NASA管道压力试验方案.docx

project: ips ii sap c0066管道压力试验方案date:2013.03.15location:nanjing dachangpiping pressure test planrev.0owner: byccontractor:ncc扬子-巴斯夫一体化石化项目byc ips nasa sap project工艺管道试压方案piping test scheme合同号：contact no.:编制:prepare:审核:review :批准:approve nanjing chemical construction co., ltd南京南化建设有限公司目录1.工程概况 project overview general122.编制依据 reference123.试压准备 pressure testing preparation24.试压操作步骤 pressure testing procedure45.管道清洗及质量控制资料文件flushing and qc documents76.注意事项 attention measures87.工作风险分析表-jsa99page 2 of 141.工程概况 project overview general南京扬子石化-巴斯夫责任有限公司（简称扬巴）ips nasa sap项目由d635电气楼（sr/rr）、d640 sap 生产线1、d642冷冻单元、d645卡车装载/卸载站、d655 ipa/洗涤塔单元、d672i 管廊组成。其中管道主要布置在d640 sap 生产线1、d642冷冻单元、d655 ipa/洗涤塔单元、d672i管廊组成。管线长度17430米，分为3大系统，共计69个子系统。管道的试压方式有水压试验、气压试验、运行测试、和外观检测。basf-ypc company limited (short for byc ) ips nasa sap project is consist of d635 electrical building ( sr/rr ), d640 sap production line 1, d642 chiller unit, d645 truck loading / unloading station, d655 ipa/ scrubber unit, d672i pipe rack. the main pipeline is in d640 sap production line 1, d642 chiller unit, d655 ipa/ scrubber unit, d672i pipe rack. pipeline length of 17430 meters, is divided into 3 systems, a total of 69 subsystems. the way of pipeline pressure test has water pressure test, pressure test, running test, and appearance test.序号no系统名system name子系统数量subsystem number1dry system212utilities253wet system232.编制依据 reference50-010-00-0-0-00-001 工艺和公用工程配管设计、布置和图纸。process and utility piping design layout and drawing.50-010-00-0-0-00-009 扬子石化-巴斯夫有限责任公司对于工艺和公用工程管道压力试验规范。pressure testing process and utility specification of byc.50-710-sa-0-1-00-001 扬巴二期改造项目高吸水性树脂装置管道特性清单一览表.byc ips ii nasa pipe specialty listasme (american society of mechanical engineers)(美国机械工程师协会) asme b31.3 process b31.3 process piping sh3501-2002石油化工有毒、可燃介质管道工程施工及验收规范 construction and acceptance code for petrochemical toxic and flammable medium pipinggb 50235-2010 工业金属管道施工验收规范code for construction and acceptance of industrial metallic pipinggb/t 20801-2006 压力管道规范 工业管道pressure piping code industrial piping3.试压准备 pressure testing preparation试验范围内的管道安装工程除涂漆、绝热外，已按设计图纸全部完成；all pipe installation excludes painting and insulation within the testing area should be completed according to the engineering drawing;焊缝和其他待检部位尚未涂漆和绝热；welds and other ready for checking position shall not apply with painting and insulation;设计介质为蒸汽和气体的管道，如有必要须增加临时支架；design medium subject to pipe with steam and gas in it, add temporary support if necessary;待试管道与无关系统已用盲板或采取其他措施隔开，试压用的盲板已做好标识，便于盲板在试压后能全部拆除； pipe which is going to test and unrelated systems have been separated by blind plate or other measures, blind plate used for pressure must be marked to remove blind plate easier after pressure test;盲板厚度选用应符合50-010-00-0-0-00-009工艺和公用工程管道压力试验规范要。blind thickness shall be as per 50-010-00-0-0-00-009 pressure testing process and utility specification of byc. 不允许参加试压的仪表元件及阀门已采用临时短管连接；those instrument components and valves prohibit for testing have connected with temporary short tube;试压用的压力表应是经过校核过且表的满刻度值为试压压力的1.5-2倍左右，每一被测系统应至少要有2块压力表；一块表装在试验系统最高点，一块表装在系统最底点。pressure testing gauge shall be calibrated and the scaled value shall be about 1.5-22 times of testing pressure; install one gauge at high point and one at low point of system.所有试压用的设备如试压泵、空压机、贮水罐等应准备好；水压试验用的临时管道已按正式工程的标准安装完成，试压后污水排放管已接入排水系统。all testing equipment such as testing pump, air compressor, water storage tank shall be ready for testing; completed the installation of the temporary pressure testing pipe according to the formal construction standard requirement; contaminate drainage pipe which applying for drain after finished testing shall connect the drainage system.管道试压前要划分好试压系统，按照ctn试压包的要求编制好试压包，试压包经过ctn工程师审核后才能按照试压包的流程和方法进行试压。pressure testing system shall be prepared prior to pressure testing and tested by system. prepare test packs per ctn requirement; test pack shall be reviewed by ctn engineers before proceeding per the routing and procedure thereof.试压包内容包括：试压包核对表、试压包线路表路径表、p&id、压力试验图例、压力试验单线图、管线清单、最新版单线图、尾项清单、试验准备清单、试验临时盲板清单、焊口图、临时支撑、压力试验仪表校核证书、压力试验安全阀证书、水质报告（不锈钢）、现场质量手册中适用的压力试验报告、现场质量手册中适用的管道清洗报告、压力试验复位清单。pressure test pack contents include test pack assembly check sheet, pressure test pack routing form, pressure test diagrams(p&ids), pressure test legend, pressure test isometric list, copy of appropriate line list, isometrics(current revision), punch list form, piping pressure test preparation checklist, list of temporary blind plates for pressure test, weld maps (pre/post nde clearance), addition of temp. supports (ref. asme b31.1 par.137.2.2) , pressure test gages calibration certificates (at time of test), pressure test relief valve certificates, water analysis report (stainless steel), appropriate pressure testing report from the site quality manual, appropriate pipe cleaning and flushing report from the site quality manual, pressure test reinstatement (post test check list) .试压流程：准备试压包、ctn ptc 审核试压包、ctn工程师检查试压包、创建现场复件、ctn 发布单线图清单给ims和pcs、ctn发布现场试压包完成管线核实、确认试压包里单线图和流程图是最新版、联合检查试压尾项、ctn确认无损探伤前清除项、改正一类尾项、ctn核实一类尾项已完成、ctn核实无损探伤后清除项、发布试压包准备清单准备试压、ctn现场见证签字、排液、复位、移交组审核试压包更新pcs、ctn发放防腐保温通知、ctn提交pcs尾项。pressure test flow: prepare test pack; ctn ptc review test pack; ctn check test pack & proceed; create field copy (scan accepted; issue isometric list to ims and pcs; ctn issue test pack (copy) to field for verification line is complete; confirm that test pack contains latest rev. iso and p&id ; pressure test punch.(joint line check led by engineer); pre-nde clearance; rectify cat.1 punch items; verify cat.1 items complete; post nde clearance; release pressure test preparation checklist& set up test; witness and sign-off test ; drain test; final reinstatement complete; review pack and update pcs; test pack complete and released for insulation; submit remaining punch to pcs .碳钢管道试验用水采用洁净的生活水，不锈钢管道采用脱盐水，脱盐水要经过分析，氯离子含量不超过100mg/l25ppm。尽可能的不不得采用气压试验。但经过ctn批准，部分管线还可以进行气压试验，气体管道系统（如空气、氮气、工厂风、仪表风、废气等管线）、系统含氰化氢、介质将被水污染或管道系统需要完全不含水可以根据 asme b31.3的 345.5和 gb50235，sh3501进行气压试验，注意这具有压缩空气释放能量的危险，因此仅限于小管径的管道。用固有介质进行试压时，系统应加压至管道系统的操作压力。test water for cs pipe shall be clean water; and for ss pipe shall be demi-water with chlorine ion content no more than100mg/l25ppm. part of the pipeline can also perform air pressure test, such as air, nitrogen, plant air, instrument air, gas pipelines can be based on asme b31.3 345.5 and gb50235, sh3501 to perform air pressure test, pay attention to the danger of compressed air energy release, so only for small diameter pipeline. when use natural medium to perform pressure test, the system shall be pressured to the pipeline system operating pressure pneumatic leak test shall be minimized. if authorized by ctn, gas piping systems (nitrogen, air etc.), systems containing hydrogen cyanide, services that will be contaminated by water or piping systems that need to be completely free from water, may be tested by pneumatic leak test in accordance with asme b31.3 section 345.5 and gb 50235-97, sh3501. note that this involves the hazard of released energy stored in compressed gas, and needs to be limited to small diameter piping only. for initial service leak testing the system shall be pressurized to the pipe system maximum operating pressure.成立专门的试压队伍，试压前进行技术和安全交底。establish special pressure test group; conduct technical and safety clarification before test.4.试压操作步骤 pressure testing procedure水压试验，注水时，首先打开管道最高处的放空阀，使管内空气可从放空处排出。first open the release valve at high point in order to get rid of the inside air while injecting the water for testing.进行水压试验时，升压应缓慢，达到试验压力后稳压10分钟，再降压至设计压力，停稳压30分钟，以压力不降、无泄漏为合格。increase the pressure slowly while performing pressure testing, keep constant pressure for 10 minutes after arriving the testing pressure, reduce the pressure to designing pressure, then stop 30 minutes, no pressure descending and no leakage will regards as qualified. 应注意水的液位差影响，不能使最低点的压力超过配管承受能力。pay attention to the effect from water level variation, the lowest point pressure is prohibited to exceed the tubing capacity.水压试验完成后，排水前首先打开放空阀，排水时应控制排放速度使系统不至产生负压效应。after finished pressure testing, open the release valve firstly previous to drainage the water; control the drainage speed so that no negative pressure inducing to system. 试压完毕后，应及时拆除盲板、临时管道等，清洁并安装上试压前所拆卸下的仪表等。remove blank, temporary pipe etc. immediately after finishing the pressure testing, those removed instruments previous to testing shall be cleaned and installed.试压过程中如遇泄漏等，做上明显标记，压力消除后进行修理，然后重新试验这部分管道。make an outstanding mark for leakage appeared during the pressure testing, repair immediately after eliminate the pressure and retesting for this part of the pipe.水压试验要求的最小试验压力不应小于管道设计压力 p的 1.5倍。当设计温度大于试验温度时，要求的最小试验压力按下述确定： for hydrostatic leak testing the minimum required test pressure shall not less than 1.5 times the pipe system design pressure p. for design temperatures above the test temperature the minimum required test pressure is determined as follows: test pressure = 1.5 * p * st / s, where: st = allowable stress of material at test temperature s = allowable stress of material at design temperature 试验压力1.5 * p * st / s, 其中 st材料试验温度时的允许应力 s材料设计温度时的允许应力 test pressure = 1.5 * p * st / s, st = allowable stress of material at test temperature s = allowable stress of material at design temperature 各温度下的允许应力见 asme b31.3附录 a表 a1。当 st/s大于 6.5时，将使用 6.5。 see asme b31.3, appendix a, table a-1, for allowable stresses at temperatures. when st/ s is greater than 6.5, 6.5 shall be used. 当按上述确定的试验压力将产生一个在试验温度下超过屈服强度的应力时，应将试验压力减小。不会产生超过屈服强度应力的最大的试验压力能够通过下列等式计算所得：where the test pressure as defined above would produce a stress in excess of the the yield strength at test temperature, the test pressure shall be reduced. the maximum test pressure at which the stress produced does not exceed the yield strength can be calculated by the following equation:max ,test, test pressure=2 * y * t * 6.895/d其中 y规定的最小屈服应力（ksi） t规定管壁厚制造公差（in） d管道外径（in） 气压试验试验压力应是管道系统设计压力的 1.1倍。for pneumatic leak testing the test pressure shall be 110% of the pipe system design pressure. 敏感性物质检漏试验的试验压力至少是 105kpa或管道设计压力的 25%中的较小值，开始时管道系统压力应逐步提高直至试验压力表压的 50%或 170kpa中的较小值以便进行初步检查。for sensitive leak testing the test pressure shall be at least the lesser of 105 kpa or 25% the pipe system design pressure. initially the pipe system shall be pressurized gradually to a gage pressure the lesser of 50% of the test pressure or 170 kpa in order to perform a preliminary check. 进行紧密性试验时应将系统充满水直至最高点（水压时）或用空气或其他惰性气体升压至 35 kpa。for tightness testing the system shall be filled with water to the highest point (hydrostatic) or pressurized to 35 kpa with air or other nonflammable gas (pneumatic) 用固有介质进行试压时，系统应加压至管道系统的操作压力。当含有气体或蒸汽时，应在压力不大于 170 kpa 时进行初步检查，压力应逐步增加以提供足够的时间允许管道补偿应变并检查泄漏。for initial service leak testing the system shall be pressurized to the pipe system maximum operating pressure. (2) a preliminary check shall be made at no more than 170 kpa pressure when the contained fluid is a gas or vapor. the pressure shall be increased gradually in steps providing sufficient time to allow the piping to equalize strains and to check leaks 对于气压试验，试验区域在试压前应清理干净，原则上该试验只在周末进行因为此时现场人员较少。只有与压力试验相关的人员被授权在试验区域参加气压试验。在通道、楼梯口和管廊下面需要设置警示标识，系统最初加压最大至 170 kpa，发现泄漏卸压修理并再次试压。人员从该区域退出后，逐步升压至要求的压力（每次 170 kpa或试验压力的 10%）并提供足够的时间允许管道补偿应变，只有在管道压力不再增加时才能检查管道系统，对所有的焊接接头、法兰连接接头或螺纹连接接头用肥皂泡检查泄漏，肥皂应是商业上专门用来进行泄漏探查的。压力试验应维持足够的时间（不能小于 10分钟）确定是否有泄漏，承包商在向授权检验员发出通知后压力维持时间没必要超过 2小时。任何泄漏都应先卸压后维修再重新试压，当正在试压的系统压力升至 0.2 mpa以上后不应对螺栓再进行紧固，试验温度不应小于 15c，对于奥氏体不锈钢试验温度可以降至 5c。for pneumatic leak tests, the test area shall be cleared before bringing the system up to pressure. in principle tests shall only be conducted during weekends when fewer personnel are present. only pressure test related personnel is authorized to attend those pneumatic tests within the test yard. warning signs need to be set up at passage ways, stair cases and underneath pipe racks. pressurize the system initially to 170 kpa maximum. release pressure and repair any leaks found and retest. with personnel vacated from the area, increase the pressure to that required by in several steps (of 170kpa or 10% of test pressure), providing sufficient time to allow the piping to equalize strains. the piping system shall be examined only when the pressure in it is not increasing. all joints welded, flanged or screwed shall then be swabbed with soap solution and checked for leaks. soap shall be a commercial preparation made specifically for leak detection. the pressure test shall be maintained for sufficient time to determine if there are any leaks but not less than 10 minutes. contractor is not required to maintain test pressure in excess of 2 hours after notification of the authorized inspector. release pressure and repair any leaks and retest. bolting shall not be tightened while systems being tested are pressured above 0.2 mpa. test temperature shall not be less than 15c. this temperature may be reduced to 5c when testing austenitic stainless steels. 对于使用固有介质进行气压试验，应按试验压力的 20%逐级升压并且在两次升压期间要留足够的时间使管道系统补偿应变并观察泄漏。可是对于压缩气体系统最初升压不应超过 170 kpa。管道系统的试验流体应通过一个微开的阀门以减少管道系统失效而产生的伤害。试验压力应维持足够的时间但不能大于 10分钟以确定是否泄漏，如有泄漏释放压力然后修理再再次试验。for the initial service leak test the test pressure shall be applied in increments of approx. 20% allowing time between increments for the piping system to equalize strains and to observe the leaks. however, for compressed gas systems the initial increment shall not exceed 170 kpa. application of the test fluid to the piping system shall be through a valve opened slightly to minimize damage in the event of a piping failure. the pressure shall be maintained for sufficient time to determine if there are any leaks but not less than 10 minutes. release pressure, repair any leaks, and retest.气压试验和固有介质进行气密试验，系统的安全阀需按照系统设定的压力校核后安装。没有安全阀的管道系统不得进行气压试验。the safety valve to be used for pneumatic leak test and initial service leak test shall be installed upon calibration per the setting pressure of the system; pipe system without safety valve shall not be performed pneumatic leak test.5.管道清洗及质量控制资料文件flushing and qc documents试验后管道系统应进行冲洗直至所有管线中的疏松氧化皮和碎片彻底清除干净。 piping systems shall be flushed after testing until all lines are thoroughly cleared of loose scale and debris.所有蒸汽管线除冲洗之外，还应在疏水器安装前进行吹扫。 in addition to flushing, all steam lines shall be blown before traps are installed. 所有进行气压试验的管线都应用空气进行吹扫直至将所有杂质清除干净。all lines tested pneumatically shall be blown with air until clear of all foreign material. 试压完成后，每个管道系统试压应使用“管道系统耐压试验条件确认与试验记录”表格或 sh3503的 j406进行记录，完成后这些表格应保存在质量控制文件中作为永久记录，这些记录包括：afterafter finished pressure testing.testtesting. test records shall be made of each piping system test utilizing a form titled, record of piping system pressure test and test condition confirmation or j406 of sh3503. these forms, when completed, shall be retained in the quality control file as a permanent record. these records shall include: 试验日期 date of test. 具有系统包号的管道和设备的标识 identification of piping and equipment with system package number.试验介质test medium. 试验压力 test pressure.最小的环境和试验介质温度 minimum ambient and test medium temperature.试验结果 test results试验操作者姓名 name of test operator.由承包商、施工检查者、授权检验师和授权代表签署的证书certification by contractor, construction examiner and authorized inspector and representative of authority when applicable. 6.注意事项 attention measures在进行压力试验时，划定试压禁区，无关人员不得进入。make a prohibited area for testing and forbidden irrespective person enter it during pressure testing time.在试压禁区，树立一告示牌，写明“正在试压”。特别在高压试验进行时，要有足够的防护措施。set up a nameplate identify with “pressure testing in progress” at the prohibited area. take sufficient protective measure specially during high pressure testing.试压时不得撞击受压部件。forbidden to impact the testing component during testing.参加试压人员分工必须明确，各司其职，操作人员必须听从指挥，认真操作。testing personnel shall divide the work clearly and be responsible respectively, listen to the order and operate seriously.试压过程中升压应缓慢，检查人员不要站在盲板的顶端，升压前应对试压设备，压力表连接管和管件，排气管及进水管等加以检查，必须保证系统的严密性和排尽管道内的空气。increase the pressure slowly during pressure testing, inspector shall not stand in front of the blank top, checking the testing equipment, pressure gauge connecting pipe and component, vent pipe and enter pipe to ensure the system tightness and exhaust all the air within the pipe.page 6 of 16工作风险分析表-jsa制定/更改jsa日期: strike out as appropriate工作许可证号 ptw no.是否需要工作许可证: 是 否发布时间:制定/更改人签字(风险分析小组人员姓名)prepared by (names of team members):批准人签字(施工主管)authorized by: (supervisor)姓名:签字:工作描述/位置:是否须要危险源隔离: 是 否详细说明:执行此项工作的小组成员team members undertaking the work我们已经阅读并了解了本项工作的安全工作程序/要求/措施,我们明白如果不能按照这些程序/要求/措施执行工作将会导致危险和接受纪律措施处理正楷姓名:签字: 日期:正楷姓名:签字:日期:正楷姓名:签字:日期:7.工作风险分析表-jsa作业步骤描述break the job down into steps. each of the steps should accomplish some major task and be logical.确认的危害及潜在的影响identify the hazards associated with each step. 风险评估*控制措施(包括现有的和建议的)using the first two columns as a guide. decide what actions are necessary to eliminate then control the hazards that could lead to an incident.负责人残余风险*残余风险是否尽可能的降低alarp*? 严重度发生概率风险 等级 严重度发生概率风险 等级 1、调节阀、变送器、孔板拆除 dismantle control valve, transformer and orifice plate1、无合格的操作平台，发生高处坠落事故。non-qualified operation platform causes falling from height.3131、搭设合格的作业平台。erect correct