长距离输调水工程大口径FRPM管道研发与工程安全保障技术

Research and safety guarantee technology of large diameter FRPM pipeline for long distance water diversion and transfer project

长距离输调水工程是中国新疆地区重要的基础生命线,其长久稳定运行对于促进经济平稳增长和保障居民供水安全至关重要。新疆位居大陆中心,属温带极端大陆性气候,其长距离输调水工程面临严峻的环境挑战。玻璃纤维增强塑料夹砂管(glass fiber reinforced plastic mortar pipes,FRPM)作为长距离输调水工程中重要的水工地下结构用材,凭借其优异的耐化学腐蚀、轻质高强、无二次污染、安装方便、综合造价低等诸多优良特性而被广泛应用于新疆地区。然而,传统FRPM管生成工艺在铺层设计与生产自动化程度方面存在一定局限,导致工程施工过程效率低下;同时,缺少统一的技术标准和设计规范也间接制约了其应用范围。此外,管道工程自动巡检技术与缺陷定量评价标准尚未统一,无法合理量化和准确评价整体工程质量。为此,依托北疆小洼槽供水工程,围绕长距离大口径FRPM管的管材铺层设计与制造工艺、工程设计、质量评定、自动巡检、运行监测与安全保障等关键技术,通过产学研用相结合,持续15年攻关,取得突破性创新成果:①引进吸收并创新了适合于长距离、高工作压力、以连续缠绕工艺为首选的FRPM管生产工艺,优化了大口径FRPM管材铺层设计方法,实现了供料—缠绕—固化—切割—检测全自动化控制,与国外同类产品标准相比,管道挠曲性能和轴向拉伸强度等提高了20%~50%;②提出了安全防护的工程和非工程措施,建立了长距离FRPM管不同缺陷类型危害性等级划分原则,创建了复杂地质条件下长距离FRPM管道工程安全评价理论与方法;③系统揭示了FRPM管质量缺陷产生机理,开发了FRPM管光固化片材局部修复工艺以及内衬聚乙烯(PE)的整体非开挖修复技术,提出了修复效果后评价方法,实现了对长距离FRPM管道工程运行安全的有效掌控。

The long-distance water diversion project is an essential lifeline project in Xinjiang region of China,and its long-term stable operation is crucial for promoting steady industrial growth and ensuring the water supply security of residents.Xinjiang is located in the center of the continent,has a temperate extreme continental climate and posing even more severe environmental challenges for long-distance water diversion projects.Glass fiber reinforced plastic mortar pipe(FRPM)serves as a crucial underground water engineering structure in long-distance water diversion projects.With its excellent resistance to chemical corrosion,lightweight,high strength,absence of secondary pollution,easy installation,and low comprehensive cost,FRPM has been widely applied in the Xinjiang region.However,traditional FRPM production processes have certain limitations in terms of layering design and production automation,leading to inefficient construction processes.Additionally,the lack of unified technical standards and design specifications indirectly limits its application scope.Furthermore,there is no unified standard for pipeline engineering automatic inspection technology and defect quantitative evaluation,making it difficult to reasonably quantify and accurately assess the overall engineering quality.Therefore,relies on the North Xinjiang Xiaowagou Water Supply Project and focuses on key technologies such as pipe laying design and manufacturing processes,engineering design,quality assessment,automatic inspection,operation monitoring,and safety assurance of long-distance large-diameter FRPM.By combining industry,academia,and research,and with 15 years of continuous efforts,breakthrough innovations have been achieved:①Introduced and innovated a FRPM production process suitable for long-distance,high working pressure applications,with continuous winding as the preferred method.Optimized the design method for large-diameter FRPM pipe laying,achieving full automation control from feeding,winding,curing,cutting to testing.Compared with similar foreign products,the flexibility and axial tensile strength of the pipes have been Improved by 20%to 50%.②Proposed engineering and non-engineering measures for safety protection,established principles for categorizing the hazard levels of different types of defects in long-distance FRPM,and developed a theoretical framework and method for safety assessment of FRPM pipeline projects under complex geological conditions.③Systematically revealed the mechanism of FRPM quality defects;developed a local repair process for FRPM using light-curing sheet materials and a non-excavation repair technology with inner PE lining.Evaluation methods for post-repair effects were proposed,achieving effective control over the safe operation of long-distance FRPM pipeline projects.