循环水安装作业指导书

1、CSPC NANHAI PETROCHEMICALS PROJECTCSPC 南 海 石 化 项 目循环水管道安装作业指导书Project Procedure: WI-8710-8100-2005项目程序: WI-8710-8100-2005SEPCO Electrical Power Construction Corporation山东电力基本建设总公司 WI-8710-8100-2005, Rev. 04 Page 2 of 48Cooling water installation修改记录 3 1.0 范围 scope 5 2.0 目的 purpose 5 3.0 职责 responsib

2、ility 5 4.0 概述 general 5 5.0 编制依据 reference 7 6.0 施工工艺及要求 construction process and requirement 7 7.0 附图 attached drawing 19 8.0 工作安全分析（JSA ） 19 9.0 附文 rider 37WI-8710-8100-2005, Rev. 04 Page 3 of 48Cooling water installationAlter Note 修改记录 WI-8710-8100-2005, Rev. 04 Page 4 of 48Cooling water install

3、ation WI-8710-8100-2005, Rev. 04 Page 5 of 48Cooling water installation1.0 范围 scope本程序适用于南海石化项目汽电联产部分，四台蒸汽轮机循环冷却水管道（CW ）安装、检验和试验。This procedure is applicable to the CW pipes erection 、inspection and acceptance. 2.0 目的 purpose本程序规范循环水管道的安装、检验和试验，规定了管道的安装工艺、顺序以及施工中应注意的事项。This procedure defines the pip

4、eserection process 、flow and attented items to ensuring pipeserection 、inspection and acceptance. 3.0 职责responsibility3.1 山东电建二公司负责循环冷却水（CW ）玻璃钢管道的安装、检验和试验。SEP2 is responsible for the erection, inspection and acceptance of the GRP CW pipe.3.2 山东电建一公司负责循环水管道的管沟开挖和回填。SEP1 is responsible for the pipe c

5、hannels excavation and backfill. 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 inspection. 4.0 概述 general4.1 厂区位于大亚湾北海岸附近，循环水母管管中心标高为3.35mHHD 。The S&P project locates at the round of north coast of Daya bay. The central elevation of central coolingwater mai

6、n pipe is 3.35mHHD.4.2循环冷却水管道（CW ）采用玻璃钢夹砂管，刚度为SN5000，设计压力为0.8MPa ，介质为淡水，设计温度为80；工作压力为0.464Mpa ；输送介质为河水，水温为34 42。The cooling water pipes are GRP pipe, which stiffness is SN5000, and the design pressure is 0.8Mpa. The pipes use fresh water, the design temperature is 80, the working pressure is 0.464Mp

7、a; the transfer medium is river water, and the working temperature is 3442.4.3 循环水管道埋设在地下，主管为变截面设计，规格有DN2000、DN1500、DN1000，支管为DN800、DN600、DN200。另有少许DN100、DN40、DN15放水排气管道。进口主管长度约200米，出口主管长度约250米。The main pipes of CW pipes which are underground are variable cross-section pipes. The main pipes sizes ar

8、e DN2000, DN1500 and DN1000 and the branch are DN800, DN600 and DN200. There are also some drainage pipes which sizes are DN100, DN40, and DN15. The length of the inlet pipe is about 200m and the outlet is about 250m.4.4 DN 200mm 的管道间采用双”O ”型带锁紧承插接头连接，短接管、支管和主管的连接采用现场开孔、粘结的方法；DN 200mm 的管道采用套管对接并粘结的连

9、接方法(详细内容见附文1 。The pipes which diameter is more than 200mm are joined by double O tightsocket, The nipple、main and branch pipes are joined through tapping or bonding. The pipes which diameter is less than 200mm are joined by sleeve joint or butt felt.4.4 汽机房两侧的循环水管道上侧路面为混凝土铺设的路面。The upside roads surf

10、ace of CW pipe on both sides of turbine hall is concrete. 5.0 编制依据 reference5.1 DEP31.40.10.19GRP pipelines and piping systems5.2 GB50268-97 给排水管道工程施工及验收技术规范GB50268-97 Supply and drainage pipe construction and acceptance technical specification.5.3 QC-8420-8300-0002循环水管道安装质量检验计划QC-8420-8300-0002Coli

11、ng Water Pipeline Erection Quality Inspection Plan5.4 WI-8710-8100-0030循环水管回填WI-8710-8100-0030Backfilling of Cooling Water Pipe5.4 施工图纸 construction drawing51-8230-8100-300051-8230-8100-3002300551-8230-8100-3006（1/2）51-8230-8100-3006（2/2）51-8230-8100-3007301044-8320-8100-0559056144-8320-8100-0600061

12、05.5 CECS129:01埋地给水排水玻璃纤维增强热固性树脂夹砂管管道工程施工及验收 Embedded supply and drain glass fiber reinforced heat hardening resin sand pipe construction and acceptance5.6 厂家资料纤维缠绕玻璃钢管安装埋地手册Manufacturer document:GRP pipe laying manual6.0 施工工艺和要求 construction process and requirement6.1 循环水管道安装的施工工艺流程图：flow chart for

13、 CW pipe erection 6.2.1 主要机具：16t 汽车吊、50t 汽车吊、手动试压泵、电动试压泵。Main tools: 16t truck crane 、50t truck crane, manual pump, motor pump6.3施工准备 Installation preparation6.3.1 施工前仔细审阅图纸，熟悉系统。Review drawings carefully before construction.6.3.2了解规范和标准的要求，掌握质量要求和验收标准，签循环水管道质量检验计划。QC-8420-8300-0002Understand the re

14、quirement of specification and standard, and master quality requirement and acceptance code and issue cooling water pipelines installation construction quality planQC-8420-8300-0002.6.3.3 对施工人员进行安全、技术交底。Make safety and technology clarification to the construction personnel.6.3.4 沟槽验收 channel accepta

15、nce管沟截面尺寸符合图纸51-8230-8100-3002。 The section size of pipe channel applies with drawing51-8230-8100-3002. 垫层厚度符合设计要求（150mm ），并夯实（夯实程度为95SPD ）；垫层应平整，用水准仪每12米检测一次垫层的标高。 The pipe sand bedding meet design requirements (150mm and ramdown. （The ram extent is 95% SPD）. Smooth the cushion and check theelevati

16、on of cushion at every 12 meters by using of level. 管沟无滑坡、积水、淤泥。由于开挖深度超过地下水位，应设置临时排水沟或集水坑。 There is no slip slope, seeper and silt of the trench. As the excavationdepth is over underground water level, set up temporary drain ditch andsump pit. 承插口安装处的凹槽开挖完毕，凹槽尺寸符合设计要求，以便于整个管身底部放在砂垫层上，均匀受力。 The excav

17、ation of the joint groove is completed and the groove sizemeets design requirements. Thus, place the bottom of pipe on the sandcushion to bear force evenly. 弯头、三通、变径管、盲端、阀门等处的固定支墩充分凝固并安装完毕，符合设计要求。 The fixed piers at the elbow, tee, reducing pipe, pipe end side and valveshould be hardened fully and c

18、ompleted erecting to meeting designrequirement.6.3.5 管道的运输及现场布管 pipe transportation and laying at site 装卸时须使用专用的吊装索具（纤维绳），防止碰损。运输时应垫稳、绑牢，不得相互撞击，在运输到现场过程中要有技术管理人员监护。 When loading and unloading, special slings should be used to preventdamage. The pipe should be steady and bound firm. It is not allowed

19、 tofoul each other. A technical management person must monitor thetransportation. 将管子、管道连接附件等依次沿一侧管沟摆放。特别注意应将每根管的承口朝向设计水流相反的方向。管道安装的详细顺序见附图1 the pipe, fitting, etc. should be put along one side of the channel. Payspecial attention to the bell direction. It should be exposed to the oppositedirection

20、of the current. The detail sequence of pipe erection seesattached drawing 1. 检查管材、管件的合格证，对管材的规格、配合尺寸、外观等进行全面检查。 Check the certificate of tubes and pipe meterials. Final check thespecification, matching size and appearance. 管道存放时应均匀支撑，防止管材变形、碰损。 The pipe should be supported evenly when placing to pre

21、ventdeformation and damage of the tubes.6.4 管道安装 pipe erection6.4.1根据施工顺序及现场情况，吊车的摆放及行走路线见附图1。According to the construction sequence and site condition, the arrangement of the crane and traveling route see attached drawing 1.6.4.2 根据管道布置图和管道的安装方向，将第一根要安装的管道用起重机缓慢吊入到管沟内，开始安装。According to the pipe arr

22、angement drawing and erection direction of the pipe, lift the first pipe to be erected slowly by crane to the trench, then begin to erect. 安装前应对管道进行复查，无标志、无编号或有缺陷者须查清修补后方可使用；承插口、橡胶圈应进行清理，不得有泥沙等杂物黏连。 Review the pipe before erection. The pipe without designation, numberand with defect could be used af

23、ter repair. Clean the bell and socket andrubber ring. No silt, etc. should adhere. 用水准仪检查管子的标高，标高偏差值值应在+30mm与-30mm 之间。 Check the elevation of the pipe by surveyor's level. The tolerance shall bewithin +30mm/-30mm. 用线坠检查管子的轴向坐标，坐标偏差值应在+30mm与-30mm 之间。 Check the axes coordinate of the pipe by wire

24、gauge. The tolerance shallbe within +30mm/-30mm.6.4.3 然后，安装下一节管道。连接前检查承口和插口，在承口上安装打压嘴。Then, erect next pipe. Check the bell and socket before connecting and erectnozzle on the 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。 Review whether the surface within the bell is smoo

25、th and whether there isany longitudinal ditch or air bubble with diameter over 1.5mm. Anylongitudinal ditch or air bubble found shall be repaired under the directionof technician from manufacturer. 复查插口，其外表应光滑，无突出处。“O ”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。 Review whether the surface of the socket is smo

26、oth and whether there isany protrusion. The step and endface of O rubber ring must not have anydelamination phenomenon. The delamination if any shall be repairedunder the direction of technician from manufacturer. 复查“O ”型橡胶圈，橡胶圈应无裂纹、气泡、疙瘩、杂质等。如有则应更换“O ”型橡胶圈。 Review whether there is any crack, air bu

27、bble, knob and foreign matteron the O rubber ring. Replace the ring if any of the above is found.6.4.4 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“O ”型圈套在插口环槽内，在“O ”型圈套上也均匀涂上一层润滑油。Adjust and align the socket and bell to be connected. Clean jointing area and ring channel. Coat a layer of lubrication ev

28、enly. Put O ring to the ring channel of the socket. Coat a layer of lubrication on the surface of O ring evenly.6.4.5管道吊入管沟内后，用龙门架（龙门架制造图见附图2）和手拉葫芦等工具进行管口对接。管沟内设专人指挥将插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 attachment drawing2

29、and chain block. A special person should be assigned to direct the join. Adjust two pipes on the same line. Tighten symmetrically with two chain blocks. Drag the pipe 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

30、 need to pullthe socket to the limiting line when erection. 检查管道的标高、坐标。 Check the elevation and coordinate of the pipe.6.4.6 接口水压试验。Hydro test for connector. 管嘴在管段正上方时，按图6.1布置打压装置。 drawing 6.1 The nozzle at top of spool, connection line as below drawing 6.1 shouwn. 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，（步骤

31、参阅附文1），按图6.2布置打压装置。 If the nozzle not at top of spool, install one nozzle at top of spool in thelocale by factory technic worker(step refer to rider 1, connection line asbelow drawing 6.2 shouwn. Drawing 6.2 试验介质采用洁净的水，水压压力值为设计压力的1.5倍。 The test medium use clean water，Watering until the pressure reac

32、h 1.5times of the pipe design pressure（12bar ）。 保压10分钟，试验用压力表读数无下降，管道无渗漏为合格。 Keep the pressure for 10 minutes. Check the tightness of the bell andsocket according to the pressure drop and leakage. 如果承插口水压试验时不合格，须将不合格管段退出，重新进行安装、试验。退管应在厂家技术人员的指导下进行，防止退管时损坏管道承插口。 If the bell and socket is not qualifie

33、d when hydraulic test, drop out theunqualified pipe section. Erect and test again. Pipe withdrawing should be done under the manufacturers technician instruction. Bell and socket of the pipe is prevented to be damaged when pipe withdrawing. 试验完毕进行泄压，因水量很少，直接排出少量水即可。 Relieve pressure after test. Disc

34、harge some water directly for the amountof water is not much.6.4.7 试验合格后，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 th

35、e bell. Use the shear resistant ability to resist the axial stress aroused by the pipe. The nylon bar should be coated lubrication oil evenly before insertion. No leakage is allowed. Squeeze the nylon bar through the insert hole on the bell. Pay attention to ensure the nylon bar shall be pushed alon

36、g tangent direction of the bell. Force evenly when pushing to prevent the nylon bar breaking till the specified length insert complete.6.4.8上述工作完成后立即回填，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及图纸51-8230-8100-3002上的要求。具体回填的程序见WI-8710-8100-0030。 Backfill immediately after the completion of

37、the above work, the socketl shall be obligated. Layering backfill shall be adopted. Backfill requirements shall apply with GB50268-97 Supply and drainage pipe construction and acceptance technical specification and drawing 51-8230-8100-3002.The main process of backfill is WI-8710-8100-0030.6.5 部分主管和

38、支管的连接采取现场开孔、粘结的连接方法，黏结处整体水压试验前不可回填，黏结工作由厂家技术人员完成，黏结时应考虑天气对黏结工作的影响，并要有防尘保护措施。胶结过程应在2小时内完成。由厂家检测黏结质量。黏结部位待整体水压试验合格后进行回填。详细的黏结程序见后面的附文2。The connection of the main pipe and branch use site tapping and bonding. No backfill is allowed before overall hydraulic test of the bonding. Bonding work shall be don

39、e by technician from manufacurer. Consider the influence of the weather to the bonding and dust protection measures should be taken. Cementing should be finished within 2 hours. Backfill after the overall hydraulic test is qualified, The main process of stick is rider 2.6.6 阀门的安装Erection of valves6.

40、6.1 阀门到货后应对阀门进行全面检查，厂家资料应齐全，表面无沙眼，操作机构灵活，水压试验合格。Carry out an overall inspection after the arrival of valves. Manufacturer s document shall be complete. There isnt any air pocket on the valve surface and the operational part shall be flexible.6.6.2 阀门搬运时不得损坏阀门，应按厂家要求储存阀门。Do not hurt valves during tra

41、nsportation. Store them according to manufacturer requirements.6.6.3阀门安装根据介质流向确定其安装方向。Determine the erection direction according to the medium flow direction.6.6.4 检验阀门安装的支撑，确定牢固后进行阀门的安装，阀门的安装位置应准确无误。Inspect the support of valve erection and make sure it is firm. The erection position of the valve s

42、hould be correct.6.6.5阀门的垫片应平整，表面光滑，如表面有气泡、沟槽，应更换合格垫片。 The valve gasket shall be flat and smooth. Any gasket with air bubble or ditch channel on the surface shall be replaced.6.6.6阀门安装前应清理干净，自然连接，无强力连接。Before erection, valves shall be cleaned up and the connection shall be naturely, without any forc

43、ed connection.6.6.7 将安装上的阀门进行调整，调整合适后将底角螺栓进行浇灌，固定阀门。Adjust the erected valves and then pour the base bolts to anchor valves.6.6.8 检查阀门的操作机构，操作机构应灵活准确，无卡涩现象。Inspect the operational part of valve. Make sure it is flexibly and precise. No block and unsmooth exist.6.6.9 转矩限制机构的保护动作准确、可靠。开度指示机构指示位置应正确。 P

44、rotection action of torque limit mechanism shall be correct and reliable. The denoting position of the opening denoting mechnism shall be correct.6.7 过路管的安装 erection of the pipe crossing road6.7.1 管道过路采用C20混凝土包层对玻璃钢管道进行保护。GRP pipe should be protected by C20 concrete clad when the pipe is crossing th

45、e road.6.7.2 安装过路管时，须在玻璃钢管外表面缠上橡胶板或垫板作保护材料，同时在路的另一侧设置一固定钢支架，将倒链或紧绳器将玻璃钢管从混凝土包层内拉出，然后按正常连接方法将管道连接。When erecting the pipe crossing the road, twist rubber plate or back plate on the outside surface of the GRP pipe as protection material. At the same time, set a fixed steel support on the other side of

46、the road. Draw the GRP pipe from the concrete clad using chain block or euphroe. Then connect the pipe using the normal connecting method.6.7.3 管道和混凝土包层间应采用水泥砂浆进行填充，填充时的最大灌浆压力不得大于0.54bar 。Fill the space between the pipe and the concrete clad using cement mortar. The maximum grouting pressure should

47、be no more than 0.54bar when filling.6.8 管道法兰安装 erection of pipe flange6.8.1 法兰安装前，应检查法兰的压力等级、规格、尺寸等参数是否符合设计要求，厂家资料应齐全。Check whether the pressure class, specification and size of the flange meet the design requirement before erection. Manufacturers document shall be all complete.6.8.2 对检查法兰的密封面及密封垫片

48、进行外观检验，不得有影响密封性能的缺陷存在。Check the sealing surface and sealing gasket of the flange visually. No defect affecting sealing performance exists.6.8.3 检查法兰端面的垂直度，偏差不大于1mm 。Check the verticality of the flange end. The deviation should be no more than 1mm.6.8.4 搬运法兰不得碰坏法兰的接触面，应按生产厂家的要求进行存放。The flange interfa

49、ce must not be collided during transportation. Flangestorage shall meet the manufacturers requirements.6.8.5 法兰连接应保持同轴，并使用同一规格螺栓、螺母，安装方向应一致，紧力均匀，并应露出23扣，螺纹处涂二硫化钼。The flange connection should keep on the same axle and use the bolt with same specification and same erection direction. Tighten symmetric

50、ally and evenly. The extrusion length of the screw should be 2-3 times of the pitch. Supramoly shall be coated on the screw thread.6.9 现场整体水压试验 hydraulic whole test on site6.9.1 管道在试验前应具备下列条件：The following conditions should be available before test: 管道的坐标、标高、坡度检查合格， 除黏结处及承插口处露外，回填完毕。 The coordinate,

51、 elevation and slope of the pipe should be checkedqualified. Backfill complete except the bonding connection and the exposure part of socket. 所有支管设置好堵板。 Closure plate shall be equipped for all branch pipes. 管道内部杂物清理干净。 Clean the inner sundries inside the pipe. 管道系统上不参与试压的设备、仪表、阀门等隔开，不得有安全阀、水锤消除器等附件。

52、 Block off the equipment, instrument and valve which are not involved inthe test. No attachment, such as safety valve, water hammer and silencer exist. 试验用临时管道、阀门及压力表等安装完成，试验用压力表采用Y-150型，精度不低于1.5级，使用前应校正。 The erection of temporary pipe, valve and manometer for test arecomplete. Use the pressure guag

53、e of Y-150. The precision of the manometer is no less than 1.5 degree. Adjust it before use. 试验段两端封闭完成，不得采用闸阀作为堵板。临时排水管道完成。 After the both ends of the test section are finished, it is not allowed to usewedge valve as plug. Temporary drainage pipe is complete. 管件的支墩、锚固设计已经达到设计强度，未设支墩及锚固设施的管件，应采取加固措施。

54、 The pier and anchor of the pipe is up to the design strength.Reinforcement measures should be taken for the pipe without pier and anchor.6.9.2 注入试验用水：water for test filling 试验用水用100的软管从距试验点最近的水源取水。 The water for test is got from the nearest water source from the testpoint by 100 hose. 充水时为防止水锤冲击，应缓

55、慢充水，充水速度约为0.6m/s，最大不超过1.8m/s。流速可通过安在管道中的流速表进行测量。进水前，应打开管道高处的排气阀, 待水灌满后，关闭排气阀和进水阀。排气阀设在支管的高处。 Fill slowly to prevent water hammer striking during water filling. The fillingspeed is about 0.6m/s and not over 1.8m/s. velocity of flow can be measured by watch of velocity of flow which be installed in th

56、e pipelines. In front of entering the water, open each high vent valve on the pipe ,Close the vent valve and inlet valve when the water is filled full. vent valve is installed high place of branch pipeline. 将管道进行充分浸泡，浸润时间为12小时。 Soak the pipe completely for 12 hours.6.9.3 用电动试压泵试压，压力逐渐升高，加压到一定数值时，停下来

57、对管道进行检查，无问题时继续加压，升至试验压力的时间不得小于1小时，以减少冲击力。水压试验用于检验管道的强度，试验压力为1.5倍的设计压力（12bar ）。 Test the pressure by manual hydraulic test pump or motor test pump. The pressure will be increased gradually. When the pressure reaches a certain value, stop and check the pipe. If there is no problem, increase the pressure continually. The time for pressure increasing to the test pressure is no less than 1 hour thus to decrease the impact force. The hydraulic test is used totest the strength of the pipe. The test pressure is 1.5 times of the design pressure （12bar ）.