地下管道水压施工方案(刘在旭)

1、中国石化集团 第十建设公司THE TENTH CONSTRUCTION COMPANY OF SINOPEC目 录Index1.概述 General introduction：22.编写依据Reference：23.压力管道水压试验 Hydraulic test of pressure piping34.无压力管道水压试验 Hydraulic test of non-pressure piping65.阀门的水压试验 Hydraulic test of valve76.质量控制Quality control97.HSE措施 HSE measures98.施工机具及手段用料 Constructi

2、on tools and measurement material10 10/101.概述 General introduction：乙烯装置地下管道主要包括循环冷却给水管道SW、循环冷却回水管道RW、中间冷却给水管道IW、污染雨水及生产污水管道SD、消防水管道FW、清净雨水管道ND。管道材质有碳钢管和玻璃钢管。碳钢管总长度约为2300米，属于压力管道。玻璃钢管主要为污染雨水及生产污水管道总长度约为2500米，属于无压力管道。有用于消防管线的阀门54个。The underground piping of ethylene plant consist of cycle cooling water

3、 supply (SW), cycle cooling water return (RW), intermediate cooling water supply (IW), contaminated rain water and production sewage drainage (SD), fire water (FW), and non-contaminated rain water(ND) piping. And the materials of the pipe are carbon steel and fiberglass reinforced plastic. The total

4、 length of the carbon steel pipe is about 2300m and belongs to pressure piping. The fiberglass reinforced plastic that the total length is about 2500m and that is main contaminated rainwater and production sewage drainage belongs to non-pressure piping. There are 54 valves used for firewater piping.

5、2.编写依据Reference：2.1.设计图纸（3102-7900-S-135）Blue print（3102-7900-S-135）2.2.给水排水管道工程施工及验收规范（GB 50268-97）Specification for construction and acceptance of water supply and sewerage piping work（GB 50268-97）2.3.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规程。（CECS 129：2001）Specification for construction and acceptance of s

6、upply and sewerage of underground FRP piping（CECS 129：2001）2.4.石油化工给水排水管道工程施工及验收规范（SH3533）Specification for construction and acceptance of supply and sewerage of petrochemical（SH3533）2.5.管道现场试压 SD-00-TSC-PP-009Field pressure testing of piping (SD-00-TSC-PP-009)2.6.现场安装管道与预制设备的气密试验 SD-00-TSC-MS-0038P

7、neumatic test of field erection piping and fabrication equipment (SD-00-TSC-MS-0038)2.7.工业金属管道工程施工及验收规范 GB20235Specification of construction and acceptance of industrial metallic piping (GB20235)2.8.质量管理手册QG/M44.000.2001Quality management handbook (QG/M44.000.2001)2.9.中国石化集团第十建设公司质量管理程序文件QG/P44.000.

8、2001Quality management procure file of the tenth construction company of SINOPEC (QG/P44.000.2001)3.压力管道水压试验 Hydraulic test of pressure piping3.1试压前的准备 Preparation before testing3.1.1.钢管水压试验的管段长度不得超过1000m，试压前应对管段内部进行清理，将泥土及杂物彻底清理干净。The spool length of tested should not be more than 1000m. The dirt a

9、nd other foreign material should be removed from the piping before hydraulic testing.3.1.2.试压管段的两端应焊接盲板。试压管段不得采用闸阀做堵板，不得带消火栓、消防水炮和其它易损件进行试压。Blind should be welded to both end of the testing spool. Gate valve is not allowed to used as block plank and the hydrant, firefighting water monitor and other

10、vulnerable parts should be isolated when testing. 3.1.3.试压管段的排水应设在管段的低点，在管段的高点应设排气阀。The drainage should be at low point and air outlet valve should be at high point.3.1.4.试压用压力表采用弹簧式压力表，压力表的量程为试验压力的1.5倍，故选用量程为4.0Mpa的弹簧压力表。精度等级为1.5级，表盘公称直径为150mm，压力表应经检测合格，并在有效期内。且压力表不少于2块。一块放在试压泵处，一块放在远离试压泵处。The pres

11、sure gauge should be spring type and the range should be 1.5 times the testing pressure. The range of 4.0Mpa spring type pressure gauge should be selected. Its precision grade is 1.5 and nominal diameter of dial plate is 150mm. The pressure gauge should be inspected for acceptance and in the validit

12、y. The quantity should not be less than 2, one is near the pressure pump and another is far from the pressure pump.3.1.5.试压管段应在低点注水，以利气体排出。 Supply water from the low point so as to vent the gas3.1.6.水压试验前，除接口焊缝处外，管道两侧及管顶以上不小于500mm，应及时进行回填，水压试验合格后，应及时将剩余部分进行回填。Both side of the pipe except welds and t

13、he part no less than 500mm above pipe top should be backfilled in time before testing. After acceptance of the testing, the rest should be backfilled timely.3.1.7.水压试验前，应找好水源点，水源点应采用SECCO指定的水源，使用洁净水。接好临时线，安装好压力表。接好后检查一遍，看是否有漏水或连接不实的地方。The water source should be settled before testing and should be c

14、leaned water appointed by SECCO. Inspect the leakage or misconnection after connecting the temporary line and erecting the pressure gauge.3.2.压力管道水压试验 Hydraulic test of pressure piping3.2.1.管道水压试验压力为P+0.5且不小于0.9 MPa，其中P为工作压力（MPa）。根据设计图纸试验压力见下表。 The testing pressure of piping is P+0.5 and no less tha

15、n 0.9Mpa. Herein P is working pressure (Mpa). See the following table for testing pressure.管道名称Pipe line管材Material接口方式Connecting type工作压力Working pressure试验压力Testing pressureDW钢管Steel pipe焊接Welding0.4MPa0.9MPaFW钢管Steel pipe焊接Welding0.81.2MPa1.7MPaSW、RW、IW钢管Steel pipe焊接Welding0.45、0.21、0.45MPa0.9MPaWW

16、，SD钢管Steel pipe焊接Welding0.9MPa1.4MPa3.2.2.试验升压时采用电动试压泵，采用分级升压，首先升压到0.3MPa进行管道焊口及支墩的检查；无异常现象时再升压到工作压力,再对管道系统及支墩进行检查；无异常现象时，再升压到试验压力。Raise pressure with electro motion testing pump and classified. First, raise pressure to 0.3Mpa and check the piping welding seams and bracket. If there is no abnormal,

17、raise the pressure to working pressure and check the piping system and bracket. Keep on raising to testing pressure when no abnormal exist.3.2.3.水压升到试验压力后，保持恒压10min，检查焊口及管道系统无异常变形及漏水现象，则管道强度试验合格。 Maintain 10min after the pressure reaching the testing pressure; inspect welding joint and piping system

18、. The piping strength is qualified if there is no abnormal and leakage.3.2.4.水压试验合格后，应立即卸压，将管道里的水排出，然后进行沟槽回填。 After qualified, release pressure timely. Drain the water and backfill the trench.3.2.5.由于消防管线系统大，加上受工期、到货时间和其它作业影响，故无法进行整体试压，必须分段进行试压。对于部分支线受材料到货计划影响，可能暂时无法安装，因此无法带支线进行试压，根据实际情况，可以考虑二次试压。对于

19、可以进行二次试压的管线，可以先进行主线试压，待主线试压完毕后，进行管沟回填。当支线材料到货后，进行支线安装，然后通水进行整体试压。For fire water system is great and is influenced by program, material delivery date and other work, integral circuit testing cannot carried out and section spool testing will be used. For some branches affected by material delivery dat

20、e, the installation cannot be executed for the moment and testing can perform without the branch. The secondary testing can be taken into account for the branches according to the site situation. 3.2.6.根据SEI和烯烃包专业负责人的协商及监理的同意，对于不能进行二次试压的消防管线焊缝进行100%超声波无损检测，一级合格、加探1%射线探伤，三级合格、并同时进行100%渗透或磁粉检验。 In acc

21、ordance with the agreement of SEI, discipline responsible personnel of ethylene package and supervisor, 100% ultrasonic test should be performed for branches that cannot carry out secondary testing. For grade , additional 1% x-ray testing should be performed and for grade , 100% penetrant test or ma

22、gnetic powder test should be performed. 3.2.7.分段试压的划分如下：400-FW-1184202、400-FW-1184203、400-FW-1184205、400-FW-1184207、400-FW-1184208、DR7和DR8、DR9和DR10单独进行试压。400-FW-1184204分三段试压，第一段为950管廊北侧65米，第二段为950管廊南侧130米，第三段为960管廊75米。400-FW-1184206分二段试压，第一段为裂解炉东侧、8#和10#路边180米。第二段为汽油加氢区（GTU）240米。Section spool testin

23、g is divided as follows. 400-FW-1184202, 400-FW-1184203, 400-FW-1184205, 400-FW-1184207, 400-FW-1184208, DR7and DR8, and DR9 DR10 are all single testing system. 400-FW-1184204 is divided into three parts to test, one is 65m north of 950 pipe racks, the second one is 130m south of 950 pipe racks, and

24、 the third one is 75m of 950 pipe racks. 400-FW-1184206 is divided into two parts to test, one is 180m east of cracker and roadside of 8# and 10#, and the other is 240 of gas hydrogenation unit（GTU）。4.无压力管道水压试验 Hydraulic test of non-pressure piping4.1.无压力管道水压试验前的准备 Preparation before testing 4.1.1.管

25、道及检查井外观质量已经验收合格 Visual quality has been inspected and accepted for the piping and inspection well.4.1.2.管道已经对每一个玻璃钢管间的接口进行单口压力试验，试验压力为0.4Mpa，压力及试验时间根据玻璃钢管生产厂家的指导人员现场的要求确定，试验合格，无渗漏现象。Single pressure test has been performed for every FRP joint. The testing pressure is 0.4Mpa and the time should be con

26、firmed according to instructing staff from FRP manufacture. The test is qualified if no leakage exist.4.1.3.全部预留孔已经封堵，无渗漏现象。且管道两端堵板承载力应大于水压力的合力。The obligated holes are all blocked and without leakage. The load bearing of blind of both ends should be more than the composite force of water force.4.2无压

27、力管道水压试验 Hydraulic test of non-pressure piping4.2.1.无压力管道应在土方回填之前采用闭水法进行严密性试验，试验管段应按井距分隔，长度不大于1km，带井试压。Leakage testing with closed water method should be executed before backfilling for non-pressure piping. Testing spool should be separated according to well distance that the length should not be mor

28、e than 1km and should carry out testing with the well. 4.2.2.试验前应对管道灌满水，使用河水对管道进行浸润，浸润时间不少于24小时。 Fill the pipe full of water before testing and soak the pipe with river water for no less than 24h.4.2.3.管道严密性试验时，应进行外观检查，不得有漏水现象符合下列规定时，管道严密性试验合格。无压力管道严密性试验允许渗水量见下表。 Visual inspection should be executed

29、 for rigorous test and is qualified when no leakage exists and the following stipulations are complied. Allowable penetration quantity for non-pressure piping sees the following table.管材Piping material管道内径（mm）Inner diameter允许渗水量（m3/24h·km）Allowable penetration quantity玻璃钢管，混凝土管FRP and concrete

30、pipe20017.6030021.6240025.0050027.9560030.0670033.0080035.3590037.505.阀门的水压试验 Hydraulic test of valve5.1.阀门水压试验前的准备 Preparation before valve testing 5.1.1.阀门进行外观检查，其零部件应齐全完好。重点是法兰密封面应符合以下规定：Carry out visual inspection to ensure all the parts are present and in good condition. The key point is that t

31、he sealing surface should comply with the following regulation.1） 法兰和盲板的密封面光洁，不得有毛刺及径向沟槽。Sealing surface of flange and blind should be smooth and free of burr and radial grooves.2） 螺栓及螺母的螺纹应完整、无伤痕、毛刺等缺陷，螺栓与螺母应配合良好。Thread of bolt and nut should be integral and free of scar, burr and other default. Th

32、e bolt and nut should engage well.3） 橡胶、石棉橡胶等非金属垫片，质地应柔韧，厚薄均匀，无老化分层现象，表面不应有折损、皱纹等缺陷。Non-metal gasket such as rubber and asbestos should be soft and uniform thickness without default of aging, lamination, damage and wrinkles.5.2.阀门水压试验 Hydraulic test of valve5.2.1.根据工程联络单YX-YJ-245中SECCO的要求，阀门应100%进行试

33、压，但是不用解体.According to SECCO requirement of project correspondence YX-YJ-245, valve should be 100% tested and should not be disintegrated.5.2.2.铸铁阀门的强度试验应符合下列规定： The strength test of cast iron valve should be in compliance with the following regulations1） 试验压力为公称压力的1.5倍； Testing pressure is 1.5 times

34、 nominal pressure.2） 保压时间不小于5分钟，阀体、填料无渗漏为合格. Maintain the pressure for no less than 5min and qualified without leakage of valve body and filling.5.2.3.阀门的密封试验压力应按公称压力或1.25倍的工作压力进行。阀门密封面的允许渗透量，应符合下表规定。 Sealing testing pressure of valves should be nominal pressure or 1.5 times nominal pressure. Allowa

35、ble penetration quantity for sealing surface of valve should be in compliance with the following regulation.阀门水压试验要求数据Required data for valve hydraulic test公称直径Nominal diameterDN (mm)渗透量Penetration quantity(cm3/min)工作压力Working pressureMPa强度试验压力Strength testing pressureMPa密封试验压力Sealing testing pressu

36、reMPa1001500.200.81.22.41.63001.50.81.22.41.64003.000.81.22.41.65005.000.81.22.41.65.2.4.密封试验合格的阀门，应及时排尽内部积水。密封面应涂防锈油，关闭阀门，封闭进出口。密封试验不合格的阀门不能进入施工现场。After sealing test qualified, drain accumulated water in time, paint rust protection agent and close the entrance. The unqualified valves are forbidden

37、to transport into construction site.5.2.5.安装前阀门的传动装置和操作机构，应进行清洗检查，更换油、脂，要求动作灵活可靠，无卡涩现象。Clean valve gearing and manipulation machine before erection and replace oil or grease. The motion should be flexible and without block. 6.质量控制Quality control6.1.试压过程，严密性试验过程作为共检点，经有关各方确认后方可进行下道工序施工。Put the rigoro

38、us test as the common inspection point in the course of testing. Only accepted by all sides, the next procedure can be performed. 6.2.在试压过程中，监督工作由质量部设专职质量检查员负责质量监督和检验工作。 A full-time quality inspector appointed by quality department will perform quality control and inspection during testing.6.3.有经监理认可合格的试压记录和探伤记录。 Testing record and NDT record accepted by supervisor is required.6.4.施工所用所有计量器具应定期送检，确保准确有效。Inspect all the gauges regular to ensure accurate and validity.6.5.及时、准确地采集相关数据，自检、专检