Design of thermal network operational-remote control system.
- Added: 14.08.2014
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Description
1. Selection of monitoring devices.
2. Control point locations.
3. Equipping each test point with elements of the UEC system.
Project's Content
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Additional information
Contents
CONTENTS
Explanatory Note
18 sheets
Selection of monitoring devices
Leaf
Control Point Locations
Leaf
Equipping control points with UEC system elements
Leaf
Procedure for installation works
Leaf
Preparation for commissioning
Leaf
Procedure of pipeline operation and control organization
Leaf
Graphic part of the project
10 sheets
Installation diagram of UEC system sheet
Leaf
Installation diagram of UEC system sheet
Leaf
Wiring Schedule Specification
Leaf
Installation of ground carpet in test points
Leaf
Connection and installation diagrams of "KT-11G" terminal
Leaf
Connection and installation diagrams of "KT-12/SHG" terminal
Leaf
Connection and installation diagrams of "KT-15" terminal
Leaf
Connection and installation diagrams of "KT-16" terminal
Leaf
Feature Point Table
Leaf
Diagram Legend Table for SIS Wiring Diagram
Leaf
Explanatory Note
The explanatory note contains a description of the adopted technical decisions on the formation of an operational-remote control system for a specific area in order to organize operational control of this area.
The note justifies:
Selection of monitoring devices.
Control point locations.
Equipping each test point with elements of the UEC system.
Procedure for installation works.
Preparation for commissioning.
Operation procedure and organization of pipeline control.
Selection of monitoring devices
The type of monitoring devices for the designed area shall be selected based on the possibility of 220V voltage supply (availability) to the designed area for the entire pipeline operation.
Since there are no such facilities in the designed area, the whole pipeline is supposed to be monitored by a portable damage detector, connecting it to the switching terminals of the KT11G and KT12/SHG brand.
The number of instruments for the designed section shall be selected based on the length of the designed pipeline section. In the case when the length of the designed area is more than the maximum controlled length by one detector (see characteristics in the certificate), it is necessary to split the heat trail into several sections with independent control systems.
Control Point Location
Control points are designed to access the signal wires of the operating personnel in order to determine the state of the pipeline.
Seventeen test points shall be installed in this designed area. According to the Code of Rules of Joint Venture 411052002 "Design and Construction of Heat Networks of a Channel-Less Steel Pipe with Industrial Insulation from Polyurethane Foam in Polyethylene Shell," the control points are located:
At the endpoints of the pipeline being designed. If the length of the section is less than 100 meters, only one end reference point is allowed.
At intermediate points of the pipeline, such that the distance between two adjacent control points does not exceed 250300 meters.
At the beginning of each side branch from the main pipeline, if the length of this branch is 30 meters or more (regardless of the location of other control points on the main pipeline).
In places where the designed pipeline will be laid by pipes not insulated in polyurethane foam (basements of houses, heat chambers).
Equipping control points with UEC system elements
3.1.Selection of characteristic points
Characteristic points are specific locations on the pipeline being designed where the monitoring system is least reliable and can be damaged more likely.
The reference point will always be specific to the pipeline, and the reference point will not always be a reference point.
3.2.The composition of the control point:
Pipe part with output cable.
Connection cable/Cable extension kit "KUK3," "KUK-5."
Switching terminal.
Ground/wall carpet - if necessary.
Case of increased sealing - if necessary.
3.4.Views of characteristic points:
isolation valves;
control points;
fixed supports;
angles of pipeline turns;
insulation termination points not equipped with a control point;
branches from the main trunk of the heating main line (tees, etc., including downcomers).
3.7.Used equipment for installation
Set for installation and repair of "MRK05" UEC system - 1 pc.
Set of materials for sealing of joints "MRK06" - 1 pc.
Test and installation tester - 1 pc.
General requirements
Installation of SDS elements of the pipe part consists in proper connection of signal conductors at pipeline joints.
Connect signal conductors at joints in strictly specified order: connect the main signal wire to the main one, and the transit one to the transit one.
The main signal conductor shall always be located to the right in the direction of the coolant.
The main signal conductor is visually different from the transit conductor by marking.
The main signal conductor shall be marked at the pipe manufacturer. Marking shall be with red paint (on the parts of the wire protruding from the insulation on the pipe ends) or the whole wire shall be tinned (white).
The transit wire is not marked and has a copper color (red).
Only the main signal wire must be connected to all branches of the pipeline, and the transit wire must pass by the branches without entering any of them.
It is forbidden to connect the side branches to the transit wire located on the left in the direction of water supply to the consumer.
Signal conductors shall be installed after steel pipe welding.
Insulation ends of all pipeline elements (straight pipes, branches, tees, fixed supports, etc.) shall be protected against moisture - protection with polyethylene film is recommended.
Install signal conductors on butt connections only after checking insulation resistance and conductor resistance (integrity check) of each pipe element.
The maximum cable length from the pipeline to the terminal is 10 m. In case a long cable length is required, install the passing terminal as close to the pipeline as possible.
Install the terminal in accordance with the indicated marking on the attached diagrams.
Installation of the pipeline element with the output cable is carried out taking into account the direction of coolant supply.
The control arrow on the shell must coincide with the direction of coolant supply to the consumer. On the return pipe, the element with the output cable is installed in the direction of the direct pipe coolant supply.
In the heat chamber, lay the cable in corrugated slag.
After completion of installation work, specify the distance between the points in the Table of Characteristic Points (sheet 9 of the Graphic part of the project) - based on the data with the as-built joint diagram.
After completion of installation works indicate in Table No. 7 "Table of connecting cables" the actual length of connecting cables installed in control points.
Procedure for installation of conductors at joints
Connect the main signal and transit wire at the pipe ends by means of crimping bushing.
With the help of passages, at the next joint, carefully straighten and stretch the wires twisted in a spiral and, without allowing fractures, arrange parallel to the pipe.
Remove the outer layer of polyurethane foam insulation to a depth of 10 mm from pipe ends at the joint using a knife.
Attach conductors (holder) to metal pipe by means of fastening tape. Two holders for different wires are fixed simultaneously with one piece of tape. The tape wraps around the steel pipe 2 times with an overlap of 10%.
Clean the wires with sandpaper from the rest of the foam and paint, and then thoroughly degrease.
Tighten the wires for "butt" connection and cut the extra parts with pieces so that there is no weakness when connecting.
Measure wire resistance at the first junction (starting from pipe end) using the test and installation tester.
Enter the taken readings in Table No. 6 "Certificate of inspection of the UEC system during installation works" - the sample is given below. Fill the table during installation work for each joint. Joint numbers shall be the same as those specified in the joint diagram.
Compare the removed wire resistance value with the standard values for a given length of mounted conductors. Standard values of wire resistance are specified in Schedule 1 "Standard wire resistance."
If the removed value is different from the target value, reconnect the wires at the previous junction.
Measure insulation resistance at the first joint using the test and installation tester.
Enter the taken readings in Table No. 6.
Compare removed insulation resistance value with standard values for given length of mounted conductors. Standard values of insulation resistance are specified in Schedule 2 "Standard insulation resistance."
If the removed value is different from the target value, reconnect the wires at the previous junction.
After elimination of detected defects perform repeated measurement of parameters.
Connect the main signal conductors at the junction.
Insert the main signal wire of the first pipe into the crimping bushing by ½ part of its length. Compress the compound with crimp mites.
Insert the main signal wire of the second pipe into the crimping bushing until stop from the other side of the bushing. Compress the joint.
The resulting compound is treated with inactive flux. Apply inactive flux to both ends of crimping bushing.
The treated compound shall be sealed using solder and soldering iron (gas or electric).
Verify that the wires are connected correctly.
Fix the soldered conductors in the slots of the rack. Do not wrap tape holders over wires.
Connect the transit signal conductors at the junction as well as the main signal wires as per item 17-22 of the present instruction.
Perform heat and waterproofing of the joint with the installed wires.
Proceed to install the system to the next pipe joint.
Install all joints on the pipeline sequentially, refer to paragraphs 2-24 of this instruction.
Measure insulation resistance and wire resistance using a test and installation tester from a fully installed UEC system and enter data in Table No. 6 "Certificate of UEC system check during installation works" in the TOTAL column.
After completion of installation works mark the connecting cables and record the marking data in Table No. 7 "Table of connecting cables."
Cable marking consists of three groups of symbols separated by a dash mark:
The first group consists of two digits. The numbers indicate the numbers of characteristic points: the first digit is the number of the characteristic point at which the cable is installed, the second digit is the number of the nearest characteristic point, towards which the pre-insulated pipeline with this cable is directed.
The second group consists of one letter and one digit. Letters and numbers indicate the purpose of the pipeline.
The third group consists of digits. The numbers indicate the physical length of the cable in meters.
Preparation for commissioning
Before commissioning of the pipeline, perform insulation resistance and conductor resistance measurements for each section of the UEC system separately. These measurements shall be performed after complete completion of installation works.
Check at acceptance
Availability and quality of insulation end plugs. End plugs shall not have cracks, cuts, delamination from the polyethylene shell and metal pipe, as well as other similar defects affecting the reliability and tightness of the structure. Metal blinds shall have protective anti-corrosion coating.
Presence of clear and correct marking on connecting cables and carpets.
Availability of all instruments, equipment and components of the UEC system specified in the design.
Match the length of the cables specified in the design with the length specified on the tag.
Correspondence of SDS actuating diagram with actual diagram.
All detected flaws and deviations from the design are specified in the Report of monitoring system operability. The UEC system is not accepted for operation. After elimination of all shortcomings, re-commissioning is performed.
Operation procedure and organization of pipeline control.
The condition of pipelines equipped with SDS should be monitored by a mobile group consisting of two people.
Such a team should be equipped with the following equipment to carry out accurate and operational verification activities:
Impulse reflectometer "Reis150M."
Program for processing and storage of reflectograms "Reid6."
Personal computer (laptop).
Portable damage detector DPPAM "PICCON."
Control and installation tester "AM2002" (or other similar equipment).
In order to quickly determine the location of the defect (if it is suddenly fixed), the group should take the following information materials with it to leave for each heating line scheduled for maintenance:
Route certificate (SDS diagram, connection diagram, etc.).
Reflectograms in the form of computer .rfg files in PC memory.
Maintenance log.
The pipeline condition check should be carried out in two types: planned and quarterly.
Piping Status Check Types
Scheduled check
Scheduled inspection (detection control) is carried out using damage detectors - stationary and portable. Detection control only allows you to determine the type and presence of a defect such as "wet" and "break." The service periodicity is at least 2 times per month (recommended 1 times per week) both for pipelines serviced with a stationary detector and for pipelines serviced with a portable detector.
The heating line status report must be entered in the Service Log. The following data is marked in the Log: date of inspection, F.I.O. of the verifier, detector readings.
Check the status of the heating line with a portable damage detector, connecting it at checkpoints No. 10, 39, 43, 49, 54, 66, 73 to the KT11G switching terminal or at checkpoints No. 20, 57 to the KT12/SHG switching terminal.
If a defect signal occurs, use the "Reis150M" pulse reflectometer to detect the defect location and perform the test in a similar manner to locator monitoring (see below).
Quarterly review
The quarterly check consists of a complete survey of the pipeline and the UEC system. Quarterly check is performed using pulse reflectometer and test and installation tester of "AM2002" type. Such control is called locator control.
Locator control allows you to determine the place of the defect, as well as record the current characteristics of the heating network section, namely, the current reflectogram, current insulation resistance, current wire resistance. The criteria for assessing the state of the pipeline are described above. All quarterly check data is entered in the Archive.
Note
All changes made to the SDS diagram during installation works shall be taken into account and indicated in the as-built SDS diagram.
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- 13.06.2019
