储罐水压试验方案.doc

个人收集整理 勿做商业用途文件类型Document type文件页数Pages 版次Version 修订说明Revision note受控编号Controlled numberGH201版Version1首次1st 储罐充水试压方案 Tank Hydro-test Plan 22012年11月1日Nov。 1, 2012 版次Edition日期Date 编制Formulated by审核Reviewed by批准Approved by中国化学工程第十三建设有限公司The 13th Construction Co.， Ltd. of CNCE 储罐充水试压方案Tank Hydrotest Plan 目录Contents 一适用范围Range of Application2二编制依据Formulation Basis 2三工程概况General2四施工工序Construction Procedure 3五施工步骤及方法Construction Procedure and Method 4 5.1 检查内容Check the contents：4 5。2 准备工作Preparatory work：4 5。3 充水试验应符合下列规定The hydro-test shall be in compliance with following regulations。.。55.4水压试验示意图Hydro-test Diagram 65。5充水过程检查Inspection for Water Filling Process7 5.6充水试验方法Hydro-test method85.7基础沉降观测Foundation Settlement Observation105.8放水检查 Inspection for Water Draining125。9试压技术要求Technical Requirements for Pressure Test13 六质量管理Quality Management136.1质量保证体系Quality Guarantee Measures：136。2质量保证措施Quality Guarantee Measures：14 七质量管理Quality Management157。1安全保证体系Safety assurance system：157.2 安全保证措施计划Planning for safety assurance measures：16 八 人力计划VII。 Planning for Labor Forces18九 机具准备 VII. Preparations of Machines and Tools18十 工作危险源分析评估及预防Work-related Hazard Analysis Evaluation and Prevention19一适用范围Range of Application 1。本方案适用于塞拉尼斯（南京)乙酰基中间体有限公司工业乙醇项目八期改造扩建罐区4台储罐的充水试验的施工.This plan is applicable to the execution of the hydro-test for 4 tanks in the modification and expansion of the tank farm of Celanese China Fast Project. 二编制依据Formulation Basis 1）钢制焊接常压容器Steel Welded Atmospheric Pressure Vessels JB/T4735-19972）立式圆筒形钢制焊接油罐施工及验收规范Code for Construction and Acceptance of Welded Steel Oil Tank of Vertical Barrel Shape GB50128-20053)石油化工钢储罐地基与基础施工及验收规范Specification for Construction and Acceptance of Steel Storage Tank Subgrade & Foundation in Petrochemical IndustrySH3528-93 4)大型焊接低压储罐设计与建造Design and Construction of Large, Welded, Lowpressure Storage TanksAPI62020095）塞拉尼斯技术要求及相关过程规定Celanese technical requirements and related process regulations 三工程概况General 序号No.位号Item名称Description规格Spec. 设备净重Net weight of equipment（t）Weight after water filling充水后重（t）水water（m3）设计压力Design pressure MpaFilling height充水高度（m)1V-732产品罐Product tank10795*975054.34930。6763-0.00154/0.0999。752V-733产品罐Product tank 10795*975054.34930。6763-0。00154/0.0999.753V-744倒液罐Offspec tank10795*975054.34930。6763-0。00154/0.0999.754V737清洗罐Cleaning tank8660975035.84599.84880.00154/0.0999。75四施工工序Construction Procedure 施工准备资料审查试验系统建立设备实体检查上水条件确认封 孔上水强度、严密性试验放 水罐体检验沉降观测Document reviewPreparations Physical examination of Equipment Setup of test systemConfirmation of filling conditionSealing Settlement observationWater filling Intensity and tightness testTank shell checkWater draining五 施工步骤及方法Construction Procedure and Method 储罐已制作完成，且具备水压试验条件，充水试验前应对罐体进行联合检查，罐体无损检测机所有配件、附件安装检测完毕检查合格后对罐体内进行清扫封闭人孔等，开始充水，进行充水试验。充水过程中充水试验要求与土建基础沉降观测结合起来,设置专人对进水和放水时间进行监控，发现异常情况应及时处理，处理合格后方可继续上水。充水试验结束后，罐体内的水应按业主要求和排放位置及时排放。Before the hydro-test, the tank shell shall be jointly inspected。 After NTD of the tank shell, and all fittings and accessories are installed， tested, inspected and accepted, clean the tank inside and close the manhole， fill water and take the hydro-test。 During water filling， the hydrotest requirements shall be combined with the civil structure foundation settlement observation, personnel shall be specially assigned for monitoring the filling and draining time, any abnormality shall be treated in time， no water can be filled in before the treatment is accepted. After completion of the hydro-test, the water in the tank shell shall be promptly drained according to the owners requirements and the location for draining。 个人收集整理，勿做商业用途5。 1储罐制造完毕后，进行充水试验，并检查下列内容：Hydrotest will be taken after the tank is finished in fabrication， and the following content shall be checked： 1）罐底严密性.Tightness of the tank bottom 2）罐壁强度及严密性。Strength and tightness of the tank shell 3）固定顶的强度及严密性。Strength and tightness of the fixed roof 4）固定顶的稳定性。Stability of the fixed roof 5)基础的沉降观测.Settlement observation for the foundation 5。2压力试验前，首先做好以下准备工作：The following preparations shall be made before the pressure test： 1)检查罐外形尺寸、附件安装是否符合要求.Check if the tank outline dimension and accessory installation satisfy requirements. 2)充水前将罐内杂物清理干净后进行封闭，罐壁上的接管均用临时盲板封闭，人孔用人孔法兰盖封闭。Before water filling， clean out sundries in the tank and close it, close the nozzle on the tank shell with temporary blind, and close the manhole with the manhole flange。 3）检查罐管口、法兰是否已焊接完，是否有漏焊部位。Check if the tank nozzle and flange are finished in welding， and if the welding on any part is missed. 4)接管补强圈用压缩空气气密工作已做完，且合格.The airtight work of the compressed air used for the nozzle reinforcing ring has been completed and qualified. 5）水源采用消防储罐的低压消防水,压力为1。5Mpa。The water is sourced from the low pressure fire water of the fire tank, and the pressure is 1.5Mpa. 6）沉降观测,储罐选定4个沉降观测点。 Settlement observation： 4 settlement observation points are selected for tanks. 7）完成罐充水前沉降观测点和基准点的设置,并测量0水位时各测点的标高。Set up settlement observation points and reference points before water filling for the tank, and measure the elevation of every measuring point when the water level is 0。 8）碳钢储罐试验应采用洁净水,试验用水温不低于5。The CS tank test shall adopt clean water， and the water temperature used for the test shall not be lower than 5。 9）V737不锈钢储罐试验用水氯离子含量不得超过25mg/L。 The content of the chloride ion in water used for V-737 SS tank test shall not be more than 25mg/L。 10)完成罐充水前沉降观测点和基准点的设置,并测量0水位时各测点的标高。Set up the settlement observation point and the reference point before water filling for the tank， and measure the elevation of every measuring point when the water level is 0。 5。3充水试验应符合下列规定：The hydro-test shall be in compliance with following regulations: 1）充水和放水过程中，打开放空孔，基础避免浸水.During water filling and draining, open the 2）充水时严格控制上水 、停水的进程，随时检查水位。During water filling, strictly control the process of water filling and water cutoff, and check the water level any time。 3)当第一台储罐进行充水试验时，应充水时快速充水到罐高的1/2,进行沉降观测，当不均匀沉降量小于5mm/天时，继续充水到罐高的3/4进行观测，当充水到（设计液位1米）进行正压试验,当不均匀沉降量仍小于5mm/天时，继续充水到最高操作液位，并保持48小时后进行观测,当沉降量无明显变化即可放水，放水时做负压试验，当沉降量有明显变化，则保持最高操作液面，每天进行定期观测，直至沉降稳定为止。When the hydrotest is taken for the first tank, the water shall be quickly filled to the point of 1/2 of the tank height during water filling， observe the settlement, when the unequal settlement is still less than 5mm/day， go on filling in water to the point of 3/4 of the tank height for observation； when the unequal settlement is still less than 5mm/day, go on filling in water to the highest operating level， and observe it after maintaining 48hrs， if the settlement doesnt obviously change, the water can be drained， if the settlement obviously changes, keep the highest operating level， and observe it regularly every day, until the settlement is steady. 本文为互联网收集，请勿用作商业用途 4）当第一台储罐罐基沉降量符合要求后，其余各罐充水试验时可取罐高的1/2和3/4进行两次观测。After the foundation settlement of the first tank meets requirements, when the hydrotest is taken for the rest tanks， the settlement will be observed twice respective at the point of 1/2 and 3/4 height of the tank。 5)基础沉降观测早、晚各观测一次，每次的沉降数据做好统计，并描绘出基础沉降变化图，便于分析. 罐基础沉降允许值(均匀沉降值)Allowable value of the tank foundation settlement (equal settlement value)储罐位号Tank No. 罐内径(mm）inner diameter of tank 任意直径方向最终沉降差允许值(mm）Allowable value of the final settlement difference in any diametrical direction V73210668160mmV-73310668160mmV74410668160mmV7378534128mmReference valve： Allowable value of the tank foundation settlement （equal settlement value） Attached table 1Floating roof tank and inner floating roof tankFixed roof tank Inside diameter of tank D(m)Allowable value of the final settlement difference in any diametrical directionInside diameter of tank D（m)Allowable value of the final settlement difference in any diametrical direction5.4水压试验示意图：Hydrotest Diagram 压力表pressure gauge储罐tank消防带fire hose另一台储罐another tank108*6阀Valve 3 1086污水井drain well阀Valve 4阀11086临时管线接入口Temporary pipe accessl 在罐区内的泡沫消防临时接入处,用临时管线(1086）接到储罐泡沫降落槽接口上；Connect the temporary pipe （1086) to the access of the tank foam descending groove at the temporary access of foam fire-proof in the tank farm。 l 按上图所示建立试压系统；Establish the pressure test system according to the above diagram。 5。5充水过程检查：Inspection for Water Filling Process 1）进水时专人看守进水阀门,严格控制水源大小，同时找专人通过U型计 观察储罐实际充水量并与进水人员配合，过程为1/2液位高度3/4液位高度 满水高度-1米满水高度 The secure water when the inlet valve， strict control of water the size of, at the same time to find someone through the U-meter Observe the the tanks actual charge water and influent personnel with the process for the liquid level of the liquid level 1/2 3/4Height 1 m full of water full of water height 2）充水试验中应加强基础沉降观测,如基础发生不允许的沉降,应停止充水,待处理后，方可继续进行试验。Do intensify settlement observation during the hydro-test, if unallowable settlement arises from the foundation, the water filling shall top， and do not go on the test before treatment. 3)充水和放水过程中应打开罐顶人孔Do open the manhole on the tank roof during the process of water filling and draining。 4）充水过程中应控制水的流速，水面上升的速度应不超过0.9m/h.Do control the flow speed of water during water filling， and the speed of water surface ascent shall not exceed 0.9m/h. 5）上水过程中在最高设计液位的50和75进行罐体检查。During water filling, check the tank body at the point of 50% and 75% of the highest design level。 5。6充水试验方法：Hydrotest method： 1）罐底的严密性，应以充水试验过程中罐底无渗漏为合格，若发现渗漏，应 放水后进行检查补焊。Tightness of the tank bottom: if the tank has no leakage during the hydro-test， it is acceptable, in case of any leakage， it shall be inspected and welding-repaired after water draining。 2）罐壁的强度及严密性试验，应以充水到设计最高液位并保持48h后，罐壁 无渗漏、无异常变形为合格,发现渗漏时应放水，使液面比渗漏处低300mm 进行修补。Strength and tightness test for the tank shell： if the tank shell is free of leakage， abnormality and deformation after the water is filled to the highest design level and maintains 48h, it is acceptable, in case of any leakage, the water shall be drained to make the water level 300mm lower than the leakage。 3）固定顶的强度及严密性试验，打开阀门1，关闭阀门2,通过消防带从罐顶部进行上水，在上水至设计液面高度下1米处时,用盲板封堵所有开孔，缓慢调节阀门1，缓慢上升，升压至试验压力（0。12Mpa）时，停止充水，进行固定顶强度及严密性试验，在罐顶涂以肥皂水检查,试验后应立即将罐顶孔开启,与大气相通，恢复到常压；Strength and tightness test of the fixed roof： open Valve 1， close Valve 2, and fill water from the tank top through the fire hose， when the water is filled to the point of 1m lower than the design level, block all openings by blinds， slowly regulate Valve 1, the pressure slowly rises, when the pressure rises to the test pressure (0。12Mpa), stop filling water， and conduct the strength and tightness test for the fixed roof， apply soapy water on the tank roof for inspection, and do open the tank roof hole immediately after the test， so as to contact the atmosphere and recover to normal pressure. 文档为个人收集整理，来源于网络4）固定顶的稳定性试验，充水到设计最高液位时，用盲板封堵所有开孔,打开阀门4、3，用放水方法进行固定顶的稳定性试验，缓慢降压，达到试验负压(-0。00162Mpa)时,观察罐顶（罐顶无异常变形为合格），试验后应立即将孔开启，与大气相通，恢复到常压；固定顶储罐在充水到8754mm液位前，应打开顶部人孔。Stability test for the fixed roof： when the water is filled to the highest design level, block all openings with blinds, open Valve 3 and Valve 4， conduct the stability test of the fixed roof by water draining， depressurized it slowly， when it is up to the test negative pressure (-0.00162Mpa）， observe the tank roof (it is acceptable if the tank roof is free of abnormality and deformation）, do open the hole immediately after the test， so as to contact the atmosphere and recover to normal pressure。 The roof manhole shall be opened before the water in the fixed roof tank is filled to the level 8754mm. 本文为互联网收集，请勿用作商业用途试验项目Test item试验方法Test method 合格标准Standard of acceptability 罐底严密性tightness of tank bottom充水试验，观察基础周边。Hydro-test, observe the periphery of the foundation。无渗漏为合格It is acceptable if no leakage. 罐壁强度及严密性试验strength and tightness test for tank shell充水至最高设计液面，保持48h。Fill water to the highest design level and maintain 48h. 无渗漏、无异常变形为合格It is acceptable if no leakage or abnormality.固定顶强度及严密性试验strength and tightness test for the fixed roof 罐内充水到最高设计液位下1m,将所有开孔封闭，缓慢充水升压，当升至试验压力时，暂停充水,在罐顶涂以肥皂水检查，试验后应立即将罐顶孔开启，与大气相通，恢复到常压When the water in the tank is filled to the point of 1m lower than the design level, block all openings by blinds， slowly fill water and boost pressure， when the pressure rises to the test pressure， suspend the filling of water， apply soapy water on the tank roof for inspection， and do open the tank roof hole immediately after the test, so as to contact the atmosphere and recover to normal pressure。a）罐顶无异常变形The tank roof is free of abnormality and deformation. b）未发现焊缝渗漏为合格It is acceptable if no leakage of welded joints is found。 固定顶的稳定性试验stability test for the fixed roof 充水到设计液位时，用放水方法进行试验，缓慢降压，达到试验负压时，观察罐顶，试验后应立即将孔开启，与大气相通，恢复到常压.When the water is filled to the design level, conduct the test by water draining method, depressurize it slowly， when it is up to the test negative pressure, do open the hole immediately after the test, so as to contact the atmosphere and recover to normal pressure。罐顶无异常变形The tank roof is free of abnormality and deformation。 5）当考虑水的重复利用，第一台罐水压试验完毕后,缓慢打开阀3，将水直接排到第二台罐里，待两罐水位平衡后，关闭阀2，然后利用消防带进行上水；In view of recycling of water, after the first tank is finished in the hydrotest， slowly open Valve 3， directly drain the water to the second tank， after the water level in the two tanks is balanced, close Valve 2， and then fill water with the fire hose. 5.7基础沉降观测Foundation Settlement Observation 1）根据储罐的体积和直径,确定储罐沉降观测的点数，见下图。Make sure the number of tank settlement observation points according to the volume and diameter of the tank, see the following drawing. 2）四台储罐分别选好基准点为控制点。Reference points are respectively selected for the four tanks as control points. 3） 空罐(上水前，第一次)1/2液位高度（第二次）3/4液位高度（第三次）满水高度（1小时第四次）满水高度-1米（第五次)满水高度（48小时后，第六次)空罐(放水后，第七次）Empty tank （before water filling, the first time） 1/2 water level (the second time) 3/4 water level （the third time） full water level （1hr， the fourth time）full water level （after 48hrs， the fifth time) empty(after wa