埋地管道施工方案(Rev3)

1、Page of16Rev.2目录ContentTOC o 1-5 h z HYPERLINK l bookmark0 编制说明Explanation1 HYPERLINK l bookmark2 编制依据Basis1 HYPERLINK l bookmark4 施工程序ConstructionPrinciple2施工前准备Constructionpreparation2 HYPERLINK l bookmark6 施工方法及质量要求Technologyandqualityrequirements3安全技术措施Safetyandtechnologymeasures13劳动力配置计划Manpowe

2、rschedule14 HYPERLINK l bookmark8 主要工、机具计划和手段用料计划Equipment,toolsandmaterialschedule15检验、测量器具配备表Inspectionandmeasuringgage16编制说明Explanation上海孚宝港务有限公司漕泾罐区埋地管道依据目前2004年3月3日RCC提供的地下消防管施工图。此方案的劳动力配置计划，主要工、机具计划和手段用料及计划检验、测量器具配备表均按施工图埋地消防管道工程4500m配备。UndergroundpipelineofCaojingtankfarmofVopakShanghaiLogist

3、icsCO.,LTDisaround4500minaccordancewiththeundergroundpipelinesketch.Thelengthofthepipelineisgiventoinstructthecompilingofconstructionorganization.Suchas,themanpowerschedule,equipment,toolandmaterialscheduleandinspection,measuringinstrument.编制依据Basis孚宝管道施工规范SP610-04SPCIFICATIONFORFABRICATION,ERECTION

4、,TESTINGANDCOMMISSONOFPIPING孚宝埋地管道防腐施工规范SP610-05SPECIFICATIONFORUNDERROUNDPIPINGPROTECTION孚宝埋地管道安装施工规范SP610-06SPECIFICATIONFORINSTALLATIONOFBURIEDPIPESASME管道施工规范ASMEB31.3ASMECodeforpressurePiping工业金属管道工程施工及验收规范GB50235-97ConstructionandAcceptanceCodeonIndustrialMetalPipelineGB50235-972.6现场设备、工业管道焊接工程

5、施工及验收规范GB50236-98ConstructionandAcceptanceCodeonEquipment&PipelineWeldingGB50236-982.7浙江天正设计院的设计图纸ConstructiondrawingsfromZhejiangTitanDesign&EngineeringCo.LTD施工程序ConstructionPrinciple埋地管道施工基本原则：先主管后支管，先大管后小管；先深管后浅管。BasicPrincipleforundergroundpipelineconstructionis:mainpipelinefirst,branchafterward

6、s.Pipelineindeepplacefirst,inshallowplaceafterwards.施工进行的施工方法，见施工流程图Constructionprocessdiagram附件1Attachment1施工前准备Constructionpreparation埋地管道工程属于隐蔽工程，要求在质量上、施工组织上进行合理的规划和控制，要求所有参加施工的员工了解地下管网施工中的关键点和难点。Undergroundpipelineisconcealedproject.Itisrequiredthatreasonableplanandcontrolforqualityandconstruct

7、ionorganizationshallbecarriedoutcarefully.Thekeypointsanddifficultpointsinundergroundpipelineconstructionshallbeknownclearlybyallthestaffworkedinthisproject.埋地管道的坐标、坡度是管网施工中最易出问题的地方，要求对每一条管线应画出它的走向图、标示书、标高、坐标、管径、高程及各个拐点、起伏点，尤其是相距交叉的管道应在交叉部位标注出高程和管径，在施工中应反复测量核实避免出现管线交叉相撞的情况。Thecoordinateandtheslopeco

8、nstructionoftheundergroundpipelineconstructionshallbetakeintocarefulconsideration.Directiondiagram,level,coordinate,diameter,Elevation,turningpointsofeachpipelineshallbemarkedclearly.Measurementofthepipelineshallbedonewelltoavoidpipelinecollisionduringtheconstructionperiod.根据施工组织的要求，合理的组织各种材料进场，尽量减少

9、占用场地，同时又能保证工程进度所需的各种材料，做好计划工作。MaterialenteringintositeshallbeorganizedreasonablyinaccordancewiththeconstructionorganizationtokeepthematerialsfortheprojectisDeliveryontimeandtoreducetheplaceoccupation.施工方法及质量要求Technologyandqualityrequirements施工测量Constructionsurvey施工前，建设单位组织有关单位向施工单位进行现场交桩。Priortocons

10、truction,Controlpointtoconstructionunitshallbecarriedoutbyrelevantunits.临时水准点和管道轴线控制桩设置牢固，易于观测，开槽铺设管道的沿线临时水准点，每200m设1个以上。Temporarydemarcationandcontrolpointofthepipelineshallbefixedsteadyandshallbemeasuredeasily.Temporarydemarcationforpipelayingofchannelshallbesetupatthedistanceof200m/each.临时水准点，管道轴

11、线控制桩，高程桩，应经过复核后方可使用并加以保护，施工过程中应经常校核，防止被破坏。Temporarydemarcation,Benchmark&Coordinatescontrolpointshallbeusedonlyaftergotcheckedandprotected.Regularcheckingfortheseitemsshallbedonewellduringtheconstructiontoensureaccuracy.施工测量的允许偏差应满足下列要求Measuringtoleranceshallbeinconformitywiththefollowingrequirement

12、s:序号S/N检杳项目Items允许偏差Tolerance1水准点测量高程闭分差Elevationdifference207L(mm)2导线测量方位角闭合差directionangledifference40乔(mm)3导线测量相对新分差relativedifference1/30004直接大量测距两次较差differenceontwicemeasuring1/5000注：1、L为水准测量闭合路线的长度（km）。Note:1.Listhelengthofclosedlinewithhorizontalmeasuring.2、n为水准或导线测量的测站数。2.nismeasuringpointsw

13、ithhorizontalorleadmeasuring沟槽开挖与回填Trenchexcavationandbackfilling开槽准备：开槽前应仔细测量放线，明确开挖的宽度、坡度和深度；在建设单位的组织下了解管线走向及地下障碍物的情况并做出标示，对于不能完全确定的地下障碍物应找斟探部门仔细的核实。Preparation:demarcationshallbemarkedcarefullypriortoexcavation.Thewidth,slopeanddepthofthetrenchshallbeknownclearly.Thedirectionofthepipelineshallbek

14、nownandtheobstaclesundergroundshallbemarkedclearly.Theunclearobstaclesundergroundshallbecheckedcarefullybyinvestigationdepartment.5.2.2开槽的原则：以机械开挖，人工清槽为主，机械开挖到管底设计深度以上100mm,然后人工清到设计标高，禁止扰动原土层。在槽底需再挖出100X200mm槽，槽内充软沙压实。Principle:mechanicalandmanualexcavationisthemainmethod.Thedepthoftheexcavationshal

15、lbeexcavatedfirstlyatabove100mmofthedesigneddepth,andfollowingmanualexcavation.Originalearthshallnotbespoiled.Inthetrench-bedachannelof100mmdepthand200mmwidthshallbeopened.Whichshallbeputsoftsandtofromcradlefortheplacementofpipingwhenproperlycompacted.5.2.3沟槽排水：因本工程地下水位较高，应在沟槽设置井点降水，将水位降至沟槽底以下0.5m；沟

16、槽开挖后沟内应设置排水沟和排水井，并及时将沟槽内的水排走。Waterdraining:de-wateringunitshallbesetupfortrench.Thelevelofthewatershallbeat0.5matthebottomofthetrench.De-watertrenchandwellshallbesetupafterexcavation.De-watershallbedonetimely.管道沟槽底部的开挖宽度按下式计算：Excavationslopeforthebottomofthetrenchshallbecalculatedasfollows:B=D+2(b+b

17、+b)1123其中：B管道沟槽底部的开挖宽度(mm)Note:BExcavationwidthatthebottomofthetrench(mm)D管道结构的外缘宽度(mm)1Dexternalwidthofthepipelinestructure(mm)1b管道一侧的工作面宽度(mm)1bwidthonthepipelineside(mm)1b2管道一侧的支撑厚度，可取150-200mmb2supportwidthonthepipelineside，normally150-200mmb3现场浇筑混凝土或钢筋混凝土管渠一侧模板的厚度(mm)b3widthonthetemplatesideofc

18、astinplaceconcreteorreinforcedconcrete(mm)沟槽开挖的坡度根据土壤地区情况，地下水位及管沟的深度来确定，必要时沟槽还需进行支撑，以保证管道施工时不塌方不影响管道的下管工作。Theslopeoftheexcavationshallbedeterminedinaccordancewiththesoiltexture,undergroundwaterlevelanddepthofthetrench.Supportshallbegivenfortrenchwhilenecessarytoavoidlandslip.管沟回填Trenchbackfilling管沟回

19、填前要求:各种隐蔽工程检查合格，包括管道坐标、标高、防腐焊接、水压试验合格并经工程监理确认，施工记录齐全；Beforetrenchbackfillingalltheconcealeditemsincludingpipelinecoordinate,elevation,weldinganti-corrosiveHydrotestshouldbegotapprovedandcheckedbythethirdpart.Alltheconstructionrecordscompleted.沟槽回填前清除槽内的杂物（木块、石块、土块等），保证沟槽内不得有积水，槽底100mm软沙，管顶150mm软沙。回填

20、土从管道两侧均匀对称倒入轻压夯实。Rubbishinthetrenchshallbecleanedpriortobackfillingtoassurethereisnotrappedwaterinthetrench.Thelayerfrombelowpipebottom100mmtoabovepipetop150mmmustusefinesand.管道两侧回填土的压实度应满足：对钢管道，其压实度不小于95%；沟槽位于路基范围以内，其管顶以上250mm范围内回填土表层的压实度不小于87%,其它部位回填土的压实度符合规范规定。沟槽位于路基以外，其管顶以上高为500mm应松填，其压实度不大于85%，

21、其余部位不小于90%。Densityoftheearthatthetwosidesofthepipelineshallbeinconformitywiththefollowingrequirements:forthesteelpipeline,densityshallnotlessthan95%.Forthetrenchwhichlocatedintheroadbed,thedensityofthesurfaceearthatthe250mmabovethepipeshallnotlessthan87%.Forotherparts,thedensityshallbeinconformitywi

22、ththerequirementsinthespecification.Forthetrenchwhichlocatedoutoftheroadbed,thedensityatthe500mmabovethepipeshallbelooselybackfilled.Thedensityshallnotmorethan85%.Forotherparts,thedensityshallnotlessthan90%.管道试压及试水合格、接口防腐完毕、检查验收合格后，可进行回填。Backfillingshallbedoneonlyafterpipelinepressuretestandwatertes

23、tapprovedandanti-corrosiveatthepipejointscompleted.雨季施工为防止未及时回填的管道漂浮，将采取管道随铺随埋的措施，对于未在地上试压的管道焊缝区域将被预留。Duringconstructioninrainyse-sonbackfillingshallbecarriedoutassoonaspipeislowedintotrenchbutweldingareashallberemainedforun-hydrotestpipeline.管道施工Pipingwork5.4.1管道安装Pipelineinstallation确保管道内干净

24、、无杂物，所有管道材料及预制完成管道端口必须封口。Theinsideofpipeshallbeclean.Thepipeshallbesealedafterwelding.分段组对，加大地上预制深度。管口组对焊接时，搭设可移动的防雨棚，保证焊接质量。已加工坡口的管端或未施工完的接口用塑料膜和胶带包敷好。Inordertomarktheinstallationmoresmoothly,theweldingworkofpipingshallbedoneoutofthetrenchasmanyaspossible.Forthegrooveandunfinishedweldjunction,Plast

25、icpaperandtapewillbeusedtoprotectit.管道安装前检查防腐层有无破损情况，否则及时修补。防腐好管道在运输、装卸、吊装过程中应做好软性隔离（如垫沙袋、使用软吊装带等）；管道氧乙炔焰切口、砂轮机打磨以及管道焊接时，也要做好有效隔离（如使用园环形隔板），防止氧乙炔焰和飞溅破坏防腐层。Priortoinstallation,Wrappinglayerofthepipeshallbecheckedfirstlytoassurethereisnodamageonit.Properprotectionforpipeshallbetakenduringtheloading.Wh

26、erethegascuttingorgrindingisexecuted,theprotectionplateshallbeusedtoprotectthewrappinglayerisfreeofanydamage.管道下沟前再次测量确认沟底的标高，管基质量，并标出管道安装中轴线。Priortolayingthepipeintotrench,thelevel,slope,andmaterialatthebottomofthetrenchshallbecheckedagain.Axlelineshallbemarkedclearly.管道下沟采用专用软吊装带。管道下管时要平稳，不得触碰沟壁或沟

27、槽支撑板等挡土设施。管沟底部间隔2-3m放置沙袋，管道下沟后平放于沙袋上，以便于管道调直对口（具体见附图3）。Specialliftingbeltshallbeusedinlayingthepipeintothetrench.Layingthepipeshallbesteady.Avoidhittingtrenchedgeorshoringsheet.Every2-3meteronthebottomoftrenchwilllaythesandbagtogivetheprotectiontothepiping.Andbythisway,itisalsoveryeasytoadjustthepip

28、ingposition.管道组对时可用龙门吊和卡具配合组对，管道定位时每根管子必须按中心线找直对中，管底与管沟基底贴合紧密。Frameandpipeclampshallbeusedforassemblingandjunctionofthepipe.Placingofthepipeshallbeinaccordancewiththecenterlineandthepipeshallbeplacedcloselywiththetrenchbed.管道上安装的法兰面与管中心线垂直，接口的两片法兰面相互平行，螺栓应自由的穿过两片法兰的螺栓孔，螺栓安装方向一致，螺母应对称紧固，紧固好的螺栓应露出螺母之外

29、23扣。Theflangeshallbeinverticalwiththepipecenter.Thetwoflangesurfaceshallbehorizontal.Theboltsshallbeinthesamedirection.Andthenutshallbefixedclosely.管道安装后，要及时将管口用塑料管帽或软木塞及厚塑料薄膜包扎封闭，以防止雨水和杂物进入管内。Afterpipinginstallation,thecorkorplasticcupwillbepluggedintobothsidestopreventtherainwaterofsundriesintothe

30、pipe.管道试压和回填要尽量安排在停雨期间进行，并且排尽沟内积水。管道清理后，要尽快组织试压和回填。如来不及试压，可将焊口两侧各1米位置留出，其余位置全部回填，防止管道漂浮。Aftercleantheinsideoftrench,thepipelinepressuretestandtrenchbackfillwillbeperformedassoonaspossible.Ifaftertrenchcleaning,thetestcantbeperformtimely,trenchbackingwillbedonefirst.And1meteronbothsideofweldingjointw

31、illbeleftwithoutbackfill.过马路埋地管施工：所有从马路或水沟下面穿过的埋地消防管，应尽量在马路施工前完成。如马路先施工，有埋地管穿过的地方应协调预留，预留宽度以管道中心两侧各500mm，待埋地管道回填后再施工。Pipeacrosstheroad:allthefirefightingwaterpipingwhichwillacrosstheroaddrainwillbedonebeforeroadanddrainconstruction.Iftheroadconstructionstart,shallwaitforpipingfirstthepipecrossingpor

32、tion.管道焊接管道焊接采用手工焊（氩弧焊打底，电弧焊填充盖面），采用“V”型坡口，其尺寸见下表，管道对口时应使内壁齐平，错口偏差为0.21,且不得大于1.5mm；Manualweldingshallbeusedforpipewelding（RootGTAW,capSMAW）.Thejointsofthepipeshallbeevenness.Thetoleranceis0.2tbutnotmorethan2mm.GrooveshallbeinthetypeofV.thesizeisasfollows.表5-3table5-3壁厚（mm）间隙（mm）错边（mm）stagger坡

33、口角度a（）thickness4-9clearance1.5-3.01.0-1.5groove10-262.0-4.01.560焊接材料：氩弧打底采用H08Mn2SiA焊丝，焊条采用J422焊条。Weldingmaterial:H08Mn2SiAforGTAW;J422forSMAW.钢管对口检查合格后可以进行点焊，点焊采用与接口相同的焊接材料，点焊时对称施焊，厚度与第一层焊接厚度一致，钢管的纵向焊缝与螺旋焊缝处不得点焊。点焊长度及间距符合下表。Tackweldingshallbedoneafterjointofthesteelpipegotcheckedandapproved

34、.Weldingshallbeusedsameweldingmaterialasjoint.Symmetryweldingshallbedonewellinspotwelding.Thethicknessshallbethesamewiththefirstlayer.Weldingshallnotbeusedinlongitudeandtraverseseamofthesteelpipe.Thelengthandthedistanceofthespotweldingshallbeinconformitywiththerequirementsgivenbelow.表5-4管径（mm）diamet

35、er点焊长度（mm）length环向点焊点（处）spotsontraversedirection350-50050-605600-70060-706$80080-100点焊间距不大于400mmthedistanceofthetackshallnotmorethan400mm.管道焊接完，水压试验前对焊缝进行外观检查，当有特殊要求时进行无损探伤检验；不合格的焊缝应返修，返修次数不得超过三次，焊缝的外观质量见下表。Visualcheckshallbedoneafterweldingandbeforewaterpressuretest.NDTtestshallbedoneinaccordancewi

36、ththerequirements.Theunqualifiedseamshallberepaired.Andrepairshallnotmorethanthreetimes.Thevisualqualityoftheseamshallbeinconformitywiththerequirementsgivenbelow.焊缝的外观质量Visualqualityoftheseam检杳项目item技术要求technicalrequirement外观visual不得有熔化金属流到焊缝未熔化的母材上，焊缝和热影响区表面不得有裂纹、气孔、弧坑和灰渣等缺陷，表面光顺，均匀，焊道与母材应平缓过渡thebo

37、dymaterialshallnotbecontaminatedwithsmeltmetal.Nocrack,airhole,unevenness,etcdefectsareallowedonthesurfaceoftheseamandheatinfectingareas.Surfaceshallbesmoothandevenness.Theseamandthebodyshallbesmooth.宽度width应焊出坡口边缘2-3mm2-3mmoftheedgeofthegroove表面余咼surfaceheight应小于或等于1+0.2倍坡口边缘宽度，且不应大于4mmshallnotmore

38、than1+0.2timesofthewidthattheedgeofthegroovandshallnotmorethan4mm.咬边overlap深度应小于或等于0.5mm，焊缝两侧咬边总长不得超过焊缝长度的10%，且连续长度不应大于100mmdepthshallnotmorethan0.5mm.thelengthoftheoverlapshallnotmorethan10%oftheseamandthecontinuousoverlapshallnotmorethan100mm.错边stagger应小于或等于0.21,且不应大于2mm(t为壁厚mm)未焊满nonwelded不允许nota

39、llowed钢管安装允许偏差Installationtolerance检查项目items允许偏差(mm)tolerance压力管道Pressurepipeline轴线位置axleposition30高程high-lift20焊缝无损检测：因设计未说明，根据规范管道对接焊缝拟按照5%比例进行射线照相抽样检查；当抽样检查未发现需返修的焊缝缺陷时，则抽样检验所代表的一批焊缝应认为全部合格；当抽样检查发现需返修的焊缝缺陷时，除返修该焊缝外，还应用原规定办法进一步检验。每出现一道不合格焊缝应再检验两道该焊工所焊的同一时间同一批焊缝，如果这两道合格，则应认为检验所代表的这一批焊缝合格。如果这两道焊缝又出现

40、不合格，每道不合格焊缝应现再检查该焊工同期同批焊缝两道，当再次检验的焊缝均合格时，则可认为检验所代表的一批焊缝合格。当再次检验又出现不合格时，应对该焊工同期同批焊缝进行全部检验，该焊工需重新考试合格后上UU岗。注：同期同批焊缝指一个阶段内同一条线的焊缝。NDE：the5%RTwillbeperformedaccordingtotheSpecification(ASMEB31.3;GB50235).Ifnodefectwasfound,thisbatchofweldingjointwillbeconsideracceptance.Ifanydefectwasfound,theinspectedw

41、eldjointwillberepairedaccordingly.AndthemoreRTwillbeperformedaccordingtotheSpecification.管道防腐Pipelineanti-corrosion本工程地下管道防腐见防腐施工程序。Themethodoftheundergroundpipelineanti-corrosionofthisprojectcanbefindinanti-corrosiveconstructionprocedure.压力管道的强度及严密性试验Strengthandtightnesstestforpressurepipeline.5.4.

42、5.1管道试验前，应对管道、伸缩器、节点、支墩、井及其它附属构筑物进行检查，对管道的标高、坐标及回填质量进行检查，管道的施工记录是否齐全等。Priortotest,pipeline,flexibleinstrument,joint,support,wellandotheraccessoriesofthepipe,elevationandcoordinationofthepipe,backfillingqualityandconstructionrecordofthepipelineshallbecheckedfirstly.编制试压系统图及平面布置图（具体见附图1、2），试压系统图应包括设置紧

43、急排放管线。确定分段试压顺序，确定好管线的注水点、排水点，压力表的设置位置，压力表的量程及精度等级应满足规范要求，使用前应校正，向管内注水时注意排气以保证管道充灌水，气体排尽。WaterPouringanddrainingpointshallbeassured.Thelocation,dominationandpreciseclassofthepressuregageshallbeinconformitywiththerequirementsofthespecification.Checkshallbedonepriortouse.Gasdrainageshallbetakenintocons

44、iderationwhilepouringwaterintopipe.管道内充满水后，升压时要缓慢分级升压，每升一级应检查支墩，管身及接口，当无异常现象后再继续升压。水压升至试验压力后保持10分钟，压力降不应大于0.05Mpa，检查接口、管身无破损及漏水现象时管道强度试验为合格。Afterwaterpouring,Pressurepromotingshallbeslowandpromotedbyclass.Support,pipeandjointshallbecheckedafteroneclasspressurepromoting.Pressureshallbekeptfor10minute

45、safterpressurereachthetestpressure.Ifthereisnodamageandwaterleakageofthejointandpipe,thestrengthtestshallbeeligible.管道强度试验合格后进行管道严密性试验，压力应保持不变，不渗不漏为合格。Tightnesstestshallbedoneaftereligiblestrengthtest.Theamountofthewaterleakageshallbelessthantherequirementofthespecification.管道压力试验的试验压力见下表Testpressur

46、eforstrengthtestisasfollows.官材种类material工作压力P(Mpa)working试验压力（MPa）testpressurepressure钢管steelpipe0.8管道试验合格后，竣工前应进行冲洗，冲洗采用洁净水流且不小于l.Om/s，连续冲洗直至出口处的浓度，色度与入口处的冲洗水强度，色度相同为止。Flushingshallbedoneafterpipelinetestandbeforecompletionoftheconstruction.Thewaterusedforflushingshallbecleanwaterandthevelo

47、cityofthewatershallnotlessthan1.0m/s.Theflushingshallbefinishedwhenthedensity,colorofthewaterattheexitisthesamewiththeentrance.安全技术措施Safetyandtechnologymeasures所有参与施工的人员应进行入场安全教育，了解业主的安全管理制度，熟悉施工现场的作业环境，签字、安全协议。Alltheconstructionworkersshouldpasssafetytraining.Alltheworkersshouldbeacquaintancewithth

48、esafetyrulesgivenbytheowner.Andalltheworkersshouldknowtheworkingcircumstancesandshouldsignthesafetyagreements.项目部针对专业作业情况制定安全管理措施，组织相关人员学习，落实各种安全劳保用品，技术措施准备情况，以保证各种安全管理的措施落实到位。Safetymeasureforspecialdisciplineshallbesetupbyprojectorganization.PPEshallbeequippedcompletely.Allkindsofsafetymeasuresshal

49、lbecarriedoutcarefully.施工人员入场作业必须穿戴好劳保用品。PPEshallbewornwellwhileworkerenteringintosite.管道施工时要办理动土证、动火证，狭处作业，许可证等，禁止盲动。EarthWorkCertification,HotWorkCertification,andcertificationforworkinginnarrowplaceshallbecompleted.Workingwithoutcertificationisstrictlyforbidden.土方开挖后应及时的加支撑，开挖时按要求放坡，开挖拉走禁止在沟边堆放大量的土方，回填的土方应按规范要求堆到距沟边0.5米以外。Supportshallbes