5万吨年合成橡胶项目 管道试压吹扫施工方案.docx

ning bo sk epdm projectconstruction scheme for pipeline pressure testing and purgingrev. : 1page : 204 of 204date : 03. 8. 2013doc no. : 12099d-00000-ms-pi-0001construction scheme for pipeline pressure testing and purging管线试压吹扫施工方案project no. : 12099d项目编号 : 12099dproject name : ningbo sk 50000t/y epdm project项目名称 : 宁波sk 5万吨/年合成橡胶项目owner : ningbo sk synthetic rubber co.ltd业主 : 宁波sk合成橡胶有限公司site : ningbo china位置 : 中国宁波市 0rev版次date 日期status 状态prpd编制chkd 审核appd 批准appddateclient业主1 general概述to ensure pipeline pressure testing and purging work of ningbos 50,000 tons / year synthetic rubber project to finish in order, safely and efficiently. we formulate this solution.为保证宁波50000吨/年合成橡胶项目中管道试压，吹扫工作有序，安全，高效的完成,特制定本方案。 2 scope 范围the program includes requirements and specifications of pipeline cleaning, pressure test, pressure test safety work.本方案包括了管线清扫，压力试验，试压安全等工作的要求和规范。3 reference 参考文件3.1 applicable documents 应用的标准和规范3.1.1 all testing shall be in accordance with the standard. asme b31.3 压力管道规范 asme b31.1 动力管线规范new caledonia codes and regulations.new caledonia 规范标准3.2 all piping systems testing shall conform to the requirements of the specification authorized by the company. 所有管线系统的试验都必须与业主批准的规格书要求一致。4 engineering general stiuation 工程概况 the ug piping includes three parts, ug firefighting piping, ug waste water piping & ug public utility piping. the total quantity of the work is about 5700 diameter-inch. the material included as follows.本项目的埋地管道包含三个部分，埋地的消防管道，埋地的污水管道及埋地的公用管道。总的焊接量大约为5700直径英寸。所包含的材料如下表。no./序号item/条目qty/数量unit/单位1carbon steel pipe/碳钢管道2870.2m/米2stainless steel pipe/不锈钢管道320.6m/米3carbon steel fittings/碳钢管件121ea/个4stainless steel fitttings/不锈钢管件50ea/个5carbon steel flange/碳钢法兰100pc/片6stainless steel flange/不锈钢法兰15pc/片7bolts & nuts/螺栓和螺母832set/套8gasket/垫片86pc/片9valve/阀门20ea/个5 resources(equipment and manpower) 资源（设备及人员）5.1 the following equipment will be utilized for the purpose以下设备将被利用no. 序号equipment 设备qty数量1welding machine 焊机12pressure gauges with calibration certificates 带校准证书的压力表43pressure relief valve with calibration certificates 带校准证书的减压阀24pressurizing pump 增压泵15test manifold / end blinds/spade 试压缓冲罐（见下图）16portable ovens 手提式焊条保温桶1 temporary materials list for pressure testno.standard and descriptionunitquantityremarks1hydraulic test pump, 0-10.0mpaea12pipe，asme b36-10 astm a106 gr.b,pe seamless,dn15* s-80mm20003needle valve female end, astm a105n 800lbs, sw dn15ea64hose, 0-5mpa*1mea25check valve female end, astm a105n 800lbs, sw dn15ea16sockolet, mss sp astm a105n,sw 3000lbs dn150*15ea57cap, a234gr.wpb-std,dn150*s-stdea28pipe, asme b36-10 astm a106 gr.b,pe seamless,dn150* s-stdmm6009safety valve,ea110pressure gage,ea211chart recorder，ea112suckle, mss sp astm a105n,sw 3000lbs dn150*20ea213pipe, asme b36-10 astm a106 gr.b,pe seamless,dn20* s-80mm30014needle valve female end, astm a105n 800lbs, sw dn20ea215temporary flange，weld neck flange, astm a105n groove rtj,300lbs, dn205.2 the following manpower identified by trade will be deployed for the job以下经行业鉴定的人员将被调遣no. 序号manpower 人员qty数量1foreman 队长12qc inspector 质检员）13fabricator & fitter 管工24welders 焊工15helpers 辅助工26safety officer 安全员17electrician 电工18total 总计96 work sequence工作步骤after the completion of piping installation, all pipeline systems shall be cleaned and do pressure testing.当管线安装完成后，整个管线系统应进行清扫和压力试验。after the completion of piping installation , all pipeline systems shall be checked carefully until owner feels satisfied, then cleaning and pressure testing can be started.管线安装完成后, 应该对整个工艺线路进行仔细检查直到业主满意, 然后进行管线清扫和水压试验。check the pressure pump outlet pressure relief valve to ensure it is in a normal state before pressure testing. the relief value jump valve is 5% above the maximum test pressure.在系统试压前，检查打压泵出口压力安全阀是否处在正常状态; 压力安全阀起跳值为超过最大试验压力5%。mark all internal components and their subordinate components which are removed during the pipeline pressure test or remove parts properly reset after the test.标记压力试验期间管线移除的所有内部件及其所属零件或移除位置以确保试验后零件正确复位。7 flushing清扫7.1 general总述7.1.1 after installation, all pipelines, containers, tanks and equipment should be cleaned by air (or clean water) until all impurities are cleaned out of tube; due to process considerations, some equipment and process piping is not allowed to damp.安装完后, 所有管线、容器、罐和设备应该用空气(或洁净的水)进行彻底清扫。直到管内所有杂质被清理出来; 出于工艺考虑, 有的设备和工艺管线不允许潮湿。7.1.2 the cleaning work of piping system shall be done one by one and be according to the pressure test flow diagram.依照压力试验流程图，管线系统清扫工作应逐个系统完成。7.1.3 control valves, volumetric flowmeter, turbine meters, rotary type (table /) meter or release device can not be washed.控制阀, 容积式流量计，涡轮计，旋转型(表/)计或释放装置不能被冲洗。7.1.4 in all cases flushing shall be carried out for a minimum of 30 minutes, with the following specific system criteria:所有情况下清扫工作最短维持30分钟，以下指定系统的标准为： in an open system, flushing shall be continued until flushing water leaving the system is clear and free of all foreign debris. 在开式系统中，持续清扫直到流出系统的清洗水干净，无油且不含其他异物碎片等。 in a closed system, flushing shall be continued until the circulating pump strainer is free of foreign debris and circulating water is clear. 在闭式系统中，持续清洗直到循环泵滤网上没有异物碎片且循环水干净。7.1.5 water flushing should be continued until clean water appeared at the discharge point for at least one minute.冲洗水应该持续不断，直到在排放口流出洁净水至少一分钟以上为止。7.1.6 during air blowing, after there is no dust found from vent by eyes, it is ok when no sundries found on target-card put on vent point within 5 min.空气吹扫过程中，当目测排气无烟尘时，应在排气口设靶板检验， 5分钟内靶板上无杂物为合格。7.1.7 in general, the flushing medium velocity should at least equal the process design velocity. the following conditions must meet the minimum speed:通常情况下，清扫介质的速度至少要与设计速度相等。以下情况需达到规定的最小速度： up to and including dn 200; 3 m/s. dn200以下包含dn200，3m/s。 greater than dn 200 up to dn 500; piping shall be flushed with the highest possible velocity which can be obtained from the available water source. 大于dn200直到dn500，用水源处所能提供的最高流速清扫管线。 piping larger than dn 500; piping shall be visually inspected followed by hand cleaning. 大于dn500，外观检查后进行手工清洗。7.1.8 flushing operations may be carried out in conjunction with hydrostatic testing of completed systems in order to minimize the number of flange connections to be opened.系统安装完毕后，清扫与水压试验协同进行，以减少需要拆开的法兰的数量。7.1.9 in order to avoid unnecessary consumption of operational service gaskets, all temporary connections for flushing operations shall be installed using temporary gaskets.为减少不必要的垫片的使用数量，所有冲洗过程中的临时连接均用临时垫片。7.1.10 the contractor shall provide suitable connections to the flushing medium source as well as connections to drainage points and source of circulating water.承包商应为清扫介质源、泄放口和循环水的排水口处提供合适的连接件。7.1.11 unless otherwise specified, the contractor shall provide suitable cleaning circulation pump or flushing pump.除非另有说明，承包商应提供合适的循环泵或清洗泵。7.1.12 the contractor shall provide suitable temporary pipe connections, hose connections, blind flanges, temporary gaskets, temporary strainers and dummy spools as required for flushing.承包商应为冲洗工作提供合适的临时管接头，软管接头，盲板法兰，临时垫片，临时滤器及短管。7.1.13 the contractor shall restore all systems to their design conditions after flushing and cleaning is complete.清扫结束后承包商应将所有系统恢复到设计状态。7.1.14 in general all instruments in the system to be flushed shall be isolated by test blinds, or removed unless they are permitted to remain in place.通常，所有需要清扫的系统中的仪表都要用盲板隔离开或移除，除非经允许可以不隔离或移除。7.1.15 orifice plates, flow nozzles or other similar restrictions shall not be installed until the system is flushed.除非系统已清扫完成，才允许安装节流板，流量喷嘴及其他类似设备。7.1.16 flanged control valves up to dn 200 removed for the hydrotest shall not be reinstalled prior to flushing. where there is no bypass, a spool piece shall be installed.清洗前不安装因试压而拆下的dn200以下的控制阀。没有旁路时可在该处加一段短管。7.1.17 control valves greater than dn 200 and where valves are welded into the line shall be fully opened prior to flushing and fixed in that position for the duration of the operation.与管线焊接的大于dn200的控制阀在清洗前将其完全打开并在清扫期间将其固定在打开位置。7.1.18 dont install online instrument before sweeping, such as a rotary flow meters, volumetric flowmeter. the bypass where the open need a short time of chocked up with cleaning and then use a blind flange.清扫前不安装在线仪表，如旋转式流量计，容积式流量计。有旁路的地方，其开口端要经过短时间的清扫然后用盲板堵死。7.1.19 during cleaning, isolate or remove the pressure gauge and pressure gauge in place joint.清扫期间，隔离或拆除已就位的的压力表及压力表接头。7.1.20 installed in the interior of the container or float float level gauge should be isolated and open to air.安装在容器或浮球室内的液位计浮子应被隔离且与大气联通。7.1.21 where vessels and other pieces of equipment are included in hydrotest packs, the following shall be observed:包含在水压试验范围之内的容器及其他设备部件，应注意以下几点： where possible, all connecting pipes should be flushed starting at the vessel in order to avoid disassembling of flange connections. filling of those vessels shall be done using the lowest possible point for flushing connection. 可能的情况下，所有的连接管线都应该从容器开始清洗避免拆开法兰连接。应使用最低注入口为容器清洗注水。 pumps, compressors and other rotating equipment shall not be flushed. flange connections to such equipment shall be disconnected prior to flushing and equipment shall be protected with blinds. 泵，压缩机及其他旋转设备不进行清扫。清扫前拆开与这些设备相连的法兰，并用盲板将设备接口堵死。 heat exchangers may be flushed through if the feed line is thoroughly cleaned first. 热交换器的供水管线经彻底清扫后可对热交换器进行清扫。7.1.22 equipment previously tested shall be blanked off and shall neither be flushed through, nor allowed to accumulate foreign matter removed from the piping. 经过试验的设备应隔开；不吹扫，也不允许从管系出来的物质聚集在设备处。7.2 flushing preparation清扫准备7.2.1 the pipelines shall be checked as follows to carry out the flushing correctly before the water flushing or air blowing.管线用水或空气吹扫之前，应该依据下列各项仔细检查从而确保正确地完成吹扫工作。7.2.2 all required welding, stress relief & ndt has been completed and all supports are in place including temporary supports. 完成所需的焊接、应力释放和无损检测，并且所有的支撑(包括临时支撑)要就位于适当位置。7.2.3 all high point vents are open and necessary valves are installed. 打开所有高点放空，并安装所需阀门。 7.2.4 filter elements, restriction orifices, chokes, and pilot tubes have been removed. 过滤元件、限流板、节流阀及导管要拆下。 7.2.5 all block valves and blinds are in their proper position as test drawing.所有关断阀和盲板要按试压图置于正确的位置。7.2.6 all relief valves have been properly isolated or removed. 所有泄放阀要隔开或拆下。7.2.7 all rupture disks have been replaced with suitable blinds.所有爆破膜要用合适的盲板替换。7.2.8 instrumentation tube, if feasible, shut the valve in the first shut-off valve at the break.仪表管如果可行的话，在第一个关断阀处断开。7.2.9 additional temporary supports have been installed, if necessary, on vapor or gas piping to support the additional test fluid weight. 如果必需, 在蒸汽或气管线上增加临时支架，以承受额外的测试流体重量。7.2.10 open all one-way valve and make the direction consistent with the test medium flow direction, pun discharge ball valve is in a state of half open.打开所有单向阀并使其方向与测试介质流动方向一致，双关断排放球阀处于半开状态。7.2.11 all pressure switches, pressure indicators, level controls and level switches are removed or blocked-off, if not suitable for pressure. 如果不适应压力的话，所有压力开关、压力表、液位控制和液位开关要拆下或隔开。7.2.12 before pressure test all the system should be checked according to the latest revision p&id and iso. all the system must be confirmed that the piping connecting (instrument and equipment installed) is right including. 所有系统压力试验之前，应按最新版p&id和三维图检查；确保所有系统的管线连接(包括仪表和安装的设备)是正确的。7.3 flushing medium清扫介质7.3.1 flushing water should be fresh water for normal pipelines. (or compressed air employed for flushing must be dry.) 普通管线的清扫用水为洁净的淡水。（如果用压缩空气吹扫，必须是干燥的)。7.3.2 for water flushing, flushing water for stainless steel shall contain less than 30ppm of chlorides. 不锈钢管道的清扫要使用氯离子含量低于30ppm的洁净淡水。8 pressure testing压力试验ds8.1 general 概述8.1.1 before the first operation, unless there are special specifications stated in the book and has been tested equipment and pipelines, all installed pipeline pressure test should be performed.在首次运作之前，除规格书中有特殊说明外和已经做过试验的设备及管线，所有的已安装管线都应进行压力试验。8.1.2 pressure test package include a pressure test diagram based on piping and instrumentation diagrams showing the extent of pipe work to be included in each test. the scope of each separate test shall be the maximum practicable, considering adequate relief protection and available test fluid. the pressure equipment directive (ped) category assessment shall be clearly indicated on the diagram.压力试验包包括基于管线与仪表图表的压力试验图表，可显示出每个试压的管线作业量。每个单独试验范围应有最佳足够释放保护、可用试验介质。ped级别估定应在图表中清楚说明8.1.3 the pressure test includes hydrostatic pressure and pneumatic test. the value of hydrostatic pressure test shall be 1.5 times of the design pressure. the pneumatic pressure test shall be 1.1 times of the design pressure. the pressure test is the one that is performed to confirm the piping systems have the sufficient strength safety against static pressure and no leakage from any joints. the line checking is performed before pressure test. the pipeline checking in the pressure test is particularly performed to check the condition of piping work including leakage.管道压力试验包括水压试验和气压试验; 水压试验时试验压力应为设计压力的1.5倍，气压试验压力为设计压力的1.1倍。压力试验的目的是确认管线系统是否具有足够的安全强度以承受静压和确认接头是否泄漏，压力试验前管线必须仔细检查。压力试验时要仔细检查管线的运行情况以及是否泄漏。8.1.4 the process line lists indicate the line number, description, piping material service class, design pressure, design temperature, insulation and tracing requirements, minimum test pressure for each line, and ped category. the type of pressure test and test medium will be noted in the table.工艺管线清单中应标明管线号，描述，管线材质等级，设计压力，设计温度，绝缘及跟踪要求，每条管线的最小试验压力及ped类别。表格中还要注明试压类型及试压介质。8.1.5 lines in vacuum service, unless governed by specific design conditions, shall be tested at a minimum of 1.03 barg (15 psig).对于真空系统，除非设计条件所限，试验压力最小为1.03barg（15psig）。8.1.6 all welds of the piping system to be tested shall not be painting. piping such as open drains, vents, discharge piping which is open to the atmosphere shall not be pressure tested, but atmospheric pressure test or service test is required.所有要试压的管线的焊缝不能涂油漆; 开排管线，放空管线，排水管线等常压管线不要求做压力试验，但必须做泄漏试验或工作介质试验。8.1.7 an alternative of testing before erection is allowed where hydrostatic and/or pneumatic testing are considered impractical.水压试验和气压试验都不切实际时，在安装前，可采用其他可替代的方法试验。8.1.8 alternative testing consists of testing in spools, and, then once erected, performing 100% radiographic and mpi/dpi examination of the field welds.可替代的试验方法包括管段试验以及安装之后，对现场焊接进行100%的x光照相及mpi/dpi检验。8.1.9 in general instrument piping shall be tested pneumatically. if instrument piping is hydrostatic tested, it shall be tested up to the first block valve. testing of instrument piping beyond the first block valve shall be limited to in service testing unless otherwise agreed in advance in writing.一般, 仪表管要进行气压试验; 如仪表管要进行水压试验, 那只能试第一个截止阀之前的管线; 第一个截止阀之后的管线, 只做工作介质试验测试, 否则要得到书面认可。8.2 test medium 测试介质8.2.1 the test shall be preferably hydrostatic using water unless there is a possibility of damage due to freezing;or, if the system operation or piping material would be adversely affected by water. where this is the case, any other testing medium will follow the recommendations of asme b31.1/b31.3/ped 97/23/ce.所有试验均优选水作为试验介质，除非用水可能造成冻伤或对系统管线材料造成损害。这种情况下，其他任何试压介质都要符合asme b31.1/b31.3/ped 97/23/ce 规定。8.2.2 potable water or fire water may be used. a suitable filter should be provided in the filling line to the system where foreign matter such as sand, dust, or other particulates are present.饮用水及消防水可以采用。如果水中含有沙子，粉尘或其他颗粒，应在注水管线上添加一台滤器。8.2.3 stainless steel piping vessels and equipment shall be tested with fresh water containing less than 30ppm of chlorides. piping, vessels, and equipment must be drained thoroughly after testing. it should be noted that risk of pitting corrosion is considerably diminished if the time between pressure testing and start-up is as short as possible. if the time is anticipated to be longer than one week, flushing with condensate or demineralised water is recommended. draining and drying out of the piping is the most important.不锈钢管线用氯离子含量低于30ppm的洁净淡水作水压试验介质。试压结束后，管线，容器及设备中的水要彻底排放干净。如果从试压结束到管线正式启用这段时间越短，产生的腐蚀斑也会大量减少。如果预计这段时间会超过一星期，当用冷凝水或脱去矿物质后的水冲洗。排放及干燥是最重要的。8.2.4 pneumatic test shall use dry (dewpoint - 40c or lower), clean, non-oil air or nitrogen. air from oil lubricated compressors shall not be used.气压试验应该使用干燥(结露点在-40c以下)，清洁，不含油的空气或氮气。不能使用来自滑油压缩机的空气。8.2.5 lube oil or hydraulic oil systems consisting of small piping or tubing may be tested with service medium.润滑油或液压油系统是由小管径的管道组成的，可以用介质油来试压。8.2.6 liquid mediums other than water shall:1. be non toxic;2. have a flash point of 60 degrees celsius or above, and shall not be used within 25 degrees celsius of that flash point;3. be used at a temperature at least 10 degrees celsius below the atmospheric boiling point and at least 5 degrees celsius above the solidification point for the liquid.除水外其他液体试压介质要满足以下要求：1. 无毒；2. 介质闪点在60摄氏度以上，闪点在25摄氏度以下的不能使用。3. 试压温度至少低于大气压下该介质沸点温度10摄氏度且其凝固点要高于5摄氏度。8.3 test preparation 试验准备3.3.1 planning 计划the contractor shall prepare a system pressure test package for each test system including a pressure test diagram based on piping and instrumentation diagrams showing the extent of pipe work to be included in