中英文版贮槽水气压试验新课件.docx
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中英文版贮槽水气压试验新课件
越南太原梅塞尔1000m3低温液体贮槽项目
VietnamTaiyuanMesser1000m3cryogenicliquidtankproject
低温液体贮槽
cryogenicliquidtank
试压方案
Pressuretestplan
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
Ninthsub-companyofSichuanChemicalConstructionLTD
目录Catalog
一、试压依据和要求3
Thebasisandrequirementsofpressuretest3
二、试压准备4
Pressuretestpreparation4
三、试压方法5
Pressuretestmethod5
四、安全注意事项:
16
TestNote:
16
一、试压依据和要求
Thebasisandrequirementsofpressuretest
1、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。
cryogenicstoragetankconstructiondrawingsandtechnicaldocuments.,Aftertheinstallationofcryogenicliquidstoragetank,waterpressuretestshouldbecarriedouttoensurethesafetyoftrialoperationandachievethepurposeofasuccessfuloperation.
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。
Beforethetestmustbesetupthecorrespondingexhaust,drainageport,andsafetyanalysis,todevelopasafetyemergencyplan.
2、试验方法选择
2,selectionoftestmethods
试压方法按照设计要求选择,拟采用以下试压方法。
Pressuretestmethodaccordingtothedesignrequirements,tobeusedinthefollowingtestmethod.
试压方法表Testmethodtable
序号NO
试压方法
Pressuretestmethod
试验压力
Testpressure
试验介质
Testmedium
1
预压试验Preloadingtest
常压Atmosphericpressure
水water
2
正压试验Positivepressuretest
最高液位+25KPA
Highestlevel+25KPA
水+氮气
Water+nitrogen
3
负压试验negativepressuretest
-5pa
二、试压准备
Pressuretestpreparation
1、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.Jointinspectionbeforetrial
Tanksystempressuretestbeforethecompletionoftheconstructionofthetwostoragetankstoconductacomprehensiveinspection,todeterminethepressuretestoperation,andthentotheowners,supervisionunitstoreport,conductajointinspection,toconductareviewofthesitetoconfirm:
(1)thestoragetankconstructionprocessinformationiscomplete;
(2)theinstallationofthetankinstallationworksincludingtheinstallationofthefirstpartoftheinstrumenthasbeencompleted;
(3)pressuretestairintakepipeandsafetyexhaust/watervalvehasbeenidentified;
(4)thetankconnectionpipehasbeeninstalled;
(5)theweldsandotherpartsshallnotbeconcealed;
(6)thesafetyandreliabilityoftemporaryreinforcementmeasures;
(7)eachinstrumenthasbeenconnectedinplace,specificationsandaccuracytomeettherequirements;
(8)atestplanisapproved,andthetechnicaldisclosure.
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.Storagetankpressuretestpreparationprocedure
(1)watervaportothescene;
Waterqualityrequirements:
watertemperatureislessthan49degrees,chlorineion,25ppm,nogrease,pHvalue6-8,cleanandclear
Airrequirements:
nitrogen+oilfreedrycompressedair
三、试压方法
Pressuretestmethod
1、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.waterinjection
▼testbefore,allmustgothroughtheinnerpottestandinspectionlogfilesignatureandconfirmation.
▼allrust,oil,dirt,mud,sand,etcfromtheinnertankwall,condoletopclean.
▼testbefore,alltheinnerpotbodyweldingworkshallbecompleted(orwaterinjectionintheprocessofwaterpressuretestworkdoesnotallowfortankbodyafterweldingwork);
▼intankbottomclean,vacuumtestcheckfinished,haveallsolderjoints,leakagepoints,hardhitpointsarcwoundeddressing.
▼theinnerpotalltheweldingwork(includingtubereinforcementplate,temporaryplate)andnondestructivetestingisaccomplished.
▼injectionwithendofconveyingequipment,pipelinesystem,debuggingqualified,canworkwaterfloodingexperimentwascarriedoutatanytime.
▼canchooseone,whenwaterflowisnotlessthan80m3/h,centrifugalpumpheadisnotlessthan37m.Inletpipeinstalledonthepipemouth,andconnectfirmly,drainageinselectiveattentionarestrictlyprohibitedwithinthewaterwillbealotoftestingonthegroovearelinkingpieceoffoamglassblock.
▼Settings,checkwhetherthereservoirinterlayerlightingisingoodcondition,theinsulationoftheelectricalequipmentareingoodcondition.
▼beforethewatertothewaterpipedoappearanceinspection,toensurethatwillnotleakduringtheprocessofwaterpipes.
▼cansoffillingwaterbeforeandduringtheprocessofwaterfilling,keepingthemanholeofthevaultsofthepersonnelinandoutoftheopen.
▼tankmeasurementpointset
N0.1测量点示图MeasuringpointSchematicdiagram
内罐底板向上1m的处设置12个沉降测量点,下图2示。
Atthebottomoftheinnertankbottomsetup12pointmeasurementpoints,Figure2
N2.测量点示图MeasuringpointSchematicdiagram
▼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。
▼infrontofthewaterfilling,contractorshouldbeonthebasisofmeasurement,atthesametimebytheowneronthebasisofthecivilengineeringconstructionpilecapsonthebasisofmeasurement,andrecordthedata.Measurementpersonneltodeterminetheinnerpot12pointsand12pointsontheedgeofthepilecaps,andrecordthedata.
Finalsettlementofanytwopointsinshouldbeabletomeetthebasicplaneofunevensettlementdifferenceisnotmorethan15mm.
▼tankoverdonotconnectwithexternalpiping,loosenandexternalpipelineflangeconnection.
2、水气压试验
2.Water/gaspressuretest
2.1水压试验
2.1Waterpressuretest
水压试验简图Hydrostatictestdiagram
▼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
▼hydrostatictestprocedure
a,themaximumheightofthewaterinthetankbydrawingprovisions.
b,waterinjectionintothedetailsofthecurveshownbelow
▼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。
▼hydrostatictestprocessmonitoring
A,inthewaterinjectionprocesstocheckintothewaterline,onlyrelatedtothetestingprocessofpersonnelisallowedtoenterwithinthescopeofthesecuritycordon.
B,todowellinwaterinjectionprocesswaterinjectionflowobservation,regularlytoobserveeveryday,makeeveryhourwaterinjectionheightoftherecord.Anomalieswerefoundinwaterinjectionprocesstoimmediatelystoppouring.
C,waterinjectionprocessshouldpayattentiontoobservetheinnerpotwall,foundtohaveabnormalnoiseandleakagephenomenonshouldimmediatelystopwater,andwaterleveldropsbelowtheleakagepoint300mm,repairtheleakagepoint,nondestructivetesting,andthenbacktowaterinjectiontest.
D,observersonthelidwhenmeasuringwaterinjectionmustbe1group,2andfastenyourseatbelt.
E,intheprocessofwaterinjectionmustmeasurethefollowingdata
Measureandrecordonthestageinfrontofthewaterinjectionof12pointelevationandtheinnerpotelevationoftheinitialdataof12pointsintheprocessofwaterinjection,atthehighestlevelof1/4,1/2,3/4hhhandthemaximumlevelmeasuredandrecordedonthestageatfourpointsofelevationandtheinnerpoteightpointsofelevation,observingtheconditionofthefoundationsettlement.Foundthattheextentofsubsidenceisgreaterthanthefollowingtwopoints:
(1),suchastanksgradientisgreaterthanthe1:
500(radialdifference:
diameter).
(2),tankselevationdifferencesettlementofarbitrarypointshallnotbemorethan1/500ofthetankcircumferenceandnotgreaterthanthegradientvaluesoftank,mustimmediatelystoptheprocessofwaterinjection,andnotifythecontractorortheownerrepresentativeonsite.
Afterwaterinjection,intheprocessofwaterinjectionandwaterfloodingbefore,inthecircumferentialdirectionatabout3mintervalsorringbeamunder1/4,middle,edge,measureandrecordthelevelnessofthefoundationslab.Shouldbeinfrontofthewaterinjection,1/4highly,1/2,3/4height,measuredafterfillandempty.Andinthecircumferentialdirection,theintervalof3m'spositionwithinthemeasuringtankandoutertankfoundationsettlementdifference.
F,whenwaterinjectiontoreachthehighestlevel,shouldstoppouring.Keepthehydrostaticpressurefor24hours,guaranteethestabilityoffoundationundertheconditionofstaticpressureuniformchange,untilnolongersedimentation.
Afterstablegasandliquidcombinationexperimentwascarriedout
G,andwaterdrainageprocessisconsistent,in3/4h,1/2h,handaquarterofempt