Overhaul of the heating line on the territory of the HBC between TK-11 A and TK-11 B

Contents

1 General provisions

2 Initial data

3 Climatic data

4 Characteristics of the design object

5 About a Linear Object

6 Thermal mechanical solutions

6.1 Basic technical and economic characteristics of the designed linear object

6.2 Piping Design

6.3 Cleaning and flushing of pipelines

7 On-line remote monitoring system

8 Architectural and construction solutions

9 Installation Instructions

10 Anti-corrosion protection measures

11 Transportation and storage of materials

12 Technical and economic indicators

13 Solutions providing reliability of linear object

Appendix A. Technical assignment for the development of design documentation for the facility "Overhaul of the heating line on the territory of the HBC from TK-11 A to TK-B in Kamyshin," issued by LUKOIL-TTK LLC (Appendix No. 1 to Contract No. 13/2-124 dated 02.04.2013)

Appendix B. Topographic survey M 1:

1 General provisions

This design documentation provides for the overhaul of the heating line on the territory of the KhBK from TK11 A to TK11 B in Kamyshin, two Dn- 108 mm pipelines with a length of 134 p.m. in an impassable channel using high factory readiness pipes in PPU insulation for the needs of the LUKOILTTK branch in Volgograd.

The development of design documentation is caused by the device of the system of operational remote control (UEC) of insulation humidification.

2 Initial data

Initial data for development of design documentation:

1. Technical assignment for the development of design documentation for the facility "Overhaul of the heating line on the territory of KhBK from TK11A to TK11B in Kamyshin," issued by LLC LUKOILTTK Branch in Volgograd (Appendix No. 1 to Contract No. 13/2124 dated 02.04.2013, see Appendix A to the Explanatory Note).

Topographic survey of M 1:500 (see annex B to the Explanatory Note).

4 Characteristics of the design object

The heating line section is located on the territory of the KhBK from TK11A to TK11B in Kamyshin.

The designed section of the heating line runs along the existing trace of the heating line underground in the existing impassable channels. Start point - TK11 A, end point - TK11 B.

5 About a Linear Object

The design documentation of the repaired section of the heating line is developed on the basis of the terms of reference (Appendix No. 1 to Contract No. 13/2124 dated 02.04.2013). The heating network is serviced by LUKOILTTK LLC Branch in Volgograd.

The project provides for the overhaul of the direct and return pipelines using high factory readiness pipes in PPUU-108 mm insulation in a polyethylene shell using an operational remote control system (UEC) according to GOST 307322006.

6 Thermal mechanical solutions

6.1 Basic technical and economic characteristics of the designed linear object

Coolant parameters: 130-70 0С.

Operating pressure in the pipeline system does not exceed 1.6 MPa.

The heat supply system is double-tube.

Heat supply scheme - closed.

The diameter of the pipelines is 108 mm.

The type of laying of heat networks is underground channel-free in the lower trays of existing impassable channels.

The length of the pipeline section is 134 p.m.

Compensators - according to design calculations in existing niches.

Design solutions for laying the thermal network are made in accordance with the requirements of SNiP 41022003 and SP 411052002.

6.2 Piping Design

The main pipelines of thermal network are provided from steel seamless pipes of Article 20 Ø108x6.0 of GOST 873278 of high factory readiness in PPUizolyatsiya in a polyethylene cover with application of a system of the operating remote control (ORC) in accordance with GOST 307322006.

Compensation of heat extensions of pipelines is carried out due to natural angles of route rotation (installation technique II - self-compensation) and U-shaped compensators.

Damping gaskets made of expanded polyethylene with size of 2000x1400x45 mm are provided on compensators and turning angles for compensation of temperature extensions.

For joints, treatment with two-component mastic "Vektor1025," "Vector-1214" TU 57750041704575199, TU 57750031704575199 is provided.

6.3 Cleaning and flushing of pipelines

Prior to commissioning, heat networks must be washed to clean the inner surface of pipes from accidental ingress of construction debris, sand, rust, scale, etc.

Washing is carried out until the water is completely clarified. Flushing water with special transport tanks shall be taken to the designated places.

At the end of flushing, double sampling is provided.

In case of negative conclusion, repeated washing is required.

7 On-line remote monitoring system

The system of on-line remote control (UEC) is designed to control the state of humidity of the thermal insulation layer made of polyurethane foam and to detect areas with high humidity of insulation. This system allows timely and with greater accuracy to find the places of damage, namely moisture penetration into the heat insulation layer or separation of wires of the UEC system.

Installation of the UEC system shall be carried out in accordance with the design scheme 11.04.TMODK, l.2, agreed with the operating organization.

Piping insulation status and exact location of damaged area shall be monitored using a portable damage detector

multilevel "PICCON." The device is connected to the conductors of the UEC system using special terminals. Connecting cables to boxes with terminals are laid in steel galvanized pipes.

The pipeline has two indicator conductors made of non-insulated soft copper of grade MM, with a section of 1.5 mm2 for operational control over the state of polyurethane foam insulation and shell. They are installed inside the thermal insulation layer of polyurethane foam, parallel to the pipe axis and located on the "3" and "9" clock. The main signal wire is a wire located to the right in the water supply direction on both pipelines. The main wire during installation enters all its branches, is the main one for determining the state of the pipeline. The second signal conductor is a transit conductor. It does not pass into any branch of the heating line, but passes along the shortest path between the start and end point of the pipeline and serves to form a signal loop.

The state of insulation and integrity of signal conductors shall be checked at the following stages of construction:

- before installation of pipeline section;

- before termination of joints;

- upon completion of insulation of joints along the whole length of the pipeline;

- upon completion of UEC system installation.

Acceptance of UEC systems should be carried out by representatives of the construction organization and the organization that installed and adjusted the UEC system, together with representatives of the operating organization.

8 Architectural and construction solutions

Laying of heat network is designed underground without channel in existing lower trays of impassable channels.

Compensators, taking into account the existing operational scheme, are kept U-shaped.

Steel shaped parts: taps, end elements, fixed supports are accepted according to GOST 307322006.

Existing pipe slopes are maintained. During pipeline installation the utility lines remain intact, but it is necessary to carry out works in compliance with safety measures as per SNiP 12032001.

9 Installation Instructions

Installation, laying and butt welding with full penetration of pipeline welds shall be performed in accordance with GOST 1603780 "Welded joints of steel pipelines. Main Types, Structural Elements and Dimensions, SNiP 41022003 "Heat Networks," PB 1057303 "Rules for Arrangement and Safe Operation of Steam and Hot Water Pipelines," ST493 70011892966404 "Steel Pipes and Shaped Articles with Thermal Insulation from Polyurethane Foam with Containment. Specification, "SNiP 41022003" Heat Networks. "

It is necessary to perform tests of the installed pipeline of the thermal network for strength and density, the test pressure is 16 kgf/cm2. Perform rengenographic

inspection of welded joints of pipelines.

All welds shall be checked by NDT. After completion of tests perform insulation of joints. After that, the heating line trench is backfilled.

For transverse butt welded joints, the length of the free straight section in each direction from the seam axis must be at least 150 mm, taking into account the ends of shaped articles free of insulation.

Prior to installation of the pipeline section, the state of insulation and integrity of signal wires of the UEC system and individual elements are checked. SDS is checked by high-voltage testers.

During welding operations it is necessary to:

- avoid the possibility of heating the polyurethane foam insulation to a temperature above 130 ° C in order to avoid toxic emissions at the workplace;

- thoroughly clean the surfaces of the non-insulated ends of the heat conductors from the polyurethane foam residues before welding.

Heat insulation of welded joints on the route shall be performed after 100% testing by non-destructive method.

During construction of heating line install UEC conductors on butt joints of pipelines. The wires shall be installed in such a way that the main signal wire is located on the right in the direction of water supply to the consumer, and the side branches shall be included in the rupture of the main signal conductor. It is forbidden to connect the side branches to the transit wire. Connection of conductors is given in UEC section. Upon completion of works check insulation resistance and wire loop resistance of UEC system. Then joints are closed by means of heat-shrinkable coupling, SGP components are filled.

Clean the outer surface of the butt joint by previously removing the SGP layer from the end surface of the pipe to a depth of about 330 mm. Wires of control system are connected using dielectric holders. Treat the shell and inside the clutch against contamination with a wire brush so that the surface is rough. Place the coupling in the center of the joint and mark the edge of the casing on the shell with a marker.

Drill a small hole (5 mm) in the casing to allow air to flow out during shrinkage. Move the coupling by 1 m from the joint.

For insulation of joints, components of polyurethane foam (A and B) of the "ISOLAN" brand with two types of foaming agents, the most common, allowed for use and providing the following requirements, are used:

- density not less than 60 kg/m3;

- high heat resistance up to 130 ° С (short time - 150 ° С);

- preservation of thermomechanical and heat-insulating properties of polyurethane foam for at least 30 years of operation;

- high dielectric values and low water permeability due to a large number of closed cells;

- high adhesive strength.

SGP components are stored in hermetically closed container in dry rooms at temperature from 10 to 25 ° С. SGP components shall be protected from moisture and direct sunlight .

Prior to filling of SGP components the ambient air temperature shall not exceed + 30 ° С.

Mixing and pouring of components is performed in accordance with the process instruction.

When using non-dosed SGP components, they are measured from the container with measuring circles according to the SGP flow table and mixed with a mixer in a bucket during 2030 sec. Thoroughly mixed components are poured into the coupling through a pouring hole. At ambient temperature below 18 ° C, preheat the components and junction before filling.

When the foam approaches the filling hole, a drain plug is clogged with a hammer, which provides air and excess foam outlet. Output of small amount of foam indicates complete filling of joint volume and correct calculation of SGP components norm. After the foam hardens, the drainage plug is removed, the surface of the coupling is cleaned from excess foam. Make the surface of the casing in the area of ​ ​ plugs rough using skin. Heat the casing in the area of sealed holes up to 40 0С. Heat the patch on the side of the adhesive coating. Place the patch in the center of the hole. Hold the patch until it sticks to the surface.

Pipelines laid in existing trays are laid on a sandy base with a thickness of s = 170 mm, compaction factor ≈0,96, with sand sprinkling 200 mm above the tray. Pipes should be sprinkled from sand with filtration coefficient of at least 5 m/day. Sand shall have a fraction size of not more than 5 mm and shall not contain large inclusions with sharp edges. After backfilling the sand shall be pressed with compaction factor ≈0,98. After filling of pipelines with sand, backfilling of trenches with soil with ramming is performed. Under the roads - backfilling with sand with layer-by-layer tamping with a vibration roll.

Backfill material should not contain stones, crushed stone, granules with a grain size of more than 16 mm, plant residues, debris, clay. Joints fall asleep after hydraulic tests and their insulation. Place signal marking tape above trays with pipelines.

11 Transportation and storage of materials

Pipelines shall be transported and stored in accordance with GOST 307322006.

The transport of insulated pipes shall be carried by road vehicles with an elongated trailer or other transport adapted for the transport of pipes. Transport shall be provided with a device to prevent the rolling and movement of products in the body during transportation. It is recommended to use 100 x 100 mm bar products. The free ends of the pipes shall not extend beyond the dimensions of the vehicle by more than 1 m.

Installation of insulated pipes in the vehicle shall be carried out in even rows without overhangs.

When loading and unloading heat-insulated pipes and elements, special measures must be taken to ensure the safety of protective shells and heat-insulating layer made of polyurethane foam. Unloading of heat insulated pipes and other elements at the construction site should be carried out mechanically using lifting mechanisms and high-strength soft towels.

When using crossbars and high strength soft towels or steel slings with end grips, their length should be selected so that the angle between them at the point of attachment to the hook is not more than 90 °.

To prevent unwinding of the lower row of pipes during transportation under the extreme pipes, special shoes should be installed that prevent damage to the containment and heat insulation layer.

Storage and storage of insulated pipes on construction sites shall be carried out in stacks on prepared and leveled site, with the lower row of pipes being located on sand cushions:

- not less than 300 mm high;

- width 0.81.2 m.

The height of the stack of insulated pipes shall not exceed 2 m. Measures against pipe rolling shall be provided. Different types of insulated products and parts shall be kept separately.