阅读说明：本技术 一种在役管道预浸料修补施工方法 (in-service pipeline prepreg repair construction method ) 是由 黄金柏 刘长海 于 2019-07-11 设计创作，主要内容包括：本发明公开了应用于油气输送管道修复补强领域的一种在役管道预浸料修补施工方法,该方法包括如下步骤：施工前准备；管道表面清理；缺陷填平操作；涂刷抗阴极剥离底漆；缠绕修复补强用纤维增强预浸料；加热加压固化操作；补强层边界及端部封口处理；防腐处理。该施工方法中预浸料的应用,减少了施工现场的配胶、手工涂刷浸渍纤维布等操作步骤,保障了修复材料质量。同时该方法利用缠绕设备对纤维增强预浸料进行缠绕操作,确保了修复效率和质量,避免人工缠绕时预紧力不足导致的缠绕松动、纤维布褶皱不平、偏斜等现象的发生,且合适的预紧力有助于修复材料层与层之间的粘结、排除缠绕时裹挟的气泡,提高了施工质量。(The invention discloses an in-service pipeline prepreg repair construction method applied to the field of oil and gas transmission pipeline repair reinforcement, which comprises the following steps: preparation before construction; cleaning the surface of the pipeline; performing defect filling operation; coating a cathode stripping resistant primer; winding, repairing and reinforcing fiber reinforced prepreg; heating, pressurizing and curing; sealing the boundary and the end part of the reinforcing layer; and (5) performing antiseptic treatment. The application of the prepreg in the construction method reduces the operation steps of glue preparation, manual brushing of impregnated fiber cloth and the like on a construction site, and ensures the quality of the repair material. Meanwhile, the method utilizes winding equipment to wind the fiber reinforced prepreg, so that the repair efficiency and quality are ensured, the phenomena of loose winding, uneven fiber cloth folds, deflection and the like caused by insufficient pretightening force during manual winding are avoided, the proper pretightening force is favorable for repairing the adhesion among layers of the material, the bubbles wrapped during winding are eliminated, and the construction quality is improved.)

1. a prepreg repair construction method for an in-service pipeline is characterized by comprising the following steps:

(1) preparation before construction: preparing related tool materials, confirming the number of repairing and reinforcing layers and repairing and reinforcing areas according to the defect size and the performance of the repairing material of the pipeline (1), and performing corresponding paying-off positioning operation on the repairing and reinforcing areas before construction;

(2) Cleaning the surface of the pipeline (1): carrying out surface rust removal operation on the repair reinforcement area to ensure that the surface of the repair reinforcement area is free of attachments such as grease, dirt, oxide skin and the like, wherein the surface temperature of the repair reinforcement area is higher than the dew point by 3 ℃;

(3) Defect filling operation: repairing and filling the volume type defect part on the surface of the pipeline (1) at the repair and reinforcement area by using special defect filling putty (2) until the surface of the defect part is flat;

(4) Coating cathodic disbonding resistant primer (3): uniformly brushing the cathodic disbonding primer (3) to the surface of the repair reinforcement area, wherein the brushing thickness is more than 0.3 mm;

(5) Fiber-reinforced prepreg (4) for winding repair reinforcement: after the surface dryness of the cathodic disbonding primer (3) coated in the step (4) is confirmed, cleaning dirt such as moisture, dust and the like on the surface of the cathodic disbonding primer (3), and then carrying out laying operation on the fiber reinforced prepreg (4) by using winding equipment according to laying data calculated in the step (1);

(6) Heating and pressurizing curing operation: dismantling the winding equipment, carrying out pressurization fastening operation on the fiber reinforced prepreg (4) by using a vacuum auxiliary curing device, and then carrying out heating curing operation on the fiber reinforced prepreg (4) by using a heating device;

(7) And (3) sealing the boundary and the end part of the reinforcing layer: dismantling a heating device and a vacuum auxiliary curing device, forming a repair reinforcing layer by using the special filling putty (2), the anti-cathodic disbonding primer (3) and the fiber reinforced prepreg (4), and then coating the joint of the end part of the reinforcing layer, the edge of the reinforcing area and the surface of the pipeline (1) with the anti-cathodic disbonding primer (3) to form a slope structure by using tools such as a spatula;

(8) and (3) antiseptic treatment: and (5) after the surface of the anti-cathodic disbonding primer (3) in the step (7) is dried, winding and wrapping the repair reinforcing area by using external anticorrosive materials such as a cold winding tape, a polyethylene heat shrinkage tape and the like.

2. The in-service pipeline prepreg repair construction method according to claim 1, wherein the pipeline (1) surface cleaning operation in the step (2) adopts sand blasting to remove rust so as to enable the surface of the pipe body to reach Sa2.5 grade standard or adopts manual grinding to remove rust so as to enable the surface of the pipe body to reach St3 grade standard.

3. the in-service pipeline prepreg repair construction method according to claim 1, wherein the special defect-filling putty (2) in the step (3) is composed of a component A and a component B, and the special defect-filling putty (2) comprises the following components in parts by weight: 3-5 parts of a component A, and 1.5-2.5 parts of a component B;

the component A comprises the following components in percentage by mass: 25-45% of bisphenol A epoxy resin, 15-25% of novolac epoxy resin, 3-10% of calcined alumina coarse powder and 20-40% of fumed silica;

The component B comprises the following components in percentage by mass: 20-35% of modified phenolic aldehyde amine curing agent, 5-10% of modified polyamide curing agent, 55-65% of quartz coarse powder and 5-10% of silane coupling agent;

the particle size of the calcined alumina coarse powder is 200-1250 meshes; the particle size of the quartz coarse powder is 200-800 meshes.

4. The in-service pipeline prepreg repair construction method according to claim 1, wherein the cathodic disbondment resistant primer (3) in the step (4) is composed of a component a and a component b, and the cathodic disbondment resistant primer (3) comprises the following components in parts by mass: 3-5 parts of a component a and 1 part of a component b;

The component a comprises the following components in percentage by mass: 35-55% of bisphenol A epoxy resin, 15-25% of novolac epoxy resin, 10-30% of sericite, 15-25% of alumina and 0.2-0.5% of polysiloxane defoaming agent;

the component b comprises the following components in percentage by mass: 60-85% of modified arylamine curing agent, 10-35% of imidazole modified amine curing agent and 5-15% of silane coupling agent;

the particle size of the sericite is 800-1250 meshes, and the particle size of the alumina is 800-1250 meshes.

5. the in-service pipeline prepreg repairing construction method according to claim 1, wherein the uneven surface repairing operation is performed after the surface drying of the filling putty and the anti-cathodic disbonding primer in the steps (3) and (4) is completed, and the uneven surface repairing operation is performed by repairing a concave part, a convex part or other defects existing after the surface drying by using a tool, the filling putty and the anti-cathodic disbonding primer to repair the surface to be flat.

6. The in-service pipeline prepreg repair construction method according to claim 1, wherein the fiber-reinforced prepreg (4) in the step (5) comprises reinforcing fibers, and the reinforcing fibers are polyimide fibers, carbon fibers, glass fibers or Kevlar fibers.

7. the in-service pipeline prepreg repair construction method according to claim 1, wherein the winding device in the step (5) comprises a turning moving device (51), a prepreg unreeling device (6), a compacting device (7) and an isolating film reeling device (5), the turning moving device (51) is used for achieving the circumferential rotation and axial moving operation of the winding device, the prepreg unreeling device (6) is used for placing the fiber reinforced prepreg coiled material, the compacting device (7) is used for compacting the surface contact position of the fiber reinforced prepreg (4) and the pipeline (1), and the isolating film reeling device (5) is used for receiving the isolating film of the fiber reinforced prepreg (4).

8. The in-service pipeline prepreg repair construction method according to claim 7, wherein the steering movement device (51) comprises a ring support, a plurality of annular movement wheels and transverse movement wheels, the ring support is sleeved on the pipeline (1), the annular movement wheels and the transverse movement wheels are arranged at the end part of the ring support facing the pipeline (1) along the circumferential direction, the annular movement wheels realize coaxial relative rotation operation of the ring support and the pipeline, the transverse movement wheels realize reciprocating motion of the ring support along the axis direction, the annular movement wheels and the transverse movement wheels are not in contact with the pipeline (1) simultaneously, the prepreg unwinding device (6), the compressing device (7) and the isolating film winding device (5) are connected on the ring support and move along with the ring support, and the prepreg unwinding device (6), the compressing device (7) and the isolating film winding device (5) realize synchronous work along with the annular movement of the ring support and advance The process.

9. the in-service pipeline prepreg repair construction method according to claim 8, wherein the circular support comprises two sets of circular fasteners respectively fastened to two ends of the pipeline (1) to be repaired, the circular fasteners are composed of two opposite semicircular steel pipes, one end of each semicircular steel pipe is hinged, the other end of each semicircular steel pipe is provided with a corresponding locking structure, the semicircular steel pipes are fastened to the pipeline in a butt joint manner to form the fixed and supporting circular support, and the annular moving wheels and the transverse moving wheels are respectively arranged on two sides of each set of circular fasteners.

10. the in-service pipeline prepreg repair construction method according to claim 1, wherein the heating and pressurizing curing operation of the step (6) comprises the following steps:

(A) dismantling the winding equipment which is applied in the step (5);

(B) Installing and operating a vacuum auxiliary curing device: wrapping and winding the breathable isolation cloth (8), the shaping film (9), the breathable felt (10) and the vacuum bag (11) outside the repairing layer in sequence, bonding the periphery of the vacuum bag (11) on the surface of the pipe body by adopting a sealing adhesive tape (12), and installing a vacuum nozzle inside the vacuum bag,

(C) And (3) air tightness detection operation: the vacuum nozzle is connected with a vacuum pump (15) and carries out vacuumizing operation, and the vacuumizing operation is stopped after the air tightness detection meets the requirement;

(D) heating and curing operation: and (2) wrapping an electromagnetic heater clamp sleeve matched with the surface structure of the pipeline (1) outside the vacuum bag (11), switching on a power supply to heat the prepreg to 50-80 ℃, opening a vacuum pump (15), vacuumizing for 30min, then closing, heating the prepreg to 80-120 ℃, and preserving heat for 1-3h until the repair reinforcement material is completely cured, wherein the heating and curing operation is completed.

Technical Field

The invention relates to an in-service pipeline prepreg repair construction method applied to the field of oil and gas conveying pipeline repair reinforcement.

Background

the buried oil and gas transmission pipeline usually has a plurality of pipe body defects caused by corrosion, natural disasters, artificial damage and the like, and the defects can be continuously developed to cause accidents such as pipeline leakage, burst and the like along with the extension of service time, thereby threatening the safe operation of the in-service pipeline and seriously affecting the transmission operation capability of the pipeline. In recent years, the composite material repair and reinforcement technology is rapidly developed and widely applied to the maintenance and overhaul of the defective pipeline. The repair technology is characterized in that the composite material sleeve is wound and wrapped on the damaged part of the pipeline to form a whole with the defective pipeline, so that the annular tensile force and the axial stress caused by the internal pressure of the original pipeline are jointly born, the pressure born by the damaged pipe wall is reduced, and the aim of repairing and reinforcing is fulfilled. Compared with the traditional method, the composite material repairing technology has greater advantages in safety, economy and efficiency and becomes a better choice for the oil and gas pipeline repairing technology. At present, a product of the composite material repairing and reinforcing technology mainly comprises three parts: the fiber reinforced composite material kit, the cathodic disbonding resistant primer and the defect filling putty, and the repair and reinforcement construction process mainly comprises a preforming method and a wet winding method. The two construction methods are different in that the pre-forming method needs to be prepared into a composite material suite in a factory and adopts interlayer adhesive to bond with the steel pipe to form a whole in a construction site; the wet winding method needs to prepare an adhesive for dipping in a construction site, brush the adhesive on the flexible fiber cloth and then wrap the flexible fiber cloth on the surface of the steel pipe for curing and forming.

the field construction repair of the defective pipeline by adopting the preforming method and the wet winding method has the following problems:

(1) The preparation of the two-component adhesive. Due to the influence of factors such as technical proficiency and responsibility of site constructors, the problems that the preparation of the two components in proportion is wrong, the adhesive cannot be fully and uniformly stirred and the like exist in the actual glue preparation operation, the mechanical property of the cured fiber composite material is reduced, and the purposes of repairing and reinforcing cannot be effectively exerted are caused.

(2) The problem of uneven adhesive leakage coating or brushing is solved. In the process of winding preformed composite materials (dry construction) or fiber cloth (wet construction), due to the influence of manual operation and field construction environment, problems of missing coating, uneven coating of an adhesive and the like often occur, the composite materials cannot be effectively bonded or the fiber cloth cannot be fully impregnated, and the effectiveness and the durability of a repairing layer cannot be predicted.

(3) repairing the wrapping and winding problem of the reinforcing material. When the composite material coiled material (a pre-forming method) or the flexible fiber cloth (a wet winding method) is artificially wound on site, the pre-tightening force between layers is insufficient, the winding is loose, and the fiber cloth has the phenomena of deviation, folding and the like. The defects of layering, hollowing and the like appear after the actual repair is finished, the composite material cannot fully play the aim of reinforcing repair, and corrosive media are left to enter a channel to accelerate the aging and failure of a repair layer.

(4) The fiber reinforced composite material is cured and formed. At present, the pre-forming method and the wet winding method are mostly used for carrying out curing molding under the condition of normal temperature, and due to the influence of site construction quality and severe environments such as cold, humidity and the like, the strength uniformity of a repairing layer is poor, and the repairing effect cannot be ensured.

Due to the influence of the construction quality of the repair and reinforcement operation of the fiber reinforced composite material, various mechanical property values of the repair layer are uncertain variables, and the effectiveness and the durability of the repair and reinforcement effect are unpredictable. In addition, in practical application, due to the difference between the expansion coefficient and the mechanical property of the composite material and the pipeline, when the composite material is influenced by the periodic internal stress change of the pipeline and the change of the external environment, the repairing layer and the pipe body generate destructive phenomena such as debonding and layering, the pressure-bearing capacity of the defective pipeline cannot be effectively recovered, and the expected repairing and reinforcing service life requirement cannot be met.

Disclosure of Invention

The invention aims to provide an in-service pipeline prepreg repair construction method which can effectively improve the quality of repair engineering.

the technical scheme adopted by the invention for solving the technical problems is as follows:

A prepreg repair construction method for an in-service pipeline comprises the following steps:

(1) preparation before construction: preparing related tool materials, confirming the number of repairing and reinforcing layers and repairing and reinforcing areas according to the size of the pipeline defect and the performance of the repairing material, and performing corresponding paying-off positioning operation on the repairing and reinforcing areas before construction;

(2) cleaning the surface of the pipeline: carrying out surface rust removal operation on the repair reinforcement area, wherein the surface of the repair reinforcement area is free from attachments such as grease, dirt, oxide skin and the like, and the surface temperature of the repair reinforcement area is higher than the dew point by 3 ℃;

(3) defect filling operation: repairing and filling the volume type defect part on the surface of the pipeline at the repair and reinforcement area by using special defect filling putty until the surface of the defect part is smooth;

(4) Coating cathode stripping resistant primer: uniformly brushing the cathodic disbonding primer on the surface of the repair reinforcement area, wherein the brushing thickness is more than 0.3 mm;

(5) winding, repairing and reinforcing fiber reinforced prepreg: after the surface dryness of the cathode stripping resistant primer coated in the step (4) is confirmed, cleaning dirt such as moisture, dust and the like on the surface of the cathode stripping resistant primer, and then carrying out laying operation on the fiber reinforced prepreg by using winding equipment according to laying data calculated in the step (1);

(6) Heating and pressurizing curing operation: dismantling the winding equipment, fastening and pressurizing the fiber reinforced prepreg by using a vacuum auxiliary curing device, and then heating and curing the fiber reinforced prepreg by using a heating device;

(7) and (3) sealing the boundary and the end part of the reinforcing layer: dismantling a heating device and a vacuum auxiliary curing device, forming a repair reinforcing layer by special filling putty, anti-cathode stripping primer and fiber reinforced prepreg, and then smearing the joint of the end part of the reinforcing layer, the edge of a reinforcing area and the surface of the pipeline into a slope structure by using tools such as a spatula and the like by adopting the anti-cathode stripping primer;

(8) And (3) antiseptic treatment: and (5) after the surface of the anti-cathode stripping primer in the step (7) is dried, winding and wrapping the repair reinforcing area by using external anticorrosive materials such as a cold winding tape, a polyethylene heat shrinkage tape and the like, so that the construction operation is finished.

The construction method comprises the steps of firstly carrying out calculation limiting operation of tools before construction and pre-repair, and then cleaning the surface of the pipeline to a preset requirement to ensure the bonding stability of a subsequent pipe body and construction materials. And then, repairing operation is carried out on a construction area through special defect filling putty, cathode stripping resistant primer and fiber reinforced prepreg, then heating and pressurizing curing are carried out on the construction area through a vacuum auxiliary heating device, and sealing treatment and external anticorrosion treatment are carried out on the port of the reinforcing layer, so that all construction is completed. According to the construction method, the winding equipment is utilized to wind the fiber reinforced prepreg, so that the repair efficiency and the repair quality are ensured, the phenomena of loose winding, uneven fiber cloth folds, deflection and the like caused by insufficient pretightening force during manual winding are avoided, the proper pretightening force is favorable for bonding between layers of the repair material, bubbles wrapped during winding are eliminated, and the pipeline repair quality is improved.

further, the pipeline surface cleaning operation in the step (2) adopts sand blasting to remove rust so that the surface of the pipe body reaches Sa2.5 grade standard or manual grinding to remove rust so that the surface of the pipe body reaches St3 grade standard.

further, the special defect-filling putty in the step (3) is composed of a component A and a component B, and comprises the following components in parts by mass: 3-5 parts of a component A, and 1.5-2.5 parts of a component B;

the component A comprises the following components in percentage by mass: 25-45% of bisphenol A epoxy resin, 15-25% of novolac epoxy resin, 3-10% of calcined alumina coarse powder and 20-40% of fumed silica;

The component B comprises the following components in percentage by mass: 20-35% of modified phenolic aldehyde amine curing agent, 5-10% of modified polyamide curing agent, 55-65% of quartz coarse powder and 5-10% of silane coupling agent;

the particle size of the calcined alumina coarse powder is 200-1250 meshes; the particle size of the quartz coarse powder is 200-800 meshes.

Further, the cathodic disbondment resistant primer in the step (4) is composed of a component a and a component b, and the cathodic disbondment resistant primer comprises the following components in parts by mass: 3-5 parts of a component a and 1 part of a component b;

The component a comprises the following components in percentage by mass: 35-55% of bisphenol A epoxy resin, 15-25% of novolac epoxy resin, 10-30% of sericite, 15-25% of alumina and 0.2-0.5% of polysiloxane defoaming agent;

the component b comprises the following components in percentage by mass: 60-85% of modified arylamine curing agent, 10-35% of imidazole modified amine curing agent and 5-15% of silane coupling agent;

the particle size of the sericite is 800-1250 meshes, and the particle size of the alumina is 800-1250 meshes.

And (3) further, after the surface drying of the filling putty and the anti-cathode stripping primer in the steps (3) and (4) is finished, an uneven surface repairing operation is arranged, wherein the uneven surface repairing operation is to repair the concave, convex or other defects existing after the surface drying by using tools, the filling putty, the anti-cathode stripping primer and the like until the surface is flat.

further, the fiber reinforced prepreg in the step (5) comprises reinforcing fibers, and the reinforcing fibers are polyimide fibers, carbon fibers, glass fibers or Kevlar fibers.

Further, the winding device in the step (5) comprises a turning moving device, a prepreg unreeling device, a pressing device and an isolating film reeling device, wherein the turning moving device is used for realizing the operation of circumferential rotation and axial movement of the winding device, the prepreg unreeling device is used for placing the fiber reinforced prepreg, the pressing device is used for pressing the contact position of the fiber reinforced prepreg and the surface of the pipeline, and the isolating film reeling device is used for accommodating the isolating film of the fiber reinforced prepreg.

Further, turn to the mobile device and include ring support, a plurality of hoop removal wheel and lateral shifting wheel, the pipeline is located to the ring support cover, hoop removal wheel and lateral shifting wheel set up in the tip of ring support towards the pipeline along circumference, the coaxial relative rotation operation of ring support and pipeline is realized to the hoop removal wheel, the reciprocating motion of ring support along the axis direction is realized to the lateral shifting wheel, hoop removal wheel and lateral shifting wheel contact with the pipeline simultaneously, preimpregnation material unwinding device, closing device and barrier film coiling mechanism connect on the ring support and move along with the ring support, preimpregnation material unwinding device, closing device and barrier film coiling mechanism realize the synchronous working process along with the hoop motion of ring support.

Further, the ring support comprises two groups of circular clamping pieces which are respectively clamped at two ends of the pipeline to be repaired, the circular clamping pieces are composed of two semicircular steel pipes which are arranged oppositely, one end of each semicircular steel pipe is hinged, the other end of each semicircular steel pipe is provided with a corresponding locking structure, the semicircular steel pipes are clamped on the pipeline to form the ring support for fixing and supporting, and the annular moving wheels and the transverse moving wheels are respectively arranged at two sides of each group of circular clamping pieces.

further, the heating and pressing curing operation of the step (6) includes the steps of:

(A) Dismantling the winding equipment which is applied in the step (5);

(B) installing and operating a vacuum auxiliary curing device: wrapping the repairing layer with air permeable isolation cloth, shaping film, air permeable felt and vacuum bag, bonding the periphery of the vacuum bag on the surface of the pipe body with sealing adhesive tape, and installing vacuum nozzle inside,

(C) and (3) air tightness detection operation: the vacuum nozzle is connected with a vacuum pump and carries out vacuumizing operation, and the vacuumizing operation is stopped after the air tightness detection meets the requirement;

(D) Heating and pressurizing curing operation: and (3) wrapping an electromagnetic heater clamping sleeve matched with the surface structure of the pipeline outside the vacuum bag, switching on a power supply to heat the prepreg to 50-80 ℃, opening a vacuum pump to vacuumize for 30min, then closing the vacuum pump, heating the prepreg to 80-120 ℃, preserving heat for 1-3h until the repair reinforcement material is completely cured, and completing the heating and curing operation.

The invention has the beneficial effects that:

1. The operation steps adopt a pre-impregnation method to repair and reinforce the pipeline, the pre-impregnation method is used as a product of a wet winding method, and the difference between the operation steps and the wet winding method is that automatic equipment is adopted in a factory to impregnate a resin system into continuous fibers, the proportion of resin and fibers and the uniformity of the thickness of a resin layer are ensured, the resin has good wettability to the fibers, the quality of the repair material is stable and good, so that the performance of the material is fully exerted, the quality of repair is guaranteed, the operation steps of glue preparation, coating and the like on a construction site are reduced, and the influence of human factors on the quality of the repair material is reduced. In addition, an uncured fiber reinforced prepreg system adopted by the prepreg method, namely a resin system in the prepreg, plays a corresponding protection role on fibers, and avoids the phenomena of distortion, bending and the like of fiber cloth in the transportation and use processes, so that the strength of the fiber cloth is greatly reduced, and the repair reinforcement performance is influenced;

2. the construction step adopts mechanized equipment to wrap the wound prepreg, so that the repair efficiency and repair quality are ensured, the phenomena of loose winding, uneven fiber cloth folds, deflection and the like caused by insufficient pretightening force during manual winding are avoided, the proper pretightening force is favorable for bonding between layers of the repair material, bubbles wrapped and clamped during winding are eliminated, and the performance of the repair material is ensured;

3. the method for arranging the annular moving wheels and the transverse moving wheels in a matched mode effectively improves the working flexibility of the equipment, improves the moving efficiency of the equipment, avoids repeated dismounting and mounting operations of the equipment, improves the working efficiency, and simultaneously ensures the working quality and improves the operating efficiency by the synchronous working arrangement method among the structures;

4. The heating and pressurizing mode is favorable for the curing operation of the repair system, the excess resin is extruded, bubbles and cavities between layers are eliminated, the compactness of the reinforcing material is increased, the consistency of the strength of a repair layer is ensured, the bonding force between the reinforcing material and a pipe body is improved, the defects of debonding, layering, cracking and the like of the repair material and the pipe body are avoided, the repair and reinforcement quality is ensured, meanwhile, the heating speed is increased by adopting electromagnetic heating, the temperature uniformity of a heating area is good, and the repair efficiency and the repair quality are ensured.

Drawings

FIG. 1 is a schematic cross-sectional view of a repaired pipeline in an in-service pipeline prepreg repair construction method according to the present invention;

FIG. 2 is a radial cross-sectional view of FIG. 1;

FIG. 3 is a schematic view of a connection structure of a winding device and a repaired pipeline of the in-service pipeline prepreg repair construction method of the invention;

FIG. 4 is a schematic view of structural connection in a heating, pressurizing and curing operation of the in-service pipeline prepreg repair construction method of the invention;

FIG. 5 is an enlarged view of the structure of the area A in FIG. 4;

labeled as: pipeline 1, special defect leveling putty 2, anti negative pole peeling primer 3, fibre reinforcing preimpregnation material 4, barrier film coiling mechanism 5 turn to mobile device 51, preimpregnation material unwinding device 6, closing device 7, ventilative barrier cloth 8, design membrane 9, ventilative felt 10, vacuum bag 11, joint strip 12, electromagnetic heating cutting ferrule 13, electromagnetic heating control box 14, vacuum pump 15.

Detailed Description

The invention is further described with reference to the following figures and detailed description.

this technical scheme adopts prepreg to restore the reinforcement to the pipeline, and the operation step is as follows:

1. preparation before construction:

(1) preparing relevant tool materials: the composite material comprises fiber reinforced prepreg 4, special defect filling putty 2, cathodic disbonding resistant primer 3, winding equipment, a vacuum auxiliary curing device, a heating device and the like.

the special defect-filling putty 2, the cathode stripping resistant primer 3 and the fiber reinforced prepreg 4 can be purchased in the market. Meanwhile, the special defect-filling putty 2 can also be produced according to the following mixture ratio: the special defect-filling putty 2 consists of a component A and a component B, and the special defect-filling putty 2 comprises the following components in parts by weight: 3-5 parts of a component A, and 1.5-2.5 parts of a component B; the component A comprises the following components in percentage by mass: 25-45% of bisphenol A epoxy resin, 15-25% of novolac epoxy resin, 3-10% of calcined alumina coarse powder and 20-40% of fumed silica; the component B comprises the following components in percentage by mass: 20-35% of modified phenolic aldehyde amine curing agent, 5-10% of modified polyamide curing agent, 55-65% of quartz coarse powder and 5-10% of silane coupling agent. Meanwhile, in order to ensure the quality of the produced product, the particle size of the calcined alumina coarse powder is 200-1250 meshes, and the particle size of the quartz coarse powder is 200-800 meshes, so that the defect of the pipeline is filled by using the defect filling putty 2 with high compressive strength, the load of the pipeline is effectively transferred, and the repair quality is ensured.

the corresponding cathodic disbonding resistant primer 3 is produced according to the following mixture ratio: the adhesive comprises 3-5 parts of a component a and 1 part of a component b in parts by mass; the component a comprises the following components in percentage by mass: 35-55% of bisphenol A epoxy resin, 15-25% of novolac epoxy resin, 10-30% of sericite, 15-25% of alumina and 0.2-0.5% of polysiloxane defoaming agent; the component b comprises the following components in percentage by mass: 60-85% of modified arylamine curing agent, 10-35% of imidazole modified amine curing agent and 5-15% of silane coupling agent. Meanwhile, the particle size of the sericite is 800-1250 meshes, and the particle size of the alumina is 800-1250 meshes, so that the best bonding between the repairing material and the pipeline 1 is ensured, and galvanic corrosion is avoided.

In addition, the fiber-reinforced prepreg 4 can be selected from polyimide fibers, carbon fibers, glass fibers, Kevlar fibers or other high-performance fibers meeting the strength requirement, so that the product performance is improved, and the repair quality is ensured.

(2) calculating the number of layers to be repaired and determining a repair reinforcement area according to the defect size and the performance of the repair material of the pipeline 1;

(3) Before construction, paying off and positioning at the position needing repair and reinforcement, marking subsequent defect filling, priming paint coating and repair material winding, and marking the reinforcement area with a striking color such as red, yellow and the like.

2. cleaning the surface of the pipeline 1: the surface cleaning process of the pipe body 1 is a key step for judging whether the reinforcement repair reaches the standard or not, in order to ensure that the best bonding effect between a repair material and the pipe 1 is achieved, the surface of the repaired area of the pipe 1 is ensured to be free of attachments such as grease, dirt, oxide skin and the like, sand blasting is recommended to be adopted to remove rust so that the surface of the pipe body reaches the Sa2.5 standard, and if manual polishing is used for removing rust, the surface of the pipe body is required to reach the St3 standard. Meanwhile, the surface temperature of the pipeline 1 before repair construction should be higher than the dew point by more than 3 ℃.

3. Defect filling operation: the special defect filling putty 2 is used for carrying out repairing and filling operations on volume type defect parts on the surface of the pipeline 1 at the repairing and reinforcing area, such as concave parts of honeycombs, pitted surfaces, small holes and the like on the surface of the pipeline 1, and the surface of the defect parts is repaired to be flat, so that the effect of leveling with the surface of the pipeline as shown in figure 2 is achieved.

4. Coating cathodic disbonding resistant primer 3: the cathodic disbonding resistant primer 3 is uniformly coated on the surface of a repair reinforcing area, and the coating thickness is more than 0.3mm, so that the best bonding between a repair material and the pipeline 1 is ensured, the cathodic disbonding resistant performance of a repair system is improved, and the occurrence of carbon fiber galvanic corrosion is avoided.

5. Repairing an uneven surface: and (4) respectively inspecting the surface of the pipeline 1 repaired in the steps (3) and (4), and then respectively repairing the defects such as sagging, sinking and protruding parts by using tools, defect filling putty 2 and anti-cathode stripping primer 3 until the surface flatness of the pipeline 1 meets the requirement.

6. Winding repair reinforcement fiber reinforced prepreg 4:

Firstly, after the surface of the cathodic disbondment resistant primer 3 coated in the step 4 is confirmed to be dried, dirt such as moisture and dust is cleaned on the surface of the cathodic disbondment resistant primer 3, the surface is confirmed to be free from dirt such as moisture and dust, and then a winding device is used for laying the fiber reinforced prepreg 4 on the marked pipeline defect part according to the number of repairing layers and the repairing width which need to be wound and are calculated in the step 1.

the laying equipment comprises a turning moving device 51, a prepreg unreeling device 6, a compacting device 7 and an isolating film reeling device 5 as shown in fig. 3. The steering movement device 51 is composed of a circular ring support, a circular ring movement wheel and a transverse movement wheel. The ring support comprises two groups of circular clamping pieces which are respectively clamped at two ends of the pipeline 1 to be repaired, the circular clamping pieces are composed of two semicircular steel pipes which are oppositely arranged, the two ends of each semicircular steel pipe can be connected through a locking structure, and then the pipeline 1 is stably sleeved with the circular clamping pieces. At the moment, the semicircular steel pipe can be hinged at one end and connected at the other end in a locking way. And the corresponding annular moving wheel is circumferentially arranged at the end part of the semicircular steel pipe facing the pipeline 1, at the moment, the annular support is in contact with the pipeline 1 through the annular moving wheel, the axis direction of the annular moving wheel is parallel to the axis direction of the pipeline 1, and the corresponding moving wheel can drive the annular support to realize coaxial relative rotation operation with the pipeline. Meanwhile, the steering and moving device 51 may be provided with corresponding transverse moving wheels, which are arranged in the same way as the moving wheels, but the axial direction of the transverse moving wheels is perpendicular to the axial direction of the pipeline 1, so that the steering and moving device 51 can move parallel to the pipeline 1, but the operation process should ensure that the annular moving wheels and the transverse moving wheels do not contact with the surface of the pipeline 1 at the same time. The prepreg unwinding device 6, the compacting device 7 and the barrier film winding device 5 are all mounted on the turning and moving device 51 and can rotate along with the turning and moving device.

the prepreg unreeling device 6 is used for placing fiber-reinforced prepreg coiled materials, the compacting device 7 is used for compacting the fiber-reinforced prepreg 4 and the surface contact position of the pipeline 1, and the isolating film reeling device 5 is used for accommodating isolating films of the fiber-reinforced prepreg 4. Because the two layers of upper and lower isolating films are usually attached to two sides of the prepreg in the production process of the composite material, the worker needs to install the isolating film winding device 5 at the front end and the rear end of the prepreg unwinding device 6 respectively, and the front end and the rear end in the above contents are distinguished and limited according to the working direction. According to the rotating working direction, the worker installs the pressing device 7 between the prepreg unreeling device 6 and the isolating film reeling device 5 at the rear end. When working, the compacting device 7 pushes down and presses the fiber reinforced prepreg 4 to the position attached to the pipeline 1, and the pressure is adjusted according to the requirement. As shown in fig. 3, the release film winding device 5 located at the front end of the prepreg unwinding device 6 in the working rotation direction performs a winding operation on the release film on the lower surface of the fiber reinforced prepreg 4 in contact with the pipe 1, and the lower surface of the fiber reinforced prepreg 4 with the lower release layer removed is exposed to the air and is then connected to the surface of the pipe 1 by a pressing operation of the pressing device 7 in response to the rotation operation. And the isolating film rolling device 5 positioned on the other side of the pressing device 7 rolls the isolating film positioned on the upper surface of the fiber reinforced prepreg 4. And the rolling operation of the barrier film of this upper surface is gone on after closing device 7 operation is accomplished, has avoided closing device 7 and fiber reinforcement preimpregnation material 4's direct contact, has guaranteed closing device 7's clean and tidy nature of structure, has avoided being stained with of fiber reinforcement preimpregnation material 4 to leave simultaneously, has guaranteed the repair effect. And the mechanized construction mode avoids the fiber reinforced prepreg 4 from wrinkling and deviation during winding, saves manpower and improves construction efficiency. In addition, the winding equipment provides proper pretightening force and is provided with a pressing device for winding and pressing at the same time, so that air bubbles and hollows can be effectively eliminated, and the bonding between layers of the prepreg is enhanced. Since the pressing device 7 is fixed on the ring support, the relative position of the two is not changed, and the pressing device can rotate along with the ring support to apply pressing force continuously towards the pipeline. Meanwhile, the pressing device 7 can be provided with a rubber roller parallel to the axis of the pipeline 1 towards the pressing action of the pipeline 1, and then the acting force between the pipeline 1 and the pressing device 7 is rolling friction force, so that the running smoothness is ensured, and the blockage of the acting force in the tangential direction to the running operation is avoided. The unreeling operation of the prepreg unreeling device 6 can directly realize corresponding traction force through the limiting effect of the pressing device 7 on the prepreg, and the unreeling operation of the prepreg unreeling device 6 is further promoted. At this moment, the acting force of the prepreg unreeling device 6 to the prepreg coiled material is properly increased, and the required traction acting force is increased, so that the tension in the prepreg laying process is kept, and the laying quality is guaranteed. And the usable transmission structure of above-mentioned barrier film coiling mechanism 5 realizes rotating the rolling operation through the rotation of ring support to it, and for example the drive operation of coiling mechanism is realized through the belt gyro wheel, and the action wheel contacts with the pipeline surface, utilizes its surface friction to realize the drive to the action wheel then, and the barrier film that corresponds is accomodate the coiled material and is connected from the driving wheel. When the driven wheel rotates along with the driving wheel under the action of the belt, the isolating film accommodating coiled material rotates along with the rotation of the circular ring support. Therefore, the prepreg unreeling device 6, the pressing device 7 and the isolating film reeling device 5 can realize synchronous working processes along with the annular movement of the annular support, so that the working progress consistency is realized. And the staff can realize the adjustment of unreeling tension, pressing force and rolling tension in the above-mentioned working process through the structure setting according to technical common knowledge to guarantee the operation of laying equipment and lay the quality, easily subsequent operation effect's performance.

7. Heating and curing operation: the method comprises the following steps:

(A) Dismantling the winding equipment which is applied in the step 6;

(B) installing and operating a vacuum auxiliary curing device: the outside of the repair layer is sequentially wrapped with a wound breathable isolation cloth 8, a shaping film 9, a breathable felt 10 and a vacuum bag 11 as shown in figure 5, the periphery of the vacuum bag 11 is bonded on the surface of the pipe body by adopting a sealing rubber strip 12, a vacuum nozzle is arranged in the vacuum bag, the breathable isolation cloth 8 is used for preventing the fiber reinforced prepreg 4 from being bonded with an outer layer material, the shaping film 9 is used for fixing and uniformly pressurizing the fiber reinforced prepreg 4, the breathable felt 10 provides a uniform and smooth air path for vacuumizing, and meanwhile, the vacuum bag 11 can seal a pressurizing area, so that pressure difference between the inside and the outside of the prepreg in the bag applies pressure to the fiber reinforced prepreg 4;

(C) And (3) air tightness detection operation: as shown in fig. 4, the vacuum nozzle is connected with the vacuum pump 15 and performs a vacuum pumping operation, and the vacuum pumping operation is stopped after the air tightness detection meets the requirement;

(D) heating and pressurizing curing operation: and (3) wrapping an electromagnetic heater sleeve matched with the surface structure of the pipeline 1 outside the vacuum bag 11, switching on a power supply to heat the prepreg to 50-80 ℃, turning on a vacuum pump 15 to vacuumize for 30min, then closing the vacuum pump, heating the prepreg to 80-120 ℃, preserving heat for 1-3h until the repair reinforcement material is completely cured, and completing the heating, pressurizing and curing operation.

The operation step is cured under the fastening condition, so that bubbles generated during winding and curing can be effectively discharged, the adhesion with the pipeline 1 is enhanced, and phenomena such as debonding, layering, hollowing, cracking, bubbling and the like are effectively prevented. Meanwhile, the electromagnetic heating clamping sleeve can realize rapid temperature rise in several minutes, and the working efficiency is improved. After the heating and pressing operations are completed, the surface of the pipe 1 is formed into a structural layer as shown in fig. 1.

8. and (3) sealing the boundary and the end part of the reinforcing layer: after the repair reinforcing material is cured, the electromagnetic heating equipment and the vacuum auxiliary curing device such as sealant, a vacuum bag, an air-permeable felt, a shaping film, an air-permeable isolating cloth and the like are removed in sequence. And then, coating the end part of the reinforcing layer and the lap joint part of the reinforcing layer and the pipe body with a cathode stripping resistant primer 3 to form a slope by using a spatula so as to prevent external corrosive media from entering the repairing layer by taking the boundary and the end as passages in the future.

9. and (3) antiseptic treatment: and (5) after the surface of the anti-cathode stripping primer 3 in the step (8) is dried, winding and wrapping the reinforcing layer by using external anticorrosive materials such as a cold winding tape, a polyethylene heat shrinkage tape and the like, so that the repairing operation is finished.

in order to verify the practical effect of the construction method for repairing and reinforcing the pipeline by adopting the prepreg, the operation steps of the invention are adopted to carry out a reinforcing and repairing test on the test pipeline, and the mechanical properties of the repairing material after the repairing and reinforcing are carried out without adopting mechanical winding and pressurization are contrastively researched. The comparative results are shown in table 1 below.

TABLE 1

According to the contents in the table 1, compared with the manual winding, heating and curing operation, the construction method provided by the invention reduces the thickness of the reinforcing layer of the fiber composite material, greatly improves the tensile strength, the tensile modulus, the bending strength, the interlaminar shear strength and the peeling strength, and ensures the repair quality of the pipeline. Meanwhile, the mechanized equipment repair reinforcement is superior to manual repair in quality and speed, repair efficiency and repair quality can be guaranteed, winding looseness caused by insufficient pretightening force during manual winding and phenomena such as uneven fiber cloth folds and deflection are avoided, the proper pretightening force is helpful for bonding between layers of repair materials, bubbles wrapped and clamped during winding are eliminated, and the performance of the repair materials is guaranteed.

The above-mentioned embodiments are intended to illustrate the objects, technical solutions and advantages of the present invention in further detail, and it should be understood that the above-mentioned embodiments are only exemplary embodiments of the present invention, and are not intended to limit the present invention, and any modifications, equivalents, improvements and the like made within the spirit and principle of the present invention should be included in the protection scope of the present invention.