深圳DN1200原水管改清水管-内穿钢管非开挖修复工程
本项目地处深圳交通最繁忙的道路，采用了萨德公司最先进的钢管内穿和Slip-Joint修复技术，为深圳供水保驾护航。
深圳笔架山水厂-东湖水厂DN1200原水管修复工程
非开挖内穿钢管修复工艺介绍
Rehabilitation of DN1200 raw water main
from Bijiashan Water Plant to Donghu Water Plant at Shenzhen
01
项目简介
修复工程作业范围示意图
深圳东湖水厂在扩能改造期间减产10万吨每天，为保障罗湖区的正常供水，需要对笔架山水厂至东湖水厂长约6.5公里的DN一千二原水管进行修复，将其改造成输送清水至东湖水厂的主干管道。
At Shenzhen, the Water treatment capacity of the Donghu Water Plant will be reduced by 100,000 tons per day during its expansion and reconstruction works. In order to ensure the normal water supply in Luohu District, it is necessary to repair the original DN1200 raw water pipe from Bijiashan Water Plant to Donghu Water Plant with a total length of 6.5 km transform this pipe main into a drinking water main.
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02
问题和修复目的
待修复的 DN1200原水管始建于上世纪90年代，直管段材质多为预应力钢筋混凝土管，弯头及特殊段为钢管。钢筋混凝土管承插口处普遍存在漏水、裂缝问题；钢管段内防腐脱落，管身和焊缝处锈蚀严重。原管道的结构已无法保证供水安全。
业主提出修复目的如下：
1. 输水流量达到每天10万吨；
2. 设计压力提升至0.6兆帕（MPa）；
3. 提升管道卫生性能，将原水管改造为清水管；
4. 新管道需要具备完全独立结构性；
5. 在今后运营过程中，方便抢修和维护。
The original DN1200 pipe was laid in the 1990s. The straight pipe sections are mostly reinforced concrete pipes, and the elbows and special sections are steel pipes. Water leakage and cracks were the common problems at the sockets of reinforced concrete pipes; internal coating falling off inside the steel pipe, the pipe and welds were severely corroded. The structure of the original pipeline could not guarantee the safety of the water supply.
The purposes of rehabilitation are as follows:
1. to transport 100,000 tons per day;
2. to increase the design pressure to 0.6 MPa;
3. to improve the sanitary performance and transform raw water pipe into drinking water pipe;
4. to have fully independent structure after rehabilitation;
5. convenient for repairing and maintenance during the operation.
03
工艺选择
内穿管作业中
原管线地处深圳市区交通繁忙地段，交通压力大，地下综合管线错综复杂，不具备全线开挖施工条件。经过对多种修复工艺的比选和论证，业主最终决定采用法国萨德公司推荐的内穿钢管修复工艺，该工艺为完全整体结构性修复工艺。
The original pipeline is located in a heavy traffic area in the centre of Shenzhen, where the underground pipelines situation is very complicated and the excavation construction method is not permitted. After comparison and study of different rehabilitation methods, the client finally decided to adopt Steel Pipe slip-lining trenchless method recommended by SADE,which is a completely integral structural repairing technique.
04
方案实施
穿管作业现场
本项目采用“EPC总承包模式”，在具体工艺选择和实施过程中，充分体现了法国萨德公司“百年企业”的国际领先的技术优势和综合实力。
1. 国内首次在大口径长输管线修复施工中使用3D扫描和模拟技术
现状管线资料缺乏，无法准确定位管道具体位置，这给制定详细施工方案带来了非常大的困难。为此，萨德公司将3D扫描技术应用在管道现状调查和内穿钢管的施工模拟上。
The design and implementation of this PEC project fully demonstrated SADE's world-leading technologies and comprehensive strength as a century-old enterprise.
1. The first time in China that 3D scanning and simulation technology is applied to the rehabilitation of large-diameter and long-distance pipeline.
The lack of information such as the pipeline’s accurate location makes it very difficult to formulate a detailed construction plan. Therefore, SADE has used 3D scanning technology to investigate pipeline condition and to simulate the new steel pipe slip-lining process.
3D扫描作业中
3D扫描数据输出
2. 国内首次使用内穿Slip-Joint钢管修复技术，而且修复口径最大、修复长度最长
原钢筋混凝土管道的管节接口处普遍存在转角，这种管线走向的“曲折”往往给内穿管工艺带来相当大的实施难度。萨德公司为此特别选用了带Slip-Joint接头的钢管进行内穿。该接头为萨德公司专利技术，可以保证新钢管“服帖地”跟着原管道的走向逐节内穿到位。
具体施工步骤是将每节钢管放下工作井，将其牵引至上一根钢管末端，在原管道内连接安装，重复上述过程直至完成该施工段最后一个管节的安装。然后在钢管接头处，进行内部焊接。
3. 在实测数据分析的基础上，对原钢管段进行结构加强和内喷涂修复
选取有代表性的原钢管段进行取样检测，用实验数据来确定原钢管的材料性能。萨德委托由中国合格评定国家认可委员会（CNAS）认可的第三方实验室对样品进行全面的检测、分析和评估，主要包括几何尺寸、内外防腐、金相分析和力学性能等，从而得出原钢管材料为铁素体基低碳钢，拉伸试验结果符合Q235限值的结论。
在上述实验和分析的基础上，对原钢管进行全面、彻底的除锈处理，采用超声波探伤仪检测所有原焊缝质量，并使用测厚仪测量原钢管残余有效壁厚，从而有针对性地对原焊缝、漏点、裂缝、壁厚薄弱等结构性缺陷进行全面补焊加强，最后喷涂环氧树脂防腐层，使修复后钢管内部焕然一新。
2. The first time in China that Slip-Joint Steel Pipe is applied to the rehabilitation of pipeline, and this project has the largest diameter and longest length among the similar rehabilitation projects
There are always angle deviations at the joints between original reinforced concrete pipes, and this kind of 'bent' often brings considerable difficulties to the implementation of the Slip Lining process. SADE has designed special steel pipes with Slip-Joint for this project, the joint is a patented technology of SADE, which can ensure that the new steel pipe could be 'closely' inserted in place one by one in accordance with the direction of the original pipeline.
The new steel pipes of the standard section are put down into the working pit, then are pulled inside the original pipe up to the end of the previous steel pipe, and connected by the special joint. the above procedure is repeated until the installation of the last section. The internal welding is carried out at each joint to connect all the new steel pipes as a whole pipeline.
3. Based on the analysis of sampling, the original steel pipes were repaired by structural reinforcement and internal spraying
SADE selected representative samples on the original steel pipes and commissioned a third-party laboratory accredited by CNAS to conduct comprehensive testing, analysis and evaluation of the samples, including geometric dimensions, internal and external coating, metallographic analysis and mechanical properties testing. It is concluded that the original steel pipe material is low-carbon steel, and the tensile test results meet the Q235 limit.
On the basis of the above testing and analysis, Sade carried out a comprehensive de-rusting treatment on the inner wall of the original steel pipe.
An ultrasonic flaw detector was used to detect the quality of all original welds, and a thickness gauge was used to measure the residual effective wall thickness of the original steel pipe. Therefore, the original weld, leakage, cracks, wall thickness and other structural defects are strengthened through supplementary welding. Finally, an epoxy resin anti-corrosion coating is sprayed on the inner wall of the renewed steel pipe.
原钢管修复后实拍
4. 阴极保护方案优化
为保证钢管修复后的长期使用寿命，在对管道全线进行了土壤腐蚀性、电阻率检测和杂散电流调查的基础上，针对修复工艺的特点进行专项设计，优化了牺牲阳极的布设数量和位置。
4. Optimization of cathodic protection
To ensure the long-term service life of the renewed steel pipeline, Sade conducted the soil corrosion, conductivity test and stray current investigation, to optimize the cathodic protection design, especially the number and location of sacrificial anodes according to the characteristics of the slip-lining process.
土壤电阻率检测数据图
05
总结
SADE项目现场团队合影
本工程所采用的内穿钢管修复工艺的优点可以总结如下：
1.修复后全新的内穿钢管具有整体独立承压结构，完全结构性；
2.钢管材料强度高，与其他方案相比管壁最薄，可以最大限度地保留过水断面；
3.钢管的维修和连接方便，便于今后运营养护。
The advantages of the slip lining technique used in this project can be summarized as follows:
1. After repairing, the new inner steel pipe has a fully independent pressure-bearing structure, which is completely structural;
2. The steel pipe material has high strength, and the pipe wall thickness is the thinnest compared with other solutions, which can preserve the maximum water cross-section.
3.The steel pipe is easy and fast for repairing and connection, convenient for maintenance during future operation.
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