4.1 Construction process flow
The CIPP lining inversion method for repairing gas pipelines is carried out under the construction conditions as shown in Fig. 3:
The construction process of repairing gas pipelines with CIPP flipped inner lining is shown in Fig. 4. The project excavates small work pits on both sides of the pedestrian walkway at the intersection of Yaoyuan Avenue and Shugang Avenue, cuts open the original gas pipeline, and uses a pipeline inspection robot to perform pipeline inspection. Then, a pipeline cleaning system is used to clean the impurities inside the gas pipeline. The high-pressure gas provided by a high-power air compressor is used to flip the inner lining hose, and after flipping is completed, the pressure is maintained for a period of time to ensure adhesive curing, allowing the lining soft pipe to fully adhere to the gas pipeline, and finally use special cutting tools to remove excess solidified inner lining hose from the pipeline end. The pipeline is welded, the working pits are backfilled, and the work is inspected and tested for quality assurance.
4.2 Key Construction Links
4.2.1 Excavation of work pits
The main focus of the project construction layout work is on setting up work pits. The location of the work pit takes into account the safety of surrounding buildings and traffic impacts caused by excavation, as well as the special requirements of non-excavation repair and renewal projects for the work pit. The project fully utilizes the terrain and combines with the transportation routes inside and outside the site, making reasonable use of effective space, and chooses to set up work pits at the shoulders on both sides of the cross road, that is, excavate one at each end of the gas pipeline crossing section, and excavate a guide groove with a slope of about 20°on one side of the operation pit. According to the on-site conditions of the gas pipeline, the work pit is excavated and the bottom surface is treated. The broken length of the original gas pipeline is about 2.5 meters, and the exposed section of the pipeline is not less than 0.5 meters. The ends are neat and smooth, and burrs are polished off.
4.2.2 Flip operation
Pre-roll the inner lining hose coated with adhesive into the compartment of the inner lining pipe flipping chamber, and then drive it to the working pit at the construction site. Start the air compressor unit to flip the inner lining pipe in the chamber into the old and cleaned pipes that have passed the inspection,as shown in Fig. 5. Control the temperature of the flipping chamber to be less than 20°C to prevent premature curing reaction of the resin due to excessive temperature. The entire process of flipping the lining relies on the action of compressed fluid to push the flipping head forward in the original pipeline. During the process, attention should be paid to real-time monitoring of flipping pressure and control of flipping speed. The flipping pressure is controlled within 0.05 ~ 0.1MPa to ensure that the hose can fully expand during the flipping process without exceeding its bearing capacity limit. The flipping speed should be controlled at 2m/min to 3m/min, and special attention should be paid to the pushing situation when the inner lining pipe passes through the bends or elbows during the feeding process. The flipping speed of the inner lining hose is approximately linearly related to air pressure. Maintaining a constant speed of the flipping head is a key step in ensuring that the inner lining material can be uniformly adhered and avoiding wrinkles and bubbles[5]. If the speed is too fast, problems such as folding, wrinkling, and insufficient space for tight fitting of the inner lining hose may occur. On the other hand, if the speed is too slow, it will cause the adhesive to flow to the bottom of the pipe due to excessive stock, resulting in inconsistent thickness of the inner lining inside the pipe, thereby affecting the repair effect and the overall performance of the pipeline. After flipping, the length of the resin impregnated hose extending from both ends of the original pipeline should be greater than 1m[6].
4.2.3 Curing and forming
After confirming that the inner lining pipe is flipped to the other end of the gas pipeline, install the end flange blind plate, increase the pressure of the entire line to 0.08MPa, and close the knife valve and air compressor. Sufficient curing time is crucial for ensuring the quality of the repair, to ensure that the inner lining hose can fully stretch and tightly adhere to the original pipeline inner wall during the curing period, preventing gaps that may lead to inner wall wrinkles. Usually, the lower the ambient temperature, the longer the curing time is required. To artificially shorten the curing time, catalysts can be added to shorten it. The soil temperature during the construction of this project is 20℃, and the solidification time will last for 72 hours according to Table 5. During the entire curing period, the pressure inside the pipe remains positive, causing the inner lining pipe to come into close contact with the original pipeline. Due to the fact that the curing process itself is a violent exothermic reaction [7]. This requires attention to the temperature changes inside the pipe during construction, to avoid heat accumulation on the inner wall of the lined hose in some positions, which may cause damage to the prefabricated structure of the lined hose and affect the surface morphology interface of the cured "new" pipe inner wall. After confirming the curing process, wait for the temperature inside the tube to naturally cool down and slowly release pressure to prevent shrinkage cracks in the inner lining tube[8].
Table 5
Room temperature curing
|
Accelerated curing
|
soil temperature
℃
|
Minimum curing time
hour
|
soil temperature
℃
|
Minimum curing time
hour
|
25
|
48
|
≥ 10
|
24
|
20
|
72
|
< 10
|
24
|
15
|
96
|
Additional catalyst needs to be added
|
10
|
120
|
4.2.4 End treatment
The end treatment mainly includes sealing and cutting work. After cutting, the burrs at both ends are trimmed and treated, and applying a quick-setting waterproof material at the interface between the inner lining pipe and the inspection well to fully ensure that there is no leakage between the inner lining pipe and the old pipeline. Remove the devices at both ends and use special tools to strip off the inner lining of about 20cm on both ends, making sure the cuts are neat. When the inner lining pipe is not tightly attached to the original pipeline, a resin mixture should be filled for sealing[9]. Then weld the short pipes of the inner lining work pit in sequence, and protect the completed inner lining section while welding to avoid damaging the inner lining material at the welding points. The welding standard shall comply with the Construction and Acceptance Specification for Industrial Pipeline Welding Engineering of Field Equipment (GB50236).As shown in Fig. 6.