地下GRP管道施工方案.docx

地下GRP管道施工方案.docx

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地下GRP管道施工方案

MethodStatementUndergroundGRP

PipingInstallationWorks

Title:

UndergroundGRPPipingInstallationProcedure

TCCPreparedBy

Name:

Position:

Signature:

Date:

DAELIMApproval

Name:

Position:

Signature:

Date:

ApprovedByClient

Name:

Position:

Signature:

Date:

Rev.0

ThisDocumentisthepropertyofTCC.Issuedto,andusedbyothersneedsthewrittenapprovaloftheTCCQualityManager.

CONTENTS

1.0Purpose

2.0Scope

3.0Reference

4.0Responsibilities

5.0EquipmentsandTools

6.0LaminationProcessSequence

7.0BondingMaterials

8.0ReceivingHandlingandStoringofPipe

9.0ArrangePipeinTrench

10.0JointLaminateProcedure

11.0QualityRequirements

12.0SafetyPrecaution

13.0Attachments

1.Purpose

ThismethodstatementistoguidebuttjointwraplaminationworkofU/GGRPpipingsystemintheArabianChlorVinylProject.

2.Scope

ThisMethodStatementcoversthefieldlaminationjointsinstallationmethodofundergroundGRPpiping.

ThisprocedureisapplicabletoallU/GGRPpipediameters.

RelateddataofU/GpipingGRPpartisasfollowing:

Systemdescription

Materialclass

Diameterrange

ConnectionMethod

WW

DGAANA

4”,6”,8”,10”,12”,20

Butt&wrapjointlamination

ACW

DGAANA

4”

Butt&wrapjointlamination

PCS

DGAANA

4”

Butt&wrapjointlamination

3.Reference

1Thedrawingof

080036-AA-DA-100201~400207U/GCompositeDWG

2Specification:

080036-AA-SG-007SpecificationforUndergroundPiping&SurfaceDrainage

080036-XH-SG-003Specificationforpipingconstruction

080036-XZ-SG-001SpecificationforPipingDesign

080036-QZ-PL-001ProjectQualityPlan

080036-XH-SG-006SpecificationforIdentificationofPipingMaterial

080036-XH-SL-005SpecificationforPipingMaterial

AMIANTITdocument:

FieldButt&WrapJointProcedureForGRP/FRPPiping

InstallationandHandlingInstructionsForRigidJointPipe

FieldLaminationProcesssheet

4.Responsibilities

4.1GRPManager

InchargeofalltheactivityduringtheGRPpipeconstruction.Mainlyinvolvethesafety,techniqueandqualityproblemsduringtheconstruction,preparingandcarryingouttheconstructionschedules.

4.2QCSupervisor

InchargeofskilltrainingforallthepersonnelwhowillengagetheGRPpipingwork,analyzingthesafetyissuesandprovidingprecautions.Applyingforworkpermits

4.3QCInspector

CompilingQCprecautions,solvingtheQCissuesduringGRPpipingconstruction,takingpartinqualityinspectionandacceptanceandtakingthemajorresponsibilitiesforthequalityoftheGRPpiping.

5.EquipmentsandTools

ThebelowitemsareusedfortheGRPPipinghandlingandConstruction:

☻Boomtrucks,trailersandcranes,shackles,slingsbelts,supports,crosstieforpipingtransportation

☻Anglegrinder,diamondblades,diegrinderandflapwheelsforcuttingandgrinding

☻Squarebasin,paintrollers,brushesandSteelgroovedrollersforlamination

☻HotairdryerandDigitalinfraredthermometerforcuring（ifrequired）

☻MeasuringtapeandBarcolhardnesstesterforlaminationtest.

☻Mobiledrumcradle,spilldecks,pluglesstapandsteelgantriesforresinstore.

☻Glasscuttingtable,rollingtubes,knives,bladesandscissorsforglassprepare.

☻Buckets,Liquidstoragecontainers,platformbalance,stirrer,spilltraysforresinmeasureandmixture.

☻Dispensingbottles（orsimilartools）andchemicalagentbottlesformeasuringandbringingcatalysttosite.

☻Brassbristles,plasticbrush,cleaningbasin,dusterclothfortoolscleaning.

6.laminationProcessSequence

7.BondingMaterials

Usedcomponents

RESIN:

EpoxyvinylesterresinsuppliedfromAmiantit,andtobemixeditwithcatalyst.

CATALYST:

Methylethylketoneperoxide.

Mat&WOVENROVING:

glassreinforcementforjointstructure.

BONDINGMATERIALSSTORAGEandUSAGE:

DetailsseeattachmentA:

FieldButt&WrapJointProcedurePage4to5.

Thelocationofresin,W-Fluid,catalyst&glassreinforcementcontainerasshowinfigure7-1

Figure7-1

Storageoutlineofchemicalcontainerdetailsseeattachment-F:

InteriorlayoutforAmiantitResin&Catalyst

8.Receiving,HandlingandStoringofPipe

DetailsseeattachmentB:

InstallationandHandlingInstructionsForRigidJointPipePage2to4.

InspectingPipe

●AllpipesreceivingatsiteshallbeinspectedaccordingtoSpecificationforPipingMaterial.

●Brokenpipebundles,crushedfittingsboxesshouldbecheckedcarefully,scratchedandgougedandpipewithcrushedorsplitendsarenotallowedtouse,damageclaimsproceduresmustbeinitiatedpriortoacceptingtheshipment.

●Donotdisposeofanydamageditems.Ifanyimperfectionordamageisfound,immediatelysegregatetheaffectedpipesandcontactDealim.Donotusepipethatappearsdamagedordefective.

HandlingPipe

●Pipes,fittingsandprefabricatedparts（spools）havetobetransportedbysuitabletrucks.Thesetrucksmusthaveflatfloors.Checkandremoveanyprojectionsornailsetc.beforeeachload.Materialsmustbesecuredforexamplebyusingwedgesandwoodensupports.Thesesupportsmusthaveaminimumwidthof10cm,avoidingsharpedges.Thesupportdistancesmustnotexceed2.5m.

●Donotliftthepipebypassingaropethroughthesectionendtoend.

●Anypartofthetruckhastobeprotectedbywoodorrubberwhereverincontactwiththeproducts.Ifpipesarehandledbyaforklifter,theforksmustbecoveredwithrubberorplastic.

●Forworkonthepipe,suchascutting,preparingends,orcleaning,two-pointsupportisrecommendedfor20-footlengths,andthree-pointsupportfor40-footlengths.Supportwoodshouldbeensurednonails.

●Thebestwayforfittingstobetransportedisincratesorontopallets.Directcontactbetweenproductsduringtransportmustbeavoided.

PipeStorage

●Donotlaythepipesdirectlyontheground,railsorconcretefloors.

●Ensuresuitablesupportsareusedforexamplewoodenbeams,measuring10x5cm.Toavoiddamagetomachinedpipeends,stackingshouldbeundertakenwithcare.Themachinedendsmustbeprotectedforexamplebypolyethylenecoveredstrawmatsorpolyethylenenetting.

●Iftheproductisstackedtoohighforlongstorageperiods（6-12months）.Itisrecommendedthattheproductisstoredundertarpaulinsor（white）polyethylenesheeting.

●Pipestacksshouldhavesidesupportsorblockstopreventrollingorslippingofthestackduringstormyweather.Aleveled,softearthsurfacefreeofrocksandotherhardorsharpobjectsisrecommended.

9.ArrangePipeinTrench

PrepareandassemblepipeandjointsinaccordancewiththeISOdrawing,usingspecialcaretokeepjointsurfacecleananddry.

Positionpipeontimbersacrossditchasshowninfigure-1.Blockintopositiontoholdalignmentandpreventlateralmovement.

Jointthepipesufficientlyinadvanceofthepipeloweringoperationsothatnomovementofthepipewilltakeplaceatlocationwherejointsarebeingcured.Anyvibrationormovementofuncuredorpartiallycuredjointswillincreasetheriskofjointfailures.

Shouldbemakesurethedepthofthetrenchbeforelowingthepipe.Figure-1

Withpowerequipmentormanpower,raisethepipeslightlytoslidethetimbersupportfromunderthepipe.Lowerthepipeintothetrench.Donotdroporlowersuddenly.Repeattheaboveoperationateachsupport.Useropeorwebbedslingforliftingpipe.Ifmanpowerisused,itissuggestedthattwomenbeusedforlifting6-inchpipe,andfourmenandmuchmorebeusedforthe8-inchandbiggerpipe.

10.JointlaminationProcedure

10.1Cutting

Thisinitialstepshallbeapplicableonlyifapipeendneedstobecutandreplaced,orapipelengthrequiresfieldadjustment.Markthepipesectiontobecutusingawrap-aroundandawhitemarker.

Cutthepipeusingahacksaworadiamondcuttingdisc,makesurethatapropersquarecuthasbeenmade.Ensurethatcutendsremainwithinthetolerancesasshowintable10.1.

Table10.1:

Maximumtoleranceonsquareofcuttedpipeend

PipeSizeRange

Tolerance

（mm）

（mm）

（inch）

25-100

1-4

1.5

150-400

6-16

3.0

10.2Grinding

Grindingandcleanningthetotalexternalsurface.MakesurethatthepipeendsaregrindedaswellastherequiredlengthasattachmentC:

Fieldlaminationprocesssheet.

Startthelaminationofthefittedsectionswithintwohoursaftersanding;re-sandingofthelaminationareashallberequiredifthewaitingperiodexceedstwohours.

Bondingsurfacesmustbedryandcleanbeforesanding.Useflapperwheelsanderswithasmalldrillingmachine（1700-2000rpm）oremeryclothwithagridof60.Sandedsurfacesmusthaveadull,freshfinish,notapolishedlook.Removeanypossibledewbyslightlyheatingthepipeendsbyahotairdryer.

OtherdetailsseeattachmentA:

FieldButt&WrapJointProcedurePage7.

10.3Fittingup

1Checkthealignmentandfixingthepipeendsascloseaspossible,thenpreparetheputty.

2Applytheputtywithaputtyknifefillingallthegap;

3Afterthefillingofthegap,theputtyshallpolymerize,withoutmovingandbumpingthepieces.

4Oncecompletedthehardeningoftheputty,grindtheoutsideofthepipejointandcleanwithairblowandcleandustercloth.

Note:

Thegapshouldnotexceedthe5mmorasperrecommendedbyPipemanufactureratanycase.

10.4FieldJointKitsPrepare

DetailsseeattachmentA:

FieldButt&WrapJointProcedurePage8FIELDJOINTKITS.

Eachjointkitshouldbestoredinacloseroomtoavoiddust,damp&directsunlight,andshouldbestoredinadryareaandlessthan65%humidityinordertoavoidsurfacecondensationwhenusedinwarmerconditionsoutside.

10.5Laminationonthepipejoint

DetailsseeattachmentA:

FieldButt&WrapJointP