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來源：http://m.xintli.net/ 日期：2024-05-10
管道溝槽連接如何選材？
How to select materials for pipeline trench connections?
管道溝槽連接技術(shù)興起于20世紀50年代的美國，90年代末引入。此后，以其安裝便捷、質(zhì)量可靠、經(jīng)濟等突出優(yōu)點，迅速被國內(nèi)市場所接受和推廣。在法規(guī)政策的積極引導下，目前該技術(shù)已廣泛應(yīng)用于消防給水、生活給水、空調(diào)、污水處理、石油化工、熱電及軍工等多個領(lǐng)域[1]，并逐步取代法蘭和焊接這兩種傳統(tǒng)的管道連接方式，成為氣、液管道連接的首推技術(shù)。雖然管道溝槽連接技術(shù)推廣應(yīng)用了較長時間，但由于相關(guān)人員的認識不足、缺乏經(jīng)驗、疏于管理等多方面原因，導致管件松脫、接頭滲水等質(zhì)量通病多有發(fā)生。本文將從材料選擇、安裝工藝、支（吊）架設(shè)置等角度，分析管道溝槽連接質(zhì)量問題的產(chǎn)生原因，并就確保管道溝槽連接質(zhì)量提出見解與體會。
The pipe trench connection technology emerged in the United States in the 1950s and was introduced to China in the late 1990s. Afterwards, with its outstanding advantages such as convenient installation, reliable quality, and economic and environmental protection, it was quickly accepted and promoted in the domestic market. Under the active guidance of national regulations and policies, this technology has been widely applied in various fields such as fire water supply, domestic water supply, central air conditioning, sewage treatment, petrochemicals, thermal power, and military industry [1], gradually replacing the traditional pipeline connection methods of flange and welding, and becoming the leading technology for gas and liquid pipeline connection. Although the pipeline trench connection technology has been widely promoted and applied for a long time, due to various reasons such as insufficient understanding, lack of experience, and neglect of management by relevant personnel, common quality problems such as loose fittings and joint water seepage often occur. This article will analyze the causes of quality problems in pipeline trench connections from the perspectives of material selection, installation technology, and support (hanger) settings, and provide insights and experiences on ensuring the quality of pipeline trench connections.
2、材料選擇
2. Material selection
2.1管材
2.1 Pipe materials
2.1.1管道類型的選擇
2.1.1 Selection of pipeline types
管道類型是影響管道溝槽連接質(zhì)量的一項重要因素。溝槽連接方式適用的管道類型較為廣泛，《溝槽式連接管道工程技術(shù)規(guī)程》（CECS151∶2003）指出：“溝槽連接方式可用于鍍鋅焊接鋼管和焊接鋼管、鍍鋅無縫鋼管和無縫鋼管、不銹鋼管等，或內(nèi)壁涂塑或襯塑的上述各種管材。”但是，由于焊縫形式對鋼管溝槽連接質(zhì)量有一定影響，焊接鋼管的焊縫突出，不利于鋼管的壓槽。因此，在安裝施工時應(yīng)無縫鋼管，其次是直縫焊管，避免選用螺旋焊管。如確需使用螺旋焊管，也應(yīng)配套使用相應(yīng)的溝槽管件，如上海威遜就為螺旋鋼管設(shè)計配備了帶溝槽短管的超越式接頭和凸緣式接頭，以此了螺旋鋼管溝槽連接的接口密封難題。
The type of pipeline is an important factor affecting the quality of pipeline trench connections. The groove connection method is applicable to a wide range of pipeline types. The "Technical Specification for Groove Connection Pipeline Engineering" (CECS151:2003) points out that "the groove connection method can be used for galvanized welded steel pipes and welded steel pipes, galvanized seamless steel pipes and seamless steel pipes, stainless steel pipes, etc., or various types of pipes with inner wall coated or lined with plastic." However, due to the influence of weld seam form on the quality of steel pipe groove connection, the weld seam of welded steel pipes is protruding, which is not conducive to the groove pressing of steel pipes. Therefore, seamless steel pipes should be preferred during installation and construction, followed by straight seam welded pipes, and spiral welded pipes should be avoided. If it is necessary to use spiral welded pipes, corresponding groove fittings should also be used. For example, Shanghai Weixun has designed spiral steel pipes with groove short pipes and flange joints to solve the interface sealing problem of spiral steel pipe groove connections.
2.1.2管道的質(zhì)量要求
2.1.2 Quality requirements for pipelines
由于溝槽管件與管道外壁接合，因此，管道外徑偏差過量將使管道與卡箍不匹配，會造成接頭滲水。此外，管材材質(zhì)不合格，鍍鋅層不牢固，管壁厚度不足，都將會在壓槽時可能造成管子斷裂、鍍鋅層大量脫落或高頻焊縫開裂，終導致接頭滲水或斷裂。因此，嚴格控制管材質(zhì)量關(guān)重要。各類管材均應(yīng)符合相應(yīng)的標準，如鍍鋅焊接鋼管應(yīng)符合《低壓流體輸送用鍍鋅焊接鋼管》（GB/T3091）的規(guī)定，無縫鋼管應(yīng)符合《輸送流體用無縫鋼管》（GB/T8163）的規(guī)定，涂塑鍍鋅焊接鋼管和涂塑無縫鋼管應(yīng)符合《給水涂塑復合鋼管》（CJ/T的規(guī)定等。此外，鋼管壁厚還應(yīng)滿足小壁厚要求。
Due to the joint between the groove fittings and the outer wall of the pipeline, excessive deviation in the outer diameter of the pipeline will cause mismatch between the pipeline and the clamp, resulting in water seepage at the joint. In addition, substandard pipe materials, weak galvanized layer, and insufficient wall thickness may cause pipe fracture, significant detachment of galvanized layer, or high-frequency weld cracking during groove pressing, ultimately leading to joint seepage or fracture. Therefore, strict control of pipe quality is crucial. All types of pipes should comply with corresponding national standards. For example, galvanized welded steel pipes should comply with the provisions of "Galvanized Welded Steel Pipes for Low Pressure Fluid Transportation" (GB/T3091), seamless steel pipes should comply with the provisions of "Seamless Steel Pipes for Fluid Transportation" (GB/T8163), coated galvanized welded steel pipes and coated seamless steel pipes should comply with the provisions of "Composite Steel Pipes for Water Supply Coating" (CJ/T), etc. In addition, the wall thickness of the steel pipes should also meet the minimum wall thickness requirements.
2.1.3管口的圓整度控制
2.1.3 Control of roundness of pipe openings
管口的圓整度不足也是影響管道溝槽連接質(zhì)量的重要原因。施工前，應(yīng)對進場管材的圓整度進行檢查。檢查可按照下述方法進行：將管道截面分為8等分，分別測量4條直徑尺寸，與標準值進行對比。凡圓整度不達標的管段應(yīng)整圓或切除。
The insufficient roundness of the pipe mouth is also an important reason affecting the quality of pipeline groove connection. Before construction, the roundness of the incoming pipes should be checked. The inspection can be carried out according to the following method: divide the pipeline section into 8 equal parts, measure 4 diameter sizes separately, and compare them with the standard values. Any pipe section that does not meet the roundness standard should be rounded or cut off.
管道的圓整度不達標，往往是由于運輸或裝卸過程中管道遭受碰撞或管材相互擠壓所造成。韓國在管材運輸中有很好的經(jīng)驗，該國的工程技術(shù)人員采用在管端頭裝設(shè)十字支撐架的辦法，較好地了管道受壓變形的問題，值得學習和推廣。
The roundness of pipelines that do not meet the standard is often caused by collisions or mutual compression of pipes during transportation or loading and unloading. South Korea has good experience in pipe transportation, and its engineering and technical personnel have adopted the method of installing cross support frames at the pipe ends, which effectively solves the problem of pipeline compression deformation and is worth learning and promoting.
2.2溝槽管件
2.2 Trench fittings
2.2.1殼體材質(zhì)的選擇
2.2.1 Selection of shell material
溝槽管件的殼體材質(zhì)有球墨鑄鐵、鑄鋼或鍛鋼等幾種，不同材質(zhì)的溝槽管件耐壓性能不同，脆性、抗疲勞性能等也有所區(qū)別，應(yīng)根據(jù)工程實際需要合理選用。
There are several types of shell materials for groove fittings, such as ductile iron, cast steel, or forged steel. Different materials of groove fittings have different pressure resistance, brittleness, and fatigue resistance, and should be selected reasonably according to the actual needs of the project.
2.2.2橡膠密封圈的選擇
2.2.2 Selection of rubber sealing rings
橡膠密封圈分為天然橡膠、合成橡膠、硅橡膠等幾大類，應(yīng)根據(jù)管道傳輸介質(zhì)的性質(zhì)和溫度、使用場合等需求正確選用。輸送生活飲用水的管道可采用天然橡膠、合成橡膠或硅橡膠，并應(yīng)符合《生活飲用水輸配水設(shè)備及防護材料的性評價標準》（GB/T17219）和現(xiàn)行有關(guān)標準的規(guī)定；輸送含油和化學品等介質(zhì)的管道應(yīng)采用合成橡膠；輸送空調(diào)冷卻水的管道，由于使用環(huán)境及系統(tǒng)季節(jié)性運行的要求，需要橡膠密封圈具有一定的抗疲勞、抗老化性能，因此，應(yīng)優(yōu)先選用合成橡膠或硅橡膠。
Rubber sealing rings are divided into several categories, including natural rubber, synthetic rubber, silicone rubber, etc. They should be selected correctly according to the properties and temperature of the pipeline transmission medium, as well as the needs of the usage situation. The pipelines for transporting drinking water can use natural rubber, synthetic rubber, or silicone rubber, and should comply with the national "Safety Evaluation Standards for Drinking Water Transportation and Distribution Equipment and Protective Materials" (GB/T17219) and the relevant national standards currently in use; Synthetic rubber should be used for pipelines transporting media such as oil and chemicals; Due to the requirements of the operating environment and seasonal operation of the system, the pipes conveying cooling water for air conditioners need rubber seals with certain fatigue resistance and aging resistance. Therefore, synthetic rubber or silicone rubber should be preferred.
2.2.3正確選擇溝槽管件類型
2.2.3 Correct selection of trench pipe fittings type
溝槽管件有多種類型，其中剛性接頭與撓性接頭，開孔式機械三通、四通與溝槽式三通、四通，單片法蘭與溝槽法蘭等，作用類似，但使用場合卻有所區(qū)別。在安裝前，應(yīng)對各種接頭及配件的性能、使用條件做深入的了解，做到正確選用。
There are various types of grooved pipe fittings, including rigid joints and flexible joints, perforated mechanical tees, tees and grooved tees, tees, single piece flanges and grooved flanges, etc., with similar functions but different usage scenarios. Before installation, it is necessary to have a thorough understanding of the performance and usage conditions of various joints and accessories to ensure correct selection.
（1）剛性接頭與撓性接頭。在工程施工中，由于技術(shù)交底及質(zhì)量監(jiān)控的不到位，工人對剛性接頭和撓性接頭常常不加區(qū)分，隨意使用，從而給整個管路系統(tǒng)的可靠運行和正常維護帶來隱患。如：生活熱水系統(tǒng)，系統(tǒng)運行溫度與管道安裝時的溫度差值可達到60℃，鋼管長6m，產(chǎn)生的熱膨脹應(yīng)力將達到1200kg/mm2。如果管道采用剛性連接，將會引起支架變形，并導致管道系統(tǒng)遭受破壞。因此，對接頭管件應(yīng)加以區(qū)分并合理選用。
(1) Rigid and flexible joints. In engineering construction, due to inadequate technical disclosure and quality monitoring, workers often indiscriminately use rigid and flexible joints, which poses hidden dangers to the reliable operation and normal maintenance of the entire pipeline system. For example, in a domestic hot water system, the difference between the operating temperature of the system and the temperature during pipeline installation can reach 60 ℃. With a steel pipe length of 6m, the thermal expansion stress generated will reach 1200kg/mm2. If the pipeline is rigidly connected, it will cause deformation of the support and result in damage to the pipeline system. Therefore, joint fittings should be distinguished and selected reasonably.
①生活熱水管道、空調(diào)水管道、露天管道，為有效補償因熱脹冷縮所引起的管道位移，以上三類必須使用撓性接頭，如果伸縮段的位移超過了撓性接頭的總補償量，還應(yīng)考慮加裝金屬膨脹節(jié)。
① For domestic hot water pipelines, air conditioning water pipelines, and outdoor pipelines, in order to effectively compensate for pipeline displacement caused by thermal expansion and contraction, flexible joints must be used for the above three types. If the displacement of the expansion section exceeds the total compensation amount of the flexible joint, the installation of metal expansion joints should also be considered.
②溫差變化不大的管道，如室內(nèi)消防管道，可以大量使用剛性接頭。但在長直管路的中段應(yīng)安裝一定數(shù)量的撓接頭，用以補償長直管段的少量熱膨脹量，確保整個管道系統(tǒng)處于運行狀態(tài)。
② Pipes with little temperature difference, such as indoor fire pipes, can use a large number of rigid joints. But a certain number of flexible joints should be installed in the middle section of the long straight pipeline to compensate for the small amount of thermal expansion in the long straight pipeline section, ensuring that the entire pipeline system is in a safe operating state.
③有溫度補償功能的彎管、折線形管道，應(yīng)在其產(chǎn)生角變位的管段上安裝撓性接頭。
③ Flexible joints should be installed on the pipe sections that produce angular displacement in bent pipes and curved pipes with temperature compensation function.
④泵房管道則建議使用撓性接頭，以減少噪聲并削弱振動傳導。
④ Flexible joints are recommended for pump room pipelines to reduce noise and weaken vibration transmission.
⑤埋地管道宜采用撓性接頭，可有效應(yīng)對不均勻沉降導致的管道系統(tǒng)局部變形。
⑤ Flexible joints should be used for buried pipelines to effectively cope with local deformation of the pipeline system caused by uneven settlement.
⑥小弧度弧形管道的連接，必須采用撓性管接頭。可先按直線管道裝配，再折轉(zhuǎn)管道，使其達到預定轉(zhuǎn)角。但無論在何種情況下其轉(zhuǎn)角均不得超出溝槽管件說明書所限定的數(shù)值。
⑥ The connection of small arc pipelines must use flexible pipe joints. You can first assemble the pipeline in a straight line, and then bend the pipeline to reach the predetermined angle. However, in any case, its turning angle shall not exceed the value specified in the instruction manual of the trench fittings.
（2）開孔式機械的三通、四通，與溝槽式的三通、四通相比，每個連接部位少用了2個溝槽式接頭，從而降低了工程成本。但是由于開孔式機械三通、四通屬馬鞍形拼合式開孔套筒結(jié)構(gòu)，與溝槽式三通、四通相比強度較弱。因此，在接頭受力較大的部位應(yīng)避免使用開孔式機械三通、四通，如在立管上設(shè)置支管的部位等。在橫管上設(shè)置支管，可采用機械三通、四通，但支管的管徑不得過大，必須保證鉆孔后管道的強度不受到損害，否則容易發(fā)生管道滲漏。
(2) Compared with groove type tees and tees, the three-way and four-way of perforated machinery use two fewer groove type joints at each connection point, thereby reducing engineering costs. However, due to the saddle shaped assembled perforated sleeve structure of the perforated mechanical tee and cross, their strength is weaker compared to the grooved tee and cross. Therefore, in areas with high stress on the joint, the use of perforated mechanical tees and tees should be avoided, such as in areas where branch pipes are installed on the riser. Mechanical tees and tees can be used to install branch pipes on horizontal pipes, but the diameter of the branch pipe must not be too large. It is necessary to ensure that the strength of the pipeline after drilling is not damaged, otherwise pipeline leakage may occur.
（3）單片法蘭與溝槽法蘭在大多數(shù)情況下可以互用，但單片法蘭在與蝶閥相連接時，兩者的密封橡膠接觸，不易緊密固定連接，容易造成接口滲水。因此，在蝶閥與法蘭連接時應(yīng)采用溝槽法蘭，避免使用單片法蘭。2.2.4溝槽管件的質(zhì)量要求工程中出現(xiàn)的卡箍斷裂、橡膠密封圈損壞、緊固件螺栓斷裂等質(zhì)量問題，很大程度上是由于不恰當?shù)剡x用溝槽管件或使用質(zhì)量低劣的溝槽管件所造成。因此，應(yīng)從進貨、檢驗、技術(shù)等方面嚴格把關(guān)，避免不適用、不合格產(chǎn)品進入施工環(huán)節(jié)。
(3) Single piece flange and groove flange can be used interchangeably in most cases, but when connected to a butterfly valve, the sealing rubber of the two is in contact, making it difficult to tightly fix the connection and easily causing water leakage at the interface. Therefore, groove flanges should be used when connecting butterfly valves to flanges to avoid using single piece flanges. Quality requirements for trench fittings in section 2.2.4. Quality issues such as broken clamps, damaged rubber sealing rings, and broken fasteners and bolts in engineering are largely caused by improper selection of trench fittings or the use of low-quality trench fittings. Therefore, strict control should be exercised in aspects such as procurement, inspection, and technology to prevent unsuitable and unqualified products from entering the construction process.
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