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Made in China, Shengyang FRP

Tel: 0536-4971568

Fax: 0536-4832568

Q Q541725060

Manager: Yin Huibin

Mobile: 13583651568

Address: No. 388, FRP Industrial Park, 2km south of Anqiu toll station, Weifang, Shandong, China

Installation and construction technology of FRP pipe

1. Component inspection: the pipe size shall meet the requirements of standards and specifications. The pipe end shall be marked with the material execution standard, specification type, etc., and the product quality certificate and acceptance content shall be provided. The inner surface of the pipe shall be smooth without cracks, layering, pinholes, impurities, rubber poor areas and bubbles, the end surface of the pipe shall be flush without burrs, and the outer surface shall be free of obvious cracks, layering and other defects. All surfaces inside and outside the socket and spigot shall be smooth and free from cracks, fractures or other defects detrimental to the service performance of the connection surface. The steps and end faces of the O-ring groove must be bonded as a whole without layering. The thickness of the pipe shall meet the use requirements.

It is strictly prohibited to use recycled rubber for sealing rubber ring. Its appearance shall be intact without joints, and there shall be no cracks, impurities and bubbles on the surface. The specification and appearance size must be consistent with the processing size of the pipe ring groove. The cross section diameter difference of rubber ring shall not exceed 0.5mm, and the diameter difference of rubber ring shall not exceed 10 mm. The performance index of rubber ring shall be subject to the guarantee of sealing and no leakage, and generally shall meet the following requirements: hardness (Shore A) 45-55; tensile strength greater than 16 MPa; elongation greater than 500%; deformation less than 20%; aging coefficient 0.8 (70 / 44h).

2 pipeline loading and unloading

(1) the pipeline shall be handled with care during loading and unloading, and it is strictly prohibited to fall or impact.

(2) the working position of the pipeline loading and unloading equipment must be stable, and the lifting capacity of the equipment must be reliable.

(3) the ipeline can be lifted by one or two supporting points. The pipeline shall be balanced in the air. It is strictly prohibited to use ropes to penetrate both ends of the pipeline for loading and unloading.

(4) the hoisting rope used for loading and unloading shall be flexible and wide belt, sling or rope. It is strictly prohibited to use wire rope or chain to hoist the pipeline.

3 material storage

(1) when the pipeline arrives at the site, it shall be transported to the corresponding operation section for immediate construction. If the construction cannot be carried out immediately in case of force majeure, the pipe material shall be stored.

(2) the auxiliary connection materials of FRP pipes include glass fiber yarns, chopped felt, glass cloth and other reinforcing materials and resins, curing agents, accelerators, anti-aging agents and other matrix materials, and various kinds of cement. These materials must be stored in a dry place without direct sunlight. Rubber ring shall be sun proof and away from heat source, and shall not contact with grease and organic solvent. Pipes and pipe fittings shall be stacked according to types, specifications and grades. Soft cushions shall be added between layers to keep away from heat sources and inflammable and explosive materials. They shall not be stored in the open for a long time to prevent exposure to the sun.

(3) when the pipeline is directly stored on the ground, the ground shall be flat. It is strictly prohibited to store the pipes on sharp hard objects, and the stacked pipes shall be provided with wooden wedges to prevent rolling.

(4) pipes shall be stored according to specifications. Sleepers shall be placed on each layer of pile, and the spacing between sleepers shall be less than 1 / 2 of the pipe length. The stacking height of pipes shall not be higher than 2m, and pipes above dn1400 shall not be stacked.

4 foundation trench treatment

(1) trench excavation

1) mechanical excavation shall be adopted for trench excavation. Manual excavation as a supplementary method. During excavation, the surface of trench bottom shall be continuously flat. The trench wall shall be graded according to the situation. With assurance. Remove boulders larger than 38mm in diameter or angle stones larger than 25mm. And remove the objects that may fall and collide on the ditch. To prevent damage to the pipe.

2) the section size of the trench shall meet the requirements of the design documents. It shall also conform to the provisions of gb50268-97 and cecs129:2001; the width of the trench shall be convenient for the laying and installation of pipes, the operation of tamping machines and tools and the discharge of groundwater. The small width b of the trench shall be calculated according to the following formula:

B > D+2s

Where B - small width of groove (mm);

D - outer diameter of pipe (mm)

S -- distance from pipe wall to groove wall (mm)

The distance between pipe wall and trench wall should be in accordance with table (recommended s value)

(2) foundation trench treatment

1) foundation trench treatment is an important process to ensure the quality of pipeline construction. If the geological conditions are not good when slotting. It shall be treated according to the design documents and corresponding specifications to avoid uneven settlement. Increase the local stress of the pipeline. If there is local overbreak. It is also required to backfill and compact to the bottom elevation of the trench according to the design requirements.

2) excavation of pipe joint socket working pit. Its bottom width shall be greater than the outer diameter of the socket. The length shall cover 200 mm before and after the bell mouth. Dn1000-1600 pipes. The depth shall be in the range of 400-500mm. After the completion of interface construction. Backfill with the same material and density as the sand cushion.

(3) trench acceptance

According to the small acceptance length specified in the project. On the basis of qualified self inspection by the construction unit. The supervision unit, together with the construction, design and construction unit, shall check the elevation, bottom width, cushion material thickness and other indicators of the trench bottom. Hand over to the installation unit after being qualified.

(4) pipe thrust buttress

1) fixed buttress shall be set at the turning, reducing and tee of the pipeline. The buttress shall enclose the pipe fittings and be set on the undisturbed soil. Pipeline displacement shall not exceed the design requirements.

2) the thrust buttress shall be supported on the original soil layer, otherwise the soil shall be compacted in layers.

3) the gate must be strong enough. The device for fixing the gate, such as the snap ring and buttress, shall be set in the gate shaft.

4) when the longitudinal angle of pipeline laying is greater than 15, it shall be installed from bottom to top and anchored.

5 pipeline installation

(1) in order to ensure the installation accuracy and the uniform stress of the pipeline after installation, the pipe fittings can be made on site by professional personnel according to the site size.

As FRP is a kind of composite material, many factors affect its corrosion resistance and construction quality. At the same time, in addition to the prefabrication of some pipe fittings, most of the pipe fittings, supporting processes and connections are hand pasted on site, which is greatly affected by the external conditions. Pay attention to the following points when presetting on site:

A. In case of glue flow, the first possibility is that the resin viscosity is too small, 2% - 3% active silica powder can be added properly; the second possibility is that the ingredients are not uniform, and the resin solution should be fully stirred; the third possibility is that the amount of curing agent is insufficient, and the amount of curing agent should be adjusted properly.

B. if the product surface is sticky, one possibility is that the crosslinker in the product surface resin volatilizes too much, and the benzene ethylene in the resin volatilizes so that the proportion is out of balance, resulting in non curing. The prevention methods include avoiding the high temperature before resin gelation, controlling ventilation and reducing volatilization. The second possibility is that the air humidity is high, and the water can delay the curing and prevent the polymerization of the resin. Therefore, the weather with low relative humidity is selected for construction. Special measures shall be taken in rainy and snowy weather.

C. if there are many bubbles in the product, one possibility is that the resin consumption is too much and the bubble content of the glue solution is too much, so the glue consumption should be strictly controlled. At the same time, pay attention to the way of mixing to prevent excessive bubbles.

D. if the products are layered, check whether all glass silk cloth is dewaxed or damped, select "three no" glass silk cloth, and dry it before use. At the same time, check whether the amount of glue is insufficient, or the glass fiber cloth layer is not compacted. When pasting, use enough glue liquid and scrape hard to make the layer compact and catch up bubbles.

E. if incomplete curing occurs, mainly due to insufficient or invalid amount of curing agent, the original paste shall be removed and the paste shall be made again after inspection.

(2) cutting of FRP pipe

Draw the cutting line at the place to be cut, including cutting line, through cutting line connected with the cutting hole, and cut off the pipe or hole according to the position of the cutting line with the angle grinder equipped with the cutting saw blade. The cut shall be flat with a deviation of 2mm and coated with resin. Square holes shall not be cut when holes are cut on glass steel pipes.

(3) when running the pipe, the pipe socket shall face the direction of incoming water. In order to facilitate the exhaust during the pressure test of the pipe orifice, the pressure test hole shall be facing upwards during the installation of the glass steel pipe. The allowable deviation is + 5mm. When the GRP is put into the trench, it shall not collide with the trench wall, the transportation pipeline in the trench shall not disturb the foundation, and each pipe shall be staggered 0.4m along the trench direction.

(4) before installation, clean the pipe surface, groove and rubber ring, apply lubricant to the rubber ring and put it into the groove from the bottom without any distortion, and check the overall rubber ring seal in place along the circumference by hand.

(5) mark points and bumps. Take LX value from the center of pressure test hole of socket. Mark points evenly from the center of two rubber rings of the socket to the direction of the mark ring of the socket (see Figure 1). It is installed by the method of manual chain collision. Slowly push the socket into the socket, and the end line of the socket shall coincide with the marked point. It is installed in place.

(6) after installation, use a steel ruler to detect the distance from the mark point to the outer wall of the seal ring groove. It is qualified if the difference between L and l is controlled within 3mm (see Figure 2)

6 pipe port pressure test

As the double "O" ring of socket type is used to connect the FRP pipes, each pipe installed shall be pressed at the socket to test the sealing effect of the double "O" ring. Use the pressure test pump to directly pass through the pressure test hole on the top of the pipe. Add water and pressurize to 1.5 times of the working pressure of the pipeline, then stop the pump (open the drain valve to exhaust during the operation), observe for 2min, the pressure drop value shall not exceed 5% of the test pressure, and there is no leakage at the nozzle. The nozzle pressure test is qualified. If the pressure drop drops quickly. It indicates that the sealing effect is not good and needs to be reinstalled to ensure the overall pressure test of the whole pipeline system is successful.

7 pipeline acceptance

(1) check the radial deflection value. According to the requirements of the specification, within 24 hours after the installation of FRP pipes, the initial radial deflection of the pipes shall be tested, and the pipes shall be free of bulge, flat and other sudden changes.

(2) hydrostatic test. In order to comprehensively check the installation quality of the pipeline, the pressure test shall be carried out according to the test method specified in the code for construction and acceptance of water supply and drainage pipeline engineering, and the allowable water seepage can be carried out according to the steel pipe standard.

(3) due to the use of spigot and socket type double "O" seal ring connection between FRP pipes, each pipe installed shall be pressed at the spigot and socket to test the sealing effect of double "O" seal ring. Use the pressure test pump to directly pass through the pressure test hole on the top of the pipe. Add water and pressurize to 1.5 times of the working pressure of the pipeline, then stop the pump (open the drain valve to exhaust during the operation), observe for 2min, the pressure drop value shall not exceed 5% of the test pressure, and if there is no leakage at the nozzle, the pressure test at the nozzle is qualified. If the pressure drop drops rapidly, it indicates that the sealing effect is poor, and it needs to be reinstalled to ensure the overall pressure test of the whole pipeline system is successful.

8. Pipe withdrawal operation and repair method

(1) in the installation process of FRP pipes, there are often unqualified phenomena. Generally, there are three reasons for the unqualified installation of FRP pipes: first, the quality difference between the pipe socket and the spigot, which is ignored in the factory inspection; second, there are sand particles in the socket that have not been removed; third, the rubber ring is not installed in place, resulting in its distortion or deformation, or both sides in the installation process As long as the installation of FRP pipe is not qualified, it is necessary to withdraw the pipe, check the rubber ring and find out the reason for re installation.

If the above situation occurs, the hydraulic jack is proposed to be used for pipe withdrawal in the project. The tools used are hydraulic jack and support (see Fig. 3). The support can be made of L5 angle steel with a length of 300 mm. The 60mmx60mm iron plate with a thickness of 10 mm is welded on one end of the angle steel, and two 10 round steels with a length of 30 mm and a spacing of 100 mm are welded on the outside of one side of the angle steel along its length direction perpendicular to the surface of the angle steel plate. When using, first drill 2 holes with a spacing of 10 of 100mm on the pipe socket to exit along the pipe axis direction at a proper position, insert the round steel of the support into the drilling hole (the end with a plug on the angle steel must be opposite to the main port), then close the base of the jack to the main port of the pipe, support the top of the jack on the plug of the angle steel support, and press the pressure bar of the jack , you can easily exit the pipe in a short time. Then, the hole on the socket is screwed up and blocked with a 12mm screw with resin, and the pipe withdrawal is completed.

(2) FRP pipes are hard to avoid damage during transportation, installation and backfilling. Before water injection and pressure suppression, the pipes must be inspected once after. The maintenance personnel are difficult to move in the pipes and the maintenance speed is slow, which affects the progress of the whole project. A simple pipeline truck can be made on site for maintenance. Select a section of abandoned pipeline (the diameter of the pipeline is one class smaller than the pipeline to be repaired), cut the length of about 900mm, cut the pipeline in the direction of the pipe axis, and cut the plate with an arc length of 500mm as the vehicle plate of the pipeline car, and install the universal wheel on four corners. (refer to figure 4) when repairing the pipeline, place the pipeline truck in the pipeline, the maintenance personnel will drill into the pipeline, lie on the back of the car, and use the pedal car to quickly carry out the maintenance.

9 trench backfilling

(1) after the pipeline is connected, hydrostatic test and backfilling must be carried out as soon as possible to prevent the pipeline from floating and thermal deformation.

(2) according to the design requirements, the backfill materials of the pipe area shall be selected, and the correct pipe area shall be backfilled and compacted. The haunch corners at both ends of the bottom of the pipeline shall be backfilled and compacted according to the requirements of the design bearing angle.

(3) before backfilling, the sundries in the trench shall be removed and the accumulated water shall be removed. Backfilling shall not be carried out under the condition of accumulated water.

(4) the pipe area shall be backfilled symmetrically and layer by layer instead of one side. The thickness of each backfill shall be determined according to the backfill material and method. Gravel and gravel should be 300 mm and sand 150 mm.

(5) the pipe area shall be compacted from both sides of the pipe trench wall at the same time, gradually approaching to the pipe wall direction, and one side compaction is strictly prohibited. The compaction of pipe top shall reach the required compactness, and the compactness of backfill in pipe area shall be 95%.



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Made in China, Shengyang FRP

Tel: 0536-4971568

Fax: 0536-4832568

Q Q541725060

Manager: Yin Huibin

Mobile: 13583651568

Address: No. 388, FRP Industrial Park, 2km south of Anqiu toll station, Weifang, Shandong, China