油气田非金属管道失效预测及防控技术研究进展

doi:10.16085/j.issn.1000-6613.2023-0452

化工进展 ›› 2024, Vol. 43 ›› Issue (3): 1118-1132.DOI: 10.16085/j.issn.1000-6613.2023-0452

• 化工过程与装备 • 上一篇

油气田非金属管道失效预测及防控技术研究进展

张玉红¹(), 李轩宇², 冯春健³, 马春迅¹, 张晨¹, 周洋洋¹, 毕海胜¹()

^1.青岛科技大学机电工程学院，山东青岛 266061
^2.中国石油集团渤海石油装备制造有限公司辽河热采机械制造分公司，辽宁盘锦 124209
^3.中石化石油工程设计有限公司，山东东营 257000

收稿日期:2023-03-23 修回日期:2023-05-06 出版日期:2024-03-10 发布日期:2024-04-11
通讯作者: 毕海胜
作者简介:张玉红（1998—），女，硕士研究生，研究方向为油气储运系统安全检测技术。E-mail：3451086638@qq.com。
基金资助:
山东省油气储运安全重点实验室开放基金;中央高校基本科研业务费专项(19CX05007A);国家重点研发计划(2021YFB3401400)

Research progress on failure prediction and prevention technology of non-metallic pipes in oil and gas fields

ZHANG Yuhong¹(), LI Xuanyu², FENG Chunjian³, MA Chunxun¹, ZHANG Chen¹, ZHOU Yangyang¹, BI Haisheng¹()

^1.College of Electromechanical Engineering, Qingdao University of Science & Technology, Qingdao 266061, Shandong, China
^2.Liaohe Thermal Recovery Machinery Branch of CNPC Bohai Petroleum Equipment Manufacturing Co. , Ltd. , Panjin 124209, Liaoning, China
^3.Sinopec Petroleum Engineering Corporation, Dongying 257000, Shandong, China

Received:2023-03-23 Revised:2023-05-06 Online:2024-03-10 Published:2024-04-11
Contact: BI Haisheng

摘要/Abstract

摘要：

油气田金属管道腐蚀穿孔风险日趋严重，管道泄漏事故时有发生，玻璃钢管、钢骨架增强聚乙烯复合管、柔性复合管等非金属管道以其良好的耐蚀性和适用性在油气田开发生产系统中逐渐受到青睐。然而，由于管道在长期服役过程中遭受内外压载荷、介质腐蚀等老化作用，随之而来的诸如基体开裂、管体脆断、纤维/基体界面脱黏、层间分离等各种失效问题亟待解决。基于此现状，文章综述了油气田常用非金属管道特点、应用、失效原因，以及非金属管道探测定位、无损检测技术、风险评估和寿命预测方法，针对非金属管道损伤失效的预防在管道制造、施工、运行、应用、维修及关键技术等方面提出了相关建议，并对非金属管道失效预防技术攻关方面进行展望，为非金属油气管道失效预测方法及其防控技术的相关研究提供有效支撑。

关键词: 非金属管道, 失效, 检测技术, 风险评估, 预测方法

Abstract:

The corrosion and perforation risk of metal pipes in oil and gas fields is becoming more and more serious, and pipeline leakage accidents often occur. Non-metallic pipes such as glass steel pipe, steel skeleton reinforced polyethylene composite pipe and flexible composite pipe are gradually favored in oil and gas field development and production system for their good corrosion resistance and applicability. However, due to the aging effects of internal and external pressure load and medium corrosion during the long-term service of the pipe, various failure problems such as matrix cracking, pipe body brittle, fiber/matrix interfacial debonding, interlayer separation and so on need to be solved urgently. Based on this situation, this paper summarized the characteristics, application and failure causes of non-metallic pipelines commonly used in oil and gas fields, as well as the detection and positioning, non-destructive testing technology, risk assessment and life prediction methods of non-metallic pipelines, and put forward relevant suggestions on the prevention of non-metallic pipeline damage and failure in pipeline manufacturing, construction, operation, application, maintenance and key technologies. The paper also prospected the key issues of non-metallic pipeline failure prevention technology to provide effective support for the relevant research of non-metallic pipeline failure prediction methods and prevention and control technologies.

Key words: non-metallic pipelines, failure, detection technology, risk assessment, prediction method

中图分类号:

TE88

张玉红, 李轩宇, 冯春健, 马春迅, 张晨, 周洋洋, 毕海胜. 油气田非金属管道失效预测及防控技术研究进展[J]. 化工进展, 2024, 43(3): 1118-1132.

ZHANG Yuhong, LI Xuanyu, FENG Chunjian, MA Chunxun, ZHANG Chen, ZHOU Yangyang, BI Haisheng. Research progress on failure prediction and prevention technology of non-metallic pipes in oil and gas fields[J]. Chemical Industry and Engineering Progress, 2024, 43(3): 1118-1132.

图/表 20

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类型	组成	优点	缺点	适用场合
高压玻璃钢管	玻璃纤维和特殊树脂复合	耐腐蚀，强度高，水力特性好，维护费用低且可设计性强^[19-20]	连接、拐弯处渗漏，脆性大，T≤93℃，DN≤400^[21-23]	高压注水系统、注聚合物、低压气液混输、污水管道
钢骨架塑料复合管	高密度聚乙烯塑料、钢丝或钢带复合	耐压耐蚀；摩擦小、不易结垢、结蜡；保温和机械性能好^[24]	施工专业性强；冬季管道易冻结、冻胀，T≤80℃，p≤4MPa^[25]	油田注水系统和输送聚合物母液
柔性复合管	改性高密度聚乙烯为内层，增强纤维为中间层，聚乙烯为外层	承压能力大，柔性好、适用地形起伏地区，管径20~300mm^[26-27]	接头易泄漏，不适合输送高温介质，T≤100℃	气田开发注醇、油气水集输管线、海上油气开发^[28]
连续增强塑料复合管	钢丝及不同性能的聚乙烯	耐高温、柔韧性好、一般优于柔性复合管	易发生脆断，抗破坏能力差且不易修复	油气集输、注水，地形起伏较大区块
塑料合金复合管	内层塑料合金，增强层为玻璃纤维、环氧树脂或不饱和聚酯树脂，外层为抗老化、抗冲击的树脂层^[29]	管道防腐蚀性能更好，内壁光滑且不易结蜡，阻力系数小	会出现连接接头失效情况	油田注水和污水处理系统、原油集输系统

类型	组成	优点	缺点	适用场合
高压玻璃钢管	玻璃纤维和特殊树脂复合	耐腐蚀，强度高，水力特性好，维护费用低且可设计性强^[19-20]	连接、拐弯处渗漏，脆性大，T≤93℃，DN≤400^[21-23]	高压注水系统、注聚合物、低压气液混输、污水管道
钢骨架塑料复合管	高密度聚乙烯塑料、钢丝或钢带复合	耐压耐蚀；摩擦小、不易结垢、结蜡；保温和机械性能好^[24]	施工专业性强；冬季管道易冻结、冻胀，T≤80℃，p≤4MPa^[25]	油田注水系统和输送聚合物母液
柔性复合管	改性高密度聚乙烯为内层，增强纤维为中间层，聚乙烯为外层	承压能力大，柔性好、适用地形起伏地区，管径20~300mm^[26-27]	接头易泄漏，不适合输送高温介质，T≤100℃	气田开发注醇、油气水集输管线、海上油气开发^[28]
连续增强塑料复合管	钢丝及不同性能的聚乙烯	耐高温、柔韧性好、一般优于柔性复合管	易发生脆断，抗破坏能力差且不易修复	油气集输、注水，地形起伏较大区块
塑料合金复合管	内层塑料合金，增强层为玻璃纤维、环氧树脂或不饱和聚酯树脂，外层为抗老化、抗冲击的树脂层^[29]	管道防腐蚀性能更好，内壁光滑且不易结蜡，阻力系数小	会出现连接接头失效情况	油田注水和污水处理系统、原油集输系统

探测方法	原理	应用局限
探地雷达法	依靠电磁波的传播、反射进行工作，根据反射波形的强度、时间、传播路径等信息确定地下管道结构和具体深度	受管道埋深^[36]影响较大，不适用于山地管道检测
示踪法	将金属导线或示踪探头随管道同时埋于地下，利用接收器接收来自金属导线或探头的电磁信号确定管道位置和埋深	不适用于在役管道探测，且探测深度有限，具有一定的局限性
声学管道定位法	依靠声波的传播和反射，经数据分析获取图像来实现定位	只能探测已知大致走向的管道

探测方法	原理	应用局限
探地雷达法	依靠电磁波的传播、反射进行工作，根据反射波形的强度、时间、传播路径等信息确定地下管道结构和具体深度	受管道埋深^[36]影响较大，不适用于山地管道检测
示踪法	将金属导线或示踪探头随管道同时埋于地下，利用接收器接收来自金属导线或探头的电磁信号确定管道位置和埋深	不适用于在役管道探测，且探测深度有限，具有一定的局限性
声学管道定位法	依靠声波的传播和反射，经数据分析获取图像来实现定位	只能探测已知大致走向的管道

检测技术	适用管道类型	可检测缺陷类型	优缺点
射线检测	热塑性塑料管、增强热固性塑料管、增强热塑性塑料管、内衬管	气孔、夹杂、分层、脱黏、裂纹等	检测面积大、速度快，可检测表面及内部缺陷，无法获取缺陷深度、检测试件不能太厚且存在辐射^[44]
超声检测	热塑性塑料管、增强热固性塑料管	气孔、分层、脱黏、夹杂、裂纹等	灵敏度高、指向性好、穿透能力强，需要耦合剂，不适合深层缺陷检测
声发射检测	增强热固性塑料管、增强热塑性塑料管	裂纹扩展、纤维断裂、泄漏、应变、分层等	可实现缺陷定位、实时监测，对微小缺陷不敏感，需耦合剂和传感器
渗透检测	热塑性塑料管、增强热固性塑料管、增强热塑性塑料管、内衬管	表面开口缺陷	方便简单、成本低廉、缺陷显示直观、灵敏度高，但检测速度慢
红外热成像检测	热塑性塑料管、增强热固性塑料管、增强热塑性塑料管、内衬管	结垢、壁厚主要偏差、内壁缺陷深度、接头内缺胶	非接触式，检测面积大，可检测外部和内部缺陷，但检测精度有限，数据处理耗时长且只能从一侧进行识别^[45]

油气田非金属管道失效预测及防控技术研究进展

Research progress on failure prediction and prevention technology of non-metallic pipes in oil and gas fields

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检测技术	适用管道类型	可检测缺陷类型	成熟度
超声导波技术	增强热固性树脂管、增强热塑性塑料管、热塑性复合管、热塑性塑料管道	管道变形、接头缺陷、裂纹、分层	有实际产品，已有相关实验证明有效性
微波检测技术	增强热固性树脂管、增强热塑性塑料管、热塑性复合管、热塑性塑料管道	树脂固化程度、纤维和基体脱黏、纤维失效、基体开裂、分层、冲击损伤	处于研究阶段，已有相关实验证明有效性，多应用于非金属零件检测
超声相控阵技术	非金属管道	电熔、热熔对接接头（体积型缺陷检测）、裂纹、穿孔、分层	已有现场应用（接头处）
太赫兹波检测技术	增强热固性树脂管、增强热塑性塑料管、热塑性复合管、热塑性塑料管道	裂纹、孔隙、分层、毫米级变形、剩余壁厚、泄漏	多用于航空航天领域，目前尚未应用于非金属管道方面

寿命预测方法	原理	特点
SH	利用PE材料在高温下拉伸时裂纹中微纤维产生应变硬化特性来预测管道寿命	无需表面活性剂、试验时间短，但要求温度高，尚处于理论研究阶段
PENT	试样置于80℃的空气或水中并施加静载荷，经计算可预测带有初始缺陷的压力管道寿命	实验时间较长，部分试验需在应力腐蚀开裂介质中进行，预测准确度不高
长期静液压实验	将充满介质的管材样品置于一定温度介质中，施加不同压力直至最终破坏，经数据拟合确定管道失效寿命与应力关系	实验周期长，滞后于管道发展速度，但预测结果准确、可靠度高
循环载荷CRB实验	室温下循环拉伸试样并发生慢速裂纹扩展直至失效，基于线弹性断裂力学的理论进行寿命预测	实验时间短、无需表面活性剂，无法直接测量裂纹深度，预测较为保守
老化实验	基于失效依据和实验数据作图拟合公式计算寿命	预测结果准确，但实验条件再现性差

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