帶壓開孔技術(shù)方案

PagePage#of10ExecutionplanforHot-tapping帶壓開孔執(zhí)行計(jì)劃I、ProjectOverview一、工程概況Hottappingsystem:PGsystem開孔系統(tǒng)：丙二醇系統(tǒng)Hottapping:2positions開孔數(shù)量：2個(gè)Icejamming:2sections4positions,6mintotal冰塞數(shù)量：2段4處，總長約6米II、CompilationBasis二、編制依據(jù)SteelPipingSealingTechnicalRegulation《鋼質(zhì)管道封堵技術(shù)規(guī)程》（SY／T6150.1－2003）SteelPipingWeldingandInspection《鋼質(zhì)管道焊接及驗(yàn)收》（SY/T4103—1995）IndustrialMetallicPipingEngineeringConstructionandInspectionCode《工業(yè)金屬管道工程施工及驗(yàn)收規(guī)范》（GB50235-97）III、Constructionsequence三、施工方案（1）Sequence順序：Preparations準(zhǔn)備工作Shortpipepreparation短管制備weldingunderpressure帶壓焊接valvetest閥門單獨(dú)試驗(yàn)valveinstallation閥門安裝pressuretestforthesystem整體試壓一—hottapping開孔（2）thescheduledtimeisasthefollowingtable計(jì)劃時(shí)間如下表：S/NItem項(xiàng)目Start開始時(shí)Finish結(jié)束Remarks備

序號間時(shí)間注1Hottappingproposalsubmission帶壓開孑L方案提交7月15日7月15日2JSAsubmissionJSA提交7月15日7月15日3Pipefittingsdelivery管件到場7月20日7月20日4Pipesdelivery管材到場7月20日7月20日5Scaffolderection腳手架搭設(shè)8月2日8月2日6Insulationremoval保溫拆除8月2日8月2日7Pipefabrication管段預(yù)制8月2日8月2日8Weldingunderpressure帶壓焊接待業(yè)主通知9Valvetest(leakageandstrength)閥門試驗(yàn)(泄露，強(qiáng)度)9月20日9月20日10Valveinstallation閥門安裝9月25日9月25日11Testbeforehottapping開孑L前試驗(yàn)待業(yè)主通知12Hottapping開孑L待業(yè)主通知(3)：Hottappingsequence帶壓開孔的順序Phase1,Tie-inNo.6,PGSPhase2,Tie-inNo.7,PGR(4)：開孔節(jié)點(diǎn)圖Tie-inNo.DetailXYZ(GateValve)6ADN150DN120DN1207ADN150DN120DN120

|-vDETAII.|-vDETAII.IV、Checkbeforeconstruction:Personalprotectiveclothingmustbeworn.includinghardhat,safetyglassesworkgloves,coverallsandsafetybootsEnsurethattheHotTappingDatainformationcorrespondstotheactualonsitesituation.Confirmpipelinepressureandinsureitiswithintheoperationalratingoftheequipment.Confirmpipelinetemperatureandinsureitisbelowtheoperationalratingoftheequipment.Confirmpipelinecontents.Checksitesurroundingsforpotentialhazards.Makesurethatallthecorrectmeasuressuchasscaffolding,barricades,warningsigns,fireextinguishers,etcareinplace.四、施工前檢查必須穿帶好個(gè)人防護(hù)衣著。包括、安全帽、安全眼鏡、工作手套和安全鞋。確認(rèn)帶壓開孔數(shù)據(jù)信息與現(xiàn)場情況一致。確認(rèn)管道壓力，確信在設(shè)備的額定操作壓力范圍內(nèi)。確認(rèn)管道溫度，確信低于設(shè)備的額定操作溫度。確認(rèn)管道內(nèi)介質(zhì)。檢查現(xiàn)場周圍環(huán)境以防潛在傷害。確定所有安全措施已到位，如腳手架，路障，警告標(biāo)示，滅火器等。V、PressuretestprocedureVisualcheckweldednozzleorfittingfreefromanydefects.Installvalvetonozzleorfittingandtightbolt&nutcorrectlyInstallhottapmachinetothevalve&openthevalveConnecthydrostaticpumptoinletofthehottapmachineOpenhottapmachineventportvalveOperatehydrostaticpumpuntilwatercomeoutfromventvalve&shutoffthevalveIncreasehydrostaticpressurewhichequalto1.5timesoflinepressureShutoffthepumpinletvalvetomaintainpressureHoldingthepressurefor15minutesReleasepressure&dismantlepump五、壓力試驗(yàn)程序目測焊接短管或三通是否完好無缺安裝閥門到短管或三通上并正確鎖緊螺絲及螺母安裝開孔工具到閥門上并打開閥門連接水壓試驗(yàn)泵到開孔機(jī)入口打開開孔機(jī)排空閥門操作水壓試驗(yàn)泵至水從排空閥溢出并關(guān)上閥門增加水壓壓力至等于1.5倍母管內(nèi)壓關(guān)上泵進(jìn)口閥門并保持壓力保壓十五分鐘10.泄壓及拆除泵V、Inspectionbeforeopening:EnsurethattheValvetobehottappedhasbeenpositionedandweldedcorrectlytothepipeline.Allnon-destructiveandhydro-testingshouldhavebeencompletedandevaluated.Obtainallpermitsandauthorisationrequiredpriortothecommencementoftheworks.Equipmentconnectionpictureasshownbelow六、開孔前檢查確認(rèn)帶壓開孔閥門已就位和正確地焊到管線上。所有無損檢測和水壓試驗(yàn)已完成并已評定。開工前得到許可和授權(quán)。設(shè)備連接如下圖所示S"iSOOrnrrhihottaplinestopof>e<rairairandiSOmmfetrualis^ijon抑個(gè)HottapfittingS"iSOOrnrrhihottaplinestopof>e<rairairandiSOmmfetrualis^ijon抑個(gè)HottapfittingBasicprocedureInstallfiningAndu^lveonexistingpipel和eInstallhotlapmachinePerformhotTapthroughilieopenvaEve(specialdeviceretainstheVoupoifremovedduringtheoperation)ICutteras&einblyr&iractedHottapvalveclosedHat怡卩rrwchi門七retnovedtoallowcomwctionton&wpipeVII、HotTapprocedureAttachsuitableadaptorhousingtodrillingmachine,ensuringthattheclassratingisasperthevalvetobetapped.SelectappropriateHotTapcutter.Attachselectedcuttertodrillingmachine.Ensurethatallbolts,pinsandretainersarecorrectlyfixed.Selectappropriatepilotdrilltosuitthecutterdepthandtoensurethatthecouponisretained.Checktheswingretainingwiresonthepilotdrillandreplaceifdefective.Attachpilotdrilltothedrillingmachineandtighten.Retractcutterandpilotassemblyintothedrillingadaptorhousingandmeasurethedistancefromthehousingflangetothecutterteethandthepilotdrilltip,andrecord.Measuredistancefromthevalveflangetothetopofthepipeandrecord.Calculatethetraveldistanceofthedrillingmachineusingthemeasurementsobtainedin(7)&(8)above,togetherwiththeactualpipecuttingdepth.Ensurethatthedrillingmachinehassufficienttravel.Attachdrillingmachinetovalvetobehottapped,ensuringtheuseofthecorrectgasket.Pressuretestassemblytoensurethatthefittingsandmachineareleakfree.Advancethecutter,manuallynotwithpowerfeed,throughthevalveandstub.Checkthatthedistancetravelledonthedrillingmachinecorrespondstothecalculateddistanceforthepilotdrilltocontactthetopofthepipe.Commencedrillingoperation.Adjusttheairsupplytoalterthecutterspeed.ObservethemeasurementsonthedrillingmachineandproceedtocutuntilthecalculateddistanceforthecompletionoftheHotTappingisreached.NOTE:Thecuttermayjamnearthecompletionofthecut.Thisisduetotheexpansionofthecouponduetotheresidualforcesinthepipe.Ifthecutterjamsnearcompletionofthetapping,stopthemachineandbackthecutteroffbeforerestartingthetappingoperation.Oncethecutterhastravelledthecalculateddistanceandthetappinghasbeencompleted,stopthemachineandadvancethecuttermanuallytoensurethatthetappingisactuallythroughthepipewall.Retractthecutterintothedrillingadaptor.Closethevalvethathasbeentapped.Bleedthepressureinthedrillingassemblyviathebleedpointonthedrillingadaptor.Unboltthedrillingmachineandremove.Removethecouponfromthepilotdrill.Disassemblethedrillingmachine,cleanandreplaceinthetransportcontainer.Thecuttingsequencyasshownbelow①-②-③-④七、帶壓開孔程序連接適配套到鉆機(jī)上，確認(rèn)其等級符合帶壓開孔用閥門。選擇合適的熱開孔刀具。將選好的刀具連接到鉆機(jī)上，確認(rèn)全部螺栓，銷和保持器正確地固定。選擇合適的先導(dǎo)鉆頭，適合刀具深度，確認(rèn)割下物件被扣留住。檢查在先導(dǎo)鉆頭上的游動(dòng)扣絲，如果失效必須更換。將先導(dǎo)鉆頭連接到鉆機(jī)上并固定牢。將刀具和先導(dǎo)鉆頭組件縮進(jìn)適配套，測量適配套法蘭至刀具齒和先導(dǎo)鉆頭尖的距離，并作記錄。測量閥門法蘭至管頂?shù)木嚯x，并作記錄。用上述7、8的測量值結(jié)合管