储罐置换和预冷(20140303).docx

Outline Procedure For Tank Purge & Cooldown For Tanks T101 to T106储罐T101T106的置换和预冷程序概述目录1. SCOPE应用范围12. SAFETY安全22.1 Tank Solation储罐隔离33. INTRODUCTION简介33.1 Preamble前言33.2 System Description系统描述33.3 Data Recording, Monitoring and Storage数据记录、监视和存储43.4 Pre-Commissioning Requirements试车准备工作要求43.5 LNG Tank Pre-Commissioning LNG储罐试车准备工作43.5.1 Execution Plan and Planning Requirements 执行计划和要求43.5.2 HSE and Regulatory Requirements HSE和规范要求53.5.3 Temporary Facilities 临时设施64. CRITERIA OF DRYING AND PURGING 干燥和置换标准85. FINAL CHECKS AND SET-UP 最后检测和设置96. QUALITY AND QUANTITY OF NITROGEN GAS 氮气的质量和用量107. NITROGEN DRY OUT AND PURGE 氮气干燥和置换107.1 Summary of Tank Pre-commissioning 储罐预试车概述107.2 Dry Out and Purge of Zone A (Step-1) 干燥和A区置换（步骤1）127.3 Dry Out and Purge of Zone B, (Step-2) B区的干燥和置换(步骤2)137.4 Dry Out and Purge of Zone C (Step-3 C区的干燥置换（步骤3）147.5 Dry Out and Purge of Zone D (Step-4) D区的干燥置换（步骤4）157.6 Channeling 窜流167.7 Nitrogen Purge Control Parameters 氮气吹扫控制参数168. COOL-DOWN 预冷268.1 General 原则268.2 Preliminaries准备工作269. COOL DOWN, METHOD预冷方法279.1 General Description整体描述279.2 Cool Down Of Tanks & In-Tank Pumps 储罐与罐内泵的预冷289.2.1 Overview 概述289.2.2 Detailed Cooldown Procedure详细冷却过程3210. DECOMMISSIONING停运3610.1 Decommissioning Preparation 停运准备3610.2 A Brief Description 简要说明3611. APPENDIX section 附录部分3711.1 Appendix 1 附录13711.2 Appendix 2 附录23811.3 Appendix 3 附录33811.4 Appendix 4 附录4391. SCOPE应用范围This specification sets out an outline description of the procedure to be used in the Purging and Cool Down of Tanks T101 to T106. These tanks are designed for the storage of Liquefied Natural Gas on the Shandong LNG Facility, Qingdao, P. R. China.该文件对山东LNG项目液化天然气储存设备，储罐T101T06的氮气置换和预冷程序步骤进行了概括说明。This procedure consists of two steps:1) Inert gas to dry and purge the tank of air2) Product gas to purge the inert gas and cool the tank置换和预冷程序包括两个步骤：1) 向储罐置入氮气，置换出空气并对储罐进行干燥2) 向储罐置入产品气，置换出氮气并对储罐进行预冷This procedure sets out the method and the safety requirements to complete this process.该程序提出了完成储罐置换和预冷的方法和安全性措施。This specification is an outline procedure and is not intended to cover all aspects of the operation. The full procedure, to be developed by SEI, will include:需要指出的是，本文件是置换和预冷过程的概括说明，并不涵盖执行过程的所有细节。SEI设计的储罐置换和预冷的完整的程序应包括：Safety Section安全部分Data Log sheets数据日志表Acceptance sign off验收签字表Vent log放空日志Cool down log预冷日志Notes:注：1) “Product” stated in this procedure refers to Liquid Natural Gas (LNG) at -163C。“Product gas” stated in this procedure refers to warm (ambient temperature) LNG vapour.2) Valve numbers shown relate to P&IDs6279-C-D-DA-TND-370/C926-00-4506279-X-Z-DM-SGZ-3010026279-X-Z-DM-SGZ-301011All valve numbers etc. shall be confirmed with the final issue of the P&IDs.1) 以上所指产品为-163摄氏度下的液化天然气（LNG）以上所指产品气为在环境温度下气化的LNG蒸汽2) 涉及阀门位号的P&ID图6279-C-D-DA-TND-370 / C926-00-4506279-X-Z-DM-SGZ-3010026279-X-Z-DM-SGZ-301011P&ID最终发布前需对以上所有阀位号进行最终确认。2. SAFETY安全Pre-commissioning shall be carried out under a permit to work system:试车准备工作须在允许开工的条件下执行。All systems, sub systems or equipment items which are undergoing pre-commissioning shall be clearly identified as per the Project Health, Safety and Security Plan. No person other than approved commissioning personnel shall work on the system or equipment without prior written authorization of the system responsible Commissioning Engineer.所有与试车准备工作相关的系统、子系统或设备均须按照工程的健康和安全计划严格确认。除经由系统调试工程师书面授权的工作人员外，任何人不得对系统或设备进行操作。Oxgen Deficient Atmosphere缺氧环境A hazardous oxygen-deficient atmosphere is air (oxygen plus nitrogen) with an oxygen content less than 19.5% by volume. The nitrogen purge activity replaces the normal air inside the tank with nitrogen, thus creating a hazardous oxygen-deficient atmosphere.有危险的缺氧环境是指氧气含量少于19.5%体积分数的大气。氮气置换过程将罐内空气置换出来，该过程将导致缺氧环境的产生。Extreme care must be exercised during purge activity to prevent personnel access to any hazardous oxygen-deficient atmosphere, which could be present at exhaust points and vents. This caution will extend to locations around the tank piping and nozzles. Personnel safety will be the primary concern during pre-activity safety planning meetings. The following provisions will be made to mitigate the risk of nitrogen related incidents.置换预冷过程中，禁止任何人进入缺氧环境，并针对该情况进行应急演练。缺氧环境可能出现在排气点、放空点。因此需要在储罐管道和喷嘴（接管）处设置警示标志。工程安全会议应将工作人员的安全作为首要问题考虑。为降低缺氧环境带来的风险，务必遵循以下几项规定。Extensions shall be installed on the tank nozzles used for venting, such as dome vent, annular vents, cool down line, in-tank pump discharge vents, cool down line vent, inner bottom vent, and lower bottom vent, to exhaust gas away from personnel working on top of the tank.储罐放空喷嘴必须有一定延伸，使罐顶工作人员远离缺氧环境。例如罐顶放空、环形空间放空，预冷管线、罐内泵放空，预冷管线放空、内罐罐底放空，底部放空等。All Nitrogen emission locations shall be marked off with hazardous area barrier tape. Each sample point will be equipped with a warning notice that sampled gas contains nitrogen. Hose connections should be clearly marked as nitrogen connections. All valves used in the purging procedure must have a warning notice for the presence of nitrogen.氮气排放场所须设立危险区域隔离带，取样点必须设置警示标志，提醒工作人员排出气体中含有氮气。软管连接须明确标志为氮气连接。所有置换和预冷程序使用的阀门必须设置警示标识，流体内包含氮气。2.1 Tank Solation储罐隔离Prior to beginning the tank purging activity, the storage tank must be isolated from other piping and vessels, in particular must be isolated from any LNG containing facilities. Isolation from LNG containing piping and equipment will be made by block valve and / or spade. Isolation of the working volume from non-hydrocarbon sections will also be made by valve and spade isolation. .All isolations must be installed, tagged and signed-off before starting the procedure.在进行储罐置换和预冷前，必须保证储罐与其他管线和容器相隔离，特别是与LNG储存设施相隔离。储罐通过阀门或其他截断设备与LNG管线和设施相隔离。工作空间与非烃类部分的隔离同样要通过阀门和截断设备实现。在程序执行之前所有隔离设备都必须满足安装、标记和验收的要求。Only the Nitrogen supply and required vents shall not be isolated.只有氮气供应管线和必要的放空管不需要被隔离。3. INTRODUCTION简介3.1 Preamble前言To ensure the economical use of nitrogen the tank shall be dried with dehumidified air to reduce the moisture content. To reduce the oxygen content in the tank to a safe level and to further dry the inner tank, the tank will be purged with Nitrogen. Target moisture dewpoint is -20C and required oxygen endpoint is 8% 0xygen or less.为确保氮气使用的经济性，储罐应当先采用干燥空气除湿，从而降低含水量。为使储罐内的氧含量降低到一个安全水平，同时为了进一步干燥储罐内罐，储罐将进行氮气置换。露点要求达到-20，氧含量要求小于或等于8%。Pre-commissioning activities:试车准备工作：Hydrotest, Pneumatic test, drying and nitrogen purge of tanks etc shall be supervised and performed by suitably qualified personnel. A template for the list of essential personnel for each activity will be used. This needs to be completed before the beginning of each activity. The purge and cool down pre-commissioning activities are to be carried out in accordance with this procedure and under the guidance of the respective Commissioning Managers.储罐的水压试验、气压试验、干燥和氮气置换等工作，应当由相关合格人员监督和执行。每次准备工作执行前，参加该项工作的人员均需填写人员名单表。置换和预冷这项试车准备工作须在各试车管理人员的指导下，按照此程序执行。3.2 System Description系统描述Reference should be made to the tank P &IDs as listed in Section 1 (Scope), note 2 LNG Tank System consists of:依照第1节应用范围中备注2所列储罐P&ID图，LNG储罐系统应包括： T101 to T106, 6 LNG tanks. T101T106,6个LNG储罐 In-tank Pumps 罐内泵 In-tank Pump Tube Suction Foot Valves 罐内泵吸入底阀 Tank Pressure Relief Valves 储罐压力安全阀 Tank Vacuum Relief Valves 储罐真空安全阀 Snuffing Package for Tank PRV vents 储罐压力安全阀放空管灭火方案 Associated Piping, Instrumentation and Intelligent Customer Support System functions.相关管道、仪表和智能客户支持系统。3.3 Data Recording, Monitoring and Storage数据记录、监视和存储Each activity will be monitored and recorded from start to finish. Record templates, and parameters to be monitored are shown in the Appendix section. Record templates are to be used for recording and monitoring data that cant be obtained from the Distributed Control System (DCS). Data that can be obtained from the DCS will be monitored and recorded in the DCS. The valve and safety item registers are to be signed off at the beginning of each activity. This is required to ensure that the relevant valves are in the right position / status. All data recorded manually or in the DCS is to be filed and stored. 自试车准备工作开始到结束，每个操作步骤均将被监控和记录。记录模板和需要监控的参数参见附录。记录模板表将用于记录和监控在分布式控制系统（DCS）中不能获取的数据。可从DCS中获取的数据将在DCS里被监控和记录。在每一步程序执行前，阀门和安全项目登记表必须完成验收签字，确保相应的阀门在正确的位置/状态。所有数据需要手动记录，DCS中的数据须存档保存。Nitrogen purge activity: Record templates for this activity are located in the Appendix Section.氮气置换：本次试车准备工作的记录模板在附录里。3.4 Pre-Commissioning Requirements试车准备工作要求 Dry air to be used for drying shall have a dew point less than 35C Inner tank shall be free from moisture and debris. In-tank pumps and their corresponding foot valves shall be installed. Tank instrumentation is mechanically complete, calibrated and loop tested but not commissioned Nitrogen to be used for purging is dry nitrogen. Dewpoint of -60 C or less.用于干燥用的干燥空气露点应小于-35。罐内应无残留水和杂物。罐内泵及其相应的底阀应安装完成。罐上相关仪表完成机械竣工，经过校准和环路测试，但未投入使用。用于置换的氮气为干燥氮气，露点为-60或小于-60。3.5 LNG Tank Pre-Commissioning LNG储罐试车准备工作3.5.1 Execution Plan and Planning Requirements 执行计划和要求The main pre-requisites that must be met prior to initiation of nitrogen purge of the LNG tank are listed below: Tank should be mechanically complete and construction check sheets approved Temporary Network Processing Unit is available Check to ensure tank stairway and emergency ladder are accessible and clear of debris. Ensure that there is sufficient lighting on tank roof, staircases and at ground level for night time operation. Check that all mobile radios, spare radios and battery chargers are operational and available for the duration of this process. Minimum manning on the LNG tank is observed throughout. All necessary, approved tools are available. Tank is properly isolated as per the Nitrogen Purge Valve Registers. Piping and tank valves are clearly identified for nitrogen inlet and tank venting. HSE requirements, as listed below, are in place.在LNG储罐氮气置换开始之前，必须满足的主要先决条件如下：储罐已完成机械竣工，且施工检查表通过批准。临时网络处理单元正常有效。检查以确保储罐爬梯和应急梯是可用的，应急梯上无碎片杂物。确保罐顶、应急梯和地面在夜间作业时照明情况良好。检查所有的移动式无线电通信设备、备用无线通信设备和电池充电器，确保设备在整个工作过程中能够持续地操作和使用。在整个过程中观察LNG储罐的最小人员配置。所有必要的、经批准的工具均可用。依据氮气置换阀门登记表，对储罐进行隔离。用于氮气进入和储罐放空的管道和阀门须明确标识。在下文中列出的HSE要求已经满足。3.5.2 HSE and Regulatory Requirements HSE和规范要求The following HSE and regulatory requirements must be completed before pre-commissioning of this system can commence: Ensure all work is carried out following the work permit system. Ensure vendors / suppliers at site conform to site safety regulations. Erect barriers and signs around purge discharge areas, prohibiting entry of unauthorised personnel at grade level. Ensure that personnel working with the system are aware of the hazards of Nitrogen used during pre-commissioning Refer to the Project Health and Safety Plan for details of safety procedures to be followed at site during pre-commissioning. Ensure all safety equipment including respirators and oxygen metre is available in the tank area. 下列HSE和规范要求必须在本系统开始试车准备工作之前完成：确保所有的工作在有工作许可证的前提下完成。确保供应商在现场符合现场安全管理规定。在置换排放区域竖起障碍物和标志牌，禁止未授权人员进入该工作区域。确保系统工作人员对试车准备工作执行过程中氮气的毒害性有明确认识。参考试车准备工作期间为安全程序所制定的健康和安全计划。确保罐区所有的安全设备正常有效，如呼吸器和含氧量测定仪。3.5.3 Temporary Facilities 临时设施The use of temporary vents, strainers, blind flanges, removable spools etc. is to be controlled by the relevant commissioning engineer. A register by system to record the use and removal of the above must be kept using a record template. An example is shown in the appendix section. All temporary vents, strainers, blind flanges, removable spools etc. should be numbered and labelled for easy identification. Any temporary equipment used shall be correctly certified.临时排气阀、过滤器、盲法兰、可拆卸电缆线等设施的使用由试车相关技术工作人员控制。对上述设施使用和移除的记录须使用统一的模板，模板样本表参加附录。为便于识别，所有临时排气阀、过滤器、盲法兰、可拆卸电缆线等应进行编号和标记，且所有临时设备的使用均应进行核实。The following temporary equipment will be required for pre-commissioning activities:试车准备工作可能用到临时设备如下：Description描述Purpose目的Quantity数量Oxygen Monitor氧气监测仪To be available for use by Commissioning personnel working near the tank purge outlets可由试车人员在储罐置换排气出口附近使用2Oxygen Meter氧气测量仪To measure the oxygen content of the purge gas displaced from the tank during purge operation用于测量置换操作期间自储罐置换出来的气体的含氧量2Dew point meter露点测量仪To measure dew point at various points during purge operation.用于测量置换操作期间不同监测点的露点2Temporary vent pipe, sampling point or isolating valve at tank nozzles: N9, N11A/B, N13, N23A/B and N24A/B and at each pump head N18A-Cand N20A-C.临时放空管，采样点或位于储罐排气口的隔离阀：N9、N11A/B、N13、N23A/B、N24A/B，以及每个泵压头处的N18A-C和N20A-CTo purge out nitrogen and out of spec methane gas from the tank to a safe location. Additional height of vent pipe will be needed to make it safe for personnel.用于置换出储罐中的氮气以及将储罐中甲烷转移到安全区域。为了确保工作人员的人身安全，放空管有必要增加长度。1 set per nozzle每个排气口设置1个Temporary vent pipe, sampling point or isolating valve at tank nozzles :N23A,N24A,N23B,N24B临时放空管、采样点或位于储罐排气口的隔离阀：N23A、N24A、N23B、N24BTo route purge gas from the dome space (Zone A) to the secondary bottom / TCP purge (Zone D) via the under bottom pipe work. See fig 1 in sect. 7.1用于使置换气体沿顶部空间（区域A）到罐底第二层（区域D）的路径进行吹扫置换。见章节7.1中的图11 N23A,N24A and 1 N23B, N24BNetwork Processing Unit网络处理单元To monitor / record data and to control instruments usually controlled through the Distributed Control System.用于监视/记录数据以及通过DCS控制仪器设备1Nitrogen Production Unit制氮装置To produce dry nitrogen for purging用于产生置换操作用的干燥氮气2Hose软管For purging and nitrogen pressurization duties. (Supplied with test certificate)用于吹扫和氮气充压。（要求有检测证书）5Manometer压力计For measuring the tank pressure during nitrogen purge as tank instruments may not be available在储罐仪表不可用的情况下，用于测量氮气置换期间的储罐压力2Calibrated Pressure Gauge标准压力表Monitoring tank pressure测量储罐的压力31” to 2” connector1寸到2寸的变径连接管For connecting the 1 utility nitrogen line to 2” hose connection用于连接1寸氮气管线和2寸软管2Differential Pressure Indicator At N13 and N23A位于N13和N23A上的压差指示器For commissioning用于试车1Differential Pressure Indicator At N23A and N24A位于N23A和N24A上的压差指示器For de-commissioning用于停车13.5.4 Pre-commissioning Preparation 预试车准备Tank isolation needs to be configured, verified, and signed off in accordance with the Valve Register. (An example is shown in the appendix section). On site, each of these valves will have a DO NOT OPERATE tag securely attached showing the valve tag number. All valves not mentioned in this register should be as per the projects P&IDs. 如附件中的例子，对储罐的隔离设施按照阀门清单设置、查验并签字确认。在现场，每个阀门都附有一个标有阀门位号的标识牌，上面写着“不许操作”。在这个清单里没有提到的所有阀门应该按照项目P&ID编码标识。To provide redundant isolation and additional safety, the relevant flanges / valves on interconnecting piping to T101 to T106 shall be configured with isolation spades or removable spools. 为了提供充分的隔离和额外的安全，T101到T106之间相互连接的管线上的相关法兰/阀门应该设有隔离插板或可拆除的短管。Tank T101 to T106 isolations need to be configured, verified, and signed off as per the Valve registers.储罐T101到T106的隔离需要按照阀门清单设置，查验并签字确认。4. CRITERIA OF DRYING AND PURGING 干燥和置换标准Criteria of Oxygen purging and drying using Nitrogen gas shall be as follows:用氮气置换和干燥储罐的标准如下：ZONE (See Fig.1)区域（见图1）DRYING DEW POINT 水露点O2PURGE CONCENTRATION (VOL %)置换后氧气的体积分数PURGE D