埋地GRP管施工措施(中英）2

　Storage, transportation, installation, pressure testing and flushing of GRP pipe in Nanhai HDPE/PP plant. 本程序适用于南海石化项目 PP+HDPE 装置 GRP 管道的管沟开挖回填、管材现场装卸保管倒运、安装、试验、冲洗的施工。

　References And Applicable Codes 参考文件 2.1

　 NH-HDPE+PP-QCPR-322 Procedure for Dimensional Control 尺寸控制程序 2.2

　 NH-HDPE+PP-WPR-211 Procedure for Hydrostatic Testing and Flushing of Piping 管道水压试验及冲洗程序 2.3

　 NH-HDPE+PP-WPR-206 Procedure For Excavation & Backfilling 土方开挖及回填施工程序 2.4

　 NH- HDPE+PP-PR-242 Method statement in rainy season 雨季施工措施 2.5

　 SP-8310-0000-0026 Materials & workmanship specification permanent UG work 地下施工材料及技术要求 2.7

　 Code for construction and acceptance of water supply and sewerage pipelines. GB 50268 – 97 给水排水管道工程施工及验收规范 2.8

　 Guide of Specifications for Installation of Underground GRP Pipe LZF-0623-01-03

　地下GRP管安装手册 5.2 测量放线、管沟开挖 Setting-out and Trench excavation

　 General requirements for setting-out and trench excavation refer to NH-HDPE+PP-WPR-206 Procedure For Excavation & Backfilling. The trench figure as follow:测量放线、管沟开挖一般施工要求见NH-HDPE+PP-WPR-206土方开挖及回填施工程序，管沟图如下：

　 Method statement for GRP pipe installation 埋地 GRP 管施工措施编号 Ref.No:

　NH- HDPE+PP-

　WPR-210 Plant:

　PP+HDPE contractor:

　 TCM REV：B Client:

　 CSPC Subcontractor:

　CP6CC Page 3

　of 13

　 Figure 4.2 Trench Dimension “A” (see Figure 4.2) must always be wide enough to allow for adequate space to ensure proper placement of backfill in the haunch region and to operate compaction and excavate equipment. Bottom width of pipe trench shall be twice the pipe diameter plus 600mm, but in any case not less than 1.0meter.图4.2中A的尺寸必须满足开挖回填机械和人工作业的要求，管沟底宽一般为管直径加600,但不少于1.0M。

　When raining during construction and water level rising, the solution refers to NH- HDPE+PP-PR-242 Method statement in rainy season. 施工时遇上雨天及高水位时，处理要求见NH- HDPE+PP-PR-242雨季施工措施.。

　5.3 Pipe Bedding After excavation, a sand bag should be laid at the bottom in every 4 meter, and the net height of bag should be 100 mm. Excavating a little deeper at the joint of pipe, and the thickness of pipe bed cannot be less than 50mm.Filling with sands ＆ water and compacting as specified when backfilling. 在管沟挖好后，底部每根管每隔4米放一个沙袋，压管后沙袋净高100mm，管子的接头处挖深一些,管床的厚度不能低于50 mm，回填时按规定充沙放水密实。

　 Method statement for GRP pipe installation 埋地 GRP 管施工措施编号 Ref.No:

　NH- HDPE+PP-

　WPR-210 Plant:

　PP+HDPE contractor:

　 TCM REV：B Client:

　 CSPC Subcontractor:

　CP6CC Page 4

　of 13

　Figure 4.5 Proper bedding support Figure 4.6 Improper bedding support 5.5

　管道安装 Piping Installation The laying of pipes shall be in the order of main pipe first, and then branch; large pipe first, and then small pipe to ensure the accuracy of coordinate of the joint with outside. Surveying shall be performed to confirm the location of placement of all pipe-fittings, both at installation and later, when backfilling reaches the middle of the pipe.管子按先主管后支管、先大管后小管的顺序铺设，确保与外界相连点的坐标的准确性。安装时和回填至管子中部时都需进行测量，以确认所有管件的安放位置。

　5.5.1 Joining Pipes

　管道连接 5.5.1.1 Double "O" rings with locking key 带锁的双O型环连接。

　The jointing method to be used for the GRP Pipe system is a combination of GRP butt/strap joint and double “O” ring bell and spigot joint as shown below. 这种连接方式使用在 GRP 管承插接头上，双 O 型环承插连接形式如下：

　 Method statement for GRP pipe installation 埋地 GRP 管施工措施编号 Ref.No:

　NH- HDPE+PP-

　WPR-210 Plant:

　PP+HDPE contractor:

　 TCM REV：B Client:

　 CSPC Subcontractor:

　CP6CC Page 5

　of 13

　Figure 3.1-2

　Ring l and spigot locking joint A

　准备

　Preparation a)

　Ensure that the outside diameter of the spigot end of the pipe is thoroughly cleaned and free of any dust, sand, grit etc. 承插管接头必须十分干净，没有灰尘、沙砾等 b)

　Inspect the two "o" rings to be installed on the spigot ends of the pipes. Check to ensure the "o" rings are completely free of any damage and have been thoroughly cleaned. 检查承插头上的两个 O 型环，O 型环必须完整、干净没有受到任何伤害 c)

　Place the rings in the "o" ring grooves ensuring that the ring is uniformly stretched along its entire length and not twisted in any way (see Figure 3.2). The quickest and simplest method of doing this is to place the first "o" ring in the groove nearest the pipe end, subsequently rolling the second "o" ring into the second groove.

　把 O 型环放置在槽里，确保紧贴沟槽和没有扭曲（如图 3.2）。又快又简单的办法是先把第一个 O 型环放在离管端最近的槽里，然后把第二个 O 型环滚进第二个槽里。

　Ensure that the two pipes being joined are level, so that the spigot will fit concentrically into the bell. Two plugs are supplied fitted to the bell for joint testing. Each pipe should be installed so that one of the two plugs on the bell is on top of the pipe.确保对接的两管段水平，这样易于组装。安上杯口上接头试验用的两个堵头，其中一个必须向上。

　e) Thoroughly coat the "o" rings and inside surface of the bell with the lubricant provided.

　 Method statement for GRP pipe installation 埋地 GRP 管施工措施编号 Ref.No:

　NH- HDPE+PP-

　WPR-210 Plant:

　PP+HDPE contractor:

　 TCM REV：B Client:

　 CSPC Subcontractor:

　CP6CC Page 6

　of 13

　型环上及杯口内涂上润滑油 f)

　Using soft-slings and chain-blocks, anchor one pipe segment to the support slab to prevent accidental movement. 使用软吊索或倒链锚固一根管子，以防随意移动

　 Figure3.2

　Balancing the tension in rubber "o" ring, which also ensure the ring is not twisted. B

　组对 Alignment a)

　The pipes should be brought together using two daisy chains.

　用两个倒链对拉把两段组对在一起 b) The spigot should not be pushed home until it touches the end of the bell section. A (1-3) mm gap is required here to accommodate the tolerances for insertion of the locking chord.承插头不要插到底，予留 1-3 mm 间隙调整锁孔偏差。

　Once the joint has been completed, a visual inspection, both inside and outside the pipe, should enable the installation crew to see that the "o" rings are seated properly. If the joint is unusually tight it is a reasonable indication that an "o" ring has been displaced and the joint must be separated and remade. 组装完成，进行外观检查，O 型环在管内外壁应结合得很好。如果接头太紧，可能有一个 O 型环已移位，必须拆开重新安装。

　The locking key can now be inserted around the entire circumference.

　组装好后，锁紧管端。

　Joint Testing 接头试验

　 Method statement for GRP pipe installation 埋地 GRP 管施工措施编号 Ref.No:

　NH- HDPE+PP-

　WPR-210 Plant:

　PP+HDPE contractor:

　 TCM REV：B Client:

　 CSPC Subcontractor:

　CP6CC Page 7

　of 13

　An advantage of the GRP spigot jointing system is the fact that the joint can be hydro-statically pressure tested immediately it is made. The testing involves filling with water, the annular space of the bell and spigot, between the "o" rings and pressuring this to test pressure. GRP 管承插连接的好处是组装后接头可以马上进行水压试验，试验过程为两 O型环之间的环状空间充水和打压。

　The following equipment should be on hand for testing: 准备以下试压设备 a) ONE – hand operated, hydrostatic test pump.一台手动试压泵 b) ONE – accurately calibrated pressure gauge.一块校准过的精密压力表 c) ONE– suitably fitted connecting pressure hose for pump to pipe connection.

　一条试压软管 d) ONE– roll of P.T.E. thread sealant tape.一圈 P.T.E 密封胶带

　Procedure 过程 C1.1

　Remove the bolt plug in the test nipple that is located at the top of the bell.取下管顶的试压咀上的螺栓堵头 C1.2

　Connect the hose to the test nipple with the hand-operated pump. Ensure the screwed fitting is adequately wrapped with the sealant tape.用软管连接杯口的管咀和手动试压泵, 缠好密封胶带,确保接头密封. C1.3

　The pressure gauge will be located in the pump. Then fill water and begin test pressurize the water to the required test pressure. 试压泵装上压力表，然后充水打压直到规定的试验压力为此。

　C1.4

　After holding the pressure for 3 minutes, release the pressure and remove the hose from the inlet.稳压 3 分钟，泄压拆除软管 C1.5

　Replace the plug(s) ensuring the threads are sealed. The test is now complete and the next joint can be made.安上堵头，试验结束，准备进行下一个试验。

　C1.6 当回填至管顶以上 300 时，接头再次实验。

　Retest the joint when backfilling to 300mm above the pipe top. 5.5.1.2

　 Flanged Joints

　法兰连接

　 Method statement for GRP pipe installation 埋地 GRP 管施工措施编号 Ref.No:

　NH- HDPE+PP-

　WPR-210 Plant:

　PP+HDPE contractor:

　 TCM REV：B Client:

　 CSPC Subcontractor:

　CP6CC Page 8

　of 13

　GRP flanges should be joined according to the following procedure: (Figure 3.4.) GRP管按以下程序进行法兰连接（如图3.4）

　1）Thoroughly clean the flange face and the ‘O’ ring groove.彻底清干净法兰面和O型槽 2）Ensure the ‘O’ ring or gasket is clean and undamaged. Do not use defective gaskets or "O"ring.确保O型环或垫片干净及没有受到伤害，不要使用有缺陷的O型环或垫片。

　3）Position ‘O’ ring or gasket in groove 在槽里放置O型环或垫片。

　4）Align flanges to be jointed. 对准法兰进行对接。

　5）Insert bolts, washers and nuts. All hardware must be clean and lubricated to avoid incorrect tightening. Washers must be used on all GRP flanges.穿上螺栓垫片和戴上螺母。所有的金属件都要清干净并上润滑油，以防卡死。GRP法兰螺栓都带垫片。

　6）Using a torque wrench, tighten all bolts to 35 N•m (25 lb.-ft.) torque, [20 N•m (15 lb.-ft.) for pipe smaller than DN100] following standard flange bolt tightening sequences. 按标准要求的顺序用力矩扳手拧紧螺栓至35N.m(25 lb.-ft.)力矩[DN100以下的小螺栓20 N•m (15 lb.-ft.) ]。

　7）

　Repeat this procedure, raising the bolt torque to 70 N•m (50 lb.-ft.), [35 N•m (25 lb.-ft.) for pipe] or until the flanges touch at their inside edges. Do not exceed this torque. To do so may cause permanent damage to GRP flanges. 重复6)的动作,直到力矩达到70 N•m (50 lb.-ft.), [DN100以下的小螺栓35 N•m (25 lb.-ft.) ]或者是两法兰面刚接触为此。使用力矩不要超过规定值，不然会对GRP法兰造成破坏。

　8）Check bolt torque one hour later and adjust if necessary to 70 N•m [35 N•m for smaller than DN100]. 安装1小时后检查螺栓扭距，调整到70N.m[对DN100以下小螺栓35N.m]。

　 Method statement for GRP pipe installation 埋地 GRP 管施工措施编号 Ref.No:

　NH- HDPE+PP-

　WPR-210 Plant:

　PP+HDPE contractor:

　 TCM REV：B Client:

　 CSPC Subcontractor:

　CP6CC Page 9

　of 13

　Figure 3.4 Flange joint Note: When connecting two GRP flanges, only one flange should have a gasket groove in the face. 注：当两片GRP法兰连接时，只有一片法兰的法兰面有垫片凹槽。

　5.5.1.3 粘接 Adhesion 管线粘接按厂家的技术要求进行，由厂家派人在现场指导。Piping adhesion should be performed as per technical requirements of manufacturer, who should assign people on site to instruct this activity. 5.5.2 Sleeving 套管安装 Spools should be assembled into a whole spools after prefabricated by sections, and then positioning, backfilling and compaction carried-out. Crossing pipe heads enwrapped by burlap or rubber will be pushed slowly into the sleeve by workers with the cooperation of crane. If there are interspaced joints in crossing pipes, pressure test should be made to spools separately. When the length of crossing pipe is not enough, the trench should be lengthened along the direction of spools till appropriate. Oil-soaked jute should be used to seal the joint of pipe and spool.套管分节预制后，在管沟内组装成整根套管，定位回填压实。穿管管头用麻袋或胶皮包裹，吊车配合，人工慢慢推进。如果穿管有中间接头，管段须单独打压合格。当穿管距离不够时，在套管方向顺延管沟，直到合适。管子与套管之间用油浸黄麻堵上封口

　5.6

　Testing 试验 5.6.1 For strength and tightness test of pressure piping, the medium shall be clean water, the testing pressure for strength shall be 1.5 times design pressure but no more than the tolerance of GRP pipe, and that for tightness be design pressure. Testing requirements refer to NH-HDPE+PP-WPR-211 Procedure for Hydrostatic Testing and Flushing of Piping.

　 Method statement for GRP pipe installation 埋地 GRP 管施工措施编号 Ref.No:

　NH- HDPE+PP-

　WPR-210 Plant:

　PP+HDPE contractor:

　 TCM REV：B Client:

　 CSPC Subcontractor:

　CP6CC Page 10

　of 13

　压力管道进行强度及严密性试验，试验介质为干净水，强度试验压力为 1.5 倍设计压力,但不超过 GRP 管许可的试验压力, 严密性试验压力为设计压力。试验要求见NH-HDPE+PP-WPR-211 管道水压试验及冲洗程序。

　5.6.2

　Open-end gravity pipe systems, including ADC and CCD pipes shall be tested for water-tightness by filling water to a head of not less than 2 2. .0 0m above the soffit of the pipe at the high end but not more than 2.4m at the low end. As following: 自流管道，如ADC及CCD系统进行闭水法试验, 试验介质为干净水，试验压力为:净压头不小于2.0米,但对最低端不能超过2.4米。闭水法试验按下列程序进行：

　5.6.2.1 After water filling the test system, allow the water level to stabilize for 1 hour, record the water level at the end of this time. Measure the amount of water to restore to testing elevation.实验管段灌满水，水平面稳定1小时后开始记录。

　5.6.2.2 Record water level at 30 minutes intervals, then add water to re-store to testing elevation, record the actual amount of water added at each inspection. After 8 hours, if water-level has stabilized with no further leakage, the visual examination of the system may proceed. Manholes shall also be tested, either separately or together with the connecting pipes. In either case, testing shall be done before backfilling around the manholes, to allow visual examination for leakage or wet patches on the external wall of the manholes.每30分钟记录一次水平面，然后加水恢复测试标高，记录每次检查所加的实际水量。8小时后，假如水平面已稳定，没有任何泄露，则进行外观检查。人孔也需测试，或者单独测试，或者与连接管一起。不论是哪一种，都应在人孔周围回填完毕前进行以便检查人孔的外墙壁上是否有泄露或者湿修补。

　5.6.2.3 No leakage during testing will be allowed.试验过程中无漏水现象为合格。

　5.7 The construction requirements for piping flushing refer to NH-HDPE+PP-WPR-211 Procedure for Hydrostatic Testing and Flushing of Piping. 管道冲洗施工要求见NH-HDPE+PP-WPR-211 管道水压试验及冲洗程序。

　5.8

　Reinstatement Of Piping System

　管道系统复位 5.8.1 After piping system has been accepted, system shall be restored immediately. All blind boards shall be removed and all temporary gaskets shall be replaced with formal gaskets.管道

　 Method statement for GRP pipe installation 埋地 GRP 管施工措施编号 Ref.No:

　NH- HDPE+PP-

　WPR-210 Plant:

　PP+HDPE contractor:

　 TCM REV：B Client:

　 CSPC Subcontractor:

　CP6CC Page 11

　of 13

　系统试压、清洗合格后，管线应立即复位，试压清洗时加的盲板应拆除，所有临时垫片换上正式垫片。

　5.8.2 The records of system restoring shall be made to fill up the status of closing for pipes.管道系统复位应填写管道系统封闭记录。

　5.9

　 Back-filling 回填 Immediate back-filling after joining is suggested as it will prevent two hazards – floating of pipe and thermal movements. If lengths of pipe are placed into the trench and back-filling is delayed, each length should have the center section back-filled to the crown to help minimize misalignment and movement.

　管子连接之后应马上回填，以防浮管和热膨胀位移，如果整根管不能回填，管段中间可以进行局部回填，减少偏差和位移 Clean sand shall be laid in 100 mm layers and compacted to 95%, using hand tools or light mechanical compactors to a level 450 mm above top of pipe. Common fill material placed and compacted in 150 mm layers. Heavy mechanical compactors shall not be used until there is at least 450mm hand compacted cover over the crown of the pipe. A blunt tool may be used very effectively to push and compact the backfill under the pipe, without raising the pipe up. (See Figures 4.7 and 4.8.) Backfilling requirement refers to NH-HDPE+PP-WPR-201Procedure For Excavation & Backfilling.在管顶之上450以下，砂子回填，每层100厚，人工夯实，密实度达95%。之后，用普通材料回填，每层150人工夯实3层后可用机械压实。为免管子浮起，管底回填及压实用粗棒比较好。回填一般施工要求见NH-HDPE+PP-WPR-206土方开挖及回填施工程序。

　 Method statement for GRP pipe installation 埋地 GRP 管施工措施编号 Ref.No:

　NH- HDPE+PP-

　WPR-210 Plant:

　PP+HDPE contractor:

　 TCM REV：B Client:

　 CSPC Subcontractor:

　CP6CC Page 12

　of 13

　Figure 4.7 Ensuring firm pipe support

　Figure 4.8 Improper haunch

　 5.10 Construction Quality Records And Inspection Reports. 施工质量记录和检查报告 5.10.1 Construction quality records shall be made synchronously with construction and shall reflect the progress, these records shall be managed by an appointed Q.C. engineer and audited by piping QC engineers.施工质量记录应与施工同步，正确、真实反映施工情况，QC 工程师和技术员应经常检查各种记录，施工班组应有专人负责记录。

　5.10.2 Inspection reports shall be documented (filled out) by QC engineer to reflect the real examination contents and quality status, and approved by TCM’s representative.检查报告由QC 工程师填写，真实反映检查内容，质量情况，并经 TCM 有关人员认可。

　Revision Note

　修订注释 This procedure shall be revised if it is found to be inadequate for the proposed work upon completion of engineering/ now construction practice/ new sit information or as requested by TCM.

　若发现此程序不能充分保证工程项目的完成，遇到新的施工情况/新的现场情况或经过 TCM 负责人要求，将对该程序进行修订。

　Appendix Joint Lubricant Requirements

　 Method statement for GRP pipe installation 埋地 GRP 管施工措施编号 Ref.No:

　NH- HDPE+PP-

　WPR-210 Plant:

　PP+HDPE contractor:

　 TCM REV：B Client:

　 CSPC Subcontractor:

　CP6CC Page 13

　of 13

　 Nominal

　 Nominal Amount of Lubricant (kg) Pipe Diameter (mm)

　 Required per Joint

　100 to 250

　.050

　300 to 500

　.075

　600 to 800

　.100

　900 to 1000

　 .150 1100 to 1200

　 .200 1300 to 1400

　 .250 1500 to 1600

　 .300

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