埋地GRP管施工措施中英2.docx
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埋地GRP管施工措施中英2
CONTENTS目录
1Scope范围
2ReferencesAndApplicableCodes参考文件
3Methodstatement施工措施
4ConstructionQualityRecordsAndInspectionReports
施工质量记录和检查报告
5RevisionNote修订注释
AppendixJointLubricantRequirements
附录涂抹接头润滑油用量
1Scope范围
Thisprocedureshallapplytoexcavating,back-filling,materialhandling
Storage,transportation,installation,pressuretestingandflushingofGRPpipeinNanhaiHDPE/PPplant.
本程序适用于南海石化项目PP+HDPE装置GRP管道的管沟开挖回填、管材现场装卸保管倒运、安装、试验、冲洗的施工。
2ReferencesAndApplicableCodes参考文件
2.1NH-HDPE+PP-QCPR-322ProcedureforDimensionalControl尺寸控制程序
2.2NH-HDPE+PP-WPR-211ProcedureforHydrostaticTestingandFlushingofPiping管道水压试验及冲洗程序
2.3NH-HDPE+PP-WPR-206ProcedureForExcavation&Backfilling
土方开挖及回填施工程序
2.4NH-HDPE+PP-PR-242Methodstatementinrainyseason雨季施工措施
2.5SP-8310-0000-0026Materials&workmanshipspecificationpermanentUGwork地下施工材料及技术要求
2.7Codeforconstructionandacceptanceofwatersupplyandseweragepipelines.GB50268–97给水排水管道工程施工及验收规范
2.8GuideofSpecificationsforInstallationofUndergroundGRPPipe
LZF-0623-01-03地下GRP管安装手册
5.2测量放线、管沟开挖Setting-outandTrenchexcavation
Generalrequirementsforsetting-outandtrenchexcavationrefertoNH-HDPE+PP-WPR-206ProcedureForExcavation&Backfilling.Thetrenchfigureasfollow:
测量放线、管沟开挖一般施工要求见NH-HDPE+PP-WPR-206土方开挖及回填施工程序,管沟图如下:
Figure4.2Trench
Dimension“A”(seeFigure4.2)mustalwaysbewideenoughtoallowforadequatespacetoensureproperplacementofbackfillinthehaunchregionandtooperatecompactionandexcavateequipment.Bottomwidthofpipetrenchshallbetwicethepipediameterplus600mm,butinanycasenotlessthan1.0meter.图4.2中A的尺寸必须满足开挖回填机械和人工作业的要求,管沟底宽一般为管直径加600,但不少于1.0M。
Whenrainingduringconstructionandwaterlevelrising,thesolutionreferstoNH-HDPE+PP-PR-242Methodstatementinrainyseason.施工时遇上雨天及高水位时,处理要求见NH-HDPE+PP-PR-242雨季施工措施.。
5.3PipeBedding
Afterexcavation,asandbagshouldbelaidatthebottominevery4meter,andthenetheightofbagshouldbe100mm.Excavatingalittledeeperatthejointofpipe,andthethicknessofpipebedcannotbelessthan50mm.Fillingwithsands&waterandcompactingasspecifiedwhenbackfilling.在管沟挖好后,底部每根管每隔4米放一个沙袋,压管后沙袋净高100mm,管子的接头处挖深一些,管床的厚度不能低于50mm,回填时按规定充沙放水密实。
Figure4.5
Properbeddingsupport
Figure4.6
Improperbeddingsupport
5.5管道安装PipingInstallation
Thelayingofpipesshallbeintheorderofmainpipefirst,andthenbranch;largepipefirst,andthensmallpipetoensuretheaccuracyofcoordinateofthejointwithoutside.Surveyingshallbeperformedtoconfirmthelocationofplacementofallpipe-fittings,bothatinstallationandlater,whenbackfillingreachesthemiddleofthepipe.管子按先主管后支管、先大管后小管的顺序铺设,确保与外界相连点的坐标的准确性。
安装时和回填至管子中部时都需进行测量,以确认所有管件的安放位置。
5.5.1JoiningPipes管道连接
5.5.1.1Double"O"ringswithlockingkey带锁的双O型环连接。
ThejointingmethodtobeusedfortheGRPPipesystemisacombinationofGRPbutt/strapjointanddouble“O”ringbellandspigotjointasshownbelow.
这种连接方式使用在GRP管承插接头上,双O型环承插连接形式如下:
Figure3.1-2
Ringlandspigotlockingjoint
A准备Preparation
a)Ensurethattheoutsidediameterofthespigotendofthepipeisthoroughlycleanedandfreeofanydust,sand,gritetc.
承插管接头必须十分干净,没有灰尘、沙砾等
b)Inspectthetwo'o'ringstobeinstalledonthespigotendsofthepipes.Checktoensurethe'o'ringsarecompletelyfreeofanydamageandhavebeenthoroughlycleaned.检查承插头上的两个O型环,O型环必须完整、干净没有受到任何伤害
c)Placetheringsinthe'o'ringgroovesensuringthattheringisuniformlystretchedalongitsentirelengthandnottwistedinanyway(seeFigure3.2).Thequickestandsimplestmethodofdoingthisistoplacethefirst'o'ringinthegroovenearestthepipeend,subsequentlyrollingthesecond'o'ringintothesecondgroove.
把O型环放置在槽里,确保紧贴沟槽和没有扭曲(如图3.2)。
又快又简单的办法是先把第一个O型环放在离管端最近的槽里,然后把第二个O型环滚进第二个槽里。
d)Ensurethatthetwopipesbeingjoinedarelevel,sothatthespigotwillfitconcentricallyintothebell.Twoplugsaresuppliedfittedtothebellforjointtesting.Eachpipeshouldbeinstalledsothatoneofthetwoplugsonthebellisontopofthepipe.确保对接的两管段水平,这样易于组装。
安上杯口上接头试验用的两个堵头,其中一个必须向上。
e)Thoroughlycoatthe'o'ringsandinsidesurfaceofthebellwiththelubricantprovided.O型环上及杯口内涂上润滑油
f)Usingsoft-slingsandchain-blocks,anchoronepipesegmenttothesupportslabtopreventaccidentalmovement.使用软吊索或倒链锚固一根管子,以防随意移动
Figure3.2
Balancingthetensioninrubber'o'ring,whichalsoensuretheringisnottwisted.
B组对Alignment
a)Thepipesshouldbebroughttogetherusingtwodaisychains.
用两个倒链对拉把两段组对在一起
b)Thespigotshouldnotbepushedhomeuntilittouchestheendofthebellsection.A(1-3)mmgapisrequiredheretoaccommodatethetolerancesforinsertionofthelockingchord.承插头不要插到底,予留1-3mm间隙调整锁孔偏差。
c)Oncethejointhasbeencompleted,avisualinspection,bothinsideandoutsidethepipe,shouldenabletheinstallationcrewtoseethatthe'o'ringsareseatedproperly.Ifthejointisunusuallytightitisareasonableindicationthatan'o'ringhasbeendisplacedandthejointmustbeseparatedandremade.组装完成,进行外观检查,O型环在管内外壁应结合得很好。
如果接头太紧,可能有一个O型环已移位,必须拆开重新安装。
d)Thelockingkeycannowbeinsertedaroundtheentirecircumference.
组装好后,锁紧管端。
CJointTesting接头试验
AnadvantageoftheGRPspigotjointingsystemisthefactthatthejointcanbehydro-staticallypressuretestedimmediatelyitismade.Thetestinginvolvesfillingwithwater,theannularspaceofthebellandspigot,betweenthe'o'ringsandpressuringthistotestpressure.GRP管承插连接的好处是组装后接头可以马上进行水压试验,试验过程为两O型环之间的环状空间充水和打压。
Thefollowingequipmentshouldbeonhandfortesting:
准备以下试压设备
a)ONE–handoperated,hydrostatictestpump.一台手动试压泵
b)ONE–accuratelycalibratedpressuregauge.一块校准过的精密压力表
c)ONE–suitablyfittedconnectingpressurehoseforpumptopipeconnection.
一条试压软管
d)ONE–rollofP.T.E.threadsealanttape.一圈P.T.E密封胶带
C1Procedure过程
C1.1Removetheboltpluginthetestnipplethatislocatedatthetopofthebell.取下管顶的试压咀上的螺栓堵头
C1.2Connectthehosetothetestnipplewiththehand-operatedpump.Ensurethescrewedfittingisadequatelywrappedwiththesealanttape.用软管连接杯口的管咀和手动试压泵,缠好密封胶带,确保接头密封.
C1.3Thepressuregaugewillbelocatedinthepump.Thenfillwaterandbegintestpressurizethewatertotherequiredtestpressure.试压泵装上压力表,然后充水打压直到规定的试验压力为此。
C1.4Afterholdingthepressurefor3minutes,releasethepressureandremovethehosefromtheinlet.稳压3分钟,泄压拆除软管
C1.5Replacetheplug(s)ensuringthethreadsaresealed.Thetestisnowcompleteandthenextjointcanbemade.安上堵头,试验结束,准备进行下一个试验。
C1.6当回填至管顶以上300时,接头再次实验。
Retestthejointwhenbackfillingto300mmabovethepipetop.
5.5.1.2FlangedJoints法兰连接
GRPflangesshouldbejoinedaccordingtothefollowingprocedure:
(Figure3.4.)
GRP管按以下程序进行法兰连接(如图3.4)
1)Thoroughlycleantheflangefaceandthe‘O’ringgroove.彻底清干净法兰面和O型槽
2)Ensurethe‘O’ringorgasketiscleanandundamaged.Donotusedefectivegasketsor"O"ring.确保O型环或垫片干净及没有受到伤害,不要使用有缺陷的O型环或垫片。
3)Position‘O’ringorgasketingroove在槽里放置O型环或垫片。
4)Alignflangestobejointed.对准法兰进行对接。
5)Insertbolts,washersandnuts.Allhardwaremustbecleanandlubricatedtoavoidincorrecttightening.WashersmustbeusedonallGRPflanges.穿上螺栓垫片和戴上螺母。
所有的金属件都要清干净并上润滑油,以防卡死。
GRP法兰螺栓都带垫片。
6)Usingatorquewrench,tightenallboltsto35N•m(25lb.-ft.)torque,[20N•m(15lb.-ft.)forpipesmallerthanDN100]followingstandardflangebolttighteningsequences.
按标准要求的顺序用力矩扳手拧紧螺栓至35N.m(25lb.-ft.)力矩[DN100以下的小螺栓20N•m(15lb.-ft.)]。
7)Repeatthisprocedure,raisingthebolttorqueto70N•m(50lb.-ft.),[35N•m(25lb.-ft.)forpipe]oruntiltheflangestouchattheirinsideedges.Donotexceedthistorque.TodosomaycausepermanentdamagetoGRPflanges.重复6)的动作,直到力矩达到70N•m(50lb.-ft.),[DN100以下的小螺栓35N•m(25lb.-ft.)]或者是两法兰面刚接触为此。
使用力矩不要超过规定值,不然会对GRP法兰造成破坏。
8)Checkbolttorqueonehourlaterandadjustifnecessaryto70N•m[35N•mforsmallerthanDN100].安装1小时后检查螺栓扭距,调整到70N.m[对DN100以下小螺栓35N.m]。
Figure3.4Flangejoint
Note:
WhenconnectingtwoGRPflanges,onlyoneflangeshouldhaveagasketgrooveintheface.
注:
当两片GRP法兰连接时,只有一片法兰的法兰面有垫片凹槽。
5.5.1.3粘接Adhesion
管线粘接按厂家的技术要求进行,由厂家派人在现场指导。
Pipingadhesionshouldbeperformedaspertechnicalrequirementsofmanufacturer,whoshouldassignpeopleonsitetoinstructthisactivity.
5.5.2Sleeving套管安装
Spoolsshouldbeassembledintoawholespoolsafterprefabricatedbysections,andthenpositioning,backfillingandcompactioncarried-out.Crossingpipeheadsenwrappedbyburlaporrubberwillbepushedslowlyintothesleevebyworkerswiththecooperationofcrane.Ifthereareinterspacedjointsincrossingpipes,pressuretestshouldbemadetospoolsseparately.Whenthelengthofcrossingpipeisnotenough,thetrenchshouldbelengthenedalongthedirectionofspoolstillappropriate.Oil-soakedjuteshouldbeusedtosealthejointofpipeandspool.套管分节预制后,在管沟内组装成整根套管,定位回填压实。
穿管管头用麻袋或胶皮包裹,吊车配合,人工慢慢推进。
如果穿管有中间接头,管段须单独打压合格。
当穿管距离不够时,在套管方向顺延管沟,直到合适。
管子与套管之间用油浸黄麻堵上封口
5.6Testing试验
5.6.1Forstrengthandtightnesstestofpressurepiping,themediumshallbecleanwater,thetestingpressureforstrengthshallbe1.5timesdesignpressurebutnomorethanthetoleranceofGRPpipe,andthatfortightnessbedesignpressure.TestingrequirementsrefertoNH-HDPE+PP-WPR-211ProcedureforHydrostaticTestingandFlushingofPiping.
压力管道进行强度及严密性试验,试验介质为干净水,强度试验压力为1.5倍设计压力,但不超过GRP管许可的试验压力,严密性试验压力为设计压力。
试验要求见NH-HDPE+PP-WPR-211管道水压试验及冲洗程序。
5.6.2Open-endgravitypipesystems,includingADCandCCDpipesshallbetestedforwater-tightnessbyfillingwatertoaheadofnotlessthan2.0mabovethesoffitofthepip