帶壓開孔技術方案

PagePage#of10ExecutionplanforHot-tapping帶壓開孔執(zhí)行計劃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Icejamming:2sections4positions,6mintotal冰塞數(shù)量：2段4處，總長約6米II、CompilationBasis二、編制依據SteelPipingSealingTechnicalRegulation《鋼質管道封堵技術規(guī)程》（SY／T6150.1－2003）SteelPipingWeldingandInspection《鋼質管道焊接及驗收》（SY/T4103—1995）IndustrialMetallicPipingEngineeringConstructionandInspectionCode《工業(yè)金屬管道工程施工及驗收規(guī)范》（GB50235-97）III、Constructionsequence三、施工方案（1）Sequence順序：Preparations準備工作Shortpipepreparation短管制備weldingunderpressure帶壓焊接valvetest閥門單獨試驗valveinstallation閥門安裝pressuretestforthesystem整體試壓一—hottapping開孔（2）thescheduledtimeisasthefollowingtable計劃時間如下表：S/NItem項目Start開始時Finish結束Remarks備

序號間時間注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(泄露，強度)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人防護衣著。包括、安全帽、安全眼鏡、工作手套和安全鞋。確認帶壓開孔數(shù)據信息與現(xiàn)場情況一致。確認管道壓力，確信在設備的額定操作壓力范圍內。確認管道溫度，確信低于設備的額定操作溫度。確認管道內介質。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，警告標示，滅火器等。V、PressuretestprocedureVisualcheckweldednozzleorfittingfreefromanydefects.Installvalvetonozzleorfittingandtightbolt&nutcorrectlyInstallhottapmachinetothevalve&openthevalveConnecthydrostaticpumptoinletofthehottapmachineOpenhottapmachineventportvalveOperatehydrostaticpumpuntilwatercomeoutfromventvalve&shutoffthevalveIncreasehydrostaticpressurewhichequalto1.5timesoflinepressureShutoffthepumpinletvalvetomaintainpressureHoldingthepressurefor15minutesReleasepressure&dismantlepump五、壓力試驗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泵到開孔機入口打開開孔機排空閥門操作水壓試驗泵至水從排空閥溢出并關上閥門增加水壓壓力至等于1.5倍母管內壓關上泵進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已完成并已評定。開工前得到許可和授權。設備連接如下圖所示S"iSOOrnrrhihottaplinestopof>e<rairairandiSOmmfetrualis^ijon抑個HottapfittingS"iSOOrnrrhihottaplinestopof>e<rairairandiSOmmfetrualis^ijon抑個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上，確認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上，確認全部螺栓，銷和保持器正確地固定。選擇合適的先導鉆頭，適合刀具深度，確認割下物件被扣留住。檢查在先導鉆頭上的游動扣絲，如果失效必須更換。將先導鉆頭連接到鉆機上并固定牢。將刀具和先導鉆頭組件縮進適配套，測量適配套法蘭至刀具齒和先導鉆頭尖的距離，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的測量值結合管