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西气东输新疆段压气站埋地管道腐蚀与防腐技术研究
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摘要
西气东输管道全长3900km,其干线使用了3层PE和阴极保护系统进行联合保护,而各输气站场的埋地管线则使用了无溶剂环氧涂料进行防腐。投产初期管道运行平稳,但2007和2008年相继在轮南和哈密压气站内发现了防腐层失效,埋地管道腐蚀和泄露的情况。而四道班压气站的土壤环境和防腐方案与它们都相似,在开挖调查中也发现了类似的问题,虽然还没有穿孔泄露,但也出现了防腐层失效和较严重的腐蚀,存在较大安全隐患,因此,针对新疆段压气站出现的埋地管道外腐蚀问题,为了弄清其腐蚀发生的内在原因,认识其腐蚀规律,有针对性地进行防腐,开展了本论文的研究,以保障西气东输管道的安全连续运行,延长管道的使用寿命。
     论文的主要研究内容如下:
     (1)四道班压气站腐蚀现状调研与土壤分析。通过对四道班压气站内的埋地管道进行开挖调研,认识其防腐技术现状和管道的腐蚀现状;通过对土壤的理化性质的测试分析,研究土壤的腐蚀性。
     (2)四道班站管材腐蚀行为研究。利用室内电化学测试对管材的耐蚀性进行分析;利用室内土壤腐蚀模拟实验对土壤溶液中各因素对腐蚀的影响进行分析;利用现场埋片试验获得最直接的管材腐蚀数据,并对其规律进行分析;利用能谱分析和SEM对各管材的腐蚀特征进行分析。
     (3)站内接地网对埋地管道的腐蚀影响研究。利用电化学测试和室内浸泡实验对接地网与管道接触时可能发生的电偶腐蚀行为进行研究,结果表明电偶腐蚀效应明显。
     (4)压缩机出口排污管的电偶腐蚀实验研究。利用浸泡实验对排污管上出现的3种异种管材连接时可能出现的电偶腐蚀行为进行了研究,结果表明电偶效应明显。
     (5)无溶剂环氧涂料在四道班站土壤中的性能评价。利用模拟土壤溶液浸泡实验对无溶剂环氧涂料的防腐性能进行评价,结果表明符合设计要求的无溶剂环氧涂料能对管材提供良好的保护。
     (6)四道班站埋地管道防腐措施研究。在文献调研的基础上推荐了适合四道班站的防腐层类型,并根据前面的研究结果,提出了腐蚀治理的基本措施。
The main line of West-East gas pipeline, length 3900km, used the 3-layer PE and cathodic protection system, while solvent-free epoxy coatings are used on the buried pipelines of gas transmission stations for corrosion. The pipeline during the initial production run smoothly, but in 2007 and 2008 successively in Lunnan and Hami gas compressor station found a coating failure, corrosion and leakage of buried pipeline. And the soil situation and anti-corrosion program were similar to them; in the excavation of the survey a similar problem was also found. Although not leakage, but there have been more severe coating failures and corrosion, there was a big security risk. Therefore, against the external corrosion problems of the buried pipelines in Sidaoban gas compressor station, this thesis was studied, in order to identify the hidden causes of corrosion occurred, to understand the corrosion law, targeted for anti-corrosion, to ensure the West-East gas pipeline continuous operation in safety, extending the service life.
     The main research contents are as follows:
     (1) Surveys of corrosion status and soil analysis of Sidaoban gas compressor station. Through the excavation research of buried pipeline in Sidaoban gas compression station, their anti-corrosion technology and pipeline corrosion status were cognized; through the physical and chemical properties test analysis of soil, the soil corrosivity was studied.
     (2) Study on corrosion behavior of tubing of Sidaoban gas compressor station. Corrosion resistance of tubing was analyzed using electrochemical testing in lab; the influence on the corrosion of various factors in soil solution were analyzed using simulation experiments of the soil corrosion; the most direct corrosion data of tubing was obtained using coupon testing in situ, and the corrosion law was analyzed; each coupon's corrosion features were analyzed by using spectrum analysis and SEM.
     (3) Study on corrosion influence on the buried pipelines impacted by grounding grid. Bimetallic corrosion behavior, occurred when grounding grid contacted with the buried pipelines, was studied using electrochemical testing and immersion experiments. The results showed that the galvanic effect was obvious.
     (4) Study on bimetallic corrosion testing of blow-off pipe of compressor outlet. Bimetallic corrosion behavior, maybe occurred when the three different tubing connected successively, using immersion experiments. The results showed that the galvanic effect was obvious.
     (5) Evaluations of performance of solvent-free Epoxy coating used in the soil of Sidaoban gas compressor station. The evaluation of solvent-free epoxy coating on the corrosion performance was tested using immersion experiments with simulated soil solution. The results showed that the solvent-free epoxy coating, meeting design requirements, can provide good protection for pipe.
     (6) Study on anti-corrosion measures of buried pipeline in Sidaoban gas compressor station. Based on the research in the literature, type of coatings was recommended for Sidaoban station and, based on previous research results, the basic measures of corrosion control were put forward.
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