CN116293109A - 一种高强度抗拉柔性复合管道 - Google Patents

一种高强度抗拉柔性复合管道 Download PDF

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CN116293109A
CN116293109A CN202310232107.8A CN202310232107A CN116293109A CN 116293109 A CN116293109 A CN 116293109A CN 202310232107 A CN202310232107 A CN 202310232107A CN 116293109 A CN116293109 A CN 116293109A
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layer
steel
layers
tensile
wear
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夏平原
许晓红
陈东阳
蒋铭
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Jiangsu Zhengdao Combustible Ice Pipeline Co ltd
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Jiangsu Zhengdao Combustible Ice Pipeline Co ltd
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Abstract

本申请涉及一种高强度抗拉柔性复合管道，包括由内向外依次设置的内衬层、外骨架层、第一耐磨层、增强层、第一隔离层、内包覆层、抗拉层和外保护层；所述内衬层、内包覆层和外保护层均包括聚合物层；外骨架层包括至少两层钢帘带层，且钢帘带层的层数为偶数；增强层包括四层钢带层或圆钢异形钢层；所述抗拉层包括内向外依次设置的第一抗拉扁钢层、第二耐磨层、第二抗拉扁钢层、第二隔离层。所述第一耐磨层包括至少两层尼龙布层或者一层螺旋叠加成两层以上的尼龙布层；所述第二耐磨层包括至少两层尼龙布层或者一层螺旋叠加成两层以上的尼龙布层；所述第一隔离层和第二隔离层均包括聚酯膜层；本申请制备得到的复合管道具有较高的强度性能。

Description

一种高强度抗拉柔性复合管道
技术领域
本申请涉及柔性复合管道技术领域，尤其是涉及一种高强度抗拉柔性复合管道。
背景技术
柔性复合管道是石油天然气开采中重要的管道工具，广泛应用于陆地海洋领域的石油天然气开发，随着多年的发展，目前已经发展为金属丝增强、金属带增强、非金属丝增强、非金属带增强、异形材料增强等多种结构，同时根据使用环境不同，还可分为海洋管、陆地管；根据结构还可分为粘合型和非粘合型等等。其材质轻，耐腐蚀，方便连接，易弯折，在使用过程中具有极好的便捷性。
而复合管道在陆地、海洋作业时会伴有拖拽或摇曳的情况，且复合管道长期处于高压环境下，易导致复合管道的强度下降，从而造成复合管道出现爆管失效的现象，故有待改善。
发明内容
为了提高复合管道的强度，本申请提供一种高强度抗拉柔性复合管道。
一方面，本申请提供的一种高强度抗拉柔性复合管道，采用如下的技术方案：
一种高强度抗拉柔性复合管道，包括由内向外依次设置的内衬层、外骨架层、第一耐磨层、增强层、第一隔离层、内包覆层、抗拉层和外保护层；
所述内衬层、内包覆层和外保护层均包括聚合物层；
所述外骨架层包括至少两层钢帘带层，且所述钢帘带层的层数为偶数；
所述增强层包括四层钢带层或圆钢异形钢层；
所述抗拉层包括由内向外依次设置的第一抗拉扁钢层、第二耐磨层、第二抗拉扁钢层、第二隔离层；
所述第一耐磨层包括至少两层尼龙布层或者一层螺旋叠加成两层以上的尼龙布层；
所述第二耐磨层包括至少两层尼龙布层或者一层螺旋叠加成两层以上的尼龙布层；
所述第一隔离层和第二隔离层均包括聚酯膜层。
按照上述层结构生产得到的复合管道具有较高的强度，实际使用效果好，具体的方案分析如下：
首先外骨架层与内衬层结合在一起，使得外骨架层作为复合管道的骨架材料层，从而当复合管道输送流体时，外骨架层作为复合管道内部承受压力的主要载体，进而提高了复合管道的抗变形能力。
其次，尼龙具有良好的综合性能，包括力学性能、耐热性、耐磨损性、耐化学药品性和自润滑性；且尼龙的摩擦系数较低，使得尼龙具有一定的阻燃性，因此，采用尼龙布层制备的第一耐磨层作为外骨架层的保护层，能够抵御增强层连接于外骨架层外侧时，对外骨架层产生的剪切作用力，从而进一步提高了复合管道的抗变形能力。聚酯膜具有良好的气密性、耐热性、耐寒性、耐化学药品性和耐油性，且聚酯膜在热塑性塑料中具有优异的强韧性、抗张强度和抗冲击强度，因此，采用聚酯膜制备的第一隔离层和第二隔离层作为复合管道的层结构时，能够提高复合管道的强度和韧性。
另外，增强层位于外骨架层的外侧，并且增强层的外侧又依次设置有内包覆层、抗拉层和保护层，若干层结构最终在外保护层的作用下形成一体化结构，从而对复合管道强度的提高具有积极作用。内包覆层和外保护层均为聚合物层，从而减小了外力对复合管道在运输、安装和使用过程中造成的影响。因此，多层成型后的复合管道具有较好的强度和韧性，可以有效克服上述复合管道在高压情况下，因受到拖拽或摇曳而发生爆管失效的缺陷。
作为优选，所述聚合物层的材质选自聚乙烯、交联聚乙烯、尼龙、聚偏氟乙烯、聚苯硫醚中的一种或几种。
通过采用上述技术方案，聚乙烯、交联聚乙烯、尼龙、聚偏氟乙烯、聚苯硫醚均具有无臭、无毒的特性，不仅具有优良的耐低温性能和化学稳定性，而且能够抵御大多数酸碱的侵蚀。
另外聚乙烯、交联聚乙烯、尼龙、聚偏氟乙烯、聚苯硫醚均易于加工成型，从而该复合管道制备过程中具有较高的生产效率。
作为优选，所述第一抗拉扁钢层和第二抗拉扁钢层的材质均选自高强度扁钢。
通过采用上述技术方案，高强度扁钢具有较高的强度，不仅可以经受拉力、扭力、摩擦力等作用，又可以作为能够作为复合管道的高强度配重层，从而有效提高了复合管道的强度。
作为优选，所述钢帘带层是由树脂包覆钢帘线带得到。
通过采用上述技术方案，树脂对钢帘线带的周壁进行包覆，有效提高了钢帘带层分别与聚合物和尼龙之间的结合力，从而提高了外骨架层分别与内衬层和第一耐磨层之间的结合稳定性。
作为优选，所述树脂选自高性能热塑性树脂，所述高性能热塑性树脂包括聚乙烯。
作为优选，所述钢带层的材质选自镀锌钢带，所述圆钢异形钢层的材质选自镀锌圆钢异形钢。
通过采用上述技术方案，镀锌钢带和镀锌圆钢异形钢均具有较好的防腐性能，从而将镀锌钢带或镀锌圆钢异形钢作为复合管道中的增强层时，不仅能够提高复合管道的强度，而且能够提高复合管道的抗腐蚀性能。
另一方面，本申请提供的一种高强度抗拉柔性复合管道的制备方法，采用如下的技术方案：
一种高强度抗拉柔性复合管道的制备方法，包括以下步骤：
S1、内衬层的制备：将内衬层物料颗粒加热熔融后，经模具冷却定型，形成内衬层；
S2、外骨架层的制备：将两层钢帘带层加热后通过交叉方式正反向螺旋缠绕在内衬层的外侧，形成外骨架层；
S3、第一耐磨层的制备：将两层尼龙布层通过交叉方式正反向螺旋缠绕在外骨架层的外侧，形成第一耐磨层；
S4、增强层的制备：将四层镀锌钢带从内到外通过交叉方式正反向螺旋缠绕在第一耐磨层的外侧，形成增强层；
S5、第一隔离层的制备：将聚酯膜螺旋缠绕于增强层的外侧，形成第一隔离层；
S6、内包覆层的制备：将内包覆层物料颗粒通过挤出的方式包覆在第一隔离层的外侧，形成内包覆层；
S7、抗拉层的制备：将高强度扁钢、尼龙布层、高强度扁钢、聚酯膜层依次通过交叉方式正反向螺旋缠绕在内包覆层的外侧，形成抗拉层；
S8、外保护层的制备：将外保护层物料颗粒通过挤出的方式包覆在抗拉层的外侧，形成外保护层。
通过采用上述技术方案，钢帘带层能够在加热时发生流动变形，有效提高了钢帘带层缠绕于内衬层时的结合性。且冷却后的钢帘带层与内衬层形成一体化结构，提升了复合管道的抗变形能力，从而延长了复合管道的使用寿命。内包覆层在熔融作用下包覆于隔离层的外层，外保护层在熔融作用下包覆于抗拉层的外层，且内包覆层和外保护层均采用具有耐磨、耐刮擦、抗慢性开裂的树脂，因此，复合管道具有良好的强度和韧性。
另外，上述管道的制备方法具有操作简单的优势，因此，根据上述制备方法制备的复合管道具有生产效率高的优点。
作为优选：所述第一耐磨层、增强层、第一隔离层、抗拉层的缠绕角度与管道的轴向呈30-80°的夹角。
通过采用上述技术方案，控制第一耐磨层、增强层、第一隔离层、抗拉层的缠绕角度，使得上一层能够完全覆盖在下一层表面，实现层与层之间的高强度匹配，从而提高复合管道的强度及韧性。
综上所述，本申请包括以下至少一种有益技术效果：
1.增强层位于外骨架层的外侧，并且增强层的外侧又依次设置有内包覆层、抗拉层和保护层，若干层结构最终在外保护层的作用下形成一体化结构，从而对复合管道强度的提高具有积极作用；多层成型后的复合管道具有较好的强度和韧性，可以有效克服上述复合管道在高压情况下，因受到拖拽或摇曳而发生爆管失效的缺陷。
2.镀锌钢带具有较好的防腐性能，从而将镀锌钢带作为复合管道中的增强层时，不仅能够提高复合管道的强度，而且能够提高复合管道的抗腐蚀性能。
附图说明
图1是本申请实施例中一种高强度抗拉柔性复合管道的截面示意图。
图2是图1中A结构的局部放大图。
附图标记说明：
1、内衬层；2、外骨架层；3、第一耐磨层；4、增强层；5、第一隔离层；6、内包覆层；7、抗拉层；71、第一抗拉扁钢层；72、第二耐磨层；73、第二抗拉扁钢层；74、第二隔离层；8、外保护层。
具体实施方式
以下以下结合图1-2以及实施例和对比例对本申请作进一步详细说明，本申请涉及的原料均可通过市售获得。
实施例
实施例1
参照图1和图2，一种高强度抗拉柔性复合钢带包括由内向外依次设置的内衬层1、外骨架层2、第一耐磨层3、增强层4、第一隔离层5、内包覆层6、抗拉层7和外保护层8，且内衬层1、外骨架层2、第一耐磨层3、增强层4、第一隔离层5、内包覆层6、抗拉层7和外保护层8的轴线方向一致。
参照图1和图2，内衬层1、内包覆层6和外保护层8均包括聚合物层，且内衬层1、内包覆层6和外保护层8整体呈管材状。外骨架层2包括至少两层钢帘带层，且钢帘带层的层数为偶数；如钢帘带层的层数可以两层或四层或六层等等，本申请实施例中外骨架层2包括两层钢帘带层。增强层4包括四层钢带层或圆钢异形钢层，本申请实施例中增强层4包括四层钢带层。抗拉层7包括由内向外依次设置的第一抗拉扁钢层71、第二耐磨层72、第二抗拉扁钢层73、第二隔离层74。第一耐磨层3包括至少两层尼龙布层或者一层螺旋叠加成两层以上的尼龙布层，本申请实施例中第一耐磨层3包括两层尼龙布层，第二耐磨层72包括至少两层尼龙布层或者一层螺旋叠加成两层以上的尼龙布层，本申请实施例中第二耐磨层72包括两层尼龙布层，第一隔离层5和第二隔离层74均包括聚酯膜层。
参照图1和图2，其中聚合物层的材质选自聚乙烯；钢帘带层是由树脂包覆钢帘线带得到，且树脂选自具有高性能热塑性树脂，高性能热塑性树脂为聚乙烯；钢带层的材质选自镀锌钢带；第一抗拉扁钢层71和第二抗拉扁钢层73的材质均选自高强度扁钢。
实施例1中制得高强度抗拉柔性复合管道的参数如表1所示：
序号 功能层 厚度(mm)
1 内衬层 7.5
2 外骨架层 8.5
3 第一耐磨层 7.5
4 增强层 14.5
5 第一隔离层 3.5
6 内包覆层 3.5
7 抗拉层 15.5
8 外保护层 3.5
该高强度抗拉柔性复合钢带的加工工艺，包括如下步骤：
S1、内衬层1的制备：
将内衬层1物料颗粒加入单螺杆挤出料斗中，通过单螺杆挤出机进行挤出，单螺杆挤出机加热区分为6段，各加热区的温度分别为：第一段加热温度为80℃，第二段加热温度为160℃，第三段加热温度为180℃，第四段加热温度为195℃，第五段加热温度为205℃，第六段加热温度为220℃；使得内衬层1物料加热熔融后，经模具定型水箱冷却而形成内衬层1；
S2、外骨架层2的制备：
将钢帘线带经树脂浸润后制得钢帘带层，将两层钢帘带层通过热空气加热的方式进行加热，加热温度为300℃；再将两层钢帘带层通过交叉方式正反向螺旋缠绕在内衬层1的外侧，控制钢帘带层的缠绕角度与管道的轴向呈30-80°的夹角，形成外骨架层2，此时钢帘带层与内衬层1形成一体化结构；
S3、第一耐磨层3的制备：
将两层尼龙布层通过交叉方式正反向螺旋缠绕在外骨架层2的外侧，控制尼龙布层的缠绕角度与管道的轴向呈30-80°的夹角，形成第一耐磨层3；
S4、增强层4的制备：将四层镀锌钢带从内到外通过交叉方式正反向螺旋缠绕在第一耐磨层3的外侧，控制镀锌钢带的缠绕角度与管道的轴向呈30-80°的夹角，形成增强层4；
S5、第一隔离层5的制备：
将聚酯膜螺旋缠绕于增强层4的外侧，控制聚酯膜的缠绕角度与管道的轴向呈30-80°的夹角，形成第一隔离层5；
S6、内包覆层6的制备：
将内包覆层6物料颗粒通过挤塑机包覆在第一隔离层5的外侧，形成内包覆层6；
S7、抗拉层7的制备：
将高强度扁钢、两层尼龙布层、高强度扁钢、聚酯膜层依次通过交叉方式正反向螺旋缠绕在内包覆层6的外侧，控制高强度扁钢、尼龙布层、高强度扁钢、聚酯膜层的缠绕角度与管道的轴向呈30-80°的夹角，形成抗拉层7；
S8、外保护层8的制备：将外保护层8的物料颗粒通过挤塑机包覆在抗拉层7的外侧，形成外保护层8。
实施例2
本实施例与实施例1的区别在于：聚合物层的材质选自交联聚乙烯。
实施例3
本实施例与实施例1的区别在于：聚合物层的材质选自尼龙。
实施例4
本实施例与实施例1的区别在于：聚合物层的材质选自聚偏氟乙烯。
实施例5
本实施例与实施例1的区别在于：聚合物层的材质选自聚苯硫醚。
实施例6
本实施例与实施例1的区别在于：聚合物层的材质选自聚乙烯和聚偏氟乙烯的混合物。
实施例7
本实施例与实施例1的区别在于：增强层4包括四层圆钢异形钢层，圆钢异形钢层的材质选自镀锌圆钢异形钢。
性能检测试验方法
以下检测中实施例1-7中的复合管道的公称尺寸DN/ID150。
环刚度：参照GB/T9647《热塑性塑料管材环刚度的测定》中的相关检测方法对实施例1-7中的复合管道进行检测，并将检测数据记录在表2中。
***强度：参照GB/T6111-2003《管材耐内压试验原理及试样要求》中的相关检测方法对实施例1-7中的复合管道进行检测，并将检测数据记录在表2中。
表2
样品 环刚度(KN/m2) ***强度(KPa)
实施例1 54 23.5
实施例2 53 22.5
实施例3 55 24
实施例4 54 23.5
实施例5 55 25.5
实施例6 53 23
实施例7 55 25
通过表2的检测数据，并结合实施例1-7的检测结果来看，本申请中的复合管道具有较为优异的力学性能，可以有效减小复合管道在高压情况下，因受到拖拽或摇曳而发生爆管失效的情况，即有助于提高复合管的强度。
本具体实施例仅仅是对本申请的解释，其并不是对本申请的限制，本领域技术人员在阅读完本说明书后可以根据需要对本实施例做出没有创造性贡献的修改，但只要在本申请的权利要求范围内都受到专利法的保护。

Claims (8)

1.一种高强度抗拉柔性复合管道，其特征在于：包括由内向外依次设置的内衬层(1)、外骨架层(2)、第一耐磨层(3)、增强层(4)、第一隔离层(5)、内包覆层(6)、抗拉层(7)和外保护层(8)；
所述内衬层(1)、内包覆层(6)和外保护层(8)均包括聚合物层；
所述外骨架层(2)包括至少两层钢帘带层，且所述钢帘带层的层数为偶数；
所述增强层(4)包括四层钢带层或圆钢异形钢层；
所述抗拉层(7)包括由内向外依次设置的第一抗拉扁钢层(71)、第二耐磨层(72)、第二抗拉扁钢层(73)、第二隔离层(74)；
所述第一耐磨层(3)包括至少两层尼龙布层或者一层螺旋叠加成两层以上的尼龙布层；
所述第二耐磨层(72)包括至少两层尼龙布层或者一层螺旋叠加成两层以上的尼龙布层；
所述第一隔离层(5)和第二隔离层(74)均包括聚酯膜层。
2.根据权利要求1所述的一种高强度抗拉柔性复合管道，其特征在于：所述聚合物层的材质选自聚乙烯、交联聚乙烯、尼龙、聚偏氟乙烯、聚苯硫醚中的一种或几种。
3.根据权利要求1所述的一种高强度抗拉柔性复合管道，其特征在于：所述第一抗拉扁钢层(71)和第二抗拉扁钢层(73)的材质均选自高强度扁钢。
4.根据权利要求1所述的一种高强度抗拉柔性复合管道，其特征在于：所述钢帘带层是由树脂包覆钢帘线带得到。
5.根据权利要求4所述的一种高强度抗拉柔性复合管道，其特征在于：所述树脂选自高性能热塑性树脂，所述高性能热塑性树脂包括聚乙烯。
6.根据权利要求1所述的一种高强度抗拉柔性复合管道，其特征在于：所述钢带层的材质选自镀锌钢带，所述圆钢异形钢层的材质选自镀锌圆钢异形钢。
7.根据权利要求1至6中任一权利要求所述的高强度抗拉柔性复合管道的制备方法，其特征在于，包括以下步骤：
S1、内衬层(1)的制备：将内衬层(1)物料颗粒加热熔融后，经模具冷却定型，形成内衬层(1)；
S2、外骨架层(2)的制备：将两层钢帘带层加热后通过交叉方式正反向螺旋缠绕在内衬层(1)的外侧，形成外骨架层(2)；
S3、第一耐磨层(3)的制备：将两层尼龙布层通过交叉方式正反向螺旋缠绕在外骨架层(2)的外侧，形成第一耐磨层(3)；
S4、增强层(4)的制备：将四层镀锌钢带从内到外通过交叉方式正反向螺旋缠绕在第一耐磨层(3)的外侧，形成增强层(4)；
S5、第一隔离层(5)的制备：将聚酯膜螺旋缠绕于增强层(4)的外侧，形成第一隔离层(5)；
S6、内包覆层(6)的制备：将内包覆层(6)物料颗粒通过挤出的方式包覆在第一隔离层(5)的外侧，形成内包覆层(6)；
S7、抗拉层(7)的制备：将高强度扁钢、尼龙布层、高强度扁钢、聚酯膜层依次通过交叉方式正反向螺旋缠绕在内包覆层(6)的外侧，形成抗拉层(7)；
S8、外保护层(8)的制备：将外保护层(8)物料颗粒通过挤出的方式包覆在抗拉层(7)的外侧，形成外保护层(8)。
8.根据权利要求7所述的一种高强度抗拉柔性复合管道的制备方法，其特征在于：所述第一耐磨层(3)、增强层(4)、第一隔离层(5)、抗拉层(7)的缠绕角度与管道的轴向呈30-80°的夹角。
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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN118149184A (zh) * 2024-05-13 2024-06-07 东营新达德安新材料科技有限责任公司 一种防垢高强度海底复合柔性管材料及其制备方法
CN118149183A (zh) * 2024-05-11 2024-06-07 东营新达德安新材料科技有限责任公司 一种耐腐蚀高强度海底复合柔性管材及其制备方法

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN118149183A (zh) * 2024-05-11 2024-06-07 东营新达德安新材料科技有限责任公司 一种耐腐蚀高强度海底复合柔性管材及其制备方法
CN118149184A (zh) * 2024-05-13 2024-06-07 东营新达德安新材料科技有限责任公司 一种防垢高强度海底复合柔性管材料及其制备方法

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