地下GRP管道施工方案.doc

Construction Method StatementPage12/12Project No:080036Project Title:Arabian CHLOR VINYL ProjectClient:Sahara petrochemical company and MaadenLocation:Jubail Industrial Area, KSAMethod Statement Underground GRPPiping Installation WorksTitle:Underground GRP Piping Installation ProcedureTCC Prepared ByName : Position :Signature :Date :DAELIM ApprovalName :Position :Signature :Date :Approved By ClientName :Position :Signature :Date :Rev. 0This Document is the property of TCC. Issued to, and used by others needs the written approval of the TCC Quality Manager.CONTENTS1.0 Purpose2.0 Scope 3.0 Reference4.0 Responsibilities5.0 Equipments and Tools6.0 Lamination Process Sequence7.0 Bonding Materials8.0 Receiving Handling and Storing of Pipe9.0 Arrange Pipe in Trench10.0 Joint Laminate Procedure11.0 Quality Requirements12.0 Safety Precaution13.0 Attachments1. PurposeThis method statement is to guide butt joint wrap lamination work of U/G GRP piping system in the Arabian Chlor Vinyl Project.2. ScopeThis Method Statement covers the field lamination joints installation method of underground GRP piping. This procedure is applicable to all U/G GRP pipe diameters.Related data of U/G piping GRP part is as following:System descriptionMaterial classDiameter rangeConnection MethodW WDGAANA4”,6”,8”,10”,12”,20Butt & wrap joint laminationACWDGAANA4”Butt & wrap joint laminationPCSDGAANA4”Butt & wrap joint lamination3. Reference1 The drawing of 080036-AA-DA-100201400207 U/G Composite DWG2 Specification:080036-AA-SG-007Specification for Underground Piping & Surface Drainage080036-XH-SG-003Specification for piping construction080036-XZ-SG-001Specification for Piping Design080036-QZ-PL-001Project Quality Plan080036-XH-SG-006Specification for Identification of Piping Material080036-XH-SL-005Specification for Piping Material AMIANTIT document:Field Butt & Wrap Joint Procedure For GRP/FRP PipingInstallation and Handling Instructions For Rigid Joint PipeField Lamination Process sheet4. Responsibilities4.1 GRP ManagerIn charge of all the activity during the GRP pipe construction. Mainly involve the safety, technique and quality problems during the construction, preparing and carrying out the construction schedules.4.2 QC SupervisorIn charge of skill training for all the personnel who will engage the GRP piping work, analyzing the safety issues and providing precautions. Applying for work permits4.3 QC InspectorCompiling QC precautions, solving the QC issues during GRP piping construction, taking part in quality inspection and acceptance and taking the major responsibilities for the quality of the GRP piping.5. Equipments and ToolsThe below items are used for the GRP Piping handling and Construction: Boom trucks, trailers and cranes, shackles, slings belts, supports, crosstie for piping transportation Angle grinder, diamond blades, die grinder and flap wheels for cutting and grinding Square basin, paint rollers, brushes and Steel grooved rollers for lamination Hot air dryer and Digital infrared thermometer for curing(if required) Measuring tape and Barcol hardness tester for lamination test. Mobile drum cradle, spill decks, plugless tap and steel gantries for resin store. Glass cutting table, rolling tubes, knives, blades and scissors for glass prepare. Buckets, Liquid storage containers, platform balance, stirrer, spill trays for resin measure and mixture. Dispensing bottles(or similar tools) and chemical agent bottles for measuring and bringing catalyst to site. Brass bristles, plastic brush, cleaning basin, duster cloth for tools cleaning.6. lamination Process SequenceMaterial receivingExcavation and bedding(by civil)TransportationAnd Arrange SpoolCutting(if required)GrindingInside cleanness Inspection and Fit uplaminating of JointVisual inspectionBarcol hardness testFull water testCoordinate and elevation measurement7. Bonding MaterialsUsed components RESIN: Epoxy vinyl ester resin supplied from Amiantit, and to be mixed it with catalyst.CATALYST: Methyl ethyl ketone peroxide .Mat & WOVEN ROVING: glass reinforcement for joint structure.BONDING MATERIALS STORAGE and USAGE:Details see attachment A: Field Butt & Wrap Joint Procedure Page 4 to 5.The location of resin, W-Fluid, catalyst & glass reinforcement container as show in figure 7-1 Figure 7-1Storage outline of chemical container details see attachment-F: Interior layout for Amiantit Resin & Catalyst8. Receiving, Handling and Storing of PipeDetails see attachment B: Installation and Handling Instructions For Rigid Joint Pipe Page 2 to 4.Inspecting Pipe All pipes receiving at site shall be inspected according to Specification for Piping Material. Broken pipe bundles, crushed fittings boxes should be checked carefully, scratched and gouged and pipe with crushed or split ends are not allowed to use, damage claims procedures must be initiated prior to accepting the shipment. Do not dispose of any damaged items. If any imperfection or damage is found, immediately segregate the affected pipes and contact Dealim. Do not use pipe that appears damaged or defective.Handling Pipe Pipes, fittings and prefabricated parts (spools) have to be transported by suitable trucks. These trucks must have flat floors. Check and remove any projections or nails etc. before each load. Materials must be secured for example by using wedges and wooden supports. These supports must have a minimum width of 10 cm, avoiding sharp edges. The support distances must not exceed 2.5 m. Do not lift the pipe by passing a rope through the section end to end. Any part of the truck has to be protected by wood or rubber wherever in contact with the products. If pipes are handled by a forklifter, the forks must be covered with rubber or plastic. For work on the pipe, such as cutting, preparing ends, or cleaning, two-point support is recommended for 20-foot lengths, and three-point support for 40-foot lengths. Support wood should be ensured no nails. The best way for fittings to be transported is in crates or onto pallets. Direct contact between products during transport must be avoided.Pipe Storage Do not lay the pipes directly on the ground, rails or concrete floors. Ensure suitable supports are used for example wooden beams, measuring 10 x 5 cm. To avoid damage to machined pipe ends, stacking should be undertaken with care. The machined ends must be protected for example by polyethylene covered straw mats or polyethylene netting. If the product is stacked too high for long storage periods (6-12 months). It is recommended that the product is stored under tarpaulins or (white) polyethylene sheeting. Pipe stacks should have side supports or blocks to prevent rolling or slipping of the stack during stormy weather. A leveled, soft earth surface free of rocks and other hard or sharp objects is recommended.9. Arrange Pipe in TrenchPrepare and assemble pipe and joints in accordance with the ISO drawing, using special care to keep joint surface clean and dry.Position pipe on timbers across ditch as shown in figure-1. Block into position to hold alignment and prevent lateral movement.Joint the pipe sufficiently in advance of the pipe lowering operation so that no movement of the pipe will take place at location where joints are being cured. Any vibration or movement of uncured or partially cured joints will increase the risk of joint failures.Should be make sure the depth of the trench before lowing the pipe. Figure-1With power equipment or manpower, raise the pipe slightly to slide the timber support from under the pipe. Lower the pipe into the trench. Do not drop or lower suddenly. Repeat the above operation at each support. Use rope or webbed sling for lifting pipe. If manpower is used, it is suggested that two men be used for lifting 6-inch pipe, and four men and much more be used for the 8-inch and bigger pipe.10. Joint lamination Procedure10.1 CuttingThis initial step shall be applicable only if a pipe end needs to be cut and replaced, or a pipe length requires field adjustment. Mark the pipe section to be cut using a wrap-around and a white marker.Cut the pipe using a hacksaw or a diamond cutting disc, make sure that a proper square cut has been made. Ensure that cut ends remain within the tolerances as show in table 10.1.Table 10.1 : Maximum tolerance on square of cutted pipe endPipe Size RangeTolerance(mm)(mm)(inch)25-1001-41.5150-4006-163.010.2 GrindingGrinding and cleanning the total external surface. Make sure that the pipe ends are grinded as well as the required length as attachment C: Field lamination process sheet.Start the lamination of the fitted sections within two hours after sanding; re-sanding of the lamination area shall be required if the waiting period exceeds two hours. Bonding surfaces must be dry and clean before sanding. Use flapper wheel sanders with a small drilling machine (1700-2000rpm) or emery cloth with a grid of 60. Sanded surfaces must have a dull, fresh finish, not a polished look. Remove any possible dew by slightly heating the pipe ends by a hot air dryer.Other details see attachment A: Field Butt & Wrap Joint Procedure Page 7.10.3 Fitting up1 Check the alignment and fixing the pipe ends as close as possible, then prepare the putty.2 Apply the putty with a putty knife filling all the gap;3 After the filling of the gap, the putty shall polymerize, without moving and bumping the pieces. 4 Once completed the hardening of the putty, grind the outside of the pipe joint and clean with air blow and clean duster cloth.Note : The gap should not exceed the 5 mm or as per recommended by Pipe manufacturer at any case.10.4 Field Joint Kits PrepareDetails see attachment A: Field Butt & Wrap Joint Procedure Page 8 FIELD JOINT KITS.Each joint kit should be stored in a close room to avoid dust, damp & direct sunlight, and should be stored in a dry area and less than 65% humidity in order to avoid surface condensation when used in warmer conditions outside.10.5 Lamination on the pipe jointDetails see attachment A: Field Butt & Wrap Joint Procedure Page 8 to 11 LAMINATION ON THE PIPE JOINT of and attachment B: Installation and Handling Instructions For Rigid Joint Pipe Page 5 to 6.1 Enough catalysted resin should be prepared for about 20 30 minutes gel time and thorough mixing it.2 Spread a thin layer of catalysted resin directly on the surfaces of the pipe joint laminating area.3 Place of chopped strand mat on the surface of wet out area smoothly and wet it out with the paint wooly roller.4 Continue building by alternating chopped strand mat and woven roving and complete wetting out each one before applying the next ply. No more than 5 plies in one layer. Covered with chopped strand mat.The paint roller roll out over the plies to release big air cavities and any excessive resin. Avoid air getting into the laminate by using steel grooved roller slightly pressed to remove out the air bubbles. The angle of groove roller shall be changed time to time in order to remove the air bubbles in all directions. Keeping in consideration that very limited time has left for the resin to start getting gel, make sure all air bubbles have been taken out prior to start the plies to become hard. Stop rolling as soon as the resin begin to gel. 5 Continue this procedure until all the sections of the first layer been applied. Make sure that each section overlap with the others at least 5 cm. Let this layer lay-up cure and cool until it is comfortable to touch with the bare hand.Continue using the same procedures with the remaining layers as attachment C: Field lamination( process sheet). Make sure that the last plies of the total lay-up are chopped strand mat.CAUTION :1- Any kind of movement of pipe section could reduce the bond strength of the initial lay-up plies have not cured. While the jointing is under progress, the pipes must be restrained before moving.2- Remove the lay-up if not properly bonded to the pipe, and wash the area with solvent and not to run solvent into uncured. Before applying the lay-up on this area, insure all solvent has completely evaporated. Never allow spilled chemical on the pipe surface. This may cause damage to the pipe.3- Each joint lamination team should be formed by at least two workers, trained and skilled.Other details see attachment A: Field Butt & Wrap Joint Procedure Page 12 and attachment B: Installation and Handling Instructions For Rigid Joint Pipe Page 7.11. Quality Requirements1. The joint specification should be verified as per the AMIANTIT process.2. Visual inspection of the laminated joints for external lay-up.3. Checking the lamination thickness using the measuring tapes also the lamination width.4. Barcol hardness to check the lamination hardness should not be less than 30HBa.5. Full water test is used for gravity flow pipe when its completed. During test for filling with water, the piping shall be full of water, it will be accepted if the water level not lowering.6. Before buried, the coordinates and elevation of the pipe should be checked as per composite drawing.7. All quality inspection work should be according to ITP from DEALIM.12. Safety Precaution1、Forbidden under loading/hoisting the pipe by passing a rope through the section end to end.2、Dont use un-safety machine when cutting and grinding, anti-dust coveralls clothes, full face shield and dust mask should be used for grinding.3、Chemical splash goggles is recommended for chemicals operating; Portable water station can be used for eyewash.4、Wear resistant gloves such as: polyvinyl alcohol, butyl rubber, nitrile or neoprene. wear normal work clothing covering arms and legs. Hazard OF MATERIALS:All chemical materials must be used carefully with PPE. RESIN: Cause severe eye and skin irritation. Aspiration of material into the lungs can cause chemical pneumonitis, and other lung injury.ACCELERATOR: Do not breathe vapours and avoid contact with skin. It can cause lung damage if swallowed and cause cancer. Flammable.CATALYST: Risk of explosion by shock, friction, fire or other sources of ignition, may cause fire, Harmful if swallowed, Caused burns. Keep away from reducing agents, acids, alkalies and heavy metal compounds. Do not mix with peroxide-accelerators or reducing agents. Use only stainless steel 316, PVC, polyethylene or glass-lined equipment.Mat & WOVEN ROVING:SILICAN: Low hazard for usual handling. Repeated exposure may cause skin dryness or cracking. Keep away from heat and sources of ignition.STYRENE: a suspected carcinogen and a suspected toxin to the gastrointestinal tract, kidney, and respiratory system. Chronic exposure to styrene leads to tiredness/lethargy, memory deficits, headaches and vertigo.Portable water station and fire extinguisher should be located nearby.Before start wor