儲罐水壓試驗方案

1、 塞拉尼斯（南京）乙酰基中間體有限公司工業(yè)乙醇項目 Celanese China Fast Project文件類型Document type文件頁數(shù)Pages 版次Version 修訂說明Revision note受控編號Controlled numberGH201版Version1首次1st 儲罐充水試壓方案 Tank Hydro-test Plan 22012年11月1日Nov. 1, 2012 版次Edition日期Date 編制Formulated by審核Reviewed by批準(zhǔn)Approved by中國化學(xué)工程第十三建設(shè)有限公司The 13th Construction Co.,

2、 Ltd. of CNCE 儲罐充水試壓方案Tank Hydro-test Plan 目錄Contents 一適用范圍Range of Application2二編制依據(jù)Formulation Basis 2三工程概況General2四施工工序Construction Procedure 3五施工步驟及方法Construction Procedure and Method 4 5.1 檢查內(nèi)容Check the contents：4 5.2 準(zhǔn)備工作Preparatory work：4 5.3 充水試驗應(yīng)符合下列規(guī)定The hydro-test shall be in compliance w

3、ith following regulations.55.4水壓試驗示意圖Hydro-test Diagram 65.5充水過程檢查Inspection for Water Filling Process7 5.6充水試驗方法Hydro-test method85.7基礎(chǔ)沉降觀測Foundation Settlement Observation105.8放水檢查 Inspection for Water Draining125.9試壓技術(shù)要求Technical Requirements for Pressure Test13 六質(zhì)量管理Quality Management136.1質(zhì)量保證體系

4、Quality Guarantee Measures：136.2質(zhì)量保證措施Quality Guarantee Measures：14 七質(zhì)量管理Quality Management157.1安全保證體系Safety assurance system：157.2 安全保證措施計劃Planning for safety assurance measures：16 八 人力計劃VII. Planning for Labor Forces18九 機(jī)具準(zhǔn)備 VII. Preparations of Machines and Tools18十 工作危險源分析評估及預(yù)防Work-related Hazar

5、d Analysis Evaluation and Prevention19一適用范圍Range of Application 1.本方案適用于塞拉尼斯（南京）乙?；虚g體有限公司工業(yè)乙醇項目八期改造擴(kuò)建罐區(qū)4臺儲罐的充水試驗的施工。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. 二編制依據(jù)Formulation Basis 1)鋼制焊接

6、常壓容器Steel Welded Atmospheric Pressure Vessels JB/T4735-19972)立式圓筒形鋼制焊接油罐施工及驗收規(guī)范Code for Construction and Acceptance of Welded Steel Oil Tank of Vertical Barrel Shape GB50128-20053)石油化工鋼儲罐地基與基礎(chǔ)施工及驗收規(guī)范Specification for Construction and Acceptance of Steel Storage Tank Subgrade & Foundation in Petr

7、ochemical IndustrySH3528-93 4)大型焊接低壓儲罐設(shè)計與建造Design and Construction of Large, Welded, Low-pressure Storage TanksAPI620-20095)塞拉尼斯技術(shù)要求及相關(guān)過程規(guī)定Celanese technical requirements and related process regulations 三工程概況General 序號No.位號Item名稱Description規(guī)格Spec. 設(shè)備凈重Net weight of equipment（t）Weight after water fil

8、ling充水后重（t）水water（m3）設(shè)計壓力Design pressure MpaFilling height充水高度（m）1V-732產(chǎn)品罐Product tank10795*975054.34930.6763-0.00154/0.0999.752V-733產(chǎn)品罐Product tank 10795*975054.34930.6763-0.00154/0.0999.753V-744倒液罐Off-spec tank10795*975054.34930.6763-0.00154/0.0999.754V-737清洗罐Cleaning tank8660*975035.84599.8488-0.

9、00154/0.0999.75四施工工序Construction Procedure 施工準(zhǔn)備資料審查試驗系統(tǒng)建立設(shè)備實體檢查上水條件確認(rèn)封 孔上水強(qiáng)度、嚴(yán)密性試驗放 水罐體檢驗沉降觀測Document reviewPreparations Physical examination of Equipment Setup of test systemConfirmation of filling conditionSealing Settlement observationWater filling Intensity and tightness testTank shell checkWate

10、r draining5 施工步驟及方法Construction Procedure and Method 儲罐已制作完成，且具備水壓試驗條件，充水試驗前應(yīng)對罐體進(jìn)行聯(lián)合檢查，罐體無損檢測機(jī)所有配件、附件安裝檢測完畢檢查合格后對罐體內(nèi)進(jìn)行清掃封閉人孔等，開始充水，進(jìn)行充水試驗。充水過程中充水試驗要求與土建基礎(chǔ)沉降觀測結(jié)合起來，設(shè)置專人對進(jìn)水和放水時間進(jìn)行監(jiān)控，發(fā)現(xiàn)異常情況應(yīng)及時處理，處理合格后方可繼續(xù)上水。充水試驗結(jié)束后，罐體內(nèi)的水應(yīng)按業(yè)主要求和排放位置及時排放。Before the hydro-test, the tank shell shall be jointly inspected. A

11、fter 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 hydro-test requirements shall be combined with the civil structure foundation settlem

12、ent 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 accordi

13、ng to the owners requirements and the location for draining. 5. 1儲罐制造完畢后，進(jìn)行充水試驗，并檢查下列內(nèi)容：Hydro-test will be taken after the tank is finished in fabrication, and the following content shall be checked: 1）罐底嚴(yán)密性。Tightness of the tank bottom 2）罐壁強(qiáng)度及嚴(yán)密性。Strength and tightness of the tank shell 3）固定頂?shù)膹?qiáng)度及嚴(yán)密

14、性。Strength and tightness of the fixed roof 4）固定頂?shù)姆€(wěn)定性。Stability of the fixed roof 5）基礎(chǔ)的沉降觀測。Settlement observation for the foundation 5.2壓力試驗前，首先做好以下準(zhǔn)備工作：The following preparations shall be made before the pressure test: 1）檢查罐外形尺寸、附件安裝是否符合要求。Check if the tank outline dimension and accessory installat

15、ion satisfy requirements. 2）充水前將罐內(nèi)雜物清理干凈后進(jìn)行封閉，罐壁上的接管均用臨時盲板封閉，人孔用人孔法蘭蓋封閉。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）檢查罐管口、法蘭是否已焊接完，是否有漏焊部位。Check if the tank nozzle and fla

16、nge are finished in welding, and if the welding on any part is missed. 4）接管補強(qiáng)圈用壓縮空氣氣密工作已做完，且合格。The airtight work of the compressed air used for the nozzle reinforcing ring has been completed and qualified. 5）水源采用消防儲罐的低壓消防水，壓力為1.5Mpa。The water is sourced from the low pressure fire water of the fire t

17、ank, and the pressure is 1.5Mpa. 6）沉降觀測，儲罐選定4個沉降觀測點。 Settlement observation: 4 settlement observation points are selected for tanks. 7）完成罐充水前沉降觀測點和基準(zhǔn)點的設(shè)置,并測量0水位時各測點的標(biāo)高。Set up settlement observation points and reference points before water filling for the tank, and measure the elevation of every meas

18、uring point when the water level is 0. 8）碳鋼儲罐試驗應(yīng)采用潔凈水，試驗用水溫不低于5。The CS tank test shall adopt clean water, and the water temperature used for the test shall not be lower than 5. 9）V-737不銹鋼儲罐試驗用水氯離子含量不得超過25mg/L。 The content of the chloride ion in water used for V-737 SS tank test shall not be more tha

19、n 25mg/L. 10）完成罐充水前沉降觀測點和基準(zhǔn)點的設(shè)置,并測量0水位時各測點的標(biāo)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充水試驗應(yīng)符合下列規(guī)定：The hydro-test shall be in compliance with following regulatio

20、ns: 1）充水和放水過程中，打開放空孔，基礎(chǔ)避免浸水。During water filling and draining, open the 2）充水時嚴(yán)格控制上水 、停水的進(jìn)程，隨時檢查水位。During water filling, strictly control the process of water filling and water cutoff, and check the water level any time. 3）當(dāng)?shù)谝慌_儲罐進(jìn)行充水試驗時，應(yīng)充水時快速充水到罐高的1/2，進(jìn)行沉降觀測，當(dāng)不均勻沉降量小于5mm/天時，繼續(xù)充水到罐高的3/4進(jìn)行觀測，當(dāng)充水到（設(shè)計液位

21、1米）進(jìn)行正壓試驗，當(dāng)不均勻沉降量仍小于5mm/天時，繼續(xù)充水到最高操作液位，并保持48小時后進(jìn)行觀測，當(dāng)沉降量無明顯變化即可放水，放水時做負(fù)壓試驗，當(dāng)沉降量有明顯變化，則保持最高操作液面，每天進(jìn)行定期觀測，直至沉降穩(wěn)定為止。When the hydro-test 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 se

22、ttlement 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 obviousl

23、y 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. 4）當(dāng)?shù)谝慌_儲罐罐基沉降量符合要求后，其余各罐充水試驗時可取罐高的1/2和3/4進(jìn)行兩次觀測。After the foundation settlement of the first tank meets requirements, when the

24、 hydro-test 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）基礎(chǔ)沉降觀測早、晚各觀測一次，每次的沉降數(shù)據(jù)做好統(tǒng)計，并描繪出基礎(chǔ)沉降變化圖，便于分析。 罐基礎(chǔ)沉降允許值(均勻沉降值)Allowable value of the tank foundation settlement (equal settlement value)儲罐位號Tank No. 罐內(nèi)徑（mm）inner

25、diameter of tank 任意直徑方向最終沉降差允許值（mm）Allowable value of the final settlement difference in any diametrical direction V-73210668160mmV-73310668160mmV-74410668160mmV-7378534128mmReference valve: Allowable value of the tank foundation settlement (equal settlement value) Attached table 1Floating roof tank

26、 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水壓試驗示意圖：Hydro-test Diagram 壓力表pressure

27、 gauge儲罐tank消防帶fire hose另一臺儲罐another tank108*6閥Valve 3 108*6污水井drain well閥Valve 4閥1108×6臨時管線接入口Temporary pipe accessl 在罐區(qū)內(nèi)的泡沫消防臨時接入處，用臨時管線（108*6）接到儲罐泡沫降落槽接口上；Connect the temporary pipe (108*6) to the access of the tank foam descending groove at the temporary access of foam fire-proof in the tan

28、k farm. l 按上圖所示建立試壓系統(tǒng)；Establish the pressure test system according to the above diagram. 5.5充水過程檢查：Inspection for Water Filling Process 1）進(jìn)水時專人看守進(jìn)水閥門，嚴(yán)格控制水源大小，同時找專人通過U型計 觀察儲罐實際充水量并與進(jìn)水人員配合，過程為1/2液位高度3/4液位高度 滿水高度-1米滿水高度 The secure water when the inlet valve, strict control of water the size of, at the

29、 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）充水試驗中應(yīng)加強(qiáng)基礎(chǔ)沉降觀測，如基礎(chǔ)發(fā)生不允許的沉降，應(yīng)停止充水，待處理后，方可繼續(xù)進(jìn)行試驗。Do intensify settlement obs

30、ervation 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）充水和放水過程中應(yīng)打開罐頂人孔Do open the manhole on the tank roof during the process of water filling and draining. 4）充水過程中應(yīng)控制水的流速，水面上升的速度應(yīng)不超過0.9m/h。Do c

31、ontrol the flow speed of water during water filling, and the speed of water surface ascent shall not exceed 0.9m/h. 5)上水過程中在最高設(shè)計液位的50%和75%進(jìn)行罐體檢查。During water filling, check the tank body at the point of 50% and 75% of the highest design level. 5.6充水試驗方法：Hydro-test method: 1）罐底的嚴(yán)密性，應(yīng)以充水試驗過程中罐底無滲漏為合格，

32、若發(fā)現(xiàn)滲漏，應(yīng) 放水后進(jìn)行檢查補焊。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）罐壁的強(qiáng)度及嚴(yán)密性試驗，應(yīng)以充水到設(shè)計最高液位并保持48h后，罐壁 無滲漏、無異常變形為合格，發(fā)現(xiàn)滲漏時應(yīng)放水，使液面比滲漏處低300mm 進(jìn)行修補。Strength and tight

33、ness 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）固定頂?shù)膹?qiáng)度

34、及嚴(yán)密性試驗，打開閥門1，關(guān)閉閥門2，通過消防帶從罐頂部進(jìn)行上水，在上水至設(shè)計液面高度下1米處時，用盲板封堵所有開孔，緩慢調(diào)節(jié)閥門1，緩慢上升，升壓至試驗壓力（0.12Mpa）時，停止充水，進(jìn)行固定頂強(qiáng)度及嚴(yán)密性試驗，在罐頂涂以肥皂水檢查，試驗后應(yīng)立即將罐頂孔開啟，與大氣相通，恢復(fù)到常壓;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 fille

35、d 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 tan

36、k 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. 4）固定頂?shù)姆€(wěn)定性試驗，充水到設(shè)計最高液位時，用盲板封堵所有開孔，打開閥門4、3，用放水方法進(jìn)行固定頂?shù)姆€(wěn)定性試驗，緩慢降壓，達(dá)到試驗負(fù)壓（-0.00162Mpa）時，觀察罐頂（罐頂無異常變形為合格），試驗后應(yīng)立即將孔開啟,與大氣相通，恢復(fù)到常壓;固定頂儲罐在充水到8754mm液位前，應(yīng)打開頂部人孔。Sta

37、bility 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

38、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 8754m

39、m. 試驗項目Test item試驗方法Test method 合格標(biāo)準(zhǔn)Standard of acceptability 罐底嚴(yán)密性tightness of tank bottom充水試驗,觀察基礎(chǔ)周邊。Hydro-test, observe the periphery of the foundation.無滲漏為合格It is acceptable if no leakage. 罐壁強(qiáng)度及嚴(yán)密性試驗strength and tightness test for tank shell充水至最高設(shè)計液面,保持48h。Fill water to the highest design level

40、and maintain 48h. 無滲漏、無異常變形為合格It is acceptable if no leakage or abnormality.固定頂強(qiáng)度及嚴(yán)密性試驗strength and tightness test for the fixed roof 罐內(nèi)充水到最高設(shè)計液位下1m，將所有開孔封閉，緩慢充水升壓，當(dāng)升至試驗壓力時，暫停充水，在罐頂涂以肥皂水檢查，試驗后應(yīng)立即將罐頂孔開啟，與大氣相通，恢復(fù)到常壓When the water in the tank is filled to the point of 1m lower than the design level, bl

41、ock 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 n

42、ormal pressure.a）罐頂無異常變形The tank roof is free of abnormality and deformation. b）未發(fā)現(xiàn)焊縫滲漏為合格It is acceptable if no leakage of welded joints is found. 固定頂?shù)姆€(wěn)定性試驗stability test for the fixed roof 充水到設(shè)計液位時，用放水方法進(jìn)行試驗，緩慢降壓，達(dá)到試驗負(fù)壓時，觀察罐頂，試驗后應(yīng)立即將孔開啟，與大氣相通，恢復(fù)到常壓。When the water is filled to the design level, con

43、duct 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.罐頂無異常變形The tank roof is free of abnormality and deformation. 5）當(dāng)考慮水的重復(fù)利用，第一臺罐水壓試驗完畢

44、后，緩慢打開閥3，將水直接排到第二臺罐里，待兩罐水位平衡后，關(guān)閉閥2，然后利用消防帶進(jìn)行上水；In view of recycling of water, after the first tank is finished in the hydro-test, 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 hos

45、e. 5.7基礎(chǔ)沉降觀測Foundation Settlement Observation 1）根據(jù)儲罐的體積和直徑，確定儲罐沉降觀測的點數(shù)，見下圖。Make sure the number of tank settlement observation points according to the volume and diameter of the tank, see the following drawing. 2）四臺儲罐分別選好基準(zhǔn)點為控制點。Reference points are respectively selected for the four tanks as contro

46、l 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）滿水高度（1小時第四次）滿水高度-1米（第五次）滿水高度（48小時后，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)

47、 empty(after water draining, the sixth time) 4) 水壓試驗過程中，應(yīng)緊密跟蹤罐體每次的沉降量，檢查其是否符合規(guī)范允許值。During the hydro-test, closely track the settlement of the tank body every time, and check if they satisfy the specified allowable value. 5）儲罐基礎(chǔ)沉降允許值：充水高度為：H/2（H為罐高），沉降量<5mm/d,充水高度為：3H/4，沉降量仍<5mm/d,充水到最高液位后，保持48

48、h觀測，總沉降量<25mm.Allowable value of the tank foundation settlement: the water filling level: H/2 (H is the height of the tank), the settlement <5mm/d, the water filling height is 3H/4, the settlement<5mm/d, after the water is filled to the highest level, observe it for 48h, and the total settl

49、ement <25mm. 6)為方便測出罐內(nèi)液位的實際高度，從罐壁管口上接出一臨時閥門，并將軟管接從低接管接到罐頂，為防止塑膠管滑落，采用柔性材料將其臨時綁扎到腳手架靠里側(cè)。In order to measure the actual height of the water level in the tank, extend a temporary valve from the tank nozzle, and connect the hose to the tank roof from the lower nozzle, in order to prevent plastic pipe

50、 from sliding, bind it to the inner side of the scaffold temporarily with flexible material. 5.8放水檢查 Inspection for Water Draining 1) 放水停留時間應(yīng)符合土建專業(yè)設(shè)計文件的要求Water draining detention time shall be in compliance with the requirements of design documents of the civil work discipline. 2)儲罐試壓完畢后，放水應(yīng)排放到指定位置（

51、罐區(qū)圍堰內(nèi)部排水溝），不可就地排放使基礎(chǔ)浸水；After the tank pressure test is finished, the water shall be drained to the specified position, and cannot be drained locally for fear of foundation soaking. 3）罐內(nèi)應(yīng)徹底地進(jìn)行清掃，除去銹蝕，底板不應(yīng)有顯著的變形和明顯凸凹，各附件應(yīng)符合圖樣要求，且無異?，F(xiàn)象。The tank shall be completely cleaned, rust shall be removed, and bo

52、ttom plates shall be free of significant deformation and obvious unevenness, all accessories shall be in compliance with drawing requirements, and be free of any abnormality. 4）放水后及時將罐內(nèi)的積水和雜物清掃干凈，應(yīng)打開所有的管口和人孔，以加強(qiáng)罐內(nèi)的空氣流通，當(dāng)罐內(nèi)水吹干后，及時檢查，并用抹布清除干凈罐內(nèi)的水漬。Clean up accumulated water and sundries in the tank in

53、 promptly after water draining, all nozzles and manholes shall be opened, so as to strengthen ventilation in the tank, after the water in the tank is dried, inspect it in time and remove water stain in the tank with rags. 5.9試壓技術(shù)要求Technical Requirements for Pressure Test1.一般要求general requirements 1）

54、 試壓工作開戰(zhàn)前，施工技術(shù)人員必須對參加試壓的所有人員進(jìn)行技術(shù)交底，安全交底，嚴(yán)格 遵守安全紀(jì)律和操作規(guī)程。Before start of the pressure test, technical personnel of construction shall give technical and safety presentation to all pressure test participants, and abide by safety disciplines and operating regulations strictly. 2） 劃定危險區(qū)，并安排人員負(fù)責(zé)警戒，禁止無關(guān)人員進(jìn)入。Divide dangerous zones, and arrange persons to be responsible for alert, and no entry for unrelated personnel. 2.試驗時的要求test requirements 1） 水壓試驗時，嚴(yán)禁對罐身、接口進(jìn)行敲打或修補缺陷，嚴(yán)禁帶壓修理，泄壓后再進(jìn)行修補， 缺陷消除后重新試壓。During the hydro-test, neither knock the