ACDCCD管道安装作业书B

1、封面作者：PanHon glia ng仅供个人学习CSPC NANHAI PETROCHEMICALS PROJECTCSPC南海石化项目Working Instruction Of Underground ADC、CCD GRP Pipelines Installation地下ADC、CCD GRP管道安装作业指导书Project Procedure: WI-8710-8100-2021工程程序：WI-8710-8100-2021SEPCO Electrical Power Construction Corporation山东电力基本建设总公司版次日期出版原因编写校核审查批准A30 Dece

2、mber 03Issue For Review AndApprovalLiud on gxia nTian dex unZhaoxieShidepi ngB4 Jan uary 04Issue ForReview AndApprovalLiud on gxia nTian dex unZhaoxieShidepi ng目 录contents1.0范围scope32.0目的purpose33.0职责resp on sibility34.0概述gen eral descripti on35.0编制依据 referenee46.0施工乙及要求 con struct ion process and r

3、equireme nt47.0附图attached draw ing278.0 工作安全分析（JSA）281.0 范围 scope本程序适用于南海石化工程汽电联产部分排水管道（ ADC 、CCD ）安装、检验和实验。This procedure is applicable to theerection 、 inspection and test of drainage pipe （ADC、CCD）in Nanhai Petrochemicals Steam & Power Unit.2.0 目的 purpose本程序规范排水管道的安装、 检验和实验， 规定了管道的安装工艺、 顺序以及施工 中应

4、注意的事项。This procedure defines the erection process, sequence of the pipe and the precautions that should be taken during construction.3.0 职责 responsibility3.1 山东电建二公司负责排水（ ADC 、CCD ）玻璃钢管道的安装、检验和实验。SEP2 is responsible for the erection, inspection and test of the GRP ADC and CCD pipes.3.2 山东电建一公司负责排水管道

5、的管沟开挖和回填。SEP1 is responsible for the ditch excavation and backfill of the pipes.3.3 基建总公司负责接口协调和质量验收。SEPCO is responsible for the interface coordination and quality acceptance.4.0 概述 general description4.1 ADC 、 CCD 管道采用纤维缠绕玻璃钢管，设计压力为0.8MPa 。The ADC and CCD pipes in the turbine hall are fiber wrappe

6、d GRP pipes, whose design pressure is 0.8MPa.4.2 ADC、CCD管道埋设在地下，主管为变截面设计，规格有DN1000、DN900、DN800 ,DN700、DN600、DN500、DN400、DN250、DN200、DN100。ADC 管道总长 度约为 2274.9M ， CCD 管道总长约为 960.7M。The ADC and CCD pipes are underground. The main pipe is designed variable cross-section. The dimensions are DN1000, DN900

7、, DN800, DN700, DN600, DN500, DN400, DN250, DN200 and DN100.The overall length of the ACD pipe is about 2274.9m and the overall length of the CCD pipe is about 960.7m.4.3 DN 200mm的管道间采用双”0”型带锁紧承插接头连接，程序参考6.4.3 ; DN 200mm are joined by double O tight bell and socketwith lock. The procedure refers to

8、the sect ion of 6.4.3. The pipes with the diameter 200mm的管道，管道连接采用双”型带锁紧承插接头连接的连接 方法。连接前检查承口和插口，在承口上安装打压嘴。For the pipe with DN200mm, the pipe is connected using the method of double “ Otight bell and socket connection with lock.C heck the bell and socket before conn ect ing and erect no zzle on the

9、bell.复查承口内是否光滑，有无纵向的沟槽或直径超过1.5mm的气泡，如发现 有沟槽或直径超过1.5mm的气泡，应在厂家技术人员指导下修复。Recheck whether the surface within the bell is smooth and whether there is any Iongitudinal ditch or air bubble with diameter over 1.5mm. Any longitudinal ditch or air bubble found shall be repaired under the direction of technic

10、ian from manufacturer.复查插口，其外表应光滑，无突出处。“0 ”型圈槽的台阶及端面应无分层 现象。如有则应在厂家技术人员指导下修复。Recheck whether the surface of the socket is smooth and whether there is any protrusion. The step and endface of 0 rubber ring must not have any delaminationphenomenon. The delamination if any shall be repaired under the di

11、rection of technician from manufacturer.复查“ 0”型橡胶圈，橡胶圈应无裂纹、气泡、疙瘩、杂质等。如有则应更 换“ 0”型橡胶圈。Recheck whether there is any crack, air bubble, knob and foreign matter on the 0 rubber ring. Replace the ring if any of the above is found.6.4.3.2 将要连接的管段插口和承口调平、对中，清理连接区、环槽，并均匀涂上一 层润滑油，然后将“ 0”型圈套在插口环槽内，在“ 0”型圈套上也均

12、匀涂上 一层润滑油。Adjust and align the socket and bell to be connected. Clean joining area and ring channel. Coat a layer of lubrication evenly. Put 0 ring to the ring channel of the socket. Coat a layer of lubrication on the surface of0 ringevenly.6.4.3.3 管道吊入管沟内后，用龙门架(龙门架制造图见附图3)和手拉葫芦等工具进行管口对接。 管沟内设专人指挥将插

13、口对准前一管的承口， 调整两管在同一 直线上，用两只倒链对称拉紧，将待安装的管道拽进已安装的管道承口内。After the pipe is lift to the ditch, join by gantry frame (see attached drawing 3) and chain block. A special person should be assigned to direct the joining.Adjust two pipes on the same line. Tighten symmetrically with two chain blocks. Drag the p

14、ipe to be erected into the erected bell.通常在插口上画出深度限位线。安装时，只需将插口拉进到限位线即可。 Generally, draw the depth limiting line on the bell. It is only need to pull the socket to the limiting line when erection.用水准仪检查管子的标高，管道标高偏差值值应在+30mm与-30mm之间，Check the elevation of the pipe by water level. The tolerance of the

15、 pipe shall be within +/-30mm 。6.4.3.4 接口水压实验。Hydraulic test for joint6.4.3.4.1 管嘴在管段正上方时，按图 6.1 布置打压装置。drawing 6.1When the nozzle is at the top of the spool, testing device arrangement sees drawing 6.1.6.4.3.4.2 若管嘴不在管段正上方时，由厂家现场在管道正上方安装布置一管嘴， 按图 6.2 布置打压装置。If the nozzle is not at the top of the sp

16、ool, install one nozzle at the top of the spool in the field by factory technician. Testing device arrangement sees drawing 6.2.Drawing 6.2管道未安装前，可先在承口相应位置，由里向外用手电钻打制一个10的光孔，然后在承口里侧将光孔阔成一个沉孔，沉孔深度应确保试压嘴头部可以完全沉入管壁，在进行双“0”承插联接时不会对“0”形圈造成损伤。Before the pipe is erected, tap a 10 unthreaded hole on the cor

17、responding position of the bell from the inside to the outside by electric hand drill. Then enlarge a couterbore on the unthreaded hole from the inside of the bell. The depth of the couterbore should ensure the head of the hydraulic nozzle completely sinking into the pipe wall. No damage will be mad

18、e to t he “0” seal when making the double“0” bell and socket joint.如双“0”承插接头已安装，试压嘴在紧固过程中断裂，可用磨光机将试压 嘴突出管体部分打磨平整，然后将试压孔用玻璃钢封上，在附近重新打试 压孔。此时试压嘴无法从承口内侧插入试压孔， 而只能从承口外向内插入。 可先将试压嘴的头部截去，在试压嘴上涂抹可与玻璃钢可靠黏结的黏合剂， 然后旋入试压嘴，待黏合剂固化后再试压。If the double “0”bell and socket joint has been erected while the hydraulic no

19、zzle is broken during tightening, grind and smooth the nozzle protruding the pipe by grinding machine. Then seal the hydraulic hole by glass steel and tap pressure test hole again in the vicinity. At this time, the hydraulic nozzle cannot be inserted into the hydraulic hole from the inside of the be

20、ll. It can only be inserted from the outside to the inside of the bell. Cut the head of the hydraulic nozzle, apply bond on the hydraulic nozzle to be bound with the glass steel.Then, thread in the hydraulic nozzle. Make a pressure test after the bond is hardened.用电钻钻孔时，要先量好管道壁厚，在钻头上作出相应标记，然后进行钻 孔，钻

21、到标记时停止钻孔 .从而避免伤及内部管道。Measure the wall thickness of the pipe before boring the hole with electric drill, then draw a line on the bit. Then begin to bore the hole. Stop boring when the bit reaches the line to avoid injuring the inside pipe.64343实验介质采用洁净的水，水压压力值为设计压力的1.5倍（12bar ）。The test medium uses c

22、lean water. The hydraulic pressure is 1.5 times of the design pressure （ 12bar ）。64344保压10分钟，实验用压力表压力降不大于0.05MPa，接头无可见渗漏为合格。Keep the pressure for 10 minutes. It is considered to be eligible if the pressure drop of the gauge is no more than 0.05Mpa and there is no visible leakage.6.4.3.5.5 如果承插口水压实验时

23、不合格，按以下步骤进行：If the bell and socket is not qualified when hydraulic test, settle according to the flowing steps:.在这两个管道的内表面用打磨机打磨，以除去杂物，使内表面平整、 干净，并形成一个新的内表面，打磨宽度为500mm。Grind the internal surface of these two pipes to remove foreign matters and to make it smooth and clean, thus to create a new intern

24、al surface. The grinding width is 500mm.将管道接头处的缝隙用腻子填平，腻子为滑石粉和 Atlac430 树脂的混 合物（现场配制） 。Fill up the gap on the pipe joint with putty, which is made of talcum powder and Atlac430 resin （compounded on site）.在打磨面涂上一层 Auac430 树脂，再涂一层宽度为 500mm 短切毡 ,用 脱泡辊将气泡赶净之后 ,再涂树脂,铺以层毡,共计铺设三层 .Paint a layer of Auac430

25、resin coat on the grinding surface then coat one layer of short-cut felt with 500mm wide. After remove bubbles with debubbling roller, resin on the surface and then 3 layers of felt shall be laid. 固化。在固化过程中，要派专人看守，防止流胶。Solidification. Specified personnel shall be assigned to keep watch on the jobsit

26、e in order to prevent mastic flow. 固化后，用打磨机打磨去除毛刺。Grind burrs with grinding machine after solidification. 再均匀的涂上一层加入 5%石蜡的 Auac430 树脂。 Coat another layer of Auac430 resin with 5% olefin. 固化。Solification.6.4.3.4.6 实验完毕进行泄压，因水量很少，直接排出少量水即可。Relieve pressure after test. Discharge water directly for the

27、amount of the water is not much.6.4.3.5 实验合格后，通过承口端的锁紧棒的穿孔插入尼龙棒，通过尼龙棒的抗剪 切能力来抗管道产生的轴向应力，插入前要在尼龙棒上均匀涂上润滑油， 不得有泄露，通过承口上的插入孔，向内挤压尼龙棒，注意应保证尼龙棒 始终沿插口的切线方向推进，在推进的过程中要均匀用力，防止尼龙棒折 断。直到规定的长度完全插入。After the test is qualified, insert the nylon bar through the hole of the locking rod on the bell. Use the shear r

28、esistant ability to resist the axial stress caused by the pipe. The nylon bar should be coated lubrication oil evenly before insertion. No leakage is allowed.Squeeze the nylon barthrough the insert hole on the bell. Pay attention to ensure the nylon bar is pushed along tangent direction of the bell.

29、 Force evenly when pushing to prevent the nylon bar breaking till the specified length insertion is complete.6.4.3.6 上述工作完成后进行回填，承插口处应预留。管区采用分层回填，回填要求 应符合 GB50268-97 给排水管道工程施工及验收技术规范 。具体回填的 程序 参照程序现场开挖与回填 PR-8710-8100-0013 执行 。Backfill after the completion of the above work, the socketl shall be obl

30、igated. Layering backfill shall be adopted. Backfill requirements shall apply with GB50268-97 Supply and drainage pipe construction and acceptance technical specification.The main process of backfill refer to SITE EXCAVATION AND BACKFILL PR-8710-8100-0013 . 回填情况应符合下图 6.4.8Status of backfill should a

31、ccord below drawi ng.6.4.8644 对接包缠连接 wrapping connection6.4.4.1对于DN 200mm的管道，采用套管对接并粘结的连接的连接方法。For the pipe with DN 200mm, adopt the connection method of sleeve butt joint and bonding.644.2材料：所有需要材料由生产厂家提供。Material: All material are provided by the manu facturer。6.4.4.3原材料准备：备好原材料，布和短布毡根据产品尺提前剪裁好。所有

32、原材料 测验合格方可使用；根据图纸，找出对接的管道，并检查规格、压力等级、 工程编号、材质、厚度、长度等与图纸上的要求是否相同。Raw material preparati on: Prepare raw materials. The short felt and cloth should be cut in advanee according to their dimension. No material is used until it is tested to be eligble. According to the drawing, find out the pipe that nee

33、ds butt joint and check whether the specification, pressure class, project number, material, thickness and length are consistent with the drawing s requireme nt.6.4.4.4 连接准备 connection preparation将两管段直接对接，先将两对接头推进合缝，对正找平，使中间的离缝 尽可能的小，并用水平仪检查管线是否水平，轴心线是否在同一直线上， 方向是否正确，法兰眼是否对中。Push the two sections in

34、to the joint close and adjust them to make the cleara nee be the minimum of the required value. Check the leve In ess of the pipeli ne by level gauge, check the bend directi on and check whether the flange hole is on the cen ter.如果管道无承插口，在需要对接的地方，根据厂家提供程序，用手工或 修整机切割整齐，并用特制的砂轮，根据对接尺寸表的宽度（ 1/2），在 修整机上

35、打磨。对接的接逢处， 要求打到内衬，然后用锉将砂轮拼装缝 遗留的凸台磨平。If there is no bell and socket on the pipe, cut and trim at the place where butt joint is needed by manual or trimming machine according to procedure of factory. Grind by the special-made grinding wheel according to the width on the butt joint dimension sheet. It

36、 is required to cut to the liner at the butt joint, then grind the pending protruding part at the wheel edge joint by file. .对于要对接的弯头， 对接前要在标准墙上， 校检其是否为 90，否则， 应进行修整，直到符合要求。 对于大小头，应用水平仪检查其两端口的 平行度。对于非标角度的弯头，在对接前，也应该用带有角度的板尺， 校验其角度是否准确，以便在对接时进行适当的调整。Check the bend to be butt joined at the standard wa

37、ll before butt joining whether it is 90 degrees. If not, dress to meet the requirement. For the reducer, check the levelness of both ends by level gauge. For the bend without marking angle, also check its angle by board rule with angle before butt joining to facilitate to adjust properly when butt j

38、oining.6.4.4.5 配胶：树脂配方由生产厂家提供，配制前 ,安装者应根据当时的气温条件进行凝胶实验，确定树脂与引发剂， 促进剂的配比。凝胶时间以 2545分钟为宜，以整个工序操作完成后 3060 分钟固化为好。Glue preparation: Resin furmula shall be provided by manufcturer. Before preparation, condensing test of glue shall be done to determine the proportion of resin, initiator and promoter. Test

39、 time shall be 25-45 minutes. Solidification shall be done 30-60minutes after the completion of the whole process. 配制时，应先用称量或量杯准确量取树脂并加入促进剂(钴盐) ，搅拦 均匀后再加入引发剂。为防止未操作完，树脂提前固化，可分多次配 制。During preparation, weight accurate quantity of resin by measuring glassand put in promoter (cobalt salt). After mixing

40、 evenly, add initiator. In order to prevent the resin hardening in advance while the operation is not finished, it can be mixed in several times. 应当注意：严禁将引发剂与促进剂直接混合，否则，将发生燃烧，甚至爆炸。引发剂与促进剂在运输、贮存及搬运时，也应分离开来，并 通风、避光，否则也易发生火灾事故。Notes: It is forbidden to mix initiator and promoter directly, or burning an

41、d even explosion may occur. Initiator and promoter shall be separated during transportaion, storage and handling. They should be kept in ventilative and lucifugous condition to prevent fire.6.4.4.6 连接封口：在接缝处，刷上内衬树脂，铺上表面毡，将浸好胶的长丝绕 在对接的缝隙内。然后，铺放两层短切毡。该两层短切毡，应铺满整 个搭接面，应用毛刷和辊轮，使之浸润充分、滚压平整、无气泡和皱 纹。Connec

42、tion sealing: Brush the lining resin at the joint. Spread the surface felt. Wind the gummed filament in the butt joint. Then, spread two layers of short felt. This felt should cover the overall butt joint surface. Fully infiltrate by the application of the brush and the running roller. Roll to smoot

43、h and there is no air bubble and winkle.6.4.4.7 糊制：待封口固化后检查封口质量，有无气泡、裂纹等缺陷。如有， 则需打磨修复。用打磨机将对接面打毛，将整个对接面刷上一层胶。 根据工艺单上规定的搭接宽度和铺层顺序放短切毡，缠绕玻璃布，每 缠一层，用毛刷蘸上树脂， 使之浸透，用辊轮滚压， 赶尽气泡并抹平， 不得留有皱纹、未浸润等不良情况。糊制时对接口两边应平整整齐。Pasting: check the sealing quality after the sealing is sodified whether there are any air bubble and crack. If there are any, grind and repair. Make a coars