PCCP horizontal type automatic anti-corrosion system and method

Abstract

The invention relates to the technical field of PCCP corrosion prevention, in particular to a PCCP horizontal automatic corrosion prevention system which comprises a corrosion prevention production line and an intelligent corrosion prevention control system. Comprising an anti-corrosion production line and an intelligent anti-corrosion control system. The anti-corrosion production line comprises an upper pipe area, an anti-corrosion paint spraying room, a finished product area, a paint mixing room and a control room. The anti-corrosion paint spraying room is arranged between the upper pipe area and the finished product area; rails penetrating through the anti-corrosion paint spraying room are installed on the ground of the upper pipe area and the finished product area. The rails of the pipe feeding area and the finished product area are both slidably connected with lifting trolleys. An anti-corrosion station is arranged in the anti-corrosion paint spraying room; a transverse frame is arranged above the anti-corrosion station in the anti-corrosion paint spraying room; batch PCCP horizontal automatic corrosion prevention line design is adopted, key technical parameters such as the corrosion prevention spraying time, the spraying gun walking speed, the pipeline rotating speed, the coating rate, the spraying distance, the spraying width and the spraying angle are strictly controlled, the corrosion prevention thickness is uniform and consistent, the first-pass yield of the corrosion prevention quality is 100%, and efficient, automatic and intelligent corrosion prevention of the PCCP is truly achieved.

Description

Technical Field

[0001] The present invention relates to the technical field of PCCP anti-corrosion, and in particular to a PCCP horizontal automatic anti-corrosion system and method. Background Art

[0002] PCCP has become the preferred pipe material for buried water supply pipelines in China due to its good anti-seepage, anti-collision, anti-corrosion and high cost performance. It is also the most commonly used pipe material in the country's large-scale water diversion and regulation projects. my country has a vast territory, and there are various corrosive ions in different soils. Studies have shown that CL- in the soil mainly passes through the PCCP protective layer to react with the prestressed steel wire, causing the prestressed steel wire to corrode and rust, and then "wire breakage" occurs; SO4 2- It mainly reacts with the PCCP mortar protective layer to generate calcium aluminate, causing the surface of the mortar protective layer to expand and crack, creating cracks, further providing a channel for the CL-corroded prestressed steel wire, and accelerating the corrosion process. For this reason, an anti-corrosion layer is added to the outside of the protective layer to isolate the corrosive ions in the soil from corroding the PCCP, which has a good effect. The United States introduced epoxy coal tar anti-corrosion coatings in the 1960s and applied them to the outer anti-corrosion layer of PCCP pipelines. In recent years, we have improved on this basis and developed solvent-free epoxy coal tar anti-corrosion coatings, which have achieved better results in PCCP.

[0003] At present, PCCP mainly adopts solvent-free epoxy coal tar anti-corrosion coating, but because of its long curing time in winter, and currently mainly adopts manual grinding and multi-pass brushing methods, it often takes a long time to wait for the curing to be completed after one coat of brushing before the second coat can be applied. The whole anti-corrosion process takes 3 to 5 days to complete, which sometimes seriously affects the progress of on-site construction and installation. Some manufacturers have improved the anti-corrosion automation and gradually replaced manual labor, but they also have to rely on overhead cranes or cranes to lift the pipes to the operating platform and lift them away after the anti-corrosion spraying is completed. Although the efficiency of anti-corrosion construction has been improved to a certain extent, it is still very slow, and solvent-free epoxy coal tar cannot be sprayed thickly at one time. For the heavy anti-corrosion needs in some important projects, it requires multiple hoisting and multi-pass spraying processes, which restricts the production progress of PCCP on the production line. PCCP of different pipe diameters also need to replace the matching card table molds, and it is necessary to prepare multiple sets of card table mold tooling and replace the matching card table molds for different pipe diameters.

[0004] Therefore, in order to address the problems of low efficiency, high labor cost and poor anti-corrosion quality in the production design of the above-mentioned anti-corrosion line, a device using a batch PCCP horizontal automated anti-corrosion line design can be designed. Summary of the invention

[0005] In order to overcome the problems of low production efficiency, high labor costs and poor anti-corrosion quality in the anti-corrosion line design.

[0006] The technical solution of the present invention is: a PCCP horizontal automatic anti-corrosion system, including an anti-corrosion production line and an intelligent anti-corrosion control system;

[0007] The anti-corrosion production line includes an upper pipe area, an anti-corrosion spray paint room, a finished product area, a paint mixing room and a control room; the anti-corrosion spray paint room is set between the upper pipe area and the finished product area; rails that run through the anti-corrosion spray paint room are installed on the ground of the upper pipe area and the finished product area; lifting trolleys are slidably connected to the rails of the upper pipe area and the finished product area; anti-corrosion workstations are set in the anti-corrosion spray paint room; a cross frame is set above the anti-corrosion workstations in the anti-corrosion spray paint room; an adjustable spray gun is installed on the cross frame; the anti-corrosion workstation consists of a belt support wheel and a driving device for controlling the rotation of the belt support wheel; supporting seats that are symmetrical in front and back and equidistantly distributed laterally with respect to the rails are fixedly connected on the ground of the upper pipe area and the finished product area;

[0008] The intelligent anti-corrosion control system adopts PLC and software control. The input parameters are: pipe diameter, wall thickness, pipe length, anti-corrosion material name, anti-corrosion thickness, theoretical coating rate, loss rate, and number of anti-corrosion layers. The intelligent anti-corrosion control system automatically calculates the distance between the anti-corrosion construction spray gun and the outer surface of the pipeline, the spray machine pressure, pressure difference, spray width, heater temperature, spray gun movement speed, anti-corrosion time and required amount of anti-corrosion coating according to the input parameters. The system can also preset and save the corresponding parameters in advance according to the name of the anti-corrosion material. During the anti-corrosion construction, you can directly select the name of the anti-corrosion material to view all parameters. The construction personnel can also adjust the single parameter, and the system will immediately change the result. The intelligent anti-corrosion control system has real-time data storage function, and the system administrator has the authority to view the most recent 500 anti-corrosion records.

[0009] Preferably, an environmental temperature and humidity detection sensor is installed in the anti-corrosion spray paint room; induction-type closed rolling shutter doors are installed at both ends of the anti-corrosion spray paint room; and the distance between the supporting seat and another adjacent supporting seat is not less than 50cm.

[0010] Preferably, the intelligent anti-corrosion control system sets the distance between the spray gun and the outer surface of the PCCP protective layer to 65-80 cm, the spraying pressure of the sprayer to 2000-2200 psi, the spraying pressure difference to within 200 psi, the atomization spray width to 40-80 degrees, the spray gun and the PCCP pipeline to maintain a 90° vertical angle, the main heater temperature of the spraying equipment to 60-70°C, the preheating temperature of the sprayer pipeline to 65°C, and in winter, a heating belt or water bath is used to preheat the anti-corrosion raw materials to 25°C in advance.

[0011] Preferably, two sets of lifting arms are provided in the lifting trolley for transporting and lifting the PCCP pipeline in the horizontal and vertical directions; four belt support wheels are provided, and the belt support wheels are symmetrically distributed front and back about the rails.

[0012] Preferably, the cross frame can move longitudinally; the spray gun can move horizontally on the cross frame; limit gauges are provided at both ends of the cross frame, and the limit gauges are adjusted accordingly according to the length of the PCCP pipe.

[0013] Preferably, an anti-corrosion particle recovery device is installed in the anti-corrosion spray paint room to absorb the anti-corrosion particles sprayed by the spray gun in the air outside the pipeline, thereby preventing the anti-corrosion pitting and roughness phenomenon on the outside of the PCCP pipeline.

[0014] The PCCP horizontal automated anti-corrosion method comprises a PCCP horizontal automated anti-corrosion system as described in any one of the above, and the steps are as follows:

[0015] Step 1: Transfer the cured PCCP to the upper pipe area and place it horizontally on the support seat;

[0016] Step 2: Start the main control switch in the anti-corrosion spray paint room, and the ambient temperature and humidity detection sensor detects that when the ambient temperature is greater than 5°C; the relative humidity of the air is ≤85%; the outer surface of the substrate is greater than the dew point temperature of 3°C, the anti-corrosion construction can be carried out only when the above three conditions are met at the same time, otherwise the anti-corrosion construction is not allowed;

[0017] Step 3: When the conditions of step 2 are met, the lifting arm of the lifting trolley lifts the PCCP and transports it to the anti-corrosion workstation in the anti-corrosion spray paint room. The PCCP is placed above the belt support wheel. Then the lifting arm of the lifting trolley is lowered, and the PCCP is stably placed on the four belt support wheels. The lifting trolley moves out of the anti-corrosion spray paint room. When the lifting trolley enters and exits the anti-corrosion spray paint room, the induction-type closed roller shutter door automatically rises and automatically falls during the anti-corrosion spraying construction. At this point, the automated anti-corrosion construction is ready;

[0018] Step 4: Input the pipe diameter, wall thickness, pipe length, anti-corrosion material name, anti-corrosion thickness, theoretical coating rate, loss rate, and number of anti-corrosion layers into the intelligent anti-corrosion control system. The intelligent anti-corrosion control system will automatically calculate the distance between the anti-corrosion construction spray gun and the outer surface of the pipeline, the spray machine pressure, pressure difference, spray width, heater temperature, PCCP pipeline rotation speed, and the travel speed of the spray gun on the horizontal frame based on the basic parameters;

[0019] Step 5: Calculate the spray gun movement speed, spraying amount, and spraying time, which are automatically calculated by the intelligent anti-corrosion control system based on the pipe diameter and wall thickness parameters:

[0020] Given the basic parameters of the pipeline, such as pipe diameter D, wall thickness T, pipe length L, anti-corrosion thickness DFT1, number of anti-corrosion layers N, given theoretical coating rate TSR1, loss rate S, equipment output flow Q, required anti-corrosion thickness DFT2, corresponding theoretical coating rate TSR2, and actual coating rate PSR, the required amount of anti-corrosion coating Q1 for a single section of PCCP pipe, the moving speed of the spray gun V, and the time t for spraying a single section of PCCP can be calculated in sequence according to the following formulas;

[0021] Step 6: Set the PCCP pipeline rotation speed to go through three gears: "low speed-medium speed-high speed". During this period, the horizontal frame adjusts the distance between the spray gun and the outer surface of the PCCP. After the PCCP rotation speed and the spray gun spacing reach the set value, the spray gun switch is turned on. At this time, the spray gun evenly distributes the material along one end of the pipeline and moves at a uniform speed at the set speed. After moving to the other end, it returns to the starting point again. After two sprayings are completed, the pipeline continues to rotate at a high speed for 8 to 10 minutes, and then gradually reduces the speed until it stops. After the anti-corrosion coating is completely cured, the lifting arm of the lifting trolley lifts and lifts the pipeline to continue moving forward and runs to the finished product area. At this point, a process is completed, and the above process is repeated for each section of PCCP;

[0022] Step 7: After the anti-corrosion is completed, the PCCP stops rotating and the anti-corrosion layer is inspected for quality, including appearance quality, anti-corrosion dry film thickness, adhesion, and coating leakage point anti-corrosion quality acceptance. After passing the inspection, the lifting arm of the lifting trolley lifts up the anti-corrosion PCCP and transfers the pipeline along the rails to the finished product area to wait for loading and transportation. At this point, the horizontal PCCP automated anti-corrosion is completed.

[0023] Preferably, the rotation speed of the PCCP pipeline is set to go through three gears of "low speed-medium speed-high speed", with the low speed not exceeding 10r / min and the duration not exceeding 1min; the medium speed not exceeding 17r / min and the duration not exceeding 2min; the high speed not exceeding 60r / min and the duration not exceeding the single-section PCCP spraying time + 8min to 10min, and then the rotation speed is gradually reduced until the rotation stops, and the duration is not exceeding 5min. The entire automated anti-corrosion process of a single-section PCCP does not exceed 60min.

[0024] As a preference, the corresponding theoretical coating rate required to achieve the thickness of the anti-corrosion layer is calculated as follows:

[0025]

[0026] Actual material usage = theoretical coating rate × loss coefficient, calculated as follows:

[0027] PSR=TSR2×S

[0028] Equipment spray gun spraying area per minute:

[0029]

[0030] Spraying amount per section of PCCP pipe:

[0031]

[0032] Spraying time:

[0033]

[0034] Horizontal moving speed of spray gun:

[0035] Beneficial effects of the present invention:

[0036] 1. Abandon the existing anti-corrosion line design in the form of manual or crane hoisting, adopt batch PCCP horizontal automated anti-corrosion line design, introduce fast-curing anti-corrosion coatings such as solvent-free elastic polyurethane or improved polyurea, automate and intelligentize PCCP anti-corrosion, and strictly control key technical parameters such as anti-corrosion spraying time, spray gun travel speed, pipeline rotation speed, coating rate, spraying distance, spray width and spraying angle, so as to ensure uniform anti-corrosion thickness, 100% first-time pass rate of anti-corrosion quality, improve anti-corrosion efficiency by at least 50%, further reduce labor costs by more than 50%, and can still be constructed normally in cold winter, truly realizing efficient automation and intelligent anti-corrosion of PCCP;

[0037] 2. Combining the characteristics of solvent-free elastic polyurethane or polyurea anti-corrosion materials such as fast curing, heavy-duty anti-corrosion, high impact resistance, low temperature resistance, excellent acid, alkali and salt resistance, the anti-corrosion spray takes 1 to 2 minutes to dry on the surface, 5 to 10 minutes to dry, and can be hoisted and shipped after 20 to 30 minutes. The maximum anti-corrosion thickness can reach 2200μm at one time, and it can adapt to construction as low as -40℃. It can maximize the production efficiency of PCCP and meet the batch anti-corrosion requirements of production lines in different scenarios and environments. It is of great significance to reduce the anti-corrosion operation time, reduce the anti-corrosion cost, construction and installation cost, and improve the installation efficiency at the construction site. BRIEF DESCRIPTION OF THE DRAWINGS

[0038] Figure 1 What is shown is a three-dimensional structural schematic diagram of the PCCP horizontal automatic anti-corrosion system of the present invention;

[0039] Figure 2 Shown is a schematic diagram of the plan layout of the PCCP horizontal automated anti-corrosion system of the present invention;

[0040] Figure 3 Shown is a second three-dimensional structural schematic diagram of the PCCP horizontal automatic anti-corrosion system of the present invention;

[0041] Figure 4 Shown is a flow chart of the PCCP horizontal automated anti-corrosion method of the present invention.

[0042] Explanation of the reference numerals: 1. Upper pipe area; 2. Anti-corrosion paint spraying room; 3. Lifting trolley; 4. Rails; 5. Anti-corrosion workstation; 6. Finished product area; 7. Cross frame; 9. Paint mixing room and control room; 10. Support seat; 501. Belt support wheel. DETAILED DESCRIPTION

[0043] The present invention will be further described below in conjunction with the accompanying drawings and embodiments.

[0044] See also Figure 1-Figure 4 , the present invention provides an embodiment: a PCCP horizontal automatic anti-corrosion system, including an anti-corrosion production line and an intelligent anti-corrosion control system;

[0045] The anti-corrosion production line comprises an upper pipe area (1), an anti-corrosion spray paint room (2), a finished product area (6), a paint mixing room and a control room (9); the anti-corrosion spray paint room (2) is arranged between the upper pipe area (1) and the finished product area (6); rails (4) penetrating the anti-corrosion spray paint room (2) are installed on the ground of the upper pipe area (1) and the finished product area (6); a lifting trolley (3) is slidably connected to the rails (4) of the upper pipe area (1) and the finished product area (6); An anti-corrosion station (5) is provided; a horizontal frame (7) is provided above the anti-corrosion station (5) in the anti-corrosion spray room (2); an adjustable spray gun is installed on the horizontal frame (7); the anti-corrosion station (5) is composed of a belt support wheel (501) and a driving device for controlling the rotation of the belt support wheel (501); supporting seats (10) are fixedly connected to the ground of the upper pipe area (1) and the finished product area (6) and are symmetrical in front and back with respect to the rail (4) and are equidistantly distributed in the transverse direction;

[0046] The intelligent anti-corrosion control system adopts PLC and software control. The input parameters are: pipe diameter, wall thickness, pipe length, anti-corrosion material name, anti-corrosion thickness, theoretical coating rate, loss rate, and number of anti-corrosion layers. The intelligent anti-corrosion control system automatically calculates the distance between the anti-corrosion construction spray gun and the outer surface of the pipeline, the spray machine pressure, pressure difference, spray width, heater temperature, spray gun movement speed, anti-corrosion time and required amount of anti-corrosion coating according to the input parameters. The system can also preset and save the corresponding parameters in advance according to the name of the anti-corrosion material. During the anti-corrosion construction, you can directly select the name of the anti-corrosion material to view all parameters. The construction personnel can also adjust the single parameter, and the system will immediately change the result. The intelligent anti-corrosion control system has real-time data storage function, and the system administrator has the authority to view the most recent 500 anti-corrosion records.

[0047] Preferably, an environmental temperature and humidity detection sensor is installed in the anti-corrosion paint spraying room (2); induction-type airtight rolling shutter doors are installed at both ends of the anti-corrosion paint spraying room (2); and the spacing between the supporting seat (10) and another adjacent supporting seat (10) is not less than 50 cm.

[0048] Preferably, the intelligent anti-corrosion control system sets the distance between the spray gun and the outer surface of the PCCP protective layer to 65-80 cm, the spraying pressure of the sprayer to 2000-2200 psi, the spraying pressure difference to within 200 psi, the atomization spray width to 40-80 degrees, the spray gun and the PCCP pipeline to maintain a 90° vertical angle, the main heater temperature of the spraying equipment to 60-70°C, the preheating temperature of the sprayer pipeline to 65°C, and in winter, a heating belt or water bath is used to preheat the anti-corrosion raw materials to 25°C in advance.

[0049] Preferably, two sets of lifting arms are provided in the lifting trolley (3) for transporting and lifting the PCCP pipeline in the horizontal and vertical directions; four belt support wheels (501) are provided, and the belt support wheels (501) are symmetrically distributed front and back with respect to the rail (4).

[0050] Preferably, the cross frame (7) can be moved in the longitudinal direction; the spray gun can be moved horizontally on the cross frame (7); and limit gauges are provided at both ends of the cross frame (7), and the limit gauges are adjusted accordingly according to the length of the PCCP pipe.

[0051] Preferably, an anti-corrosion particle recovery device is provided in the anti-corrosion spray booth (2), which can absorb the anti-corrosion particles sprayed by the spray gun in the air outside the pipeline, thereby preventing the anti-corrosion pitting and pockmarking phenomenon outside the PCCP pipeline.

[0052] The PCCP horizontal automated anti-corrosion method comprises a PCCP horizontal automated anti-corrosion system as described in any one of the above, and the steps are as follows:

[0053] Step 1: The PCCP after curing is transferred to the upper support seat (10) of the upper pipe area (1) and placed horizontally;

[0054] Step 2: Start the main control switch in the anti-corrosion spray paint room (2), and the ambient temperature and humidity detection sensor detects that when the ambient temperature is greater than 5°C; the relative humidity of the air is ≤85%; and the outer surface of the substrate is greater than the dew point temperature of 3°C, the anti-corrosion construction can be carried out only when the above three conditions are met at the same time, otherwise the anti-corrosion construction is not allowed;

[0055] Step 3: When the conditions of step 2 are met, the lifting arm of the lifting trolley (3) lifts the PCCP and transports it to the anti-corrosion workstation (5) in the anti-corrosion spray paint room (2). The PCCP is placed above the belt support wheel (501). Then the lifting arm of the lifting trolley (3) is lowered, and the PCCP is stably placed on the four belt support wheels (501). The lifting trolley (3) moves out of the anti-corrosion spray paint room (2). When the lifting trolley (3) enters and exits, the induction-type closed rolling shutter door of the anti-corrosion spray paint room (2) automatically rises and automatically falls during the anti-corrosion spraying construction. At this point, the automated anti-corrosion construction is ready;

[0056] Step 4: Input the pipe diameter, wall thickness, pipe length, anti-corrosion material name, anti-corrosion thickness, theoretical coating rate, loss rate, and number of anti-corrosion layers into the intelligent anti-corrosion control system. The intelligent anti-corrosion control system will automatically calculate the distance between the anti-corrosion construction spray gun and the outer surface of the pipeline, the spray machine pressure, pressure difference, spray width, heater temperature, PCCP pipeline rotation speed (low, medium, high speed), and the spray gun travel speed data on the cross frame (7) based on the basic parameters;

[0057] Step 5: Calculate the spray gun movement speed, spraying amount, and spraying time, which are automatically calculated by the intelligent anti-corrosion control system based on the pipe diameter and wall thickness parameters:

[0058] Given the basic parameters of the pipeline, such as pipe diameter D, wall thickness T, pipe length L, anti-corrosion thickness DFT1, number of anti-corrosion layers N, given theoretical coating rate TSR1, loss rate S, equipment output flow Q, required anti-corrosion thickness DFT2, corresponding theoretical coating rate TSR2, and actual coating rate PSR, the required amount of anti-corrosion coating Q1 for a single section of PCCP pipe, the moving speed of the spray gun V, and the time t for spraying a single section of PCCP can be calculated in sequence according to the following formulas;

[0059] Step 6: Set the PCCP pipeline rotation speed to go through three gears of "low speed-medium speed-high speed". During this period, the horizontal frame (7) adjusts the distance between the spray gun and the outer surface of the PCCP. After the PCCP rotation speed and the spray gun spacing reach the set value, the spray gun switch is turned on. At this time, the spray gun evenly distributes the material along one end of the pipeline and moves at a uniform speed at the set speed. After moving to the other end, it returns to the starting point again. After two sprayings are completed, the pipeline continues to rotate at a high speed for 8 to 10 minutes, and then gradually reduces the speed until it stops. After the anti-corrosion coating is completely cured, the lifting arm of the lifting trolley (3) lifts and lifts the pipeline to continue moving forward and moves to the finished product area (6). At this point, one process is completed, and the above process is repeated for each section of PCCP;

[0060] Step 7: After the anti-corrosion is completed, the PCCP stops rotating and the anti-corrosion layer is inspected for quality, including appearance quality, anti-corrosion dry film thickness, adhesion, and coating leakage point anti-corrosion quality acceptance. After passing the inspection, the lifting arm of the lifting trolley (3) lifts up the anti-corrosion PCCP and transfers the pipeline along the rails (4) to the finished product area (6) to wait for loading and transportation. At this point, the horizontal PCCP automatic anti-corrosion is completed.

[0061] Preferably, the rotation speed of the PCCP pipeline is set to go through three gears of "low speed-medium speed-high speed", with the low speed not exceeding 10r / min and the duration not exceeding 1min; the medium speed not exceeding 17r / min and the duration not exceeding 2min; the high speed not exceeding 60r / min and the duration not exceeding the single-section PCCP spraying time + 8min to 10min, and then the rotation speed is gradually reduced until the rotation stops, and the duration is not exceeding 5min. The entire automated anti-corrosion process of a single-section PCCP does not exceed 60min.

[0062] As a preference, the corresponding theoretical coating rate required to achieve the thickness of the anti-corrosion layer is calculated as follows:

[0063]

[0064] Actual material usage = theoretical coating rate × loss coefficient, calculated as follows:

[0065] PSR=TSR2×S

[0066] Equipment spray gun spraying area per minute:

[0067]

[0068] Spraying amount per section of PCCP pipe:

[0069]

[0070] Spraying time:

[0071]

[0072] Horizontal moving speed of spray gun:

[0073] Example 1

[0074] The steps are as follows:

[0075] Step 1: The PCCP after curing is transferred to the upper support seat (10) of the upper pipe area (1) and placed horizontally;

[0076] Step 2: Start the main control switch in the anti-corrosion spray paint room (2), and the ambient temperature and humidity detection sensor detects that when the ambient temperature is greater than 5°C; the relative humidity of the air is ≤85%; and the outer surface of the substrate is greater than the dew point temperature of 3°C, the anti-corrosion construction can be carried out only when the above three conditions are met at the same time, otherwise the anti-corrosion construction is not allowed;

[0077] Step 3: When the conditions of step 2 are met, the lifting arm of the lifting trolley (3) lifts the PCCP and transports it to the anti-corrosion workstation (5) in the anti-corrosion spray paint room (2). The PCCP is placed above the belt support wheel (501). Then the lifting arm of the lifting trolley (3) is lowered, and the PCCP is stably placed on the four belt support wheels (501). The lifting trolley (3) moves out of the anti-corrosion spray paint room (2). When the lifting trolley (3) enters and exits, the induction-type closed rolling shutter door of the anti-corrosion spray paint room (2) automatically rises and automatically falls during the anti-corrosion spraying construction. At this point, the automated anti-corrosion construction is ready;

[0078] Step 4: Input the pipe diameter, wall thickness, pipe length, anti-corrosion material name, anti-corrosion thickness, theoretical coating rate, loss rate, and number of anti-corrosion layers into the intelligent anti-corrosion control system. The intelligent anti-corrosion control system will automatically calculate the distance between the anti-corrosion construction spray gun and the outer surface of the pipeline, the spray machine pressure, pressure difference, spray width, heater temperature, PCCP pipeline rotation speed (low, medium, high speed), and the spray gun travel speed data on the cross frame (7) based on the basic parameters;

[0079] Step 5: Calculate the spray gun movement speed, spraying amount, and spraying time, which are automatically calculated by the intelligent anti-corrosion control system based on the pipe diameter and wall thickness parameters:

[0080] Given the basic parameters of the pipeline, such as pipe diameter D, wall thickness T, pipe length L, anti-corrosion thickness DFT1, number of anti-corrosion layers N, given theoretical coating rate TSR1, loss rate S, equipment output flow Q, required anti-corrosion thickness DFT2, corresponding theoretical coating rate TSR2, and actual coating rate PSR, the required amount of anti-corrosion coating Q1 for a single section of PCCP pipe, the moving speed of the spray gun V, and the time t for spraying a single section of PCCP can be calculated in sequence according to the following formulas:

[0081] The corresponding theoretical coating rate required to achieve the anti-corrosion layer thickness is calculated as follows:

[0082]

[0083] Actual material usage = theoretical coating rate × loss coefficient, calculated as follows:

[0084] PSR=TSR2×S

[0085] Equipment spray gun spraying area per minute:

[0086]

[0087] Spraying amount per section of PCCP pipe:

[0088]

[0089] Spraying time:

[0090]

[0091] Horizontal moving speed of spray gun:

[0092] Taking PCCP spraying solvent-free elastic polyurethane as an example, the pipe diameter D = 1200, the wall thickness t = 25mm, the pipe length L = 5m, the anti-corrosion thickness requirement δ = 1500μm, the number of anti-corrosion layers is N = 1, 800μm, and the theoretical coating rate is 0.96kg / m 2 , the loss is controlled within 10%;

[0093] Calculate the theoretical coating rate of anti-corrosion thickness 1500μm: TSR2 = 1500*0.96 / 800 = 1.8kg / m 2 ;

[0094] Actual material consumption PSR = 1.8 kg / m 2 *10%=1.98kg / m 2 ;

[0095] Spraying area per minute S1=5.6kg÷1.98kg / m 2 =2.83m 2 ;

[0096] Spraying amount per pipe section Q1 = 1.98 * 3.14 * 1.25 * 5 = 38.86 kg;

[0097] Spraying time t = (3.14 * 1.25 * 5) / 2.83 = 6.94min;

[0098] Spray gun moving speed V = 6.94min÷(3.14*1.25m) = 1.77m / min;

[0099] That is, the intelligent anti-corrosion control system calculated that the required amount of anti-corrosion coating for a single section of PCCP pipe is 38.86kg, the moving speed of the spray gun is 1.77m / min, and the time required for spraying a single section of PCCP is 6.94min;

[0100] Step 6: Set the PCCP pipeline rotation speed to go through three gears of "low speed-medium speed-high speed". During this period, the horizontal frame (7) adjusts the distance between the spray gun and the outer surface of the PCCP. After the PCCP rotation speed and the spray gun spacing reach the set value, the spray gun switch is turned on. At this time, the spray gun evenly distributes the material along one end of the pipeline and moves at a uniform speed at the set speed. After moving to the other end, it returns to the starting point again. The low speed is not more than 10r / min and the duration is not more than 1min; the medium speed is not more than 17r / min and the duration is not more than 2min; the high speed is not more than 60r / min and the duration is not more than the single section PCCP spraying time + 8min to 10min, and then gradually reduce the speed until the rotation stops, and the duration is not more than 5min. The entire automated anti-corrosion process of a single section PCCP does not exceed 60min. After the anti-corrosion coating is completely cured, the lifting arm of the lifting trolley (3) lifts and lifts the pipeline to continue moving forward and runs to the finished product area (6). At this point, one process ends, and the above process is repeated for each section of PCCP.

[0101] Step 7: After the anti-corrosion is completed, the PCCP stops rotating and the anti-corrosion layer is inspected for quality, including appearance quality, anti-corrosion dry film thickness, adhesion, and coating leakage point anti-corrosion quality acceptance. After passing the inspection, the lifting arm of the lifting trolley (3) lifts up the anti-corrosion PCCP and transfers the pipeline along the rails (4) to the finished product area (6) to wait for loading and transportation. At this point, the horizontal PCCP automatic anti-corrosion is completed.

[0102] Table 1 is a performance analysis table of the pipeline after anti-corrosion treatment using Example 1 of the present invention.

[0103]

[0104] Table 1

[0105] The embodiments of the present invention are described in detail above with reference to the accompanying drawings, but the present invention is not limited to the above embodiments, and various changes can be made within the knowledge scope of those skilled in the art without departing from the spirit of the present invention.

Claims

1. A PCCP horizontal automatic anti-corrosion system, comprising an anti-corrosion production line and an intelligent anti-corrosion control system; characterized in that: The anti-corrosion production line comprises an upper pipe area (1), an anti-corrosion spray paint room (2), a finished product area (6), a paint mixing room and a control room (9); the anti-corrosion spray paint room (2) is arranged between the upper pipe area (1) and the finished product area (6); rails (4) penetrating the anti-corrosion spray paint room (2) are installed on the ground of the upper pipe area (1) and the finished product area (6); a lifting trolley (3) is slidably connected to the rails (4) of the upper pipe area (1) and the finished product area (6); An anti-corrosion station (5) is provided; a horizontal frame (7) is provided above the anti-corrosion station (5) in the anti-corrosion spray room (2); an adjustable spray gun is installed on the horizontal frame (7); the anti-corrosion station (5) is composed of a belt support wheel (501) and a driving device for controlling the rotation of the belt support wheel (501); supporting seats (10) are fixedly connected to the ground of the upper pipe area (1) and the finished product area (6) and are symmetrical in front and back with respect to the rail (4) and are equidistantly distributed in the transverse direction; The intelligent anti-corrosion control system adopts PLC and software control. The input parameters are: pipe diameter, wall thickness, pipe length, anti-corrosion material name, anti-corrosion thickness, theoretical coating rate, loss rate, and number of anti-corrosion layers. The intelligent anti-corrosion control system automatically calculates the distance between the anti-corrosion construction spray gun and the outer surface of the pipeline, the spray machine pressure, pressure difference, spray width, heater temperature, spray gun movement speed, anti-corrosion time and required amount of anti-corrosion coating according to the input parameters. The system can also preset and save the corresponding parameters in advance according to the name of the anti-corrosion material. During the anti-corrosion construction, you can directly select the name of the anti-corrosion material to view all parameters. The construction personnel can also adjust the single parameter, and the system will immediately change the result. The intelligent anti-corrosion control system has real-time data storage function, and the system administrator has the authority to view the most recent 500 anti-corrosion records.

2. The PCCP horizontal automatic anti-corrosion system according to claim 1 is characterized in that: An environmental temperature and humidity detection sensor is installed in the anti-corrosion paint spraying room (2); induction-type airtight rolling shutter doors are installed at both left and right ends of the anti-corrosion paint spraying room (2); and the spacing between a supporting seat (10) and another adjacent supporting seat (10) is not less than 50 cm.

3. The PCCP horizontal automatic anti-corrosion system according to claim 1 is characterized in that: The intelligent anti-corrosion control system sets the distance between the spray gun and the outer surface of the PCCP protective layer to 65-80cm, the spraying pressure of the sprayer to 2000-2200psi, the spraying pressure difference to within 200psi, the atomization spray width to 40-80 degrees, the spray gun and the PCCP pipe to maintain a 90° vertical angle, the main heater temperature of the spraying equipment to 60-70℃, the preheating temperature of the sprayer pipe to 65℃, and in winter, a heating belt or water bath is used to preheat the anti-corrosion raw materials to 25℃ in advance.

4. The PCCP horizontal automatic anti-corrosion system according to claim 1 is characterized in that: Two sets of lifting arms are arranged in the lifting trolley (3) for transporting and lifting the PCCP pipeline in the horizontal and vertical directions; four belt support wheels (501) are arranged, and the belt support wheels (501) are symmetrically distributed front and back with respect to the rail (4).

5. The PCCP horizontal automatic anti-corrosion system according to claim 1 is characterized in that: The cross frame (7) can move in the longitudinal direction; the spray gun can move horizontally on the cross frame (7); and limit gauges are provided at both ends of the cross frame (7), and the limit gauges are adjusted accordingly according to the length of the PCCP pipe.

6. The PCCP horizontal automatic anti-corrosion system according to claim 1 is characterized in that: An anti-corrosion particle recovery device is arranged in the anti-corrosion spray paint room (2) to absorb the anti-corrosion particles sprayed by the spray gun in the air outside the pipeline, thereby preventing the anti-corrosion pits and pockmarks on the surface of the PCCP pipeline.

7. PCCP horizontal automated anti-corrosion method, characterized in that It comprises a PCCP horizontal automated anti-corrosion system according to any one of claims 1 to 6, wherein the steps are as follows: Step 1: The PCCP after curing is transferred to the upper support seat (10) of the upper pipe area (1) and placed horizontally; Step 2: Start the main control switch in the anti-corrosion spray paint room (2), and the ambient temperature and humidity detection sensor detects that when the ambient temperature is greater than 5°C; the relative humidity of the air is ≤85%; and the outer surface of the substrate is greater than the dew point temperature of 3°C, the anti-corrosion construction can be carried out only when the above three conditions are met at the same time, otherwise the anti-corrosion construction is not allowed; Step 3: When the conditions of step 2 are met, the lifting arm of the lifting trolley (3) lifts the PCCP and transports it to the anti-corrosion workstation (5) in the anti-corrosion spray paint room (2). The PCCP is placed above the belt support wheel (501). Then the lifting arm of the lifting trolley (3) is lowered, and the PCCP is stably placed on the four belt support wheels (501). The lifting trolley (3) moves out of the anti-corrosion spray paint room (2). When the lifting trolley (3) enters and exits, the induction-type closed rolling shutter door of the anti-corrosion spray paint room (2) automatically rises and automatically falls during the anti-corrosion spraying construction. At this point, the automated anti-corrosion construction is ready; Step 4: Input the pipe diameter, wall thickness, pipe length, anti-corrosion material name, anti-corrosion thickness, theoretical coating rate, loss rate, and number of anti-corrosion layers into the intelligent anti-corrosion control system. The intelligent anti-corrosion control system will automatically calculate the distance between the anti-corrosion construction spray gun and the outer surface of the pipeline, the spray machine pressure, pressure difference, spray width, heater temperature, PCCP pipeline rotation speed (low, medium, high speed), and the spray gun travel speed data on the cross frame (7) based on the basic parameters; Step 5: Calculate the spray gun movement speed, spraying amount, and spraying time, which are automatically calculated by the intelligent anti-corrosion control system based on the pipe diameter and wall thickness parameters: Given the basic parameters of the pipeline, such as pipe diameter D, wall thickness T, pipe length L, anti-corrosion thickness DFT1, number of anti-corrosion layers N, given theoretical coating rate TSR1, loss rate S, equipment output flow Q, required anti-corrosion thickness DFT2, corresponding theoretical coating rate TSR2, and actual coating rate PSR, the required amount of anti-corrosion coating Q1 for a single section of PCCP pipe, the moving speed of the spray gun V, and the time t for spraying a single section of PCCP can be calculated in sequence according to the following formulas; Step 6: Set the PCCP pipe rotation speed to go through three gears of "low speed-medium speed-high speed". During this period, the horizontal frame (7) adjusts the distance between the spray gun and the outer surface of the PCCP. After the PCCP rotation speed and the spray gun spacing reach the set value, the spray gun switch is turned on. At this time, the spray gun evenly distributes the material along one end of the pipe and moves at a uniform speed at the set speed. After moving to the other end, it returns to the starting point again. After two sprayings are completed, the pipe continues to rotate at a high speed for 8 to 10 minutes, and then gradually reduces the speed until it stops. After the anti-corrosion coating is completely cured, the lifting arm of the lifting trolley (3) lifts and lifts the pipe to continue moving forward and moves to the finished product area (6). At this point, one process is completed. The above process is repeated for each section of PCCP. Step 7: After the anti-corrosion is completed, the PCCP stops rotating and the anti-corrosion layer is inspected for quality, including appearance quality, anti-corrosion dry film thickness, adhesion, and coating leakage point anti-corrosion quality acceptance. After passing the inspection, the lifting arm of the lifting trolley (3) lifts up the anti-corrosion PCCP and transfers the pipeline along the rails (4) to the finished product area (6) to wait for loading and transportation. At this point, the horizontal PCCP automatic anti-corrosion is completed.

8. The PCCP horizontal automated anti-corrosion method according to claim 7, characterized in that: Set the PCCP pipeline rotation speed through three gears of "low speed-medium speed-high speed", with low speed not exceeding 10r / min and duration not exceeding 1min; medium speed not exceeding 17r / min and duration not exceeding 2min; high speed not exceeding 60r / min and duration not exceeding single-section PCCP spraying time + 8min to 10min, then gradually reduce the speed until the rotation stops, and the duration is not exceeding 5min. The entire automated anti-corrosion process of a single-section PCCP does not exceed 60min.

9. The PCCP horizontal automated anti-corrosion method according to claim 7, characterized in that: The corresponding theoretical coating rate required to achieve the anti-corrosion layer thickness is calculated as follows: Actual material usage = theoretical coating rate × loss coefficient, calculated as follows: PSR=TSR2×S Equipment spray gun spraying area per minute: Spraying amount per section of PCCP pipe: Spraying time: Horizontal moving speed of spray gun:

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