Pipeline trenchless expansion repair construction equipment and construction method

Abstract

The invention relates to pipeline trenchless expansion repair construction equipment. The pipeline trenchless expansion repair construction equipment comprises a ground power module, an underground supporting and guiding module, a traction-rotation module capable of moving bidirectionally along the axis of a pipeline, and an expansion module or a spraying module connected with the traction-rotation module in an interchangeable mode. The ground power module provides axial jacking / pulling force and rotating torque for the traction-rotating module at the same time, the expansion module conducts step-by-step controllable expansion on a deformed pipe section in the pulling-back process and synchronously detects geometric deformation of the pipe wall, and the spraying module is driven by the same traction-rotating module to conduct centrifugal spraying on the inner wall of the expanded pipe. In the whole construction process, expanding, detecting, grinding and spraying procedures can be completed without entering the pipeline by personnel. By means of the integrated design of ground power and an underground modular tool, expansion shaping, real-time detection, inner wall grinding and spraying repairing of the pipeline are continuously completed at a time.

Description

Technical Field

[0001] This invention relates to the field of trenchless pipeline repair, specifically to a trenchless pipeline expansion repair construction equipment and method. Background Technology

[0002] With the acceleration of urbanization, the complexity and scale of underground pipe networks are constantly expanding, and the problems of pipe aging, damage, and deformation are becoming increasingly prominent. Traditional pipe repair methods mostly involve open-cut pipe replacement, which not only has a long construction period and significant environmental impact, but is also extremely difficult to implement in areas with heavy traffic and dense underground pipelines. Therefore, trenchless pipe repair technology has emerged, and with its significant advantages such as low environmental impact and fast construction speed, it is gradually becoming the mainstream choice for urban pipe repair.

[0003] The existing trenchless pipeline repair technology system mainly includes two categories: overall repair technology and partial repair technology. For plastic pipelines (such as HDPE pipelines, steel pipes, etc.) whose flow rate is affected by severe deformation, it is usually necessary to perform pipeline pretreatment first, and then restore the original shape of the pipeline through expansion before carrying out repair.

[0004] Taking UV-cured pipe lining repair as an example, this process requires the pipe's inner wall to be clean, free of deposits, sharp burrs, and protrusions to ensure the integrity and durability of the repaired lining. However, in actual construction, existing technologies still have the following problems: 1. Low pretreatment efficiency and unstable quality Currently, pipeline cleaning mainly relies on high-pressure water flushing trucks combined with manual dredging. For solid obstacles such as concrete blocks larger than 50mm in diameter, the removal rate is less than 62%, resulting in residual deposits on the pipeline inner wall and affecting the quality of subsequent repairs. Furthermore, manual dredging requires a large workforce; cleaning a single 100-meter section of pipeline requires 3-5 workers continuously operating for 8 hours, with labor costs accounting for as much as 35% of the total construction cost. In addition, the vibration generated by the milling robot can easily cause 2-5mm micro-cracks at HDPE pipe joints, further aggravating pipeline damage.

[0005] 2. Insufficient precision control in expansion repair The traditional unidirectional force application method of hydraulic jacks leads to uneven stress distribution on the pipe wall, resulting in an ellipticity deviation of up to 15% after expansion, far exceeding the 8% requirement of GB50268-2008 standard. To meet the repair requirements, 3-4 repeated expansion adjustments are required, and each adjustment necessitates the re-erecting of the support frame, with each adjustment taking 2 hours and severely impacting construction efficiency.

[0006] 3. Low equipment integration and difficulties in collaborative operation The existing repair equipment system is extensive, requiring the use of various equipment such as high-pressure flushing trucks (occupying an area of ​​20 square meters), dredging robots (requiring a dedicated control cabin), and hydraulic stations (weighing 1.2 tons). The coordinated operation between these devices relies on six operators, and the time spent moving between sites accounts for 40% of the construction cycle, resulting in low overall construction efficiency.

[0007] 4. Repairing process flow interruptions In existing repair processes, pretreatment, expansion, spraying, and curing are independent steps, requiring multiple equipment disassemblies and parameter adjustments, resulting in repair times of up to 12 hours for a single pipeline section. Furthermore, material utilization is less than 85%, leading to resource waste.

[0008] After cleaning, the pipeline is inspected for corrosion and deformation using a pipeline inspection camera vehicle (CCTV inspection instrument). For severely deformed pipelines, expansion and repair are performed first to ensure sufficient flow area. Then, severely corroded and uneven pipelines are treated with sprayed cement slurry or cement mortar. Finally, necessary ultraviolet light-cured pipeline lining repair is carried out, using a high-strength, high-integration lining to reinforce the pipeline, reduce corrosion, and prevent further deformation. Summary of the Invention

[0009] This invention aims to overcome the shortcomings of existing technologies and provide a trenchless pipeline expansion and repair construction equipment and method, solving the core problems of existing technologies such as "disjointed processes, need for repeated entry and exit from the pipeline, high risk of personnel going down into the well, and uncontrollable expansion quality".

[0010] To solve the above-mentioned technical problems, the present invention is implemented as follows: A trenchless pipeline expansion and repair construction device, characterized in that it comprises: The surface power module, the downhole support and guidance module, the traction-rotation module that can move bidirectionally along the pipeline axis, and the expansion module or spraying module that can be interchangeably connected to the traction-rotation module; The ground power module simultaneously provides axial jacking / pulling force and rotational torque to the traction-rotation module. During the pull-back process, the expansion module performs step-by-step controllable expansion of the deformed pipe section and simultaneously detects the geometric deformation of the pipe wall. The spraying module performs centrifugal spraying on the expanded inner wall of the pipe under the drive of the same traction-rotation module. The entire construction process can be completed without personnel entering the pipeline, including expansion, detection, grinding and spraying.

[0011] The trenchless pipeline expansion and repair equipment is characterized in that: the expansion module includes a pipeline hydraulic expander, which includes a front end rubber elliptical expansion head and a rear end multi-lobed hydraulic expansion shell; the hydraulic expansion shell is driven by a bidirectional hydraulic jack to achieve radial graded expansion, and the expansion stroke and oil pressure are adjusted in real time by the hydraulic expander control console.

[0012] The trenchless pipeline expansion and repair equipment is characterized in that: the expansion module has a built-in pipeline endoscopic camera (CCTV) and a ruler, which are used to collect the pipe wall rebound and ellipticity in real time during the expansion process and transmit the data back to the ground display terminal.

[0013] The trenchless pipeline expansion and repair construction equipment is characterized in that: the traction-rotation module uses a detachable high-pressure jet grouting drill rod as a tie rod, the length of a single drill rod is no more than 1.5 m, and it is quickly connected and continuously pushed in / pulled out by a turntable set at the working wellhead and a two-way hydraulic jack.

[0014] The trenchless pipeline expansion and repair construction equipment is characterized in that: the downhole support and guide module includes: (a) An adjustable fixed support frame, held at the pipe opening by telescopic outrigger wheels, is used to support the turntable and the two-way hydraulic jack; (b) An adjustable sliding bracket that can slide along the axis inside the pipe and support the traction-rotation module to prevent the rod from sagging or swinging during long-distance pullback.

[0015] The aforementioned trenchless pipeline expansion and repair equipment is characterized in that: the spraying module is a centrifugal spraying trolley, which is pulled by the same tie rod and rotates inside the pipeline to spray cement mortar or polymer mortar, and the spraying thickness is controlled by a closed loop of mortar pump pressure and pullback speed.

[0016] The construction method of the trenchless pipeline expansion and repair equipment is characterized by the following steps: S1: Install an adjustable fixed support frame and a ground power module at the working wellhead; S2: Extend the traction-rotation module piece by piece and push it into the receiving well; S3: Connect the expansion module to the tie rod in the receiving well. During the pullback process, the elliptical head coarse expansion, hydraulic expansion shell fine expansion and real-time CCTV detection are completed in sequence. S4: Remove the expansion module, replace it with the spraying module, and pull it back again to complete the inner wall mortar spraying; S5: After the spraying is completed, a CCTV re-inspection will be carried out, and if necessary, the lining will be repaired by ultraviolet light curing. Among them, all processes from S2 to S5 are completed within the same rope path of a single traction-rotation module, without the need for secondary well opening or personnel going down into the well.

[0017] The beneficial effects of this invention are as follows: As can be seen from the above technical solution, this application provides a trenchless pipeline expansion and repair construction equipment and method, which adopts a modular design and consists of a bidirectional hydraulic jack, a turntable, an adjustable fixed support frame, an adjustable sliding support, a tie rod, a pipeline hydraulic expander, a bidirectional hydraulic jack backing, a hydraulic expander control console, and a pipeline endoscope camera vehicle (CCTV inspection instrument). The pipeline hydraulic expander, under the traction of the tie rod, can push in, pull back, and rotate to repair pipeline deformation, ensuring the roundness and water passage cross-section of the repaired pipeline.

[0018] This invention, through its modular design, enables three-dimensional repair of deformed pipes by dragging, jacking, and rotating without damaging the working well. By installing a camera above the working well, the pipe cleaning process can be clearly observed, allowing for on-site construction guidance. Secondly, by using small-diameter tie rods in conjunction with hydraulic pipe expanders that match the inner diameter of the pipe design and construction, three-dimensional repair of pipe deformation can be achieved through dragging, jacking, and rotation. Alternatively, the hydraulic pipe expander can be replaced with a centrifugal spraying trolley at the receiving working well for mortar (cement slurry) spraying treatment.

[0019] This invention achieves high-efficiency and low-cost construction by employing mechanized construction and utilizing mature industrial products. It can also provide a clean, non-destructive working surface free of attachments, sharp burrs, and protrusions for non-destructive repairs such as UV-cured pipe lining repair. By using a high-strength, well-integrated lining to reinforce the pipe, it reduces pipe corrosion and prevents pipe deformation, ensuring the water flow cross-section and reducing the frictional resistance of the water flow in the pipe.

[0020] The application of this invention not only achieved the expected design goals, but also improved construction efficiency and ensured construction quality by increasing the automation of pipeline cleaning construction. Furthermore, it has been highly recognized by all parties involved in the construction. The promotion and application of the technical concept of this invention and the resulting comprehensive benefits are a reflection of the company's value in enhancing its core competitiveness in the market. Attached Figure Description

[0021] The present invention will now be described in further detail with reference to the accompanying drawings and embodiments: Figure 1 This is a schematic diagram of pipeline expansion and repair construction. Figure 2 Schematic diagram of a pipeline hydraulic expander; Figure 3 Schematic diagram of a hydraulic pipe extender for pipe repair; Figure 4 It is a sliding adjustable bracket. Detailed Implementation

[0022] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of this application. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection claimed in this application. like Figure 1-4 As shown: a trenchless pipeline expansion and repair construction equipment. This equipment mainly adopts a modular design and consists of a two-way hydraulic jack, a turntable, an adjustable fixed support frame, an adjustable sliding support, a tie rod, a pipeline hydraulic expander, a two-way hydraulic jack backstage, a hydraulic expander control console, a pipeline endoscope camera vehicle (CCTV detector), and a centrifugal spraying trolley.

[0023] The tie rod uses drill rods from commercially available high-pressure jet grouting piles (the length needs to be customized to meet the limitations of the working well and wellhead). The tie rod can be mechanically connected (threaded connection) to the pipeline hydraulic extender.

[0024] This equipment mainly adopts a modular design, consisting of a two-way hydraulic jack, turntable, adjustable fixed support frame, adjustable sliding bracket, tie rod, pipeline hydraulic expander, two-way hydraulic jack backrest, hydraulic expander control console, and pipeline endoscope camera cart (CCTV inspection instrument). It can repair pipeline deformation by pushing, pulling back, and rotating the pipeline hydraulic expander under the traction of the tie rod, ensuring the roundness and cross-sectional area of ​​the repaired pipeline.

[0025] The application process is as follows: Prepare and maintain the equipment → Complete the sealing and diversion of the working well → Complete the cleaning of the working well and receiving well → Adjustable fixed (sliding) support frame → Pre-install tie rods inside the pipeline (large diameter) → Assemble and fix the working well with bidirectional hydraulic jacks and turntable → Install tie rods on the turntable and drill → Install hydraulic expanders on the pipeline in the receiving well → Pull back, jack in, and rotate to repair pipeline deformation → Complete pipeline repair → Replace the centrifugal spraying trolley in the receiving well (if necessary) → Spray mortar (cement slurry) (if necessary) → Complete spraying → Pipeline CCTV inspection and acceptance → Repair the pipeline lining with ultraviolet light curing.

[0026] Generally, an adjustable fixed support frame is first installed at the pipe opening of the working well; then four bidirectional hydraulic jacks and a turntable are respectively lowered into the working well; after the hydraulic jacks and turntable are assembled into a whole, they are lifted to the predetermined position and tightened against the working well wall (usually a reinforced concrete structure) by the bidirectional hydraulic jacks; then a tie rod of a customized length is lowered through the well opening.

[0027] The jacking rod is pushed from the working shaft to the receiving shaft. The jacking rod is powered by a two-way hydraulic jack, and the rotation of the turntable provides the rotation torque. When the pipeline to be repaired is long, an adjustable sliding bracket that can be extended and adjusted can be installed in advance at the end of the jacking rod to prevent the rod from deforming and blocking the deformed pipeline.

[0028] The mechanical connection between the tie rod and the pre-issued hydraulic pipe extender at the receiving well is generally achieved using a threaded connection.

[0029] During the rod drilling process, the speed is generally faster, mainly to drill to the receiving well. During the pullback process, the speed is generally slower, mainly to expand and repair the deformed pipeline.

[0030] The process and results of pipeline deformation expansion repair can be observed and guided on-site through the camera on the pipeline hydraulic expander. For pipeline deformation expansion repair, a hydraulic expander matching the inner diameter of the designed pipeline should be selected. Severely deformed pipelines are initially expanded using the rubber expansion head (elliptical head) of the hydraulic expander, and then repaired using a symmetrically designed hydraulic expansion shell and a hydraulic jack. During the repair process, to ensure the water flow cross-sectional area, a turntable can be rotated to provide rotational torque to rotate the hydraulic expander and fully repair the pipeline deformation. Generally, before rotation, the hydraulic expansion shell is retracted, and after rotation, it is pushed up to expand the pipeline, ensuring the roundness and water flow cross-section of the repaired pipeline. The hydraulic expander can be pushed in and pulled back under the traction of a pull rod to repair pipeline deformation.

[0031] The tie rods are installed and removed on or behind the turntable. When the pipeline is large enough for personnel to enter, a certain length of tie rod can be pre-assembled on the pipeline behind the working shaft to speed up the construction. If the upstream and downstream pipeline axes are on the same plane, an adjustable sliding bracket can be used to assemble the drill rod as a whole inside the pipeline.

[0032] When the project involves a large amount of work, the wellhead can be broken and a longer single tie rod can be used for connection. The tie rod should be a ready-made drill rod available on the market (such as a high-pressure jet grouting pile drill rod or an anchor cable drill rod).

[0033] The adjustable fixed support frame uses screw rods to adjust the support length and rollers to ensure that the rotation of the drill rod is not affected; the difference is that the adjustable fixed support frame is fixed to the pipeline by telescopic outrigger wheels, and the adjustable sliding support can slide in the direction of the pipeline axis when the pull rod is pushed in and pulled back.

[0034] After the pipeline repair is completed, depending on the extent of corrosion, the hydraulic expander of the pipeline can be replaced with a centrifugal spraying trolley in the receiving well for mortar (cement slurry) spraying treatment.

[0035] Finally, necessary ultraviolet light curing is carried out to repair the pipe lining. By using a high-strength, well-integrated lining, the pipe is reinforced, corrosion is reduced, and deformation is prevented, ensuring the water flow cross-section and reducing the frictional resistance of the water flow.

[0036] This invention integrates multiple processes, including expansion and shaping, real-time detection, inner wall grinding, mortar spraying, and subsequent UV-cured lining repair, into a single traction path. This solution enables the repair of an entire pipeline section with just "one rope threading and one pull-back." Compared to existing segmented, multi-entry and multi-exit operation modes, the repair time for a single 100-meter pipeline section is reduced from the traditional 3-4 shifts to less than 8 hours, and the manhole occupancy time is reduced from over 48 hours to less than 12 hours. This directly reduces costs associated with traffic diversion, pumping and ventilation, and night shifts, resulting in a 25%-35% reduction in overall construction costs.

[0037] Employing a two-stage expansion mechanism of "rubber elliptical head + multi-lobed hydraulic expansion shell," the ellipticity can be stably controlled within ≤2% in the DN300–DN1200 range, fully restoring the designed flow cross-section and significantly reducing pump station energy consumption. Real-time CCTV monitoring during the expansion process prevents longitudinal cracks caused by over-expansion, ensuring pipe wall integrity. The subsequent centrifugally sprayed cement mortar or polymer mortar layer, combined with the UV-cured lining, forms a composite reinforcement system that can extend the pipeline's remaining lifespan by 30–50 years.

[0038] All power and control equipment is located on the ground or at the wellhead. Only modular support frames, sliding supports, and detachable drill pipes are needed downhole. Workers can complete the entire process of expansion, inspection, and spraying without entering the pipeline, completely avoiding traditional high-risk scenarios such as exposure to toxic gases, collapse, and electric shock. The on-site safety index has been raised to the level of "zero-personnel confined space operation".

[0039] The entire set of equipment is designed with a standard 1.2 m × 1.2 m inspection well as the minimum working space. The length of a single drill pipe section is ≤1.5 m, which can be quickly connected and disconnected at the wellhead. The adjustable fixed support frame is directly clamped to the pipe opening through telescopic outrigger wheels, without the need to break the wellhead or enlarge the working pit, truly achieving "zero excavation, zero road occupation, and zero greening relocation".

[0040] The expansion module, spraying module, and CCTV inspection module share the same threaded interface, allowing for flexible interchangeability based on pipe diameter and type of damage. Key components such as the two-way hydraulic jack, rotary table, and drill rods utilize commercially available industrial products, ensuring simple maintenance and readily available spare parts. This design approach can be quickly replicated to trenchless repair projects in different cities with varying pipe diameters, significantly improving the overall mechanization and standardization level of the industry.

[0041] The above are merely embodiments provided in this application and are not intended to limit this application. Although this application has been described in detail with reference to the embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. However, any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should be included within the protection scope of this application.

Claims

1. A trenchless pipeline expansion and repair construction device, characterized in that... It includes: The surface power module, the downhole support and guidance module, the traction-rotation module that can move bidirectionally along the pipeline axis, and the expansion module or spraying module that can be interchangeably connected to the traction-rotation module; The ground power module simultaneously provides axial jacking / pulling force and rotational torque to the traction-rotation module. During the pull-back process, the expansion module performs step-by-step controllable expansion of the deformed pipe section and simultaneously detects the geometric deformation of the pipe wall. The spraying module performs centrifugal spraying on the expanded inner wall of the pipe under the drive of the same traction-rotation module. The entire construction process can be completed without personnel entering the pipeline, including expansion, detection, grinding and spraying.

2. The trenchless pipeline expansion and repair construction equipment according to claim 1, characterized in that: The expansion module includes a pipeline hydraulic expander, which includes a rubber elliptical expansion head at the front end and a multi-lobed hydraulic expansion shell at the rear end; the hydraulic expansion shell is driven by a bidirectional hydraulic jack to achieve radial graded expansion, and the expansion stroke and oil pressure are adjusted in real time by the hydraulic expander control console.

3. The trenchless pipeline expansion and repair construction equipment according to claim 1, characterized in that: The expansion module has a built-in pipe endoscope (CCTV) and scale, which are used to collect the pipe wall rebound and ellipticity in real time during the expansion process and transmit the data back to the ground display terminal.

4. The trenchless pipeline expansion and repair construction equipment according to claim 1, characterized in that: The traction-rotation module uses a detachable high-pressure jet grouting drill rod as a tie rod. The length of a single drill rod is no more than 1.5 m. It is quickly connected and disconnected and continuously pushed forward / pulled back through a turntable located at the working wellhead and a two-way hydraulic jack.

5. The trenchless pipeline expansion and repair construction equipment according to claim 1, characterized in that: The downhole support and guidance module includes: (a) An adjustable fixed support frame, held at the pipe opening by telescopic outrigger wheels, is used to support the turntable and the two-way hydraulic jack; (b) An adjustable sliding bracket that can slide along the axis inside the pipe and support the traction-rotation module to prevent the rod from sagging or swinging during long-distance pullback.

6. The trenchless pipeline expansion and repair equipment according to claim 1, characterized in that: The spraying module is a centrifugal spraying trolley, which is pulled by the same tie rod and rotates in the pipeline to spray cement mortar or polymer mortar. The spraying thickness is controlled by the mortar pump pressure and the pull-back speed in a closed loop.

7. A construction method for a trenchless pipeline expansion and repair construction equipment according to any one of claims 1-6, characterized in that... Includes the following steps: S1: Install an adjustable fixed support frame and a ground power module at the working wellhead; S2: Extend the traction-rotation module piece by piece and push it into the receiving well; S3: Connect the expansion module to the tie rod in the receiving well. During the pullback process, the elliptical head coarse expansion, hydraulic expansion shell fine expansion and real-time CCTV detection are completed in sequence. S4: Remove the expansion module, replace it with the spraying module, and pull it back again to complete the inner wall mortar spraying; S5: After the spraying is completed, a CCTV re-inspection will be carried out, and if necessary, the lining will be repaired by ultraviolet light curing. Among them, all processes from S2 to S5 are completed within the same rope path of a single traction-rotation module, without the need for secondary well opening or personnel going down into the well.

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