧粉末层和胶黏剂层的表面，并用软胶辊对涂层进行碾压密实，进行涂膜的贴附，最终水冷定型。但是目前存在以下缺点：(1)对于焊接钢管，因涂层的第二层和第三层采用挤出缠绕的方式，在管体焊缝处会出现涂层减薄和焊缝根部涂层出现空隙等缺陷；(2)通过挤出成型3PE涂层，中间的胶黏剂层在低温及长时间服役情况下出现失效现象，使涂层分层失效。
发明内容：
本发明的目的在于克服上述现有技术的缺点，提供一种钢管3PE全粉末化涂层的喷涂工艺，该喷涂工艺不仅简单，节约资源，而且形成的3PE全粉末化涂层整体性好，在低温或长时间服役情况下不会出现分层失效。
本发明的目的是通过以下技术方案来解决的：一种钢管3PE全粉末化涂层的喷涂工艺，该喷涂工艺采用的设备包括钢管传输滚轮、中频加热装置、环氧粉末静电喷涂装置、胶黏剂粉末静电喷涂装置、聚乙烯粉末静电喷涂装置和水冷却装置，具体喷涂工艺包括以下步骤：
(1)在钢管传输滚轮的带动下，清理完成的钢管螺旋向前传输，并通过中频加热装置进行加热；
(2)加热后的钢管经过环氧粉末静电喷涂装置，环氧粉末静电喷涂装置的喷枪在加热的钢管表面喷涂环氧粉末，并熔融形成环氧粉末层；
(3)钢管继续前行，经过胶黏剂粉末静电喷涂装置，胶黏剂粉末静电喷涂装置的喷枪在环氧粉末层上喷涂胶黏剂粉末，此时环氧粉末层处于胶化状态；胶黏剂粉末在钢管余热的条件下熔融形成胶黏剂层；
(4)钢管继续前行，经过聚乙烯粉末静电喷涂装置，聚乙烯粉末静电喷涂装置的喷枪在胶黏剂层上喷涂聚乙烯粉末，此时胶黏剂层处于胶化状态；聚乙烯粉末在钢管余热的条件下熔融形成聚乙烯层；
(5)最后利用钢管余热进行聚乙烯层塑化流平，并进入水冷却装置完成涂层的定型，最终在钢管上形成3PE全粉末化涂层。
进一步，环氧粉末静电喷涂装置的喷枪、胶黏剂粉末静电喷涂装置的喷枪和聚乙烯粉末静电喷涂装置的喷枪，这三种喷枪紧邻设置，保证胶黏剂粉末在环氧粉末固化前熔融形成胶黏剂层，聚乙烯粉末在胶黏剂层固化前熔融形成聚乙烯层。
本发明的有益效果在于：
(1)本发明的喷涂工艺适用于任何管径的3PE涂层；环氧粉末层、胶黏剂层和聚乙烯层均以粉末静电喷涂的方式涂敷，不需要对管体进行二次加热，只需喷涂前对钢管进行加热，通过钢管余热使环氧粉末层、胶黏剂层和聚乙烯层固化，工艺简单，节约电力资源。
(2)本发明环氧粉末层、胶黏剂层和聚乙烯层三层都是采用静电喷涂装置进行相应的粉末喷涂，形成3PE全粉末化涂层不仅整体性更好，在低温或长时间服役情况下不会出现分层失效，而且不会因为钢管焊缝的存在使涂层减薄，或出现焊缝根部空隙的现象。
附图说明：
图1为本发明钢管3PE全粉末化涂层的喷涂工艺的工艺流程图。
其中，1-钢管，2-中频加热装置，3-环氧粉末静电喷涂装置，4-胶黏剂粉末静电喷涂装置，5-聚乙烯粉末静电喷涂装置，6-水冷却装置。
具体实施方式：
下面结合附图对本发明做进一步详细描述：
参见图1，一种钢管3PE全粉末化涂层的喷涂工艺，该喷涂工艺采用的设备包括钢管传输滚轮、中频加热装置、环氧粉末静电喷涂装置、胶黏剂粉末静电喷涂装置、聚乙烯粉末静电喷涂装置和水冷却装置，清理完成的钢管在钢管传输滚轮的带动下螺旋向前传输，依次通过中频加热装置、环氧粉末静电喷涂装置、胶黏剂粉末静电喷涂装置、聚乙烯粉末静电喷涂装置和水冷却装置。
具体喷涂工艺为：
(1)钢管传输滚轮以1-4m/min的速度带动钢管1螺旋向前传输，并通过中频加热装置2对钢管进行加热，加热温度为190-210℃；
(2)加热后的钢管1经过环氧粉末静电喷涂装置3，环氧粉末静电喷涂装置3的喷枪在加热的钢管1表面喷涂环氧粉末，并熔融形成环氧粉末层，环氧粉末层的厚度为150μm，环氧粉末静电喷涂装置3使用喷枪9-12把、一次气压0.15-0.40.4Mpa、二次出风量4-6m3/h、静电电压70-90Kv；
(3)钢管继续前行，经过胶黏剂粉末静电喷涂装置4，胶黏剂粉末静电喷涂装置4的喷枪在环氧粉末层上喷涂胶黏剂粉末，此时环氧粉末层处于胶化状态；胶黏剂粉末在钢管余热的条件下熔融形成胶黏剂层，胶黏剂层的厚度为100μm，胶黏剂粉末静电喷涂装置4使用喷枪9-12把、一次气压0.15-0.40.4Mpa、二次出风量4-6m3/h、静电电压70-90Kv；
(4)钢管继续前行，经过聚乙烯粉末静电喷涂装置5，聚乙烯粉末静电喷涂装置5的喷枪在胶黏剂层上喷涂聚乙烯粉末，此时胶黏剂层处于胶化状态；聚乙烯粉末在钢管余热的条件下熔融形成聚乙烯层，聚乙烯粉末静电喷涂装置5使用喷枪20-30把、一次气压0.15-0.4Mpa、二次出风量4-6m3/h、静电电压70-90Kv；
(5)最后利用钢管余热进行聚乙烯层塑化流平，使聚乙烯层厚度为400-500μm，最终进入水冷却装置6完成涂层的定型，钢管上形成最终的3PE全粉末化涂层。

Claims (3)

1.一种钢管3PE全粉末化涂层的喷涂工艺，其特征在于：喷涂工艺采用的设备包括钢管传输滚轮、中频加热装置、环氧粉末静电喷涂装置、胶黏剂粉末静电喷涂装置、聚乙烯粉末静电喷涂装置和水冷却装置，具体喷涂工艺包括以下步骤：
(1)在钢管传输滚轮的带动下，清理完成的钢管螺旋向前传输，并通过中频加热装置进行加热；
(2)加热后的钢管经过环氧粉末静电喷涂装置，环氧粉末静电喷涂装置的喷枪在加热的钢管表面喷涂环氧粉末，并熔融形成环氧粉末层；
(3)钢管继续前行，经过胶黏剂粉末静电喷涂装置，胶黏剂粉末静电喷涂装置的喷枪在环氧粉末层上喷涂胶黏剂粉末，此时环氧粉末层处于胶化状态；胶黏剂粉末在钢管余热的条件下熔融形成胶黏剂层；
(4)钢管继续前行，经过聚乙烯粉末静电喷涂装置，聚乙烯粉末静电喷涂装置的喷枪在胶黏剂层上喷涂聚乙烯粉末，此时胶黏剂层处于胶化状态；聚乙烯粉末在钢管余热的条件下熔融形成聚乙烯层；
(5)最后利用钢管余热进行聚乙烯层塑化留平，并进入水冷却装置完成涂层的定型，最终在钢管上形成3PE全粉末化涂层。
2.根据权利要求1所述的一种钢管3PE全粉末化涂层的喷涂工艺，其特征在于：环氧粉末静电喷涂装置的喷枪、胶黏剂粉末静电喷涂装置的喷枪和聚乙烯粉末静电喷涂装置的喷枪，这三种喷枪紧邻设置，保证胶黏剂粉末在环氧粉末固化前熔融形成胶黏剂层，聚乙烯粉末在胶黏剂层固化前熔融形成聚乙烯层。
3.根据权利要求1所述的一种钢管3PE全粉末化涂层的喷涂工艺，其特征在于：钢管传输滚轮以1-4m/min的速度带动钢管螺旋向前传输；中频加热装置对钢管进行加热，加热温度为190-210℃；环氧粉末静电喷涂装置、胶黏剂粉末静电喷涂装置和聚乙烯粉末静电喷涂装置的静电喷涂压力均为0.4Mpa；3PE全粉末化涂层中环氧粉末层的厚度为150μm，胶黏剂层的厚度为100μm，聚乙烯层厚度为400-500μm。
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