储罐水压试验方案.docx
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储罐水压试验方案
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文件页数
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受控编号
Controllednumber
GH
20
1版
Version1
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1st
储罐充水试压方案
TankHydro-testPlan
2
2012年11月1日
Nov.1,2012
版次Edition
日期
Date
编制Formulatedby
审核
Reviewedby
批准
Approvedby
中国化学工程第十三建设有限公司
The13thConstructionCo.,Ltd.ofCNCE
储罐充水试压方案
TankHydro-testPlan
目录Contents
八人力计划VII.PlanningforLaborForces18
九机具准备VII.PreparationsofMachinesandTools18
十工作危险源分析评估及预防Work-relatedHazardAnalysisEvaluationandPrevention19
一.适用范围RangeofApplication
1.本方案适用于塞拉尼斯(南京)乙酰基中间体有限公司工业乙醇项目八期改造扩建罐区4台储罐的充水试验的施工。
Thisplanisapplicabletotheexecutionofthehydro-testfor4tanksinthemodificationandexpansionofthetankfarmofCelaneseChinaFastProject.
二.编制依据FormulationBasis
1)《钢制焊接常压容器》SteelWeldedAtmosphericPressureVesselsJB/T4735-1997
2)《立式圆筒形钢制焊接油罐施工及验收规范》CodeforConstructionandAcceptanceofWeldedSteelOilTankofVerticalBarrelShapeGB50128-2005
3)《石油化工钢储罐地基与基础施工及验收规范》SpecificationforConstructionandAcceptanceofSteelStorageTankSubgrade&FoundationinPetrochemicalIndustrySH3528-93
4)《大型焊接低压储罐设计与建造》DesignandConstructionofLarge,Welded,Low-pressureStorageTanksAPI620-2009
5)塞拉尼斯技术要求及相关过程规定Celanesetechnicalrequirementsandrelatedprocessregulations
三.工程概况General
序号No.
位号Item
名称Description
规格Spec.
设备净重Netweightofequipment(t)
Weightafterwaterfilling充水后重(t)
水water(m3)
设计压力DesignpressureMpa
Fillingheight充水高度
(m)
1
V-732
产品罐Producttank
φ10795*9750
54.34
930.6
763
-0.00154/0.099
9.75
2
V-733
产品罐Producttank
φ10795*9750
54.34
930.6
763
-0.00154/0.099
9.75
3
V-744
倒液罐Off-spectank
φ10795*9750
54.34
930.6
763
-0.00154/0.099
9.75
4
V-737
清洗罐Cleaningtank
Φ8660*9750
35.84
599.8
488
-0.00154/0.099
9.75
四.施工工序ConstructionProcedure
五.施工步骤及方法ConstructionProcedureandMethod
储罐已制作完成,且具备水压试验条件,充水试验前应对罐体进行联合检查,罐体无损检测机所有配件、附件安装检测完毕检查合格后对罐体内进行清扫封闭人孔等,开始充水,进行充水试验。
充水过程中充水试验要求与土建基础沉降观测结合起来,设置专人对进水和放水时间进行监控,发现异常情况应及时处理,处理合格后方可继续上水。
充水试验结束后,罐体内的水应按业主要求和排放位置及时排放。
Beforethehydro-test,thetankshellshallbejointlyinspected.AfterNTDofthetankshell,andallfittingsandaccessoriesareinstalled,tested,inspectedandaccepted,cleanthetankinsideandclosethemanhole,fillwaterandtakethehydro-test.Duringwaterfilling,thehydro-testrequirementsshallbecombinedwiththecivilstructurefoundationsettlementobservation,personnelshallbespeciallyassignedformonitoringthefillinganddrainingtime,anyabnormalityshallbetreatedintime,nowatercanbefilledinbeforethetreatmentisaccepted.Aftercompletionofthehydro-test,thewaterinthetankshellshallbepromptlydrainedaccordingtotheowner’srequirementsandthelocationfordraining.
5.1储罐制造完毕后,进行充水试验,并检查下列内容:
Hydro-testwillbetakenafterthetankisfinishedinfabrication,andthefollowingcontentshallbechecked:
1)罐底严密性。
Tightnessofthetankbottom
2)罐壁强度及严密性。
Strengthandtightnessofthetankshell
3)固定顶的强度及严密性。
Strengthandtightnessofthefixedroof
4)固定顶的稳定性。
Stabilityofthefixedroof
5)基础的沉降观测。
Settlementobservationforthefoundation
5.2压力试验前,首先做好以下准备工作:
Thefollowingpreparationsshallbemadebeforethepressuretest:
1)检查罐外形尺寸、附件安装是否符合要求。
Checkifthetankoutlinedimensionandaccessoryinstallationsatisfyrequirements.
2)充水前将罐内杂物清理干净后进行封闭,罐壁上的接管均用临时盲板封闭,人孔用人孔法兰盖封闭。
Beforewaterfilling,cleanoutsundriesinthetankandcloseit,closethenozzleonthetankshellwithtemporaryblind,andclosethemanholewiththemanholeflange.
3)检查罐管口、法兰是否已焊接完,是否有漏焊部位。
Checkifthetanknozzleandflangearefinishedinwelding,andiftheweldingonanypartismissed.
4)接管补强圈用压缩空气气密工作已做完,且合格。
Theairtightworkofthecompressedairusedforthenozzlereinforcingringhasbeencompletedandqualified.
5)水源采用消防储罐的低压消防水,压力为1.5Mpa。
Thewaterissourcedfromthelowpressurefirewaterofthefiretank,andthepressureis1.5Mpa.
6)沉降观测,储罐选定4个沉降观测点。
Settlementobservation:
4settlementobservationpointsareselectedfortanks.
7)完成罐充水前沉降观测点和基准点的设置,并测量0水位时各测点的标高。
Setupsettlementobservationpointsandreferencepointsbeforewaterfillingforthetank,andmeasuretheelevationofeverymeasuringpointwhenthewaterlevelis0.
8)碳钢储罐试验应采用洁净水,试验用水温不低于5℃。
TheCStanktestshalladoptcleanwater,andthewatertemperatureusedforthetestshallnotbelowerthan5℃.
9)V-737不锈钢储罐试验用水氯离子含量不得超过25mg/L。
ThecontentofthechlorideioninwaterusedforV-737SStanktestshallnotbemorethan25mg/L.
10)完成罐充水前沉降观测点和基准点的设置,并测量0水位时各测点的标高。
Setupthesettlementobservationpointandthereferencepointbeforewaterfillingforthetank,andmeasuretheelevationofeverymeasuringpointwhenthewaterlevelis0.
5.3充水试验应符合下列规定:
Thehydro-testshallbeincompliancewithfollowingregulations:
1)充水和放水过程中,打开放空孔,基础避免浸水。
Duringwaterfillinganddraining,openthe
2)充水时严格控制上水、停水的进程,随时检查水位。
Duringwaterfilling,strictlycontroltheprocessofwaterfillingandwatercutoff,andcheckthewaterlevelanytime.
3)当第一台储罐进行充水试验时,应充水时快速充水到罐高的1/2,进行沉降观测,当不均匀沉降量小于5mm/天时,继续充水到罐高的3/4进行观测,当充水到(设计液位—1米)进行正压试验,当不均匀沉降量仍小于5mm/天时,继续充水到最高操作液位,并保持48小时后进行观测,当沉降量无明显变化即可放水,放水时做负压试验,当沉降量有明显变化,则保持最高操作液面,每天进行定期观测,直至沉降稳定为止。
Whenthehydro-testistakenforthefirsttank,thewatershallbequicklyfilledtothepointof1/2ofthetankheightduringwaterfilling,observethesettlement,whentheunequalsettlementisstilllessthan5mm/day,goonfillinginwatertothepointof3/4ofthetankheightforobservation;whentheunequalsettlementisstilllessthan5mm/day,goonfillinginwatertothehighestoperatinglevel,andobserveitaftermaintaining48hrs,ifthesettlementdoesn’tobviouslychange,thewatercanbedrained,ifthesettlementobviouslychanges,keepthehighestoperatinglevel,andobserveitregularlyeveryday,untilthesettlementissteady.
4)当第一台储罐罐基沉降量符合要求后,其余各罐充水试验时可取罐高的1/2和3/4进行两次观测。
Afterthefoundationsettlementofthefirsttankmeetsrequirements,whenthehydro-testistakenfortheresttanks,thesettlementwillbeobservedtwicerespectiveatthepointof1/2and3/4heightofthetank.
5)基础沉降观测早、晚各观测一次,每次的沉降数据做好统计,并描绘出基础沉降变化图,便于分析。
罐基础沉降允许值(均匀沉降值)Allowablevalueofthetankfoundationsettlement(equalsettlementvalue)
储罐位号TankNo.
罐内径(mm)innerdiameteroftank
任意直径方向最终沉降差允许值(mm)
Allowablevalueofthefinalsettlementdifferenceinanydiametricaldirection
V-732
10668
160mm
V-733
10668
160mm
V-744
10668
160mm
V-737
8534
128mm
Referencevalve:
Allowablevalueofthetankfoundationsettlement(equalsettlementvalue)Attachedtable1
Floatingrooftankandinnerfloatingrooftank
Fixedrooftank
InsidediameteroftankD(m)
Allowablevalueofthefinalsettlementdifferenceinanydiametricaldirection
InsidediameteroftankD(m)
Allowablevalueofthefinalsettlementdifferenceinanydiametricaldirection
5.4水压试验示意图:
Hydro-testDiagram
●在罐区内的泡沫消防临时接入处,用临时管线(φ108*6)接到储罐泡沫降落槽接口上;Connectthetemporarypipe(φ108*6)totheaccessofthetankfoamdescendinggrooveatthetemporaryaccessoffoamfire-proofinthetankfarm.
●按上图所示建立试压系统;Establishthepressuretestsystemaccordingtotheabovediagram.
5.5充水过程检查:
InspectionforWaterFillingProcess
1)进水时专人看守进水阀门,严格控制水源大小,同时找专人通过U型计
观察储罐实际充水量并与进水人员配合,过程为1/2液位高度→3/4液位高度
→满水高度-1米→满水高度
Thesecurewaterwhentheinletvalve,strictcontrolofwaterthesizeof,atthe
sametimetofindsomeonethroughtheU-meterObservethethetanksactual
chargewaterandinfluentpersonnelwiththeprocessfortheliquidlevelofthe
liquidlevel→1/23/4Height-1m→→fullofwaterfullofwaterheight
2)充水试验中应加强基础沉降观测,如基础发生不允许的沉降,应停止充水,待处理后,方可继续进行试验。
Dointensifysettlementobservationduringthehydro-test,ifunallowablesettlementarisesfromthefoundation,thewaterfillingshalltop,anddonotgoonthetestbeforetreatment.
3)充水和放水过程中应打开罐顶人孔Doopenthemanholeonthetankroofduringtheprocessofwaterfillinganddraining.
4)充水过程中应控制水的流速,水面上升的速度应不超过0.9m/h。
Docontroltheflowspeedofwaterduringwaterfilling,andthespeedofwatersurfaceascentshallnotexceed0.9m/h.
5)上水过程中在最高设计液位的50%和75%进行罐体检查。
Duringwaterfilling,checkthetankbodyatthepointof50%and75%ofthehighestdesignlevel.
5.6充水试验方法:
Hydro-testmethod:
1)罐底的严密性,应以充水试验过程中罐底无渗漏为合格,若发现渗漏,应
放水后进行检查补焊。
Tightnessofthetankbottom:
ifthetankhasnoleakageduringthehydro-test,itisacceptable,incaseofanyleakage,itshallbeinspectedandwelding-repairedafterwaterdraining.
2)罐壁的强度及严密性试验,应以充水到设计最高液位并保持48h后,罐壁
无渗漏、无异常变形为合格,发现渗漏时应放水,使液面比渗漏处低300mm
进行修补。
Strengthandtightnesstestforthetankshell:
ifthetankshellisfreeofleakage,abnormalityanddeformationafterthewaterisfilledtothehighestdesignlevelandmaintains48h,itisacceptable,incaseofanyleakage,thewatershallbedrainedtomakethewaterlevel300mmlowerthantheleakage.
3)固定顶的强度及严密性试验,打开阀门1,关闭阀门2,通过消防带从罐顶部进行上水,在上水至设计液面高度下1米处时,用盲板封堵所有开孔,缓慢调节阀门1,缓慢上升,升压至试验压力(0.12Mpa)时,停止充水,进行固定顶强度及严密性试验,在罐顶涂以肥皂水检查,试验后应立即将罐顶孔开启,与大气相通,恢复到常压;Strengthandtightnesstestofthefixedroof:
openValve1,closeValve2,andfillwaterfromthetanktopthroughthefirehose,whenthewaterisfilledtothepointof1mlowerthanthedesignlevel,blockallopeningsbyblinds,slowlyregulateValve1,thepressureslowlyrises,whenthepressurerisestothetestpressure(0.12Mpa),stopfillingwater,andconductthestrengthandtightnesstestforthefixedroof,applysoapywateronthetankroofforinspection,anddoopenthetankroofholeimmediatelyafterthetest,soastocontacttheatmosphereandrecovertonormalpress