地下grp管道施工方案 12页

'ConstructionMethodStatementPage12/12ProjectNo:080036ProjectTitle:ArabianCHLORVINYLProjectClient:SaharapetrochemicalcompanyandMa’adenLocation:JubailIndustrialArea,KSAMethodStatementUndergroundGRPPipingInstallationWorksTitle:UndergroundGRPPipingInstallationProcedureTCCPreparedByName:Position:Signature:Date:DAELIMApprovalName:Position:Signature:Date:ApprovedByClientName:Position:Signature:Date:Rev.0ThisDocumentisthepropertyofTCC.Issuedto,andusedbyothersneedsthewrittenapprovaloftheTCCQualityManager.ProjectDoc-No:Rev.PrincipleArabianCHLORVINYLProjectTCC-DSA-ACVP-CMS-000UndergroundGRPPipingInstallation ConstructionMethodStatementPage12/12ProjectNo:080036ProjectTitle:ArabianCHLORVINYLProjectClient:SaharapetrochemicalcompanyandMa’adenLocation:JubailIndustrialArea,KSACONTENTS1.0Purpose2.0Scope3.0Reference4.0Responsibilities5.0EquipmentsandTools6.0LaminationProcessSequence7.0BondingMaterials8.0ReceivingHandlingandStoringofPipe9.0ArrangePipeinTrench10.0JointLaminateProcedure11.0QualityRequirements12.0SafetyPrecaution13.0AttachmentsProjectDoc-No:Rev.PrincipleArabianCHLORVINYLProjectTCC-DSA-ACVP-CMS-000UndergroundGRPPipingInstallation ConstructionMethodStatementPage12/12ProjectNo:080036ProjectTitle:ArabianCHLORVINYLProjectClient:SaharapetrochemicalcompanyandMa’adenLocation:JubailIndustrialArea,KSA1.PurposeThismethodstatementistoguidebuttjointwraplaminationworkofU/GGRPpipingsystemintheArabianChlorVinylProject.2.ScopeThisMethodStatementcoversthefieldlaminationjointsinstallationmethodofundergroundGRPpiping.ThisprocedureisapplicabletoallU/GGRPpipediameters.RelateddataofU/GpipingGRPpartisasfollowing:SystemdescriptionMaterialclassDiameterrangeConnectionMethodWWDGAANA4”,6”,8”,10”,12”,20Butt&wrapjointlaminationACWDGAANA4”Butt&wrapjointlaminationPCSDGAANA4”Butt&wrapjointlamination3.Reference1Thedrawingof080036-AA-DA-100201~400207U/GCompositeDWG2Specification:080036-AA-SG-007SpecificationforUndergroundPiping&SurfaceDrainage080036-XH-SG-003Specificationforpipingconstruction080036-XZ-SG-001SpecificationforPipingDesign080036-QZ-PL-001ProjectQualityPlan080036-XH-SG-006SpecificationforIdentificationofPipingMaterial080036-XH-SL-005SpecificationforPipingMaterialAMIANTITdocument:FieldButt&WrapJointProcedureForGRP/FRPPipingInstallationandHandlingInstructionsForRigidJointPipeFieldLaminationProcesssheet4.ResponsibilitiesProjectDoc-No:Rev.PrincipleArabianCHLORVINYLProjectTCC-DSA-ACVP-CMS-000UndergroundGRPPipingInstallation ConstructionMethodStatementPage12/12ProjectNo:080036ProjectTitle:ArabianCHLORVINYLProjectClient:SaharapetrochemicalcompanyandMa’adenLocation:JubailIndustrialArea,KSA4.1GRPManagerInchargeofalltheactivityduringtheGRPpipeconstruction.Mainlyinvolvethesafety,techniqueandqualityproblemsduringtheconstruction,preparingandcarryingouttheconstructionschedules.4.2QCSupervisorInchargeofskilltrainingforallthepersonnelwhowillengagetheGRPpipingwork,analyzingthesafetyissuesandprovidingprecautions.Applyingforworkpermits4.3QCInspectorCompilingQCprecautions,solvingtheQCissuesduringGRPpipingconstruction,takingpartinqualityinspectionandacceptanceandtakingthemajorresponsibilitiesforthequalityoftheGRPpiping.5.EquipmentsandToolsThebelowitemsareusedfortheGRPPipinghandlingandConstruction:☻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.laminationProcessSequenceMaterialreceivingExcavationandbedding(bycivil)TransportationAndArrangeSpoolCutting(ifrequired)GrindingInsidecleannessInspectionandFituplaminatingofJointVisualinspectionBarcolhardnesstestFullwatertestCoordinateandelevationmeasurementProjectDoc-No:Rev.PrincipleArabianCHLORVINYLProjectTCC-DSA-ACVP-CMS-000UndergroundGRPPipingInstallation ConstructionMethodStatementPage12/12ProjectNo:080036ProjectTitle:ArabianCHLORVINYLProjectClient:SaharapetrochemicalcompanyandMa’adenLocation:JubailIndustrialArea,KSA7.BondingMaterialsUsedcomponentsRESIN:EpoxyvinylesterresinsuppliedfromAmiantit,andtobemixeditwithcatalyst.CATALYST:Methylethylketoneperoxide.Mat&WOVENROVING:glassreinforcementforjointstructure.BONDINGMATERIALSSTORAGEandUSAGE:DetailsseeattachmentA:FieldButt&WrapJointProcedurePage4to5.Thelocationofresin,W-Fluid,catalyst&glassreinforcementcontainerasshowinfigure7-1Figure7-1Storageoutlineofchemicalcontainerdetailsseeattachment-F:InteriorlayoutforAmiantitResin&Catalyst8.Receiving,HandlingandStoringofPipeDetailsseeattachmentB:InstallationandHandlingInstructionsForRigidJointPipePage2to4.InspectingPipe●AllpipesreceivingatsiteshallbeinspectedaccordingtoSpecificationforPipingMaterial.●Brokenpipebundles,crushedfittingsboxesshouldbecheckedcarefully,scratchedandgougedandpipewithcrushedorsplitendsarenotallowedtouse,damageclaimsproceduresmustbeinitiatedpriortoProjectDoc-No:Rev.PrincipleArabianCHLORVINYLProjectTCC-DSA-ACVP-CMS-000UndergroundGRPPipingInstallation ConstructionMethodStatementPage12/12ProjectNo:080036ProjectTitle:ArabianCHLORVINYLProjectClient:SaharapetrochemicalcompanyandMa’adenLocation:JubailIndustrialArea,KSAacceptingtheshipment.●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.ArrangePipeinTrenchPrepareandassemblepipeandjointsinaccordancewiththeISOdrawing,usingspecialcaretokeepjointsurfacecleananddry.Positionpipeontimbersacrossditchasshowninfigure-1.Blockintopositiontoholdalignmentandpreventlateralmovement.Jointthepipesufficientlyinadvanceofthepipeloweringoperationsothatnomovementofthepipewilltakeplaceatlocationwherejointsarebeingcured.Anyvibrationormovementofuncuredorpartiallycuredjointswillincreasetheriskofjointfailures.Shouldbemakesurethedepthofthetrenchbeforelowingthepipe.Figure-1ProjectDoc-No:Rev.PrincipleArabianCHLORVINYLProjectTCC-DSA-ACVP-CMS-000UndergroundGRPPipingInstallation ConstructionMethodStatementPage12/12ProjectNo:080036ProjectTitle:ArabianCHLORVINYLProjectClient:SaharapetrochemicalcompanyandMa’adenLocation:JubailIndustrialArea,KSAWithpowerequipmentormanpower,raisethepipeslightlytoslidethetimbersupportfromunderthepipe.Lowerthepipeintothetrench.Donotdroporlowersuddenly.Repeattheaboveoperationateachsupport.Useropeorwebbedslingforliftingpipe.Ifmanpowerisused,itissuggestedthattwomenbeusedforlifting6-inchpipe,andfourmenandmuchmorebeusedforthe8-inchandbiggerpipe.10.JointlaminationProcedure10.1CuttingThisinitialstepshallbeapplicableonlyifapipeendneedstobecutandreplaced,orapipelengthrequiresfieldadjustment.Markthepipesectiontobecutusingawrap-aroundandawhitemarker.Cutthepipeusingahacksaworadiamondcuttingdisc,makesurethatapropersquarecuthasbeenmade.Ensurethatcutendsremainwithinthetolerancesasshowintable10.1.Table10.1:MaximumtoleranceonsquareofcuttedpipeendPipeSizeRangeTolerance(mm)(mm)(inch)25-1001-41.5150-4006-163.010.2GrindingGrindingandcleanningthetotalexternalsurface.MakesurethatthepipeendsaregrindedaswellastherequiredlengthasattachmentC:Fieldlaminationprocesssheet.Startthelaminationofthefittedsectionswithintwohoursaftersanding;re-sandingofthelaminationareashallberequiredifthewaitingperiodexceedstwohours.Bondingsurfacesmustbedryandcleanbeforesanding.Useflapperwheelsanderswithasmalldrillingmachine(1700-2000rpm)oremeryclothwithagridof60.Sandedsurfacesmusthaveadull,freshfinish,notapolishedlook.Removeanypossibledewbyslightlyheatingthepipeendsbyahotairdryer.OtherdetailsseeattachmentA:FieldButt&WrapJointProcedurePage7.10.3Fittingup1Checkthealignmentandfixingthepipeendsascloseaspossible,thenpreparetheputty.2Applytheputtywithaputtyknifefillingallthegap;3Afterthefillingofthegap,theputtyshallpolymerize,withoutmovingandbumpingthepieces.4Oncecompletedthehardeningoftheputty,grindtheoutsideofthepipejointandcleanwithairblowandcleandustercloth.Note:Thegapshouldnotexceedthe5mmorasperrecommendedbyPipemanufactureratanycase.10.4FieldJointKitsPrepareDetailsseeattachmentA:FieldButt&WrapJointProcedurePage8FIELDJOINTKITS.ProjectDoc-No:Rev.PrincipleArabianCHLORVINYLProjectTCC-DSA-ACVP-CMS-000UndergroundGRPPipingInstallation ConstructionMethodStatementPage12/12ProjectNo:080036ProjectTitle:ArabianCHLORVINYLProjectClient:SaharapetrochemicalcompanyandMa’adenLocation:JubailIndustrialArea,KSAEachjointkitshouldbestoredinacloseroomtoavoiddust,damp&directsunlight,andshouldbestoredinadryareaandlessthan65%humidityinordertoavoidsurfacecondensationwhenusedinwarmerconditionsoutside.10.5LaminationonthepipejointDetailsseeattachmentA:FieldButt&WrapJointProcedurePage8to11LAMINATIONONTHEPIPEJOINTofandattachmentB:InstallationandHandlingInstructionsForRigidJointPipePage5to6.1Enoughcatalystedresinshouldbepreparedforabout20–30minutesgeltimeandthoroughmixingit.2Spreadathinlayerofcatalystedresindirectlyonthesurfacesofthepipejointlaminatingarea.3Placeofchoppedstrandmatonthesurfaceofwetoutareasmoothlyandwetitoutwiththepaintwoolyroller.4Continuebuildingbyalternatingchoppedstrandmatandwovenrovingandcompletewettingouteachonebeforeapplyingthenextply.Nomorethan5pliesinonelayer.Coveredwithchoppedstrandmat.Thepaintrollerrolloutoverthepliestoreleasebigaircavitiesandanyexcessiveresin.Avoidairgettingintothelaminatebyusingsteelgroovedrollerslightlypressedtoremoveouttheairbubbles.Theangleofgrooverollershallbechangedtimetotimeinordertoremovetheairbubblesinalldirections.Keepinginconsiderationthatverylimitedtimehasleftfortheresintostartgettinggel,makesureallairbubbleshavebeentakenoutpriortostartthepliestobecomehard.Stoprollingassoonastheresinbegintogel.5Continuethisprocedureuntilallthesectionsofthefirstlayerbeenapplied.Makesurethateachsectionoverlapwiththeothersatleast5cm.Letthislayerlay-upcureandcooluntilitiscomfortabletotouchwiththebarehand.ContinueusingthesameprocedureswiththeremaininglayersasattachmentC:Fieldlamination(processsheet).Makesurethatthelastpliesofthetotallay-uparechoppedstrandmat.CAUTION:1-Anykindofmovementofpipesectioncouldreducethebondstrengthoftheinitiallay-upplieshavenotcured.Whilethejointingisunderprogress,thepipesmustberestrainedbeforemoving.2-Removethelay-upifnotproperlybondedtothepipe,andwashtheareawithsolventandnottorunsolventintouncured.Beforeapplyingthelay-uponthisarea,insureallsolventhascompletelyevaporated.Neverallowspilledchemicalonthepipesurface.Thismaycausedamagetothepipe.3-Eachjointlaminationteamshouldbeformedbyatleasttwoworkers,trainedandskilled.OtherdetailsseeattachmentA:FieldButt&WrapJointProcedurePage12andattachmentB:InstallationandHandlingInstructionsForRigidJointPipePage7.11.QualityRequirements1.ThejointspecificationshouldbeverifiedaspertheAMIANTITprocess.2.Visualinspectionofthelaminatedjointsforexternallay-up.ProjectDoc-No:Rev.PrincipleArabianCHLORVINYLProjectTCC-DSA-ACVP-CMS-000UndergroundGRPPipingInstallation ConstructionMethodStatementPage12/12ProjectNo:080036ProjectTitle:ArabianCHLORVINYLProjectClient:SaharapetrochemicalcompanyandMa’adenLocation:JubailIndustrialArea,KSA3.Checkingthelaminationthicknessusingthemeasuringtapesalsothelaminationwidth.4.Barcolhardnesstocheckthelaminationhardnessshouldnotbelessthan30HBa.5.Fullwatertestisusedforgravityflowpipewhenit’scompleted.Duringtestforfillingwithwater,thepipingshallbefullofwater,itwillbeacceptedifthewaterlevelnotlowering.6.Beforeburied,thecoordinatesandelevationofthepipeshouldbecheckedaspercompositedrawing.7.AllqualityinspectionworkshouldbeaccordingtoITPfromDEALIM.12.SafetyPrecaution1、Forbiddenunderloading/hoistingthepipebypassingaropethroughthesectionendtoend.2、Don’tuseun-safetymachinewhencuttingandgrinding,anti-dustcoverallsclothes,fullfaceshieldanddustmaskshouldbeusedforgrinding.3、Chemicalsplashgogglesisrecommendedforchemicalsoperating;Portablewaterstationcanbeusedforeyewash.4、Wearresistantglovessuchas:polyvinylalcohol,butylrubber,nitrileorneoprene.wearnormalworkclothingcoveringarmsandlegs.HazardOFMATERIALS:AllchemicalmaterialsmustbeusedcarefullywithPPE.RESIN:Causesevereeyeandskinirritation.Aspirationofmaterialintothelungscancausechemicalpneumonitis,andotherlunginjury.ACCELERATOR:Donotbreathevapoursandavoidcontactwithskin.Itcancauselungdamageifswallowedandcausecancer.Flammable.CATALYST:Riskofexplosionbyshock,friction,fireorothersourcesofignition,maycausefire,Harmfulifswallowed,Causedburns.Keepawayfromreducingagents,acids,alkaliesandheavymetalcompounds.Donotmixwithperoxide-acceleratorsorreducingagents.Useonlystainlesssteel316,PVC,polyethyleneorglass-linedequipment.Mat&WOVENROVING:SILICAN:Lowhazardforusualhandling.Repeatedexposuremaycauseskindrynessorcracking.Keepawayfromheatandsourcesofignition.STYRENE:"asuspectedcarcinogen"and"asuspectedtoxintothegastrointestinaltract,kidney,andrespiratorysystem."Chronicexposuretostyreneleadstotiredness/lethargy,memorydeficits,headachesandvertigo.Portablewaterstationandfireextinguishershouldbelocatednearby.Beforestartwork,allrelationpeoplereceivesafetyeducationfromsafetydepartment.PPEREQUIREMENTS:SafetyglassandgogglesSafetyshoesDustmasks.SafetyhelmetSafetyharness(incaseofhighelevation).ProjectDoc-No:Rev.PrincipleArabianCHLORVINYLProjectTCC-DSA-ACVP-CMS-000UndergroundGRPPipingInstallation ConstructionMethodStatementPage12/12ProjectNo:080036ProjectTitle:ArabianCHLORVINYLProjectClient:SaharapetrochemicalcompanyandMa’adenLocation:JubailIndustrialArea,KSAFaceshieldwithglassforgrindingworks.ChemicalprotectionglovesandlatexglovesOtherDetailsseeattachmentA:FieldButt&WrapJointProcedurePage12to14.13.AttachmentsAttachment-AFieldButt&WrapJointProcedureAttachment-BInstallationandHandlingInstructionsForRigidJointPipeAttachment-CFieldLaminationProcessSheetAttachment-DJHAforGRPPipingInstallationInACVCPlantAttachment-EU/GGRPPipingOrganizationChartAttachment-FInteriorlayoutforAmiantitResin&CatalystProjectDoc-No:Rev.PrincipleArabianCHLORVINYLProjectTCC-DSA-ACVP-CMS-000UndergroundGRPPipingInstallation ConstructionMethodStatementPage12/12ProjectNo:080036ProjectTitle:ArabianCHLORVINYLProjectClient:SaharapetrochemicalcompanyandMa’adenLocation:JubailIndustrialArea,KSAAttachment-EU/GGRPPIPINGORGANIZATIONCHARTMaterialManagerSUNchanggenStorageManagerHUzhongkuiQCInspectorYANGzuoxuQCSupervisorHOUmanyiLaminatingteamIn-charge:PengF.M.Supervisor:ZhangC.L.QC:XuJ.Z.Working-crew:4TransportationteamIn-charge:GeZaiqiaoWorking-crew:1FittingteamIn-charge:PengF.M.Supervisor:ZhangC.L.QC:XuJ.Z.Working-crew:2GRPManagerLIwanjinAllmanagestaff,foremanandleadersforlaminationhavebeentrainedbypipevendorbeforestartingworkatsite.workerswhoaretrainedandqualifiedshallbeover40%ofallworkersinvolvedinGRPpipingconstruction.2Supervisorand1QCinspectorshallbetrainedbeforeworkingstart,and1coordinatormaybeneededtogetherwiththem.ProjectDoc-No:Rev.PrincipleArabianCHLORVINYLProjectTCC-DSA-ACVP-CMS-000UndergroundGRPPipingInstallation ConstructionMethodStatementPage12/12ProjectNo:080036ProjectTitle:ArabianCHLORVINYLProjectClient:SaharapetrochemicalcompanyandMa’adenLocation:JubailIndustrialArea,KSAAttachment-FInteriorlayoutforAmiantitResin&CatalystStorageResin,W-Fluid&GlassReinforcementContainerProjectDoc-No:Rev.PrincipleArabianCHLORVINYLProjectTCC-DSA-ACVP-CMS-000UndergroundGRPPipingInstallation'