中英文版贮槽水气压试验方案新.doc

越南太原梅塞尔1000m3低温液体贮槽项目Vietnam Taiyuan Messer 1000m3 cryogenic liquid tank project低温液体贮槽cryogenic liquid tank试压方案Pressure test plan编制Editor:审核Check:批准Ratify:四 川 省 化 工 建 设 有 限 公 司 第 九 分 公 司Ninth sub-company of Sichuan Chemical Construction LTD目录Catalog一、试压依据和要求3The basis and requirements of pressure test3二、试压准备4Pressure test preparation4三、试压方法5Pressure test method5四、安全注意事项：16Test Note:16一、试压依据和要求The basis and requirements of pressure test1、编制依据根据低温储槽施工图及技术文件，大型常压低温液体贮槽总体试验规程，低温液体贮槽安装完后需进行水气压试验，确保试运安全，达到一次投产成功的目的。cryogenic storage tank construction drawings and technical documents. , After the installation of cryogenic liquid storage tank, water pressure test should be carried out to ensure the safety of trial operation and achieve the purpose of a successful operation.试验前必须设置相应的排气、排水口，并进行安全分析,制定安全应急预案。Before the test must be set up the corresponding exhaust, drainage port, and safety analysis, to develop a safety emergency plan.2、试验方法选择2, selection of test methods试压方法按照设计要求选择，拟采用以下试压方法。Pressure test method according to the design requirements, to be used in the following test method.试压方法表Test method table序号NO试压方法Pressure test method试验压力Test pressure试验介质Test medium1预压试验Preloading test常压Atmospheric pressure水water2正压试验Positive pressure test最高液位+25KPAHighest level +25KPA水+氮气Water + nitrogen3负压试验negative pressure test-5pa二、试压准备Pressure test preparation1、 试压前联合检查贮槽系统试压前，先对施工完毕的两个贮槽进行全面检查，确定具备试压作业后，再向业主、监理单位汇报，进行联合检查，对现场进行审查确认：（1）贮槽施工过程资料齐全；（2）贮槽安装工程包括仪表一次部件的安装已经完成;（3）试压进气管道及安全排气/水等阀门已标识；（4）贮槽连接管道已安装完毕；（5）焊缝及其他应检查的部位不作隐蔽；（6）试压用的临时加固措施安全可靠；（7）各仪表已联接就位，规格及准确性符合要求;(8)有经批准的试验方案，并经技术交底。1. Joint inspection before trialTank system pressure test before the completion of the construction of the two storage tanks to conduct a comprehensive inspection, to determine the pressure test operation, and then to the owners, supervision units to report, conduct a joint inspection, to conduct a review of the site to confirm:(1) the storage tank construction process information is complete;(2) the installation of the tank installation works including the installation of the first part of the instrument has been completed;(3) pressure test air intake pipe and safety exhaust / water valve has been identified;(4) the tank connection pipe has been installed;(5) the welds and other parts shall not be concealed;(6) the safety and reliability of temporary reinforcement measures;(7) each instrument has been connected in place, specifications and accuracy to meet the requirements;(8) a test plan is approved, and the technical disclosure.2、贮槽试压准备程序 （1）水气至现场; 水质要求：水温低于49度，氯离子25ppm，无油脂，PH值6-8，干净清彻 气源要求：氮气+无油干燥压缩空气2. Storage tank pressure test preparation procedure(1) water vapor to the scene;Water quality requirements: water temperature is less than 49 degrees, chlorine ion, 25ppm, no grease, pH value 6-8, clean and clearAir requirements: nitrogen + oil free dry compressed air三、试压方法Pressure test method1、 注水前的准备工作和检查 试验之前、所有内罐的试验和检查记录文件必须经过签字和确认。 所有的浮锈、油迹、污物、泥砂等从内罐壁、吊顶清扫干净。 试验之前，所有内罐本体的焊接工作应当全部完成（水气压试验过程中或者注水工作后不允许进行储罐本体焊接工作）； 内罐底板清扫干净、真空试验检查完毕，已经对所有漏焊点、电弧击伤点、硬物打击点的修整。 内罐所有的焊接工作（包括管架的补强板、临时垫板）以及无损检测完成。 注水用的输送设备、管道系统连接结束，调试合格，可以随时进行注水试验工作。 进水时可选择一台，流量不小于80m3/h，扬程不小于37m的离心泵。进水管口安装在管口上，并连接牢固，排水时选择注意严禁将大量试验用水洒到内槽均压板下的泡沫玻璃砖上。 设置、检查储槽夹层的照明是否完好，电气设备的绝缘是否良好。 在进水之前要对进水管道做外观检查，以保证在进水过程中管道不会泄漏。 在内罐充水之前和充水过程中，将拱顶上的人员进出的人孔保持打开状态。 储罐测量点设置1. water injection test before, all must go through the inner pot test and inspection log file signature and confirmation. all rust, oil, dirt, mud, sand, etc from the inner tank wall, condole top clean. test before, all the inner pot body welding work shall be completed (or water injection in the process of water pressure test work does not allow for tank body after welding work); in tank bottom clean, vacuum test check finished, have all solder joints, leakage points, hard hit points arc wounded dressing. the inner pot all the welding work (including tube reinforcement plate, temporary plate) and nondestructive testing is accomplished. injection with end of conveying equipment, pipeline system, debugging qualified, can work water flooding experiment was carried out at any time. can choose one, when water flow is not less than 80 m3 / h, centrifugal pump head is not less than 37 m.Inlet pipe installed on the pipe mouth, and connect firmly, drainage in selective attention are strictly prohibited within the water will be a lot of testing on the groove are linking piece of foam glass block. Settings, check whether the reservoir interlayer lighting is in good condition, the insulation of the electrical equipment are in good condition. before the water to the water pipe do appearance inspection, to ensure that will not leak during the process of water pipes. cans of filling water before and during the process of water filling, keeping the manhole of the vaults of the personnel in and out of the open. tank measurement point setN0.1测量点示图Measuring point Schematic diagram内罐底板向上1m的处设置12个沉降测量点，下图2示。At the bottom of the inner tank bottom set up 12 point measurement points, Figure 2N2. 测量点示图Measuring point Schematic diagram 在充水前，施工方需进行基础测量，同时由业主对土建施工的基础承台进行基础测量，并记录数据。测量人员确定内罐12个测量点和承台边缘的12个测量点，并记录数据。最终基础沉降应能满足基础平面内任意两点的不均匀沉降差不大于15mm的要求。 罐上接管不得与外部配管连接，松开与外部管线法兰连接。 in front of the water filling, contractor should be on the basis of measurement, at the same time by the owner on the basis of the civil engineering construction pile caps on the basis of measurement, and record the data.Measurement personnel to determine the inner pot 12 points and 12 points on the edge of the pile caps, and record the data.Final settlement of any two points in should be able to meet the basic plane of uneven settlement difference is not more than 15 mm. tank over do not connect with external piping, loosen and external pipeline flange connection.2、 水气压试验2. Water/gas pressure test2.1 水压试验2.1 Water pressure test水压试验简图Hydrostatic test diagram 水压试验的过程a、 内罐注水最大高度按图纸规定。b、 注水过程细节曲线见图四 hydrostatic test procedurea, the maximum height of the water in the tank by drawing provisions.b, water injection into the details of the curve shown below 水压试验过程的监护a、在注水过程要随时检查进水管线，只有与测试过程有关的人员才允许进入安全警戒线的范围内。b、在注水过程要做好注水流量的观测，每天要定期观察，做好每小时的注水高度记录。在注水过程中发现有异常情况要立即停止注水。c、注水过程中要注意观察内罐壁板，发现有异常响动和漏水现象要立即停止注水，并将水位降低到渗漏点300mm以下，修补渗漏点，进行无损检测，然后再重新进行注水测试。d、注水观测人员上顶盖测时必须2人1组，并系好安全带。e、在注水的过程中须测量以下数据在注水前测量并记录承台上12个点的标高及内罐12个点的标高的初始数据在注水的过程中，在最高水位的1/4H、1/2H、3/4H和最大液位处分别测量并记录承台上4个点的标高及内罐8个点的标高，观察基础沉降的情况。发现沉降的幅度大于以下二点：、如罐体倾斜度大于1：500（径向高差：直径）。、罐体任意沉降点的高差不得大于罐体周长的1/500且不大于罐体倾斜度值，注水的过程必须立即停止，并通知总包或业主现场代表。 在注水前、注水过程中、注水后，在圆周方向上间隔大约3m或者环梁之下的1/4处、中间、边缘，测量并记录基础底板的水平度。应在注水前，1/4高度、1/2高度、3/4高度、注满和放空后分别测量。并在圆周方向上，间隔3m的位置测量内罐和外罐的基础沉降差值。f、当注水达到最高水位时，应停止注水。保持静水压力24小时，保证基础在静压条件下稳定均匀变化，到不再沉降为止。稳定后进行气液组合试验g、排水过程与进水过程一致，在3/4H，1/2H，1/4H和空罐的时，对测量点进行测量并记录数据。注意排水速度为1m/h，同时检查锚固条。排水将在气压和真空试验结束后进行。h、待水排空后测量内罐中心的沉降：内罐中心到内罐各沉降测量点的高差不得超过半径的1/300。i、沉降测量完成后进行下一步正压试验。 hydrostatic test process monitoringA, in the water injection process to check into the water line, only related to the testing process of personnel is allowed to enter within the scope of the security cordon.B, to do well in water injection process water injection flow observation, regularly to observe every day, make every hour water injection height of the record.Anomalies were found in water injection process to immediately stop pouring.C, water injection process should pay attention to observe the inner pot wall, found to have abnormal noise and leakage phenomenon should immediately stop water, and water level drops below the leakage point 300 mm, repair the leakage point, nondestructive testing, and then back to water injection test.D, observers on the lid when measuring water injection must be 1 group, 2 and fasten your seat belt.E, in the process of water injection must measure the following dataMeasure and record on the stage in front of the water injection of 12 point elevation and the inner pot elevation of the initial data of 12 points in the process of water injection, at the highest level of 1/4, 1/2, 3/4 h h h and the maximum level measured and recorded on the stage at four points of elevation and the inner pot eight points of elevation, observing the condition of the foundation settlement.Found that the extent of subsidence is greater than the following two points: (1), such as tanks gradient is greater than the 1:500 (radial difference: diameter).(2), tanks elevation difference settlement of arbitrary point shall not be more than 1/500 of the tank circumference and not greater than the gradient values of tank, must immediately stop the process of water injection, and notify the contractor or the owner representative on site.After water injection, in the process of water injection and waterflooding before, in the circumferential direction at about 3 m intervals or ring beam under 1/4, middle, edge, measure and record the levelness of the foundation slab.Should be in front of the water injection, 1/4 highly, 1/2, 3/4 height, measured after fill and empty.And in the circumferential direction, the interval of 3 ms position within the measuring tank and outer tank foundation settlement difference.F, when water injection to reach the highest level, should stop pouring.Keep the hydrostatic pressure for 24 hours, guarantee the stability of foundation under the condition of static pressure uniform change, until no longer sedimentation.After stable gas and liquid combination experiment was carried outG, and water drainage process is consistent, in 3/4 h, 1/2 h, h and a quarter of empty cans, to measure and record the data points.Pay attention to the drainage rate of 1 m/h, at the same time check the anchoring bar.Water will be carried out at the end of the air pressure and vacuum test.H, after waiting for water emptying measurement in the center of the tank settlement: the inner pot center to the inner pot of each settlement measurement point elevation difference should not exceed 1/300 of the radius.I, after the completion of the settlement measurement into the next phase of positive pressure test.2.2 正压试验的准备工作2.2 Ready to work for positive pressure test 试验压力正压试验压力为25KPa+2551mm水柱 试压前的工装准备就绪 试压的准备：a、 内罐的注水试验达到最大液位高度，内罐壁板目视检查无渗漏水迹、无变形，检验合格。b、 外罐所有的焊接工作结束，并检查合格。c、 试压前拱顶接管口全部用临时盲板封闭（除试验用管口），人孔法兰已加垫片紧固，并已关闭了所有仪表管道排气阀。d、 罐体拱顶上的临时紧急放空阀，并且已经安装就位完毕。e、 在管口上安装U型压力计就位完毕。f、 试压时用空气压缩机或进气管向罐内充气，U型压力计连接在罐顶管口上，以观察罐内正压。U型压力计示意图如图五。g、 罐体试压用的工装已安装就位完成。 test pressurePositive test pressure 25KPa = 2551mm water column pressure test before tooling up ready pressure test preparation:a, test water within the tank reaches the maximum level height, visual inspection of the inner tank wall no trace of water leakage, no distortion, inspection.b, all welding work outside the tank end, and pass the inspection.c, before the pressure test port to take over the entire dome with the temporary closure blind (except test tube mouth), manhole flange gasket tightening has been added, and have turned off all instrument piping exhaust valve.d, temporary tank dome on emergency vent valve has been installed in place and completed.e, install a U-shaped manometer place finish in the spout.f, when the tank pressure test inflatable, U-type manometer connected air compressor intake pipe or on top of the tank nozzle, to observe the positive pressure tank. U-type manometer diagram shown in Figure V.g, the tank pressure test tooling is in place to complete.U-type manometer Schematic diagram2.3 正压试验 试验示意图见图六（注意所有接管都在内槽上，或通过内筒到外筒的接管）。 2.3 Positive pressure test test is shown in Figure VI (note that all have to take over the inner tank, or by taking over the inner tube to the outer tube).N06 Positive pressure test Schematic diagram 当空气压缩机启动后，开启顶部进气阀门，使罐内气体缓慢升压至138mbar(g)检查管线是否泄漏。 调节针型进气阀向罐进气升压，升压程序为：a、 缓慢增压至156.5mbar(g)（1596mm水柱），检查管口、底板及罐体其它部位有无泄露、变形和异常。b、 缓慢增压至234.75mbar(g)（2394.5mm水柱），检查管口、底板及罐体其它部位有无泄露、变形和异常。c、 升压至250mbar(g)（2551mm水柱）时，保压1小时，将压力降至设计压力200mbar(g) （2041mm水柱），检查管口、底板及罐体其它部位有无变形和异常。 用肥皂水涂抹罐顶焊缝和所有未进行真空试验的焊缝检查有无气泡形成，全部无气泡为合格。 正压试验合格后，缓慢降压到0，进行负压试验。 When the air compressor starts, open the top of the intake valve, so that the gas tank is slightly elevated to 138mbar (g) to check the line for leaks. adjusts the needle valve to the tank into the intake boost, a boost for the program:a, slowly pressurized to 156.5mbar (g) (1596mm water column), check the nozzle, floor and other parts of the body with or without leakage, deformation and abnormal.b, slowly pressurized to 234.75mbar (g) (2394.5mm water column), check the nozzle, floor and other parts of the body with or without leakage, deformation and abnormal.c, boost to 250mbar (g) (2551mm water column), the packing one hour, the pressure was reduced to the design pressure 200mbar (g) (2041mm water column), check the nozzle, floor and other parts of the body without deformation and abnormal . tank top with soapy water and all but vacuum-weld test welds check bubble formation, no bubbles all qualified. positive after passing the test, slow down to 0, negative pressure test.2.4真空（负压）试验2.4 vacuum (negative pressure) test 真空（负压）试验简图（如图七） vacuum (negative pressure) test diagram (Figure VII)vacuum (negative pressure) test diagram (Figure VII) 真空试验压力为-5 mbar(g)-51mm水柱。 真空试验在排水过程中进行。 检查临时真空阀处于工作状态，关闭所有开孔、阀门。 注意排水速度，降压速度亦不大于1 mbar(g)/min（10.2mm水柱/分）。 当设计真空达到-5 mbar(g)，立即停止排水。注意：必须严密监控负压数值，防止超压造成储槽内凹！2.5 试验合格后，缓慢释放真空正常后，打开人孔及接管的盲板，使罐内外连通，准备排水。 排水。 vacuum test pressure -5 mbar (g) = - 51mm water column. vacuum test carried out in the drainage process. check for a temporary vacuum valve is in operation, close all openings, valves. Note drainage rate, pressure no greater than the rate of 1 mbar (g) / min (10.2mm of water / min). When designing the vacuum reaches -5 mbar (g), immediately stop the dra