A pressure-resistant corrosion-resistant cold-patching composite material for online repair and reinforcement of pipelines and a use method thereof

Abstract

The present application relates to the technical field of metal corrosion and surface treatment, and particularly relates to a cold-patching composite material for pipeline online repair and reinforcement and a use method, the composite material is composed of cold-plated aluminum coating and glass fiber cloth, the cold-plated aluminum coating is composed of the following components in percentage by mass: 25-45% of composite aromatic polyisocyanate polymer, 15-25% of composite n-butyl acetate polymer, 20-30% of aluminum powder, 5-20% of thinning agent, and the rest is synthetic resin; during preparation of the composite material, one or more than three of spraying, brushing, and rolling can be used. The present application can be used for thickening forming of the metal surface of pipeline, component and other engineering equipment, and can also be used for updating and reducing the metal plate thinning of old equipment, so as to realize thickening of the metal plate thickness of the equipment. The formula is simple, the cost of each component is low, the preparation process of the composite material is simple and operable, and the composite material has the characteristics of high bonding force, pressure resistance and corrosion resistance.

Description

Technical Field

[0001] This invention relates to the field of metal corrosion and surface treatment technology, and in particular to a pressure-resistant and corrosion-resistant cold-repair composite material for online pipeline maintenance and reinforcement, and its application method. Background Technology

[0002] As the mileage of oil and gas pipelines continues to increase, the following problems exist in pipeline emergency repair: the technical level of pipeline repair varies, and there are gaps in the research and development and application of high-pressure pipeline plugging equipment.

[0003] Pipeline repair and reinforcement play a crucial role in the normal operation of pipelines, serving as a vital means to reliably ensure their integrity and safety. Given the increasingly prominent safety issues of oil and gas pipelines, each pipeline repair and reinforcement technique has its shortcomings. For example, welding is mainly for single-point defects with shallow depths, patching is primarily for small-area, multi-point corrosion, and sleeve application is mainly for large-area corrosion. These techniques also have the following drawbacks: they require direct welding onto the in-service pipeline, posing a high risk of burn-through; there are issues with uniform force transfer between the in-service pipe body and the reinforcing steel, and the compatibility of weld material with the base material; and there is a risk of hydrogen embrittlement and cold embrittlement in high humidity and low temperature welding environments. Fixture-type techniques have disadvantages such as relatively complex construction equipment and processes, higher costs, and poor post-construction corrosion protection. Composite sleeves have high rigidity and are not easily deformed. They can only repair straight pipes and cannot be used to repair irregular parts (elbows, tees, etc.). The materials used have low strength, which limits the efficiency of pipe restoration. The manufacturing process involves a series of production processes such as extrusion, drying, heat treatment, and curing, resulting in high costs. They have weak impact resistance, poor wear resistance, and low interlayer strength. Construction requirements are high, such as the need for grinding or sandblasting of the base layer, which requires a glossy finish.

[0004] Given the shortcomings of existing traditional rust removal paint processes, it is necessary to develop new materials and methods to improve traditional material manufacturing processes and technologies, extend the service life of engineering equipment, and reduce maintenance costs. Summary of the Invention

[0005] To address the aforementioned shortcomings of existing technologies, the present invention aims to provide a pressure-resistant and corrosion-resistant cold-patch composite material for online pipeline repair and reinforcement, along with its application method. The composite material of this invention has a simple formulation, low component costs, and a simple and highly operable preparation process. It possesses high bonding strength, pressure resistance, corrosion resistance, and fire resistance. This pipeline repair and reinforcement technology can be used to thicken the metal surfaces of thinned pipelines and components, and can also be used to update and restore thinned metal plates in old equipment, thereby increasing the thickness of the equipment's metal plates, solving the challenges of emergency pipeline repair, and ensuring the long-term safe operation of pipelines.

[0006] To achieve the above objectives, the technical solution adopted by the present invention is as follows: A pressure-resistant and corrosion-resistant cold-repair composite material for online pipeline maintenance and reinforcement is composed of a cold-plated aluminum coating and fiberglass cloth; the cold-plated aluminum coating is composed of the following components: a composite aromatic polyisocyanate polymer, a composite n-butyl acetate polymer, aluminum powder, a thinning agent, and a synthetic resin. The composite aromatic polyisocyanate polymer is a polymer containing an aromatic polyisocyanate structure; The composite n-butyl acetate polymer is a polymer containing a n-butyl acetate structure; The aluminum powder mentioned is nano-alumina or pure aluminum / alloy aluminum powder; The thinning agent is a polyurethane diluent; The synthetic resin is a high molecular weight polymer.

[0007] The cold-plated aluminum coating comprises the following components by weight: 25-45% composite aromatic polyisocyanate polymer, 15-25% composite n-butyl acetate polymer, 20-30% aluminum powder, 5-20% thinning agent, and the remainder being synthetic resin.

[0008] The composite material prepared by combining the cold-plated aluminum coating with glass fiber cloth has the best performance when the composite aromatic polyisocyanate polymer is 30-40%, the composite n-butyl acetate polymer is 20-21%, the aluminum powder is 25-26%, the thinning agent is 10-15%, and the synthetic resin is 10-15%.

[0009] For cold-applied composite materials used for pipeline online repair and reinforcement, the cold-applied aluminized coating must be thoroughly mixed before brushing, spraying, or rolling the coating onto the fiberglass cloth; or the fiberglass cloth can be applied to the cold-applied aluminized coating and allowed to absorb the coating before use.

[0010] Includes the following steps: Before using the cold-plated aluminum coating, stir it at low speed with a power mixer to avoid large vortexes that generate bubbles. Use 10% butyl acetate or xylene as the thinner (the water content of the thinner must be <500ppm). Mix well (induction time is 5 minutes before use) to remove bubbles from the surface of the cold-plated aluminum coating before use. First, spray the cold-plated aluminum coating evenly onto the pipe surface, then apply fiberglass cloth, and then spray the surface again. It is required that the surface of the fiberglass cloth be sprayed evenly and that the fiberglass cloth be fully saturated with the cold-plated aluminum coating. It is required that the cloth be applied firmly and tightly, without bubbles, delamination, or paint leakage. After the cloth is applied, spray another layer of cold-plated aluminum coating for sealing and reinforcement. The thickness of a single sprayed cold-plated aluminum coating is about 32.5 μm (wet film). Two sprays together result in a 65 μm (wet film) thickness, which is more robust and can prevent the formation of bubbles. The wet film thickness of each cold-plated aluminum coating should not exceed 65 μm. The minimum coating interval is 24 hours and the maximum coating interval is 72 hours. When it is necessary to increase the thickness of the composite material, repeat step (2) to apply the number of glass fiber cloth layers until the required thickness is achieved. The prepared cold-plated aluminum coating should be used as soon as possible and used up within 4 hours after stirring. The cold-plated aluminum coating should not be exposed to air for a long time and can be used the next day. However, an appropriate amount can be used. The remaining material should be used immediately and stored in a spare metal container for reuse the next day, which can avoid the waste of engineering materials. The surface temperature of the pipe / component to be coated is allowed to be up to 120℃ (in special circumstances). The component temperature should be at least 3℃ higher than the dew point temperature of the construction environment. The relative humidity of the construction environment must be below 85%. The ventilation, dust removal, lighting, and construction scaffolding of the construction environment should all comply with the safety regulations.

[0011] The aforementioned pressure-resistant and corrosion-resistant cold-patch composite material for online pipeline maintenance and reinforcement can be used for thickening and molding the metal surface of thinned pipelines, components and other engineering equipment. It can also be used to update and restore the thinned metal plates of old equipment, thereby increasing the thickness of the equipment's metal plates.

[0012] The design concept of this invention is: After the polymerization reaction of polyisocyanate with the addition of aromatic compounds, the molecules inside the structure undergo a three-dimensional network cross-linking structure. The cross-linking density of the paint film is high, and the paint film has high resistance and toughness. After polymerization, the resistance to yellowing and hardness are stronger, which lays the foundation for subsequent reaction cracking. The composite n-butyl acetate polymer is composed of a variety of chemical additives and has the ability to be compressed and successfully incorporated into the three-dimensional crystal structure of the composite aromatic polyisocyanate polymer to form microbeads. Aluminum powder is ground to the nanoscale with metal alloys, resulting in high hardness, solvent resistance, and the ability to penetrate into microspheres. It can also undergo compression and concentration reactions with n-butyl acetate. Thinners increase the fluidity of paint and accelerate encapsulation through evaporation, making individual microbeads denser and smaller, resulting in stronger penetration. Synthetic resin plays a coordinating role in the entire process, accelerating the drying of the paint surface through air and humidity reactions, locking in the internal microspheres' reaction expansion coefficient. The microspheres continuously release their internal compressive energy according to the humidity environment, constantly expanding and pulling against the carbon steel surface. Once fully dried and released, their density exceeds that of the carbon steel surface and the density of external water molecules, preventing moisture from penetrating the carbon steel surface and thus avoiding oxidation.

[0013] Advantages of this invention: The composite material described in this invention has strong wear resistance and corrosion resistance, which can fully meet the wear and corrosion resistance requirements of pipelines, making the technology widely applicable. It is suitable for straight pipes, bends, single-point defects, multi-point defects, and large-area defects. The construction is simple and can be operated by ordinary maintenance workers, which can greatly shorten the construction and maintenance cycle.

[0014] This invention provides a pipeline repair and reinforcement technology that allows for painting even with rust, significantly reducing construction difficulty and safety hazards. The construction process is safe and environmentally friendly, requiring no open flames, and uses green and environmentally friendly materials. No grinding or polishing is needed during construction; manual rust removal to ST-2 level is sufficient, eliminating any fire hazard. The construction process eliminates the need for complex procedures such as open flames, cutting, and grinding, and does not require welding or multiple combinations of materials. It also does not have strict requirements regarding time, temperature, or the substrate. It offers high safety, requiring no open flames, no electricity, and produces no harmful gases.

[0015] Pipeline repair and reinforcement technology uses nano-alloy aluminum particles to penetrate the surface of steel, transforming the surface oxide layer into a rust-proof layer. It expands and pulls the surface to achieve a fusion effect, resulting in strong reinforcement capabilities. When combined with fiberglass cloth construction, it is as if an aluminum metal sleeve is welded onto the pipeline.

[0016] Pipeline repair and reinforcement technology has the advantages of online repair and reinforcement technology. It can be used to thicken and form the metal surface of thinned pipelines, components and other engineering equipment. It can also update and restore the thinned metal plates of old equipment to achieve the thickening of the metal plates of the equipment.

[0017] The pressure-resistant and corrosion-resistant cold-repair composite material obtained by pipeline repair and reinforcement technology has a compressive strength of not less than 8.3 MPa according to ASTM D695-15 standard; the material adhesion (pull-off method) of the composite material can reach 12.3 MPa according to GB / T 5210-2006 standard; and no visible corrosion was observed after 500 hours of testing according to ASTM B368-09 (2014) standard. Attached Figure Description

[0018] Figure 1 This is a schematic diagram of a pressure-resistant and corrosion-resistant cold-patch composite material applied to a pipeline for online maintenance and reinforcement. Figure 2 This is a schematic diagram of a pressure-resistant and corrosion-resistant cold-patch composite material applied to a storage tank for online pipeline maintenance and reinforcement. Detailed Implementation

[0019] To facilitate understanding of the present invention, a more complete description will be given below with reference to the accompanying drawings. Preferred embodiments of the invention are shown in the drawings. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a thorough and complete understanding of the disclosure of the invention.

[0020] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention pertains. The terminology used herein in the description of the invention is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. The term "and / or" as used herein includes any and all combinations of one or more of the associated listed items.

[0021] The present invention will be further described in detail below through embodiments.

[0022] Example 1 In this embodiment, a pressure-resistant and corrosion-resistant cold-repair composite material for online pipeline maintenance and reinforcement is composed of cold-plated aluminum coating and fiberglass cloth. By mass percentage, the cold-plated aluminum coating consists of the following components: 25% composite aromatic polyisocyanate polymer, 20% composite n-butyl acetate polymer, 20% aluminum powder, 10% thinning agent, and the remainder is synthetic resin.

[0023] The method for using a pressure-resistant and corrosion-resistant cold-applied composite material for online pipeline repair and reinforcement requires that the cold-plated aluminizing coating be thoroughly stirred before brushing, spraying, or rolling it onto fiberglass cloth; or the fiberglass cloth be applied to the cold-plated aluminizing coating and allowed to absorb the coating before use. The steps include: (1) Before using the cold-plated aluminum coating, use a power mixer to stir at low speed to avoid large vortexes and bubbles. Use butyl acetate as the thinner (the water content of the thinner should be <500ppm). Mix well (induction time is 5 minutes before use) to remove bubbles from the surface of the cold-plated aluminum coating before use. (2) First, spray the cold-plated aluminum coating evenly on the surface of the pipe, then apply the fiberglass cloth, and then spray the surface of the fiberglass cloth. The surface of the fiberglass cloth should be sprayed evenly and the fiberglass cloth should be fully saturated with the cold-plated aluminum coating. The cloth should be applied firmly and tightly without bubbling, delamination, or paint leakage. After the cloth is applied, spray another layer of cold-plated aluminum coating for sealing and reinforcement. (3) The thickness of a single sprayed cold-plated aluminum coating is about 32.5 μm (wet film). Two sprays together result in a thickness of 65 μm (wet film), which is more robust and can prevent the formation of bubbles. The thickness of the wet film of each cold-plated aluminum coating should not exceed 65 μm. The minimum coating interval is 24 hours and the maximum coating interval is 72 hours. When it is necessary to increase the thickness of the composite material, repeat step (2) to apply the number of glass fiber cloth layers until the required thickness is achieved. (4) The prepared cold-plated aluminum coating should be used as soon as possible and used up within 4 hours after stirring. The cold-plated aluminum coating should not be exposed to the air for a long time and then used the next day. However, an appropriate amount can be used. The remaining material should be used immediately and stored in a spare metal container for reuse the next day, which can avoid the consumption of engineering materials. (5) The surface temperature of the pipe / component to be coated is allowed to be up to 120℃ (in special circumstances). The component temperature should be more than 3℃ higher than the dew point temperature of the construction environment. The relative humidity of the construction environment must be below 85%. The ventilation, dust removal, lighting, construction scaffolding, etc. of the construction environment should all comply with the safety regulations.

[0024] The experimental data for this embodiment after using the pressure-resistant and corrosion-resistant cold-repair composite material for online pipeline repair and reinforcement are as follows: Figure 1 As shown, according to ASTM D695-15 standard, the measured compressive strength is not less than 8.3 MPa; according to GB / T 5210-2006 standard, the measured material adhesion (pull-off method) of the composite material can reach 12.9 MPa; after 500 hours of testing according to ASTM B368-09 (2014) standard, no visible corrosion was observed.

[0025] As can be seen from the results of this embodiment, the pressure-resistant and corrosion-resistant cold-repair composite material of the present invention for online pipeline maintenance and reinforcement can be used for thickening and forming of thinned metal surfaces of pipelines, components and other engineering equipment, and can also be used to update and restore the thinned metal plates of old equipment, thereby increasing the thickness of the equipment metal plates.

[0026] Example 2 In this embodiment, a pressure-resistant and corrosion-resistant cold-repair composite material for online pipeline maintenance and reinforcement is composed of cold-plated aluminum coating and fiberglass cloth. By mass percentage, the cold-plated aluminum coating consists of the following components: 30% composite aromatic polyisocyanate polymer, 25% composite n-butyl acetate polymer, 30% aluminum powder, 15% thinning agent, and the remainder is synthetic resin.

[0027] The method for using a pressure-resistant and corrosion-resistant cold-applied composite material for online pipeline repair and reinforcement requires that the cold-plated aluminizing coating be thoroughly stirred before brushing, spraying, or rolling it onto fiberglass cloth; or the fiberglass cloth be applied to the cold-plated aluminizing coating and allowed to absorb the coating before use. The steps include: (1) Before using the cold-plated aluminum coating, use a power mixer at low speed to avoid large vortexes that generate bubbles. Use 10% xylene as the thinner (the water content of the thinner must be <500ppm). Mix well (induction time is 5 minutes before use) to remove bubbles from the surface of the cold-plated aluminum coating before use. (2) First, spray the cold-plated aluminum coating evenly on the surface of the pipe, then apply the fiberglass cloth, and then spray the surface of the fiberglass cloth. The surface of the fiberglass cloth should be sprayed evenly and the fiberglass cloth should be fully saturated with the cold-plated aluminum coating. The cloth should be applied firmly and tightly without bubbling, delamination, or paint leakage. After the cloth is applied, spray another layer of cold-plated aluminum coating for sealing and reinforcement. (3) The thickness of a single sprayed cold-plated aluminum coating is about 32.5 μm (wet film). Two sprays together result in a thickness of 65 μm (wet film), which is more robust and can prevent the formation of bubbles. The thickness of the wet film of each cold-plated aluminum coating should not exceed 65 μm. The minimum coating interval is 24 hours and the maximum coating interval is 72 hours. When it is necessary to increase the thickness of the composite material, repeat step (2) to apply the number of glass fiber cloth layers until the required thickness is achieved. (4) The prepared cold-plated aluminum coating should be used as soon as possible and used up within 4 hours after stirring. The cold-plated aluminum coating should not be exposed to the air for a long time and then used the next day. However, an appropriate amount can be used. The remaining material should be used immediately and stored in a spare metal container for reuse the next day, which can avoid the consumption of engineering materials. (5) The surface temperature of the pipe / component to be coated is allowed to be up to 120℃ (in special circumstances). The component temperature should be more than 3℃ higher than the dew point temperature of the construction environment. The relative humidity of the construction environment must be below 85%. The ventilation, dust removal, lighting, construction scaffolding, etc. of the construction environment should all comply with the safety regulations.

[0028] The experimental data for this embodiment after using the pressure-resistant and corrosion-resistant cold-repair composite material for online pipeline repair and reinforcement are as follows: Figure 2 As shown, according to ASTM D695-15 standard, the compressive strength is not less than 8.0 MPa; according to GB / T 5210-2006 standard, the adhesion (pull-off method) of the composite material can reach 13.3 MPa; after 500 hours of testing according to ASTM B368-09 (2014) standard, no visible corrosion was observed.

[0029] As can be seen from the results of this embodiment, the pressure-resistant and corrosion-resistant cold-repair composite material of the present invention for online pipeline maintenance and reinforcement can be used for thickening and forming of thinned metal surfaces of pipelines, components and other engineering equipment, and can also be used to update and restore the thinned metal plates of old equipment, thereby increasing the thickness of the equipment metal plates.

[0030] The technical features of the embodiments described above can be combined in any way. For the sake of brevity, not all possible combinations of the technical features in the above embodiments are described. However, as long as the combination of these technical features does not contradict each other, it should be considered to be within the scope of this specification.

[0031] The embodiments described above are merely illustrative of several implementations of the present invention, and while the descriptions are specific and detailed, they should not be construed as limiting the scope of the invention. It should be noted that those skilled in the art can make various modifications and improvements without departing from the concept of the present invention, and these modifications and improvements all fall within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the appended claims.

Claims

1. A pressure-resistant and corrosion-resistant cold-repair composite material for online pipeline maintenance and reinforcement, characterized in that, The product includes a cold-plated aluminum coating and fiberglass cloth. The cold-plated aluminum coating comprises the following components: a composite aromatic polyisocyanate polymer, a composite n-butyl acetate polymer, aluminum powder, a thinning agent, and a synthetic resin. The composite aromatic polyisocyanate polymer is a polymer containing an aromatic polyisocyanate structure; The composite n-butyl acetate polymer is a polymer containing a n-butyl acetate structure; The aluminum powder mentioned is nano-alumina or pure aluminum / alloy aluminum powder; The thinning agent is a polyurethane diluent; The synthetic resin is a high molecular weight polymer.

2. The pressure-resistant and corrosion-resistant cold-repair composite material for online pipeline maintenance and reinforcement according to claim 1, characterized in that, The cold-plated aluminum coating comprises the following components by weight percentage: 25-45% composite aromatic polyisocyanate polymer, 15-25% composite n-butyl acetate polymer, 20-30% aluminum powder, 5-20% thinning agent, and the remainder being synthetic resin.

3. The pressure-resistant and corrosion-resistant cold-repair composite material for online pipeline maintenance and reinforcement according to claim 1, characterized in that, The best performance of the composite material is made by combining 30-40% aromatic polyisocyanate polymer, 20-21% butyl acetate polymer, 25-26% aluminum powder, 10-15% thinning agent, and 10-15% synthetic resin with glass fiber cloth.

4. The method of using a pressure-resistant and corrosion-resistant cold-repair composite material for online pipeline maintenance and reinforcement according to claim 1, characterized in that, The cold-plating aluminum coating must be stirred evenly before brushing, spraying, or rolling it onto the fiberglass cloth for use; or the fiberglass cloth can be applied to the cold-plating aluminum coating and allowed to absorb the coating before use. Includes the following steps: Before using the cold-plated aluminum coating, stir it at low speed with a power mixer to avoid large vortexes that generate bubbles. Use 10% butyl acetate or xylene as the thinner. The water content of the thinner should be <500ppm. Mix well and allow it to acclimate for 5 minutes before use to remove bubbles from the surface of the cold-plated aluminum coating. First, spray the cold-plated aluminum coating evenly onto the pipe surface, then apply fiberglass cloth, and then spray the surface again. It is required that the surface of the fiberglass cloth be sprayed evenly and that the fiberglass cloth be fully saturated with the cold-plated aluminum coating. It is required that the cloth be applied firmly and tightly, without bubbles, delamination, or paint leakage. After the cloth is applied, spray another layer of cold-plated aluminum coating for sealing and reinforcement. The thickness of a single sprayed cold-plated aluminum coating is 32.5±3μm, and two sprays are 65μm for a more robust coating, which can prevent the formation of bubbles. The wet film thickness of each cold-plated aluminum coating should not exceed 65μm. The minimum coating interval is 24 hours and the maximum coating interval is 72 hours. When it is necessary to increase the thickness of the composite material, repeat step (2) to apply the number of glass fiber cloth layers until the required thickness is achieved. The prepared cold-plated aluminum coating should be used within 4 hours after stirring. The cold-plated aluminum coating should not be exposed to air for extended periods. It can be used the next day, but an appropriate amount can be used. Any remaining material should be used immediately and stored in a spare metal container for reuse the next day, which can avoid the waste of engineering materials. The surface temperature of the pipe / component to be coated is allowed to be up to 120℃ during construction. The component temperature should be at least 3℃ higher than the dew point temperature of the construction environment. The relative humidity of the construction environment must be below 85%. The ventilation, dust removal, lighting, and construction scaffolding of the construction environment should all comply with the engineering safety regulations.

5. The application of a pressure-resistant and corrosion-resistant cold-repair composite material for pipeline online maintenance and reinforcement as described in claims 1-3, characterized in that, The composite material can be used to thicken the metal surface of thinned engineering equipment such as pipes and components, and can also be used to update and restore the thinned metal plates of old equipment, thereby increasing the thickness of the equipment's metal plates.

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