CN116851239A - Design method and application of novel protective coating system of offshore wind power tower - Google Patents
Design method and application of novel protective coating system of offshore wind power tower Download PDFInfo
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/24—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials for applying particular liquids or other fluent materials
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D5/00—Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/22—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to internal surfaces, e.g. of tubes
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05D7/00—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials
- B05D7/22—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to internal surfaces, e.g. of tubes
- B05D7/222—Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to internal surfaces, e.g. of tubes of pipes
- B05D7/225—Coating inside the pipe
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F03—MACHINES OR ENGINES FOR LIQUIDS; WIND, SPRING, OR WEIGHT MOTORS; PRODUCING MECHANICAL POWER OR A REACTIVE PROPULSIVE THRUST, NOT OTHERWISE PROVIDED FOR
- F03D—WIND MOTORS
- F03D13/00—Assembly, mounting or commissioning of wind motors; Arrangements specially adapted for transporting wind motor components
- F03D13/20—Arrangements for mounting or supporting wind motors; Masts or towers for wind motors
- F03D13/25—Arrangements for mounting or supporting wind motors; Masts or towers for wind motors specially adapted for offshore installation
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/70—Wind energy
- Y02E10/72—Wind turbines with rotation axis in wind direction
Abstract
The invention provides a design scheme of a novel coating protection system of an offshore wind power tower, which is constructed by a novel titanium-based graphene heavy-duty coating material, from design selection of materials (cold zinc-coated primer, heavy-duty primer and heavy-duty finish paint) to different sea condition areas aiming at a system, different design schemes and implementation methods are adopted, and the technical advancement and the credibility of the novel coating protection system are proved through the comparative analysis of the performances of new and old materials, so that key technical points and construction technical specifications which need to be grasped in the application process are systematically described, and the novel coating protection system of the offshore wind power tower is constructed.
Description
Technical Field
The invention belongs to the technical field of new materials and application thereof, and relates to a construction design of a novel coating protection system of a complete set of titanium-based graphene heavy anti-corrosion coating new materials on an offshore wind power tower.
Background
Offshore wind power, unlike onshore wind power, is more severe in marine environment than onshore environment, and is a major threat to the safety service of marine engineering equipment due to the influence of comprehensive factors such as high temperature, high humidity, high salt, strong ultraviolet rays, sea mud, seawater, spray splashing, marine atmosphere, continuous mechanical damage, abrasion, corrosion and the like. Meanwhile, the offshore wind power has extremely high maintenance cost due to special geographic environment and technical requirements. For example, the marine corrosion brings great potential safety hazard to the offshore wind turbine, shortens the operation life of the turbine, and greatly increases the construction investment and operation maintenance cost of wind power. Marine equipment protection technology has become an outstanding problem to be solved urgently for offshore wind power, and corrosion protection design forms an important component of offshore wind farm design.
The vast majority of current built offshore wind farms are offshore wind farms and suffer from more limiting factors. And a wind power plant is built in a deep sea area with the water depth of more than 50 meters, the wind speed is higher, the wind power is stronger, the limit is reduced, the generating capacity of a large megawatt unit can be greatly improved, and the operation and maintenance cost is saved, so that the wind power plant is a current trend of offshore wind power development. However, in a deep sea area, the environment is complex, and high wind waves bring higher requirements for corrosion protection of the wind turbine generator. The service life of offshore wind power is generally designed to be more than 20 years. The effective run time requirements for offshore wind power corrosion protection coating systems typically take more than 25 years. According to statistics, the cost of repairing the anti-corrosion coating of the offshore wind turbine is 50 times of the workshop production cost. Therefore, the high-performance anti-corrosion coating system has important significance for prolonging the service life and safely serving of the offshore wind power, and has important economic value. Therefore, research and practice of the ocean wind power anti-corrosion technology and equipment are developed, and the method has great strategic significance for the rapid and healthy development of the ocean wind power industry in China.
As shown in Table 1 of national standard coastal wind turbine anti-corrosion technical Specification (GB/T33423-2016), the anti-corrosion paint currently selected is basically an epoxy and polyurethane series traditional anti-corrosion paint. Such corrosion protection materials have been in use for decades and are still in use until now. Practical experience and experimental data for many years prove that the epoxy anticorrosive paint can generate serious pulverization phenomenon under the marine climate environment, while the aliphatic polyurethane anticorrosive paint has stronger weather resistance than the epoxy paint, but faces the marine severe corrosion environment, the old material and the performance defect are overcome, and even if the epoxy anticorrosive paint is coated with 600-1000 microns, the epoxy anticorrosive paint is difficult to ensure that the epoxy anticorrosive paint is not invalid after being used for 20 years under the marine environment. This is determined by the nature of the coating film former, which can be designed in theory, but is not a practical solution.
In order to solve the problem of long-acting protection of the offshore wind power tower (frame), a frame made of traditional anti-corrosion materials is needed to be jumped out, and a new technology, a new material and a new product are selected in the coating protection design, so that reasonable material selection and scientific matching can be carried out, and the long-acting and durability of the composite coating system in service under the marine environment can be ensured.
Disclosure of Invention
The technical scheme of the novel protective coating system of the offshore wind power tower (rack) constructed by the invention completely overturns the design of the traditional anti-corrosion coating system, and the adopted novel technology, new material and new product belong to the original intellectual property patent integration technology.
The specific technical scheme is as follows:
the first aspect of the invention provides a design method of a coating protection system of an offshore wind power tower, and different coating protection designs and coating materials are adopted for different areas and stations of the offshore wind power tower.
In one embodiment, the coating material comprises a titanium-based graphene cold-coated zinc anticorrosive paint and a titanium-based graphene marine heavy-duty anticorrosive paint.
A second aspect of the present invention provides an offshore wind tower corrosion protection coating system, the offshore wind tower comprising an ocean atmosphere, a splash, a tidal range zone and a seawater full immersion zone according to sea condition zones, the offshore wind tower corrosion protection coating system comprising:
the coating is designed into titanium-based graphene cold-coating zinc anti-corrosion primer, titanium-based graphene marine heavy anti-corrosion primer and titanium-based graphene marine heavy anti-corrosion finish at the offshore position of the outer surface of the tower in the marine atmosphere area;
the coating is designed into titanium-based graphene marine heavy-duty anticorrosive primer and titanium-based graphene marine heavy-duty anticorrosive finishing paint on the inner surface of the tower barrel in the marine atmosphere area;
the outer surfaces of the casing frames and pile foundations in the ocean atmosphere, splash and tidal range areas are coated with titanium-based graphene cold-coating zinc anti-corrosion primer, titanium-based graphene ocean heavy anti-corrosion primer and titanium-based graphene ocean heavy anti-corrosion finish;
the coating is designed into titanium-based graphene marine heavy-duty anticorrosive primer and titanium-based graphene marine heavy-duty anticorrosive finishing paint on the inner surfaces of a casing frame and a pile foundation in the ocean atmosphere, wave splash and tidal range area;
the surface of other metal fittings in the ocean atmosphere, splash and tidal range areas is coated with titanium-based graphene ocean heavy-duty anticorrosive primer and titanium-based graphene ocean heavy-duty anticorrosive finish paint;
the outer surfaces of the casing frame and the pile foundation of the seawater full-immersion area are coated with titanium-based graphene cold-coating zinc anti-corrosion primer, titanium-based graphene marine heavy anti-corrosion primer and titanium-based graphene marine heavy anti-corrosion finish;
the coating is designed into titanium-based graphene marine heavy-duty anticorrosive primer and titanium-based graphene marine heavy-duty anticorrosive finishing paint on the inner surfaces of the casing frame and the pile foundation of the seawater full-immersion area.
In one embodiment, the design thickness of the coating system on the outer surface of the tower in the ocean atmosphere area is respectively 80 mu m of titanium-based graphene cold-coating zinc anti-corrosion primer, 150 mu m of titanium-based graphene ocean heavy-duty anti-corrosion primer and 120 mu m of titanium-based graphene ocean heavy-duty anti-corrosion finish, and the total dry film thickness is 350 mu m;
the design thickness of the coating system on the inner surface of the tower in the ocean atmosphere area is 120 mu m of titanium-based graphene ocean heavy-duty anticorrosive primer and 120 mu m of titanium-based graphene ocean heavy-duty anticorrosive finishing paint respectively, and the total dry film thickness is 240 mu m;
the design thickness of the coating system is respectively 80 mu m of the titanium-based graphene cold-coating zinc anti-corrosion primer, 300 mu m of the titanium-based graphene marine heavy-duty anti-corrosion primer and 220 mu m of the titanium-based graphene marine heavy-duty anti-corrosion finish paint, and the total dry film thickness is 600 mu m;
the design thickness of the coating system is 200 mu m of titanium-based graphene marine heavy-duty anticorrosive primer and 300 mu m of titanium-based graphene marine heavy-duty anticorrosive finishing paint respectively, and the total dry film thickness is 500 mu m;
the design thickness of a coating system on the surfaces of other metal fittings in the ocean atmosphere, splash and tidal range areas is 120 mu m for the titanium-based graphene ocean heavy-duty anticorrosive primer and 200 mu m for the titanium-based graphene ocean heavy-duty anticorrosive finish paint respectively, and the total dry film thickness is 320 mu m;
the design thickness of the coating system is respectively 80 mu m of titanium-based graphene cold-coating zinc anti-corrosion primer, 120 mu m of titanium-based graphene marine heavy anti-corrosion primer and 200 mu m of titanium-based graphene marine heavy anti-corrosion finish paint, and the total dry film thickness is 400 mu m;
the design thickness of the coating system is 120 mu m of titanium-based graphene marine heavy-duty anticorrosive primer and 200 mu m of titanium-based graphene marine heavy-duty anticorrosive finishing paint respectively on the inner surfaces of the casing frame and the pile foundation of the seawater full-immersion area, and the total dry film thickness is 320 mu m.
A third aspect of the invention provides an offshore wind tower comprising an offshore wind tower corrosion resistant coating system as described above.
The fourth aspect of the invention provides a coating method of an offshore wind power tower anti-corrosion coating system, which comprises the following steps:
providing an offshore wind power tower, wherein the offshore wind power tower comprises an ocean atmosphere area, an ocean atmosphere, a splash area, a tidal range area and a seawater full immersion area according to sea condition areas;
sequentially coating a first titanium-based graphene cold zinc-coated primer, a first titanium-based graphene anticorrosive primer and a first titanium-based graphene anticorrosive finish paint on the outer surface of a tower barrel in the marine atmosphere area;
sequentially coating a second titanium-based graphene cold zinc-coated primer, a second titanium-based graphene anticorrosive primer and a second titanium-based graphene anticorrosive finish paint on the outer surfaces of a casing frame and a pile foundation in the ocean atmosphere, splash and tidal range areas;
coating a third titanium-based graphene cold zinc-coated primer, a third titanium-based graphene anticorrosive primer and a third titanium-based graphene anticorrosive finish paint on the outer surfaces of the casing frame and the pile foundation in the seawater full-immersion area in sequence; and sequentially coating a seventh titanium-based graphene anti-corrosion primer layer and a seventh titanium-based graphene anti-corrosion top coat layer on the outer surfaces of other metal parts.
In one embodiment, the thickness of the first titanium-based graphene anti-corrosion primer and the third titanium-based graphene anti-corrosion primer are both less than the thickness of the second titanium-based graphene anti-corrosion primer; the thickness of the first titanium-based graphene anti-corrosion finish paint and the thickness of the third titanium-based graphene anti-corrosion finish paint are smaller than those of the second titanium-based graphene anti-corrosion finish paint.
In one embodiment, the first titanium-based graphene cold-zinc-coated primer has a thickness of 80 μm, the first titanium-based graphene anti-corrosion primer has a thickness of 150 μm, the first titanium-based graphene anti-corrosion topcoat has a thickness of 120 μm, and the total dry film thickness is 350 μm;
the thickness of the second titanium-based graphene cold-coating zinc primer is 80 mu m, the thickness of the second titanium-based graphene anti-corrosion primer is 300 mu m, the thickness of the second titanium-based graphene anti-corrosion finish paint is 220 mu m, and the total dry film thickness is 600 mu m;
the thickness of the third titanium-based graphene cold-coating zinc primer is 80 mu m, the thickness of the third titanium-based graphene anti-corrosion primer is 120 mu m, the thickness of the third titanium-based graphene anti-corrosion finish paint is 200 mu m, and the total dry film thickness is 400 mu m;
the thickness of the seventh titanium-based graphene anticorrosive primer is 120 mu m, the thickness of the seventh titanium-based graphene anticorrosive finishing coat is 200 mu m, and the total dry film thickness is 320 mu m.
In one embodiment, the method further comprises the steps of:
sequentially coating a fourth titanium-based graphene anti-corrosion primer and a fourth titanium-based graphene anti-corrosion finish paint on the inner surface of a tower barrel of the ocean atmosphere area;
sequentially coating a fifth titanium-based graphene anti-corrosion primer and a fifth titanium-based graphene anti-corrosion finish paint on the inner surface of a casing frame and a pile foundation in the ocean atmosphere, wave splash and tidal range area;
and sequentially coating a sixth titanium-based graphene anti-corrosion primer and a sixth titanium-based graphene anti-corrosion finish paint on the inner surface of the casing frame and the pile foundation of the seawater full-immersion area.
In one embodiment, the thickness of the fourth titanium-based graphene anti-corrosion primer is 120 μm, the thickness of the fourth titanium-based graphene anti-corrosion top-coat is 120 μm, and the total dry film thickness is 240 μm;
the thickness of the fifth titanium-based graphene anti-corrosion primer is 200 mu m, the thickness of the fifth titanium-based graphene anti-corrosion finishing coat is 300 mu m, and the total dry film thickness is 500 mu m;
the thickness of the sixth titanium-based graphene anticorrosive primer is 120 mu m, the thickness of the sixth titanium-based graphene anticorrosive finishing coat is 200 mu m, and the total dry film thickness is 320 mu m.
Drawings
FIG. 1 is a schematic diagram of a service environment of an offshore wind turbine.
Detailed Description
The detailed description of the present invention will be provided to make the above objects, features and advantages of the present invention more obvious and understandable. In the following description, numerous specific details are set forth in order to provide a thorough understanding of the present invention. The present invention may be embodied in many other forms than described herein and similarly modified by those skilled in the art without departing from the spirit of the invention, whereby the invention is not limited to the specific embodiments disclosed below.
Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. Unless otherwise specifically indicated, the various raw materials, reagents, instruments, equipment and the like used in the present invention are commercially available or may be prepared by existing methods.
Some embodiments of the invention provide a design and implementation scheme of a novel protective coating system for an offshore wind power tower (rack), which are as follows:
the wind power tower comprises a wind power tower barrel, a sleeve frame, pile foundations (an atmosphere area, a splash area and a tidal range area) and other accessory matched metal components, and is shown in figure 1.
The anti-corrosion design content comprises the surface treatment and technical standard of steel, the selection of novel paint, the design of a matched composite coating system, the requirements of dry film thickness of coatings at different positions, the technical index of coating quality and the inspection standard, and is shown in table 1.
Table 1 construction design scheme of novel composite coating protection system of offshore wind power tower
Table 1 is a novel coating protection construction system of an offshore wind turbine tower, is completely different from the national standard of GB/T33423-2016 (coastal and offshore wind turbine anti-corrosion technical Specification), abandons a coating protection design system of a traditional anti-corrosion coating (epoxy and polyurethane), and is a composite coating system constructed by a novel material-graphene modified titanium-based nano heavy-duty anti-corrosion coating.
The construction confidence of the novel coating protection system of the offshore wind power tower is based on the excellent physical and mechanical properties, weather aging resistance and corrosion resistance of the novel coating material. The graphene modified titanium-based nano heavy-duty anticorrosive paint, also called titanium-based graphene heavy-duty anticorrosive paint, is a high-solid paint or solvent-free paint consisting of a main film forming matter nano organic titanium polymer (titanium base material for short), auxiliary film forming resin, graphene dispersion slurry, antirust pigment, functional filler, paint auxiliary agent and active diluent.
Understandably, graphene and flaky zinc powder are added in the titanium-based graphene cold-coating zinc coating, so that the titanium-based graphene cold-coating zinc coating has an electrochemical protection effect on steel substrates; the titanium-based graphene marine heavy-duty anticorrosive paint contains an anticorrosive pigment and a flake filler, and has anticorrosive and permeation-resistant maze effect on the coating; the two priming paint are coating matrix composed of nano organic titanium polymer as main film forming material, auxiliary resin and curing agent, and have long-acting anti-corrosion performance.
The titanium-based graphene cold-coating zinc anti-corrosion coating and the titanium-based graphene marine heavy-duty anti-corrosion coating are selected from a protective coating matrix which is formed by taking a titanium nanometer high molecular alloy copolymer as a main film forming material, graphene modified auxiliary resin, a curing agent, a small amount of environment-friendly diluent, pigment, filler, coating auxiliary agent and the like, and have the effects of physical corrosion resistance, chemical corrosion resistance, strong ultraviolet radiation resistance and weather aging resistance. The physical and chemical properties of the titanium-based graphene cold-coated zinc primer, the heavy-duty primer and the heavy-duty finish paint should meet the requirements of the technical performance indexes in Table 2.
The performance index comparison of the titanium-based graphene heavy-duty coating with the national standard requirements of the traditional coating (GB/T33423) is shown in tables 2 to 5.
Table 2 basic properties of graphene-modified titanium-based nano heavy duty anticorrosive coatings
Table 3 comparison of the Performance of titanium-based graphene nanocold-coated zinc coatings and traditional cold-coated zinc coatings
Table 4 performance comparison of graphene-modified titanium-based nanocoating with conventional epoxy-based anticorrosive coating
Table 5 Performance comparison of titanium-based graphene nano heavy-duty topcoat and conventional polyurethane topcoat
The technical index for preparing the coating performance of the titanium-based graphene heavy-duty anticorrosive paint is prepared according to third-party inspection report data based on the national paint quality inspection center. From the comparison of the performance indexes of tables 2 to 5, the novel coating materials are much higher than the performance indexes of the conventional coating materials by several times, and are not at all on one level.
The design differentiation analysis of the novel coating system for protecting the offshore wind power tower and the traditional coating system is compared with the technical performance of the novel coating system for protecting the offshore wind power tower and the traditional composite coating system, and the technical performance is shown in tables 6-7.
Table 6 design differentiation analysis and comparison of novel coating system for offshore wind tower protection and traditional coating system
Table 7 comparison of technical Properties of novel coating System for offshore wind Tower protection with traditional composite coating System
By contrast analysis, it can be inferred that the coating protection life of the novel titanium-based graphene nano heavy-duty anticorrosive material on the offshore wind power tower can be ensured to be in service for 25 years or more.
The novel coating material titanium-based graphene heavy-duty anticorrosive coating composite coating system has the advantages that the following points can be summarized:
1. the titanium-based graphene cold zinc-coated primer is adopted to replace hot galvanizing and hot zinc spraying processes which are serious in pollution and harm to physical and mental health of operators, the thickness of a coating (plating layer) is reduced, the use amount of nonferrous metals is reduced, the material cost is saved, the anticorrosion effect of a hot galvanizing layer or a hot zinc spraying layer can be achieved, and the sealing process of the galvanizing layer is omitted.
2. The titanium-based graphene heavy-duty anticorrosive paint (primer and finish paint) is adopted to replace the traditional epoxy coating system and polyurethane coating system, the design of a 800-1000 mu m thick coating is not needed, the complicated construction process of the traditional paint is simplified, the material consumption is reduced, the engineering cost is reduced, and the long-acting protection life of the same design can be achieved.
3. The popularization and application of new materials, new technologies, new products and new processes are beneficial to the technical progress and product update of advanced manufacturing industry, and the development strategy of national science and technology national architecture is embodied.
4. In the face of severe marine corrosion environment, the application of the technology of the invention has longer service life than the traditional coating protection system, and can ensure the service of the novel coating protection system to be more than 25 years without maintenance.
The present invention will be further described with reference to specific examples and comparative examples, which should not be construed as limiting the scope of the invention.
Example 1:
1. workshop construction in factory
(1) The steel surface treatment method is preferably a sand blasting or shot blasting treatment process.
(2) Before sand blasting, the condition of the base material is evaluated, sharp edges, flame cutting edges and burrs of the component and accessories permanently connected with the component are polished to smooth transition, R is more than or equal to 2mm, and weld scars and welding fusion splatter are polished and cleaned. Removing water, greasy dirt, dust and dirt, pollutant, rust, oxide scale, salt and other substances on the surface of the substrate by using solvent, emulsion, purifying compound or steam; the rust removal quality should reach Sa 2 grade specified in GB/T8923.1; roughness is treated with a suitable abrasive to the requirements of fine to medium grade (40-70 μm, ry 5) specified in international standard iso.8503-2 for surface roughness grade.
(3) The dust and abrasive attached to the surface of the base body after sand blasting is blown off by adopting anhydrous oil-free compressed air or an industrial dust remover, and the surface cleanliness is not lower than the level 2 specified in GB/T18570.3.
(4) The surface treatment should be followed by the application of the primary primer within 4 hours (when the relative humidity is less than 80%) and within 4 to 12 hours (when the relative humidity is less than 65%), and the surface treatment should be resumed beyond the above time limit or when the occurrence of back rust or surface contamination occurs.
2. Workshop coating conditions in factories
(1) Environmental conditions during construction: the temperature should be higher than 5 ℃, the relative humidity should be lower than 80%, the surface temperature of the steel plate is higher than the dew point 3 ℃, and the number of measurements per work shift should not be less than 3.
(2) The mixing proportion of the coating and the stirring process are carried out according to the specification requirements of paint suppliers, and a wet film card is used for checking the coating humidity
Whether the film thickness meets the requirements.
(3) To ensure that the edges, welds, and corners have a predetermined thickness, these portions are pre-coated prior to each coating application. Reserving site construction parts (repaired openings), and coating the formed exposed surface with primer.
(4) When the tower, the cylinder and the flange are coated with paint, cold zinc spraying primer is sprayed in advance, and the surface is protected after cold zinc spraying is finished. After the cold zinc spraying coating is completely dried, paint spraying is carried out, and the lap joint width is enough during spraying.
(5) The different products should be constructed with reference to the relevant construction process established by the suppliers.
3. Workshop coating process in factory
The spraying method is easy to use high-pressure airless spraying; it is recommended to use it in precoating small areas of paint, but must achieve a defined dry film thickness.
(1) Coating preparation
(1) The titanium-based graphene heavy-duty anticorrosive paint is a two-component paint, shi Tuqian can mix and prepare the two components, and before preparation, whether A, B components and a diluent are matched, whether the required application model is consistent or not, and whether the paint fails or not is confirmed.
(2) The component A must be stirred until the bottom is free from deposition and uniform up and down before being prepared.
(3) The A/B component is prepared according to the proportion provided by suppliers according to the requirements of the product specification, and the spraying viscosity is adjusted by a diluent, so that the paint reaches the optimal spraying state, and the thickness and quality of a single film are ensured.
(4) The dilution ratio of the coating (generally 5% -10% of the coating) is calculated according to the coating area and the single-channel film thickness, and the dosage is controlled to be used up within 0.5 hour, so that the loss and waste caused by solidification due to excessive dosage and incomplete dosage are prevented.
(5) If the paint needs to be diluted, the dosage of the paint is controlled to be not more than 20 percent, the paint is added into the component A to be uniformly stirred after being mixed according to the calculated proportion of the diluent, and then the component B is added to be stirred for 10 to 15 minutes, so that the component A, B is cured. And then standing for 5-10 minutes to eliminate air bubbles introduced by stirring. The stirring and standing time depends on the dosage, and the material is long.
(6) The mixed paint can be sprayed after being filtered by a 100-mesh filter screen. The coating is stopped immediately as soon as the coating is thickened due to excessive reaction during the coating process. The paint is discarded and should be re-compounded. The excessive reaction time of the paint is related to the ambient temperature, the time required for high temperature is short, the material is less mixed, and conversely, the time required for low temperature is long, and the mixing amount can be properly increased.
(7) The thinner is matched with the paint, and other diluents cannot be selected at will.
(2) Coating process
(1) The specific construction is to compile coating process rules according to the structure of the coated piece so as to ensure the quality of the anti-corrosion coating.
(2) The environmental conditions during coating should meet the requirements of the paint specification. The outdoor construction of the anti-corrosion layer should be stopped when meeting weather conditions such as rain, snow, fog, sand wind and the like. When the construction environment temperature is lower than-5 ℃ or higher than 40 ℃ or the relative humidity is higher than 80%, the construction is not suitable. The uncured corrosion protection layer should prevent rain leaching.
(3) And (3) after the surface pretreatment is qualified, the rust phenomenon occurs in the interval time from the application of the first primer, and the surface pretreatment should be carried out again on the rust part before the application. The large container which cannot be sandblasted in the day without exposure time is sealed to prevent convection with air outside the tank, and the rust returning time is prolonged.
(4) The titanium-based graphene nano heavy-duty anticorrosive paint is coated by adopting construction methods such as airless spraying, brushing or rolling coating, and the like, the coating is uniformly coated and cannot be omitted, and the coating method is determined according to the anticorrosive construction scheme.
4. Installation site repair process
(1) Coating repair should be carried out to the reserved joint coating and coating damage and defect caused in the transportation and installation processes, and the coating repair area is:
a) Weld joint region: an uncoated weld zone after field welding is completed;
b) Coating damage area: coating damage or damage to local coating parts caused by thermal operation, transportation, hoisting, loading and unloading and the like;
c) Localized coating with coating defects: the positions of the local coatings such as sagging, missing coating, pinholes and the like caused by improper construction in the construction process;
d) Severely contaminated portions of the coating: a localized coating location where the contaminant is severely contaminated, where the contaminant has caused damage to the coating (e.g., by cement), or where the contaminant has not been removed by simple cleaning;
e) Localized coating damage that exists during equipment servicing.
(2) Before repairing the damaged coating, surface treatment should be performed to remove loose and damaged coating, and the damaged substrate should be treated to St3 or SP11 by using a power tool. The intact coating on the periphery of the damaged part needs to be lightly roughened and polished into a smooth transition layer. The exposed metal matrix should be subjected to roughening or electrochemical etching treatment, and after the surface roughness reaches the standard, the metal matrix is repeatedly wiped with absorbent cotton balls dipped with solvent for degreasing until no color change occurs. The periphery of the substrate in the repair area is preferably ground to form a shallow trench. No rain should be applied within 4 hours after coating.
(3) The climate condition control during repair is the same as the requirements for new construction painting.
5. Coating inspection
The coating should be inspected for compliance with specifications, including visual inspection, such as uniformity, color and luster, appearance, missing coating, shrinkage cavity, bubbles, flaking, bleeding, sagging, and the like. The dry film should be checked for the following properties:
a) Dry film thickness. After coating, the dry film thickness of the coating should be determined according to the method specified in GB/T13452.2.
Average of
The dry film thickness should be greater than or equal to the design thickness value, and the dry film thickness at each point should not be less than 80% and not more than 10% of the nominal dry film thickness. If a maximum paint film thickness is desired, the maximum value is not exceeded.
b) Adhesion force. The adhesive force is measured by a pulling-off method, which accords with the specification of GB/T5210, and a coating which is not applicable to the pulling-off method is selected to be a cross-cut or cross-cut method, which accords with the specification of GB/T9286.
c) And (5) leaking and coating points. Coating in splash zone, tidal range zone and full immersion zone should be subjected to missing coating spot detection according to SY/T0063. Any point of missing coating is found to be subjected to repair coating, and the repeated measurement result of the dry film thickness at the repair part meets the design requirement.
6. Quality inspection and acceptance
Quality acceptance should include the following data:
a) The paint manufacturer produces a license (copy), a product certificate and a quality inspection report;
b) Engineering design files, construction technical schemes and the like;
c) Quality inspection records, acceptance reports and the like of the coating;
d) Rework records (if any), including rework location, cause, method, quantity, and inspection results;
e) Other related data.
7. Maintenance and servicing of coatings
(1) With the increase of the service time, the anti-corrosion coating can be aged and damaged, the sacrificial anode can be damaged, lost or the partial area can not be protected due to tide, and anti-corrosion measures should be detected and maintained regularly.
(2) In the initial stage 2a after engineering implementation, detecting at least once every half year; once a year after the operation and maintenance 2a, the frequency of detection can be increased appropriately after 10a depending on the operation of the corrosion protection system. The cycle time is one quarter, and the visible part should be checked; the cycle time is more than one quarter, and the structural surface, the welding line, the connecting position and the like of the equipment should be comprehensively checked. The following records are made for the areas to be repaired:
a) Before each maintenance, checking the coating for 1-2 times, and recording the types and area proportions of defects such as cracking, falling, foaming, rusting, powdering and the like of the coating;
b) A repair plan is made based on the inspection record.
(3) The archive data should be consulted before the maintenance and repair of the coating, and the use condition and performance of the original coating are mastered. The surface treatment should meet the following requirements:
a) If the primer is damaged, the coating is polished to the substrate, and the St3 grade requirement is met;
b) The primer is not damaged but has a soft coating, the soft part is removed, the edge of the damaged coating is polished until layering, the layering can not be performed, the polishing is smooth, and the colors of the coatings are similar;
c) When the damaged area is so large that it can be treated by the blasting method, it is preferable to re-perform the blasting treatment on the surface.
(4) The repair of the coating should meet the following requirements:
a) The repair range should be greater than the damaged surface;
b) When the primer is coated, a brush is suitable for small area, and spraying is suitable for large area;
c) The thickness of each layer of coating during repairing is required to be executed according to the original specification, and the coating interval of each layer of coating is required to be painted again when the thickness is insufficient;
d) Ventilation and illumination are provided during internal repair;
e) The environmental condition control in the repair period is the same as the requirement of new structure coating;
f) The repaired coating needs to be protected to prevent the uncured coating from trampling or damage; the immersed or possibly immersed area is required to be immersed after the coating is thoroughly cured after the coating is repaired.
The above embodiments are application flows of the present invention. The execution standard is GB/T33423-2016 coastal and offshore wind turbine corrosion prevention technical Specification.
The technical features of the above-described embodiments may be arbitrarily combined, and all possible combinations of the technical features in the above-described embodiments are not described for brevity of description, however, as long as there is no contradiction between the combinations of the technical features, they should be considered as the scope of the description.
The above examples illustrate only a few embodiments of the invention, which are described in detail and are not to be construed as limiting the scope of the invention. It should be noted that it will be apparent to those skilled in the art that several variations and modifications can be made without departing from the spirit of the invention, which are all within the scope of the invention. Accordingly, the scope of protection of the present invention is to be determined by the appended claims.
Claims (10)
1. A design method of a coating protection system of an offshore wind power tower is characterized in that different coating protection design schemes and coating materials are adopted aiming at different areas and stations of the offshore wind power tower.
2. The method for designing a coating protection system for an offshore wind tower according to claim 1, wherein the coating material comprises a titanium-based graphene cold-coating zinc anti-corrosion coating and a titanium-based graphene marine heavy-duty anti-corrosion coating.
3. An offshore wind tower corrosion-resistant coating system, wherein the offshore wind tower comprises an ocean atmosphere, a splash, a tidal range area and a seawater full immersion area according to sea condition areas, and the offshore wind tower corrosion-resistant coating system comprises:
the coating is designed into titanium-based graphene cold-coating zinc anti-corrosion primer, titanium-based graphene marine heavy anti-corrosion primer and titanium-based graphene marine heavy anti-corrosion finish at the offshore position of the outer surface of the tower in the marine atmosphere area;
the coating is designed into titanium-based graphene marine heavy-duty anticorrosive primer and titanium-based graphene marine heavy-duty anticorrosive finishing paint on the inner surface of the tower barrel in the marine atmosphere area;
the outer surfaces of the casing frames and pile foundations in the ocean atmosphere, splash and tidal range areas are coated with titanium-based graphene cold-coating zinc anti-corrosion primer, titanium-based graphene ocean heavy anti-corrosion primer and titanium-based graphene ocean heavy anti-corrosion finish;
the coating is designed into titanium-based graphene marine heavy-duty anticorrosive primer and titanium-based graphene marine heavy-duty anticorrosive finishing paint on the inner surfaces of a casing frame and a pile foundation in the ocean atmosphere, wave splash and tidal range area;
the surface of other metal fittings in the ocean atmosphere, splash and tidal range areas is coated with titanium-based graphene ocean heavy-duty anticorrosive primer and titanium-based graphene ocean heavy-duty anticorrosive finish paint;
the outer surfaces of the casing frame and the pile foundation of the seawater full-immersion area are coated with titanium-based graphene cold-coating zinc anti-corrosion primer, titanium-based graphene marine heavy anti-corrosion primer and titanium-based graphene marine heavy anti-corrosion finish;
the coating is designed into titanium-based graphene marine heavy-duty anticorrosive primer and titanium-based graphene marine heavy-duty anticorrosive finishing paint on the inner surfaces of the casing frame and the pile foundation of the seawater full-immersion area.
4. The offshore wind tower corrosion resistant coating system of claim 3, wherein the design thickness of the coating system is 80 μm for the titanium-based graphene cold-coated zinc corrosion resistant primer, 150 μm for the titanium-based graphene marine heavy-duty corrosion resistant primer and 120 μm for the titanium-based graphene marine heavy-duty corrosion resistant finish, respectively, and the total dry film thickness is 350 μm;
the design thickness of the coating system on the inner surface of the tower in the ocean atmosphere area is 120 mu m of titanium-based graphene ocean heavy-duty anticorrosive primer and 120 mu m of titanium-based graphene ocean heavy-duty anticorrosive finishing paint respectively, and the total dry film thickness is 240 mu m;
the design thickness of the coating system is respectively 80 mu m of the titanium-based graphene cold-coating zinc anti-corrosion primer, 300 mu m of the titanium-based graphene marine heavy-duty anti-corrosion primer and 220 mu m of the titanium-based graphene marine heavy-duty anti-corrosion finish paint, and the total dry film thickness is 600 mu m;
the design thickness of the coating system is 200 mu m of titanium-based graphene marine heavy-duty anticorrosive primer and 300 mu m of titanium-based graphene marine heavy-duty anticorrosive finishing paint respectively, and the total dry film thickness is 500 mu m;
the design thickness of a coating system on the surfaces of other metal fittings in the ocean atmosphere, splash and tidal range areas is 120 mu m for the titanium-based graphene ocean heavy-duty anticorrosive primer and 200 mu m for the titanium-based graphene ocean heavy-duty anticorrosive finish paint respectively, and the total dry film thickness is 320 mu m;
the design thickness of the coating system is respectively 80 mu m of titanium-based graphene cold-coating zinc anti-corrosion primer, 120 mu m of titanium-based graphene marine heavy anti-corrosion primer and 200 mu m of titanium-based graphene marine heavy anti-corrosion finish paint, and the total dry film thickness is 400 mu m;
the design thickness of the coating system is 120 mu m of titanium-based graphene marine heavy-duty anticorrosive primer and 200 mu m of titanium-based graphene marine heavy-duty anticorrosive finishing paint respectively on the inner surfaces of the casing frame and the pile foundation of the seawater full-immersion area, and the total dry film thickness is 320 mu m.
5. An offshore wind tower comprising an offshore wind tower corrosion resistant coating system according to any one of claims 3-4.
6. The coating method of the anti-corrosion coating system of the offshore wind power tower is characterized by comprising the following steps of:
providing an offshore wind power tower, wherein the offshore wind power tower comprises an ocean atmosphere area, an ocean atmosphere, a splash area, a tidal range area and a seawater full immersion area according to sea condition areas;
sequentially coating a first titanium-based graphene cold zinc-coated primer, a first titanium-based graphene anticorrosive primer and a first titanium-based graphene anticorrosive finish paint on the outer surface of a tower barrel in the marine atmosphere area;
sequentially coating a second titanium-based graphene cold zinc-coated primer, a second titanium-based graphene anticorrosive primer and a second titanium-based graphene anticorrosive finish paint on the outer surfaces of a casing frame and a pile foundation in the ocean atmosphere, splash and tidal range areas;
coating a third titanium-based graphene cold zinc-coated primer, a third titanium-based graphene anticorrosive primer and a third titanium-based graphene anticorrosive finish paint on the outer surfaces of the casing frame and the pile foundation in the seawater full-immersion area in sequence; and sequentially coating a seventh titanium-based graphene anti-corrosion primer layer and a seventh titanium-based graphene anti-corrosion top coat layer on the outer surfaces of other metal parts.
7. The method of coating an offshore wind tower corrosion resistant coating system of claim 6, wherein the thickness of the first titanium-based graphene corrosion resistant primer and the third titanium-based graphene corrosion resistant primer are both less than the thickness of the second titanium-based graphene corrosion resistant primer; the thickness of the first titanium-based graphene anti-corrosion finish paint and the thickness of the third titanium-based graphene anti-corrosion finish paint are smaller than those of the second titanium-based graphene anti-corrosion finish paint.
8. The method of coating an offshore wind tower corrosion resistant coating system according to claim 7, wherein the first titanium-based graphene cold-zinc-coated primer has a thickness of 80 μιη, the first titanium-based graphene corrosion resistant primer has a thickness of 150 μιη, the first titanium-based graphene corrosion resistant topcoat has a thickness of 120 μιη, and the total dry film thickness is 350 μιη;
the thickness of the second titanium-based graphene cold-coating zinc primer is 80 mu m, the thickness of the second titanium-based graphene anti-corrosion primer is 300 mu m, the thickness of the second titanium-based graphene anti-corrosion finish paint is 220 mu m, and the total dry film thickness is 600 mu m;
the thickness of the third titanium-based graphene cold-coating zinc primer is 80 mu m, the thickness of the third titanium-based graphene anti-corrosion primer is 120 mu m, the thickness of the third titanium-based graphene anti-corrosion finish paint is 200 mu m, and the total dry film thickness is 400 mu m;
the thickness of the seventh titanium-based graphene anticorrosive primer is 120 mu m, the thickness of the seventh titanium-based graphene anticorrosive finishing coat is 200 mu m, and the total dry film thickness is 320 mu m.
9. The method for coating an offshore wind tower corrosion resistant coating system according to any one of claims 6 to 8, further comprising the steps of:
sequentially coating a fourth titanium-based graphene anti-corrosion primer and a fourth titanium-based graphene anti-corrosion finish paint on the inner surface of a tower barrel of the ocean atmosphere area;
sequentially coating a fifth titanium-based graphene anti-corrosion primer and a fifth titanium-based graphene anti-corrosion finish paint on the inner surface of a casing frame and a pile foundation in the ocean atmosphere, wave splash and tidal range area;
and sequentially coating a sixth titanium-based graphene anti-corrosion primer and a sixth titanium-based graphene anti-corrosion finish paint on the inner surface of the casing frame and the pile foundation of the seawater full-immersion area.
10. The method for coating an offshore wind tower corrosion resistant coating system according to claim 9, wherein the thickness of the fourth titanium-based graphene corrosion resistant primer is 120 μm, the thickness of the fourth titanium-based graphene corrosion resistant finish is 120 μm, and the total dry film thickness is 240 μm;
the thickness of the fifth titanium-based graphene anti-corrosion primer is 200 mu m, the thickness of the fifth titanium-based graphene anti-corrosion finishing coat is 300 mu m, and the total dry film thickness is 500 mu m;
the thickness of the sixth titanium-based graphene anticorrosive primer is 120 mu m, the thickness of the sixth titanium-based graphene anticorrosive finishing coat is 200 mu m, and the total dry film thickness is 320 mu m.
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