pe管热熔焊接施工工法(天然气管道)

'PE管热熔焊接施工工法1概述   PE管材料属聚烯烃类高分子化合物，其分子由碳、氢元素组成，无有害元素，卫生可靠。在加工、使用及废弃过程中，不会对人体及环境造成不利影响，是绿色建材。PE管材不仅韧性、挠性好，而且焊接性能极佳，管道连接过程中施焊效果可靠，造价低；同时具有良好的气密性、耐腐蚀性和良好的抵抗裂纹快速传递能力，因而广泛用于市政、石油、化工、燃气等建设领域。PE管材的应用是2004年建设部科技成果推广项目。公司近年来开展对PE管热熔焊接技术进行研究，研究成果成功地用于珠三角地区的燃气工程，取得了较好的经济效益和社会效益。2特点2.0.1工艺流程先进，可实现全自动、半自动施工。2.0.2接头连接牢固可靠。2.0.3施工技术先进，设备操作简单，劳动强度低。2.0.4施工过程中无需配备较多的施工机具，节约成本，机动灵活。3适用范围andmunicipalpartyCommitteesessionplenarysession,addingmeasures,promotetheXXeconomic,socialandculturaldevelopment.(A)theprimaryresponsibilityforfulfillingParty5yearsXXtownguidedbythe18thespiritoftheparty,conscientiouslyimplementtheCentraleightandthreeSunsandtenrequirementsoftheprovincial,cityandCounty,putthoughtandactionintoCounty,theCountyGovernmentamajordeployment,andtheCountydisciplineInspectionCommissionplenarysession.　　Seriouslystudyingandimplementingtheimportantspeech,GeneralSecretaryoftheCommunistPartyofChinaXIJinpingprobityguidelines,theCPCdisciplinaryOrdinance,suchastheresponsibilityofuncorrupted,torealizetheChinesedreambuiltawell-offsocietyhaslaidasolidpoliticalfoundation.1.stronglyimplementationCentral,andprovincial,andmunicipalandCountyofarrangementsdeployment,insistedputstylecleangovernmentandeconomicdevelopmentworkwithdeployment,andwithcheck,andwithimplementation,strongadvancefourwindhighlightproblemspecialregulation,constantlyenhancedstylecleangovernmentandanti-corruptionstruggleofsufferingconsciousness,andplayconsciousness,andresponsibilityconsciousness,insistedtomasslineintheoffourmirrorforguide,findoutfourwindhighlightproblem12a,effectivedohassidechecksidemodified,changestyle,constantlyimprovepoliticalliteracy,Strengtheningthefourwindsproblemrectificationandconscientiouslyimplementboth,furthereffortstoimprovethePartyCommitteeonupholdingintegrityandcombatingcorruption.　　EstablishedbytheSecretaryoftheresponsibilityofhonestleadershipteam,andconscientiouslyimplementtheresponsibilityofuncorruptedparty,firmlydoesnotscratchcleanisderelictionofduty,is    本工法可用于市政建设给排水、燃气管道安装以及石油、化工、水处理等领域适用于管径大于110mm，小于425mm的管道施工(一般不允许不同材质的PE管直接对接)。4工艺原理   热熔焊焊接是利用加热工具将管道或管件端面加热到210℃左右，在可控压力下持续一定时间，使两端面熔合为一体，形成符合质量要求的管道焊接接头。5施工方法   PE管的焊接施工可以在管沟边进行也可以在管沟内进行，无论采取哪种方式都应将热熔焊机机架安置平稳。5.1施工工艺流程   管道、管件的验收→焊接准备→连接部位端部铣平和同轴度校对→测量拖拉力→在可控压力下焊接→管道吹扫→试压。5.2施工方法5.2.1管道、管件的验收   管道、管件应根据施工要求选用配套的等径、异径弯头和三通等管件。热熔焊接宜采用同种牌号、材质的管件，对性能相似的不同牌号、材质的管件之间的焊接应先做试验。主要依据:设计图纸、现行《燃气工程用埋地聚乙烯管材》GB/T15558.1、GB/T15558.2技术标准；《聚乙烯燃气管道工程技术》CJJ63技术标准。5.2.2焊接准备andmunicipalpartyCommitteesessionplenarysession,addingmeasures,promotetheXXeconomic,socialandculturaldevelopment.(A)theprimaryresponsibilityforfulfillingParty5yearsXXtownguidedbythe18thespiritoftheparty,conscientiouslyimplementtheCentraleightandthreeSunsandtenrequirementsoftheprovincial,cityandCounty,putthoughtandactionintoCounty,theCountyGovernmentamajordeployment,andtheCountydisciplineInspectionCommissionplenarysession.　　Seriouslystudyingandimplementingtheimportantspeech,GeneralSecretaryoftheCommunistPartyofChinaXIJinpingprobityguidelines,theCPCdisciplinaryOrdinance,suchastheresponsibilityofuncorrupted,torealizetheChinesedreambuiltawell-offsocietyhaslaidasolidpoliticalfoundation.1.stronglyimplementationCentral,andprovincial,andmunicipalandCountyofarrangementsdeployment,insistedputstylecleangovernmentandeconomicdevelopmentworkwithdeployment,andwithcheck,andwithimplementation,strongadvancefourwindhighlightproblemspecialregulation,constantlyenhancedstylecleangovernmentandanti-corruptionstruggleofsufferingconsciousness,andplayconsciousness,andresponsibilityconsciousness,insistedtomasslineintheoffourmirrorforguide,findoutfourwindhighlightproblem12a,effectivedohassidechecksidemodified,changestyle,constantlyimprovepoliticalliteracy,Strengtheningthefourwindsproblemrectificationandconscientiouslyimplementboth,furthereffortstoimprovethePartyCommitteeonupholdingintegrityandcombatingcorruption.　　EstablishedbytheSecretaryoftheresponsibilityofhonestleadershipteam,andconscientiouslyimplementtheresponsibilityofuncorruptedparty,firmlydoesnotscratchcleanisderelictionofduty,is    1.检查焊接机状况是否满足工作要求，检查机具各个部位的紧固件有无脱落或松动。   2.检查机电线路连接是否正确、可靠。   3.检查液压箱内液压油是否充足。   4.确认电源与机具输入要求是否相匹配。   5.加热板是否符合要求(涂层是否损伤)。   6.铣刀和油泵开关是否正常等。5.2.3连接部位端部铣平和同轴度校对   1.用干净的布清除两管端部的污物。将管材置于机架卡瓦内，使对接两端伸出的长度大致相等且在满足铣削和加热要求的情况下应尽可能缩短，通常为25～30mm。管材在机架以外的部分用支撑架托起，使管材轴线与机架中心线处于同一高度，然后用卡瓦紧固好(见图1)。   2.置入铣刀，先打开铣刀电源开关，然后缓慢合拢两管材焊接端，并加以适当的压力，直到两端面均有连续的切屑出现，撤掉压力，略等片刻，再退出活动架，关掉铣刀电源。切屑厚度应为0.5～1.0mm，通过调节铣刀的高度可调节切屑的厚度(见图2)。andmunicipalpartyCommitteesessionplenarysession,addingmeasures,promotetheXXeconomic,socialandculturaldevelopment.(A)theprimaryresponsibilityforfulfillingParty5yearsXXtownguidedbythe18thespiritoftheparty,conscientiouslyimplementtheCentraleightandthreeSunsandtenrequirementsoftheprovincial,cityandCounty,putthoughtandactionintoCounty,theCountyGovernmentamajordeployment,andtheCountydisciplineInspectionCommissionplenarysession.　　Seriouslystudyingandimplementingtheimportantspeech,GeneralSecretaryoftheCommunistPartyofChinaXIJinpingprobityguidelines,theCPCdisciplinaryOrdinance,suchastheresponsibilityofuncorrupted,torealizetheChinesedreambuiltawell-offsocietyhaslaidasolidpoliticalfoundation.1.stronglyimplementationCentral,andprovincial,andmunicipalandCountyofarrangementsdeployment,insistedputstylecleangovernmentandeconomicdevelopmentworkwithdeployment,andwithcheck,andwithimplementation,strongadvancefourwindhighlightproblemspecialregulation,constantlyenhancedstylecleangovernmentandanti-corruptionstruggleofsufferingconsciousness,andplayconsciousness,andresponsibilityconsciousness,insistedtomasslineintheoffourmirrorforguide,findoutfourwindhighlightproblem12a,effectivedohassidechecksidemodified,changestyle,constantlyimprovepoliticalliteracy,Strengtheningthefourwindsproblemrectificationandconscientiouslyimplementboth,furthereffortstoimprovethePartyCommitteeonupholdingintegrityandcombatingcorruption.　　EstablishedbytheSecretaryoftheresponsibilityofhonestleadershipteam,andconscientiouslyimplementtheresponsibilityofuncorruptedparty,firmlydoesnotscratchcleanisderelictionofduty,is    3.取出铣刀，合拢两端管，检查两端对齐情况。管材的错位量不应超过管壁厚度的10%或1mm中的较大值，通过调整管材直线度和松紧卡瓦可在一定程度上进行校正；合拢时管材两端面间应没有明显缝隙，缝隙宽度不能超过:0.3mm(D≤225mm)、0.5mm(225mm＜D≤400mm)或1.0mm(D＞400mm)。如不满足上述要求应再次铣削，直到满足为止。5.2.4测量拖拉力(移动夹具的摩擦阻力)   由于各个场地条件的不同，会导致移动夹具(包括拖动PE管)的摩擦阻力各不相同。在实际施工中应考虑这个摩擦阻力，它与工艺参数压力(说明书中规定的压力)叠加在一起得到实际使用压力。管材在夹具中夹好后，慢慢移动夹具，此时测得的力为拖拉力，可由压力表读出，做好记录。5.2.5在可控压力下焊接   正常情况下预热时间约为20分钟，加热板温度达到设定值后，放入机架，施加压力Pa1(即拖拉力和说明书中规定的压力之和)，直到两边最小卷边达到规定宽度时压力减小到规定值Pa2(使管端面与加热板之间刚好保持接触)，进行吸热，见图3。吸热时间满足后，退开活动架，迅速取出加热板，然后合拢两管端。切换时间(tu)应尽可能短，不能超过规定值。冷却到规定的时间后，卸压，松开卡瓦，取出连接完成的管材，用笔在焊口处标明编号和焊工标记，准备下一接口的焊接。如图4andmunicipalpartyCommitteesessionplenarysession,addingmeasures,promotetheXXeconomic,socialandculturaldevelopment.(A)theprimaryresponsibilityforfulfillingParty5yearsXXtownguidedbythe18thespiritoftheparty,conscientiouslyimplementtheCentraleightandthreeSunsandtenrequirementsoftheprovincial,cityandCounty,putthoughtandactionintoCounty,theCountyGovernmentamajordeployment,andtheCountydisciplineInspectionCommissionplenarysession.　　Seriouslystudyingandimplementingtheimportantspeech,GeneralSecretaryoftheCommunistPartyofChinaXIJinpingprobityguidelines,theCPCdisciplinaryOrdinance,suchastheresponsibilityofuncorrupted,torealizetheChinesedreambuiltawell-offsocietyhaslaidasolidpoliticalfoundation.1.stronglyimplementationCentral,andprovincial,andmunicipalandCountyofarrangementsdeployment,insistedputstylecleangovernmentandeconomicdevelopmentworkwithdeployment,andwithcheck,andwithimplementation,strongadvancefourwindhighlightproblemspecialregulation,constantlyenhancedstylecleangovernmentandanti-corruptionstruggleofsufferingconsciousness,andplayconsciousness,andresponsibilityconsciousness,insistedtomasslineintheoffourmirrorforguide,findoutfourwindhighlightproblem12a,effectivedohassidechecksidemodified,changestyle,constantlyimprovepoliticalliteracy,Strengtheningthefourwindsproblemrectificationandconscientiouslyimplementboth,furthereffortstoimprovethePartyCommitteeonupholdingintegrityandcombatingcorruption.　　EstablishedbytheSecretaryoftheresponsibilityofhonestleadershipteam,andconscientiouslyimplementtheresponsibilityofuncorruptedparty,firmlydoesnotscratchcleanisderelictionofduty,is 为焊接完成后的效果图。主要工艺控制参数见表1。5.2.6管道吹扫   管道吹扫与一般管道吹扫相同，主要采用爆破式吹扫，可以分段进行，介质为无油压缩空气，压力不应超过管道的工作压力。5.2.7试压   PE管道系统在投入运行之前应进行压力试验。压力试验包括强度试验和水密性试验。测试时一般采用水作为试验介质。andmunicipalpartyCommitteesessionplenarysession,addingmeasures,promotetheXXeconomic,socialandculturaldevelopment.(A)theprimaryresponsibilityforfulfillingParty5yearsXXtownguidedbythe18thespiritoftheparty,conscientiouslyimplementtheCentraleightandthreeSunsandtenrequirementsoftheprovincial,cityandCounty,putthoughtandactionintoCounty,theCountyGovernmentamajordeployment,andtheCountydisciplineInspectionCommissionplenarysession.　　Seriouslystudyingandimplementingtheimportantspeech,GeneralSecretaryoftheCommunistPartyofChinaXIJinpingprobityguidelines,theCPCdisciplinaryOrdinance,suchastheresponsibilityofuncorrupted,torealizetheChinesedreambuiltawell-offsocietyhaslaidasolidpoliticalfoundation.1.stronglyimplementationCentral,andprovincial,andmunicipalandCountyofarrangementsdeployment,insistedputstylecleangovernmentandeconomicdevelopmentworkwithdeployment,andwithcheck,andwithimplementation,strongadvancefourwindhighlightproblemspecialregulation,constantlyenhancedstylecleangovernmentandanti-corruptionstruggleofsufferingconsciousness,andplayconsciousness,andresponsibilityconsciousness,insistedtomasslineintheoffourmirrorforguide,findoutfourwindhighlightproblem12a,effectivedohassidechecksidemodified,changestyle,constantlyimprovepoliticalliteracy,Strengtheningthefourwindsproblemrectificationandconscientiouslyimplementboth,furthereffortstoimprovethePartyCommitteeonupholdingintegrityandcombatingcorruption.　　EstablishedbytheSecretaryoftheresponsibilityofhonestleadershipteam,andconscientiouslyimplementtheresponsibilityofuncorruptedparty,firmlydoesnotscratchcleanisderelictionofduty,is    1.强度试验   在排除待测试管道内的空气后，以稳定的升压速度将压力提高到要求的压力值。压力表尽可能放置在该管道的最低处。开始时，应将压力上升到工作压力并停留足够的时间保证管道充分膨胀，这一过程需2—3小时，当系统稳定后，将压力升到工作压力的1.5倍，稳压1小时，仔细观察压力表，并沿管线检查，如果在测试过程中并无肉眼可见的泄漏或发生明显的压力降，则管道通过压力试验。  2.水密性试验   水密性试验的压力应为工作压力的1.15倍，当管道压力达到试验压力后，应保持一定的时间使管道内试验介质温度与管道环境温度达到一致，待温度、压力均稳定后，开始计时，一般情况下，水密性试验应稳压24小时，如果没有明显的泄漏或压力降则通过水密性试验。6施工机具设备   按照本工法进行PE管焊接安装的主要机具见表2。7劳动力组织   每台焊机配备焊工2人，配合人员包括电工2～6名，若PEandmunicipalpartyCommitteesessionplenarysession,addingmeasures,promotetheXXeconomic,socialandculturaldevelopment.(A)theprimaryresponsibilityforfulfillingParty5yearsXXtownguidedbythe18thespiritoftheparty,conscientiouslyimplementtheCentraleightandthreeSunsandtenrequirementsoftheprovincial,cityandCounty,putthoughtandactionintoCounty,theCountyGovernmentamajordeployment,andtheCountydisciplineInspectionCommissionplenarysession.　　Seriouslystudyingandimplementingtheimportantspeech,GeneralSecretaryoftheCommunistPartyofChinaXIJinpingprobityguidelines,theCPCdisciplinaryOrdinance,suchastheresponsibilityofuncorrupted,torealizetheChinesedreambuiltawell-offsocietyhaslaidasolidpoliticalfoundation.1.stronglyimplementationCentral,andprovincial,andmunicipalandCountyofarrangementsdeployment,insistedputstylecleangovernmentandeconomicdevelopmentworkwithdeployment,andwithcheck,andwithimplementation,strongadvancefourwindhighlightproblemspecialregulation,constantlyenhancedstylecleangovernmentandanti-corruptionstruggleofsufferingconsciousness,andplayconsciousness,andresponsibilityconsciousness,insistedtomasslineintheoffourmirrorforguide,findoutfourwindhighlightproblem12a,effectivedohassidechecksidemodified,changestyle,constantlyimprovepoliticalliteracy,Strengtheningthefourwindsproblemrectificationandconscientiouslyimplementboth,furthereffortstoimprovethePartyCommitteeonupholdingintegrityandcombatingcorruption.　　EstablishedbytheSecretaryoftheresponsibilityofhonestleadershipteam,andconscientiouslyimplementtheresponsibilityofuncorruptedparty,firmlydoesnotscratchcleanisderelictionofduty,is 管管径大于200mm时，配合人员应增加到8～10人。8安全措施8.0.1带电设备必须有可靠的接地，防止触电。8.0.2预热过程中，不能触碰加热板，防止烫伤。8.0.3焊接操作人员、电工必须经培训后上岗。9技术经济分析9.0.1采用本工法施工，由于操作简单，经培训后即可上岗。9.0.2由于管材较轻，基本不使用机械吊装，节约费用，缩短施工工期。9.0.3施工设备少，机动灵活，降低工人劳动强度，适于野外作业，同时设备购置成本低，利用率高，经济效益明显。   我公司应用的实践表明，使用本方法后每年节约成本约10万元左右，约为总工程量的2.5%。10工程实例   本工法在深圳诺德金融中心埋地管燃气工程、深圳星座大厦燃气工程、东莞广彩路中压天然气工程、东莞新基大道中压天然气工程、东莞湖景大道中压天然气工程等十几项燃气管道工程中均得到推广应用，工程质量、工期进度、安全等方面都取得满意的效果andmunicipalpartyCommitteesessionplenarysession,addingmeasures,promotetheXXeconomic,socialandculturaldevelopment.(A)theprimaryresponsibilityforfulfillingParty5yearsXXtownguidedbythe18thespiritoftheparty,conscientiouslyimplementtheCentraleightandthreeSunsandtenrequirementsoftheprovincial,cityandCounty,putthoughtandactionintoCounty,theCountyGovernmentamajordeployment,andtheCountydisciplineInspectionCommissionplenarysession.　　Seriouslystudyingandimplementingtheimportantspeech,GeneralSecretaryoftheCommunistPartyofChinaXIJinpingprobityguidelines,theCPCdisciplinaryOrdinance,suchastheresponsibilityofuncorrupted,torealizetheChinesedreambuiltawell-offsocietyhaslaidasolidpoliticalfoundation.1.stronglyimplementationCentral,andprovincial,andmunicipalandCountyofarrangementsdeployment,insistedputstylecleangovernmentandeconomicdevelopmentworkwithdeployment,andwithcheck,andwithimplementation,strongadvancefourwindhighlightproblemspecialregulation,constantlyenhancedstylecleangovernmentandanti-corruptionstruggleofsufferingconsciousness,andplayconsciousness,andresponsibilityconsciousness,insistedtomasslineintheoffourmirrorforguide,findoutfourwindhighlightproblem12a,effectivedohassidechecksidemodified,changestyle,constantlyimprovepoliticalliteracy,Strengtheningthefourwindsproblemrectificationandconscientiouslyimplementboth,furthereffortstoimprovethePartyCommitteeonupholdingintegrityandcombatingcorruption.　　EstablishedbytheSecretaryoftheresponsibilityofhonestleadershipteam,andconscientiouslyimplementtheresponsibilityofuncorruptedparty,firmlydoesnotscratchcleanisderelictionofduty,is'